The Art and Science of Bending Aluminum Extrusions

The Art and Science of Bending Aluminum Extrusions is a comprehensive guide to the theory and practice of bending aluminum extrusions. Written by a team of experts from the Aluminum Extruders Council (AEC), the book covers everything from the basics of bending to advanced techniques such as roll bending and hydroforming.

The book is divided into three parts. Part 1 provides an overview of the bending process, including the different types of bends, the factors that affect bendability, and the equipment used for bending. Part 2 covers the theory of bending, including the mechanics of bending, the properties of aluminum alloys, and the design of bend tooling. Part 3 provides practical guidance on how to bend aluminum extrusions, including step-by-step instructions for different types of bends.

The Benefits of Bending Aluminum Extrusions

There are many benefits to bending aluminum extrusions, including:

Reduced material costs: Bending aluminum extrusions can reduce material costs by eliminating the need for additional parts or components.

Improved product performance: Bending aluminum extrusions can improve product performance by creating stronger and more durable products.

Increased design flexibility: Bending aluminum extrusions allows designers to create more complex and innovative products.

Reduced assembly time: Bending aluminum extrusions can reduce assembly time by eliminating the need for welding or other joining methods.

The Challenges of Bending Aluminum Extrusions

While bending aluminum extrusions offers many benefits, there are also some challenges that must be overcome. These challenges include:

Springback: Springback is the tendency of aluminum extrusions to return to their original shape after being bent. Springback can be controlled by using the proper bending techniques and tooling.

Wrinkling: Wrinkling is a surface defect that can occur when aluminum extrusions are bent too sharply. Wrinkling can be avoided by using the proper bending techniques and tooling.

Buckling: Buckling is a structural failure that can occur when aluminum extrusions are bent under excessive load. Buckling can be avoided by using the proper bending techniques and tooling.

The Proper Bending Techniques and Tooling

The proper bending techniques and tooling are essential for producing high-quality bends in aluminum extrusions. The following are some of the most important factors to consider when selecting bending techniques and tooling:

The type of bend: The type of bend will determine the bending technique and tooling that is used.

The material properties: The material properties of the aluminum extrusion will affect the bending technique and tooling that is used.

The desired bend radius: The desired bend radius will determine the bending technique and tooling that is used.

The equipment: The equipment that is used for bending will affect the bending technique and tooling that is used.