Aluminum sheet bending is an important process in the production and processing of aluminum sheets and represents a job with a high level of technical skill. Bending aluminum sheets is a standard process for any shaped aluminum sheet, unless otherwise specified by the customer. Bending conventional aluminum sheets is relatively straightforward, but bending curved aluminum sheets increases the difficulty significantly, sometimes doubling or even tripling it. This process is crucial for ensuring the overall accuracy of the aluminum sheet and must be carried out with extreme precision and accuracy.
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Conventional aluminum sheet thicknesses typically range from 1.5mm to 3.0mm, with most falling between 1.5mm to 2.0mm. Prior to bending, suitable molds must be selected and adjusted for positioning. Additionally, protective film should be applied to the grooves of the bending machine to prevent damage to the aluminum sheet during the bending process.
The standard process for bending aluminum sheets involves several steps:
1. Carefully review the aluminum sheet processing drawings and requirements to determine the bending sequence before proceeding with the bending process. Adjustments to the machine settings should be made based on the size of the internal angles to ensure that the products meet the required dimensions and quality standards.
2. Special precautions should be taken for unique situations, such as bending large-shaped aluminum sheets, which may require supporting the workpiece during bending to prevent the bending moment from causing damage to the sheet. Extra attention should also be given when bending punched, carved, or hollow aluminum sheets, as mishandling can result in cracking.
Bending serves several purposes:
1. Increasing rigidity: Bending creates an "L" structure that enhances the rigidity of the aluminum sheet. This is akin to folding a piece of paper, which prevents it from bending easily afterward.
2. Aesthetics: Aluminum sheets without bending often lack visual appeal. Bending the edges of the sheet adds height and a sense of sophistication.
3. Installation considerations: Bending creates connection points for installing aluminum sheets on wall studs or ceiling supports, ensuring that connection components are not exposed on the surface.
4. Joining: When connecting two aluminum sheets, whether with seams or flush, the edges are often bent to facilitate a seamless connection. This ensures a smooth surface when assembling the sheets.
When bending aluminum sheets, attention should be paid to four key details:
1. Operator proficiency: Operators must be highly skilled in machine operation and undergo specialized training before performing bending tasks to ensure safety.
2. Edge size: The minimum edge size must consider the dimensions of the bending machine's jaws. If the edge is too small, the jaws may not be able to grip the aluminum sheet properly for bending. The commonly accepted minimum edge size for bending equipment is 9.5mm.
3. Length of the edge: The bending machine's typical size limits the length of aluminum sheets to 6m. If longer sheets are required, grooving and manual bending techniques may be employed. However, precise calculations are necessary when employing these methods.
4. Edge radii: During bending, the inside of the aluminum sheet is compressed, while the outside is stretched, resulting in unequal radii on both sides. The radius of the edge is typically equal to the thickness of the sheet. Actual dimensions may vary slightly due to equipment, processes, and the skill level of technicians.
After bending aluminum sheets, attention should be paid to the following:
1. Handle the bent aluminum sheets with care to avoid collisions or scratches, and place them on carts according to designated areas for subsequent processes.
2. Conduct a thorough inspection to ensure that the bent aluminum sheets are free from noticeable scratches or abrasions, with the angle error within specifications and the bending height error controlled within 0.5mm.
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Company: Foshan Qi Aluminum Decorative Materials Co.,Ltd
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Aluminum is a very popular metal for industrial use because of its light weight, strength and durability. Whether you&#;re a fabricator, engineer, or simply an industrial mechanics enthusiast, you&#;ll likely need to bend aluminum at one time or another to get the right parts for your project.
Bending aluminum can be a complex process that requires considerable expertise and experience to get accurate, quality results.
In this article, the experts at our industrial machining company walk you through different techniques for bending aluminum, as well as the benefits of each method.
Metal bending, including aluminum bending, can be done in many different ways, depending on the specific needs of a project. Let&#;s look at some of the most common aluminum bending techniques.
Press bending is a technique that uses a bending press to shape aluminum into a desired form. The bending press is equipped with a folding tool, also called a die, which is designed to bend the metal into a specific shape. The die is placed on the press, and the aluminum is placed underneath it. When the press is activated, the punch moves downward, bending the aluminum into the desired shape.
This technique is ideal for projects requiring right angles and simple shapes. It is also suitable for projects that require high volumes of production, as it allows for the efficient and rapid bending of large quantities of aluminum.
One of the advantages of press folding is its precision. Dies are made to exacting specifications, ensuring accurate and consistent results every time. Additionally, the press can be equipped with a bending force measurement system, which allows for the control for the pressure applied to the aluminum to avoid any deformation or damage.
Sheet metal bending uses a machine called a &#;sheet metal brake&#; to bend sheet metal or aluminum into precise angles. The sheet metal brake is equipped with two parallel beams, also known as &#;bending edges,&#; that bend towards each other to form an angle and bend the desired material.
This technique is suitable for projects that require more complex angles and precise shapes, such as rounded or tapered shapes. It is also ideal for projects that require repetitive shapes, as the sheet metal brake can be programmed to repeat identical shapes on each cycle.
One of the advantages of sheet metal bending is its precision. Additionally, this technique can be used to bend large sheets of aluminum, making it an ideal option for projects requiring high volumes of production.
Coil bending uses a machine called a &#;sheet metal roller,&#; which is equipped with a cylinder that rotates to bend aluminum into curved and circular shapes. The cylinder can be adjusted to create tighter or looser curves, and some models of sheet metal rollers are equipped with a measurement system to ensure optimal precision.
This technique is particularly relevant for projects requiring curved or circular shapes, such as round boxes or pipes. It is also optimal for projects involving repetitive shapes, as the sheet metal roller can be programmed by a conventional machinist to reproduce identical shapes on each cycle.
The plate rolling technique uses a machine called a &#;rolling machine&#; that is equipped with two or three cylinders. The cylinders rotate at different speeds, allowing the aluminum to be bent into a cylindrical or conical shape. The rolling machines can be manual or automated, depending on the required production volume.
Like the previous technique, this method is suitable for projects requiring cylindrical or conical shapes, such as tubes, air ducts, chimneys, or tanks. It is also optimal for projects involving mass production.
Additionally, this technique can be used to bend aluminum sheets of different thicknesses, making it an ideal option for projects requiring varied dimensions.
Hand folding is an ancient technique that is often used for projects requiring a complex and unique shape that cannot be achieved with automated folding techniques. This technique is also ideal for projects requiring a low volume of production or unique pieces.
Hand folding requires considerable technical skill and experience to achieve accurate and high-quality results. Our machine maintenance experts are capable of accurately measuring the angles and dimensions of a piece, as well as handling the aluminum with care to avoid creases, cracks, or deformations.
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