Bending Aluminum Sheet Minimum Radius

The minimum bend radius data shown in these charts is measured to the inside of the bend.

Bending aluminum sheet minimum radius.

The minimum inside bend radius is even larger when bending with the grain. We go beyond the general rules of sheet metal bending as our customers want tight bend radii for sheet metal parts. Say you get a print that says you need to bend a part to an external angle of 100 degrees that s an internal angle of just 80 degrees. Still if you want to avoid cracking abide by the minimum bend radius in 0 25 in thick 6061 t6 which is quite large see figure 3 and avoid bending acute angles.

It is most economical to use a single bend radius throughout the design but if necessary you can utilize multiple radii. Aluminum is typically thicker and stronger and requires more force to bend as well as consideration of edge conditions and punch nose radii. Recommended minimum bend radii for steel and aluminum. To keep it simple i also use a 2 mm inside radius.

Table 1 preferred recommended 90 degree bend radii for various sheet metals. It is possible to choose other bends if you require but additional lead time and tooling charges may apply. The minimum bend radius for aluminum when working with aluminum over sheet metal several variables need to be considered. The tables below show bend radii and minimum bend sizes for materials and tooling combinations stocked by protocase.

The bend radii listed are standard minimum if manufacturing for aircraft and aerospace applications. In steel between 0 5 and 0 8 in. Radii for various thicknesses expressed in terms of thickness t. This tool allows you to determine tonnage internal radius v die opening and minimum flange you just have to insert the characteristics of the sheet metal to be bent.

Sheet metal bend radii if these guidelines are not followed more research and or some form of analysis may be requried. The tool can calculate the required bending force for bending aluminum stainless steel mild steel and weldox or strenx high strength steels. Let s say i have a 2 mm thick sheet and i want to bend it. Thick grade 350 and 400 may have a minimum bend radius of 2 5 times the material thickness when transverse bending while longitudinal bending may require a minimum bend radius that s 3 75 times the material thickness see figure 1.

I can now see that the minimum flange length is 8 5 mm for such a bend so i have to keep it in mind when designing. Discover all our calculation tools in the calculators section of the top menu. Aluminum where necessary 5052 h32 may be bent to 1t and 6061 t6 to 1 1 2t. Use this document to choose values that are both manufacturable and meet your needs.

Bend radii minimum bend sizes.