Bending Aluminum Sheet Minimum Radius

Say you get a print that says you need to bend a part to an external angle of 100 degrees that s an internal angle of just 80 degrees.

Bending aluminum sheet minimum radius.

To keep it simple i also use a 2 mm inside radius. Thick grade 350 and 400 may have a minimum bend radius of 2 5 times the material thickness when transverse bending while longitudinal bending may require a minimum bend radius that s 3 75 times the material thickness see figure 1. Bend radii minimum bend sizes. We go beyond the general rules of sheet metal bending as our customers want tight bend radii for sheet metal parts.

Recommended minimum bend radii for steel and aluminum. Still if you want to avoid cracking abide by the minimum bend radius in 0 25 in thick 6061 t6 which is quite large see figure 3 and avoid bending acute angles. The minimum bend radius data shown in these charts is measured to the inside of the bend. It is most economical to use a single bend radius throughout the design but if necessary you can utilize multiple radii.

Aluminum is typically thicker and stronger and requires more force to bend as well as consideration of edge conditions and punch nose radii. Since commercial sheet metal bending can be done with less concern for stresses caused during forming operation the radius can be near zero for thin sheet metal. The minimum bend radius for aluminum when working with aluminum over sheet metal several variables need to be considered. It is possible to choose other bends if you require but additional lead time and tooling charges may apply.

Radii for various thicknesses expressed in terms of thickness t. The tool can calculate the required bending force for bending aluminum stainless steel mild steel and weldox or strenx high strength steels. In steel between 0 5 and 0 8 in. Sheet metal bend radii if these guidelines are not followed more research and or some form of analysis may be requried.

This tool allows you to determine tonnage internal radius v die opening and minimum flange you just have to insert the characteristics of the sheet metal to be bent. Table 1 preferred recommended 90 degree bend radii for various sheet metals. Aluminum minimum bend radii for 90 degree cold forming of sheet and plate. Use this document to choose values that are both manufacturable and meet your needs.

The minimum inside bend radius is even larger when bending with the grain. I can now see that the minimum flange length is 8 5 mm for such a bend so i have to keep it in mind when designing. The bend radii listed are standard minimum if manufacturing for aircraft and aerospace applications. The tables below show bend radii and minimum bend sizes for materials and tooling combinations stocked by protocase.

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