Complete guide to bending aluminum sheet metal. Learn about alloy selection, temper effects, cracking prevention, and surface protection for aluminum parts.
Introduction
Aluminum bending presents unique challenges due to its low elastic modulus, soft surface, and varying properties by alloy. At Fulei Metal, we bend aluminum components for automotive, aerospace, and consumer goods clients.
Aluminum Bending Characteristics
Low elastic modulus (70 GPa) means more springback than steel despite lower yield strength. Soft surface is easily scratched. Different alloys and tempers bend very differently. Some alloys crack at tight radii.
Alloy and Temper Selection
Soft Alloys
5005-O: excellent bending, minimal springback. 3003-O: very soft, excellent bending. 5052-O: good bending, slightly stronger.
Medium Alloys
5052-H32: most common, good bending with moderate springback. 5005-H24: similar to 5052-H32.
Hard Alloys
6061-T6: challenging, prone to cracking, needs larger radii. 7075-T6: very difficult, rarely bent. 2024-T3: difficult, aerospace applications.
Minimum Bend Radii
Soft alloys: 0.5-1.0 times thickness. Medium alloys: 1.0-1.5 times. Hard alloys: 1.5-3.0 times. Always test new alloys.
Springback Compensation
Soft alloys: 1-2 degrees. Medium: 2-3 degrees. Hard: 3-5 degrees. Use real-time angle measurement. Update database with actual values.
Surface Protection
Apply protective film before bending. Use polished or chrome-plated tools. Use nylon inserts for critical parts. Handle with clean cotton gloves. Use interleaving paper between finished parts.
Cracking Prevention
Use larger bend radii for hard alloys. Bend across the grain. Use annealed material where possible. Deburr edges before bending. Test bend samples.
Tooling
Wider die openings reduce force and marking. Polished tools prevent scratching. Standard punches with appropriate nose radius work for most alloys.
Applications
At Fulei Metal, we produce aluminum bent parts for electronic enclosures, automotive brackets, heat sink components, lighting fixtures, and consumer electronics.
Conclusion
Aluminum bending requires understanding alloy-specific behavior. At Fulei Metal, our experience with all aluminum alloys ensures quality bent parts for international clients.