‘Aluminium alloy bending process: shaping elegant curves and enhancing material properties’

In the aluminum fabrication industry, and forming is a key process for manufacturing complex curved parts.It plays a vital role in the aviation, aerospace, automotive,  construction, and high-speed train industries. However, the process also faces many challenges. Today, I will share some common problems and their solutions in the Aluminum Profile Bending and forming process.

 Frequently Encountered Issues:

 Deviation in Profile Contour: Caused by factors such as mold springback, inconsistent material properties, non-uniform radius of curvature, and non-uniform cross-sectional dimensions.  

Surface Defects: Including cracks, shrinkage wrinkles, bending surface depressions, and side droop marks.

Twisting After Bending: Usually caused by profile cross-sectional area asymmetry and stress imbalance.

 Excessive Perpendicularity: Related to the asymmetry of the profile's cross-sectional area.Process Length of the Profile: Affects cost and productivity.

Production Safety: The most important consideration in industrial production.

Solutions:
Mold Adjustment: Adjust the mold to better match the desired curvature and reduce springback based on calculations and tests.
Surface Defects Correction: Fix cracks and wrinkles by redesigning the cross-section or tweaking the tension.
Bend Twist Correction: Prevent twists by increasing tension and holding the bend longer.
Correcting Perpendicularity Issues: Adjust the mold curvature to correct excessive perpendicularity caused by cross-sectional area asymmetry.
Optimizing Material Usage: Cut down on waste by calculating the optimal length for the bending process.
Enhance Safety Measures: Implement additional guards and provide comprehensive operator training to ensure safety during the stretching process.