Bending Aluminum Stock

[TheClaw]

I installed an Odyssey PC925 this weekend and made a hold down out of 1/8 x 1" anodized stock. I made the bends in my vise. I must have made them too sharp because I'm getting stress cracking on the outside of the bends.

Any suggestion on how to bend the bar with more or a curve to it or less stress? Don't feel like investing in any expensive metal brake or anything like that right now. Just looking for a kindler gentler bend.

<a href="http://www.flickr.com/photos/stufffromthekilinskis/8919525312/" title="IMG_6359 by theclaw900, on Flickr"><img src="http://farm9.staticflickr.com/8117/8919525312_9f98826422.jpg" width="500" height="333" alt="IMG_6359"></a>


Thanks

 

[rockwithjason]

did you try to heat it or was the bend cold?

 

[TheClaw]

did you try to heat it or was the bend cold?

Cold

I had protected the piece with some blue painters tape since I had to bang on it somewhat.

 

[bhalv]

I would leave it as is, or if you want you can try some heat to help the metal along next time. It's not like you're making structural pieces or anything.

 

[pattenp]

You need to research about bending aluminum. I believe you are not to heat it to bend it.

Edit: May be you can heat it, read this post........

http://www.garagejournal.com/forum/showthread.php?t=147276

 

[TheClaw]

I would leave it as is, or if you want you can try some heat to help the metal along next time. It's not like you're making structural pieces or anything.

I like this. I figured I'd keep it as is and if I saw it cracking some more, I'd make another bracket trying a different method.

 

[j p smith]

Not sure but some aluminum bends easier, t-4, t-5 comes to mind but am not sure. Jeff

 

[rharman]

I use these. Seem to work OK for light duty. I think I got them from Rockler or Lee Valley.

 

[MP&C]

That could have been 6061 alloy, which is less friendly to sharp bends and prone to cracking. Anodized finish does not like bending either, so part of what you are seeing is part of that. For better results with sharp bends, use 5052 alloy.

 

[TheClaw]

I use these. Seem to work OK for light duty. I think I got them from Rockler or Lee Valley.

That could have been 6061 alloy, which is less friendly to sharp bends and prone to cracking. Anodized finish does not like bending either, so part of what you are seeing is part of that. For better results with sharp bends, use 5052 alloy.

Roger, Those look pretty slick. I'll have to find those. I track this car and I'm going to bet at some point these bends might break. The one pictured is the second piece I made. The first broke while I was adjusting the angle of one of the bends. I cant imagine it's that strong once it's bent and may give way.

I picked this material up at my local Ace Hardware. I'll see if I can come up with some 5052.

Thanks for all of the help.

Jeff

 

[theoldwizard1]

That could have been 6061 alloy, which is less friendly to sharp bends and prone to cracking. Anodized finish does not like bending either, so part of what you are seeing is part of that. For better results with sharp bends, use 5052 alloy.

The alloy has more to do with bending AL than anything. Some alloys would have broken completely on a 90° bend.

 

[Crusty Nut]

Anneal it first, bend it, and the act of bending will harden it back up. But some 5052 would be a better jumping off point.

 

[Crusty Nut]

I don't work with aluminum all that much and when I do it is usually just a simple bracket. My local scrap yard always has old roadsigns for scrap price. That is mostly all I use. I don't know he compound, but that is some hard stuff. It will crack or just break off with a bend like that. But, after annealing you can almost bend it with your hands.

 

[jmarkwolf]

The hardware store will be unlikely to tell you what the alloy is.

Find a shop in your area and buy 5052 alloy, or order it from Mcmaster Carr.

It'll bend much nicer.

 

[bczygan]

Got a torch set?
Torch anneal it, and bend in a wood V-block form with clamps , a drill press or an arbor press (Maybe even a stout bench vise). Or rig up a hydraulic press of some kind.

 

[TheClaw]

The hardware store will be unlikely to tell you what the alloy is.

Find a shop in your area and buy 5052 alloy, or order it from Mcmaster Carr.

It'll bend much nicer.

You're right. Even the label didn't identify what alloy it was. there's a Metal Supermarket near me. Only problem they have pretty limited hours. Have to catch them on a day off.

Got a torch set?
Torch anneal it, and bend in a wood V-block form with clamps , a drill press or an arbor press.

That sure beats ordering the metal tool from Veritas. A short piece of hardwood would be an easy tool.

 

[retrobuilder]

Heating should not bee required. As mentioned by others a 5052 is better and easily cold formed. My experience with hardware and big box store aluminum is the hardness and lack of bending ease.

2000 and 5000 series are good. 6061, 6063 and 7075 are very prone to cracking.

 

[Kevin54]

6061-0 will bend easily as it is soft. What you are bending is likely along the lines of 6061-T6 maybe which is hard and you WILL get stress cracks. Also, you don't want your inside radius any smaller than the material is thick, so if you want to bend something that is 1/8" thick, you want to bent it around a 1/4" rod, if it is a material that is bendable. Once you get into the "T"'s as in T4 or T6 you are going to have problems.

Stay completely away from any 7000 series as it is going to be harder yet.

I would say that with the stress cracks that are showing now, and you won't be experiencing movement other than vibration, you should be fine without it breaking off.

 

[theoldwizard1]

6061-0 will bend easily as it is soft. What you are bending is likely along the lines of 6061-T6 maybe which is hard and you WILL get stress cracks. Also, you don't want your inside radius any smaller than the material is thick, so if you want to bend something that is 1/8" thick, you want to bent it around a 1/4" rod, if it is a material that is bendable. Once you get into the "T"'s as in T4 or T6 you are going to have problems.

This man knows his stuff ! From Wikipedia

5052 aluminium alloy - 5052 is an aluminium alloy, primarily alloyed with magnesium and chromium. It has good workability (can be bent easily), medium static strength, high fatigue strength, good weldability, and very good corrosion resistance, especially in marine atmospheres.

6061 aluminium alloy - 6061 is a precipitation hardening aluminium alloy, containing magnesium and silicon as its major alloying elements. It has good mechanical properties and exhibits good weldability. It is one of the most common alloys of aluminium for general purpose use. It is commonly available in pre-tempered grades such as 6061-O (annealed) and tempered grades such as 6061-T6.