On Jul 24, 1:29*pm, Jon Elson wrote:
wrote:
I need to bend some 6061T6 .040 aluminum that is a U shape, 8" wide
with 2" legs. I wanted to know if I mark exactly the 8" and make the
bend will the radius cause the overall width to be less or more than
the 8". I dont want to waste material by trying to bend 8" width and
then the overall width is either 7 7/8" or 8 1/8", any suggestions?
Thanks,
Mike

Have you done a test bend on a piece of scrap from the same batch? *It
probably will bend OK if you leave the brake clamp back a bit to make a
wider bend. *If the test DOES crack, you need to wipe soap on the bend
line and heat with a torch until the soap turns brown, then quench in
lots of water while still hot. *This anneals the aluminum at the bend
region, and should allow much easier bending without cracking.

Others have answered the bend allowance part of your question.

Jon

Another way is to cut and bend a narrow strip and pad the clamp jaw
with it to increase the bend radius. This usually works with 0.062"
6061-T6 in either direction (yes, it has a grain).

5052 bends better.