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

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

More than 8" by the amount of the thicknesses of the two legs and part
of whatever radius is in the corners.

Also 6061-T6 might crack. Use T0 or T4, i's "softer".

RR

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

You need to search on bending allowance. I archived this from this NG a
long time ago:

For 90 deg bends in cold rolled steel the following works well for me:- L=
(0.71xT)+(1.57xR) Where L=length of stock for each bend. T=material thickness
R= inside radius of bend. For hot rolled substitute (0.64xT) for (0.71xT) The
eight times rule is that a vee width of eight times material thickness will
give you an inside bend radius equal to the material thickness.

I would be somewhat concerned about cracking on T6 heat treated 6061. Maybe
you should anneal the material in the bend areas?

Grant

wrote: 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?
^^^^^^^^^^^^^^^^^^^
Yes. Do a few test strips. That's not "waste." That's *planning.*

On Thu, 24 Jul 2008 07:09:02 -0700 (PDT), 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

Take a look at these these resourses.

http://neme-s.org/dave_bono.htm

http://neme-s.org/images/PDF%20Files/bending.pdf



Errol Groff

Instructor, Machine Tool Department
H.H. Ellis Technical High School
Danielson, CT

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

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.

Jim Wilkins wrote:

5052 bends better.

And 2024 is a royal pain, even if you anneal it, it will still
break sometimes. I prefer 3003 and 5052 for jobs that need
bending. But, these alloys are a lot softer than 6061, so that
can be a problem.

Jon

Jon Elson fired this volley in
:

Jim Wilkins wrote:

5052 bends better.

And 2024 is a royal pain, even if you anneal it, it will still
break sometimes. I prefer 3003 and 5052 for jobs that need
bending. But, these alloys are a lot softer than 6061, so that
can be a problem.


Alclad is tough stuff, but a set of radiusing noses will help a hunk.

LLoyd