Aluminum Tubing Issues

[MClarkCT]

Hey Guys New Here, Trying to bend Some Tube and there is a constant failure rate happening.

Machine : BLM_Elect80
Tooling: Bend Die 3"CLR
Material :
AL - 6061 T1 OD 2" &1/2" // ID 2.37" // WT .065 Seamless Round
AL - 6063 T52 OD 2" &1/2" // ID 2.37" // WT .065 Seamless Round
AL - 5052 T0 OD 2" &1/2" // ID 2.37" // WT .065 Seamless Round


With the 6061 It was first Ordered as T6, this was to Brittle to Bend, So It snapped on first bend. Then brought down to a T1. This Process Caused the tube to Oval. Wouldn't fit on the Mandrel and thus also Caused it to Snap.

With the 6063 T52 It showed up Oval and Had Varying Wall thickness. This material was set aside , Some of it was Oval Enough to Try and out of 10 bends only two worked.

With the 5052-0 It Appears it's as well To soft or To Brittle.
It snapped on first bend as well.

Can anyone lend any Ideas to how I may fix these issues?
I have already Changed the Pressures from the bender etc...

We are Leaning towards using the 6063 T52.
Wondering If a Heating Process Before Bending is suggested or anything else?

Thank you in Advance!!!

 

[MClarkCT]

This is in the Wrong Location , Can a Mod please more it to Materials?

 

[cloa]

Seems an entirely appropriate location- its a metals posting.
Materials is for posts that don't fit anywhere else like choice between materials.

 

[cloa]

If you are still keen for it to be in Materials Forum,
Click the Inappropriate post? button and make a new post in the Materials Forum yourself.

 

[MClarkCT]

We can leave it here , I'm not up to par with how the layout of this forum is I thought it went into another section.

Anyone have any Ideas?

 

[MClarkCT]

Bump.

 

[1gibson]

Heat it up a little first?

 

[MClarkCT]

That is a thought both myself and the company owner have thought of, We how ever if we can want to steer clear of that process. He Is Currently Looking for a Oven that will fit our warehouse / needs.

 

[Compositepro]

Bending 2.5" tubing to a 3" center line radius requires over 40% stretch and compression of the outer and inner fibers. That will require a ductile alloy and suitable tooling. Check the aluminum alloy properties for a suitable strain capability.

 

[berkshire]

If you have heat treat capability you could try heating and quenching the tube and trying to bend in the Aq or w temper.
On as sharp a bend as that, you may have to have a couple of goes at it. You could also try loading the tube with Cerrobend.
B.E.

The good engineer does not need to memorize every formula; he just needs to know where he can find them when he needs them. Old professor

 

[boo1]

tough bend:

With the AL try 5052 H34

Look at

http://www.woolfaircraft.com/methods.html

http://www.hossfeldbender.com/video-tutorials/

consider sand packing or heating?

 

[boo1]

also

 

[MClarkCT]

Again , This is a Mandrel Machine, Sand Packing or packing of any kind if out of the Question.

I'm working with some companies to get a hold of some 3003 H14, and some 6063 T52 .071

One of them is actually bending up some of our crazy bends so they can suggest a Grade of Aluminum.

 

[berkshire]

Since I do not know what the end use is. Can you talk to your customer about increasing the inside radius of the bend?

I am presuming you have already played with the mandril withdrawal speeds and distances.
If you can generate an oval tube. have you looked at getting a finished part by using a string of balls on a cable?
B.E.

The good engineer does not need to memorize every formula; he just needs to know where he can find them when he needs them. Old professor

 

[MClarkCT]

We are the Customer this is for in house manufacturing, and all we have is this Radius. All the Aluminum we Will bend is for Engine Front Mount / Intake kits.

Today after we bend up some Stainless we are going to mess with the Position of the Mandrel and see what else we can play with. Were going to attempt to heat up the bending sections as well before bending and see how that goes.

 

[ornerynorsk]

That's a very tight radius with a very thin wall for that kind of OD. Are you using a wiper die?

It is better to have enough ideas for some of them to be wrong, than to be always right by having no ideas at all.

 

[MClarkCT]

yes there is a wiper, Were looking into getting a Delring wiper. It's supposed to aid the bend / pull better then the current material.