How to bend an aluminum profile

Aluminum profile bending

Bent aluminum profiles are in demand in many industries, because they are lightweight, durable and easy to install on various surfaces. Bending metal structures, including aluminum profiles, requires compliance with high quality production and standards. Our company operates in accordance with GOST 18970-84 (Metal forming), GOST 17365-71 (in the part “Minimum pipe bending radii”).

On our three-roll roll forming machine we bend window, door and mullion-transom systems made of aluminum alloys. We also carry out bending of special profiles, bending for fire protection systems and bending of frames for suspended ceilings. We also perform bending according to customer drawings.

We bend profiles from various metals:

- aluminum;
- black metal;
- stainless steel;
— galvanized metal;
- brass;
- copper

Working on a three-roll profile bending machine allows you to bend frames, imposts, sashes from aluminum profiles along the radius of both cold and warm series.

Bending aluminum profiles of window and door systems for the manufacture of frame and stained glass structures, as well as for entrance lobbies and internal and external doors.

Bending directions

Bending along the frame radius

Bending along the radius of the impost

Bending along the radius of the sash

Bending along the radius of spar

Bending of post-transom systems

On our three-roll profile bending machine we bend post-transom systems made of aluminum profiles with a bending radius both constant and variable.

This type of system is the most common among all facade glazing systems, these are mullions, crossbars, decorative covers, clamps

Bending for fire protection systems

Bending of steel profiles for fire protection systems is used in the manufacture of window and door structures when it is necessary to ensure the fire resistance of the room.

Our equipment and work experience allows us to carry out bending for fire protection systems in accordance with all fire safety requirements.

Bending of special profiles

Possessing high-tech bending equipment and a team of experienced specialists, we offer our customers services for rolling metal products along radii of varying complexity and geometry.

By contacting us for flexible non-standard profiles with an individual cross-section, you will receive a guaranteed high result.

Frame bending for suspended ceilings

Manufacturing a frame for suspended ceilings is one of the popular aluminum profile bending services. We work with profiles designed for fastening stretch ceilings, both European and domestic manufacturers.

Bending according to customer drawings

Working with profiles of non-standard sections requires the design and production of an individual technological chain. Our experience usually gives positive results.

Source: https://profgibteh.com/gibka-alyuminievogo-profilya/

How to bend an aluminum profile with your own hands

Add to bookmarksPrint version

Almost every owner has a situation when it is necessary to change the bend of a metal rod to install a greenhouse or install a sewer system. Since it is quite easy to bend a profile pipe at home with your own hands, you do not need to involve specialists for this work.

How to bend a profile pipe at home without a pipe bender

The average homeowner rarely has special equipment available. Therefore, you need to know how to correctly bend an aluminum or steel pipe yourself for a greenhouse, canopy (canopy) and other needs without a pipe bender.

Photo - pipe bending without a pipe bender

It is very convenient to carry out this work using a welding inverter and a household grinder. To begin with, a drawing is developed, from which the required angle will be drawn and calculated in the future. The diagram must accurately measure the rounding.

Step-by-step instructions from an expert on how to bend pipes using a vice, grinder and welding machine:

If you plan to bend the corrugated pipe in a semicircle, then at the site of the intended bend, several thin cuts are made using a grinder;
You can do the work yourself only if you first fix the reinforcement in a clamping vice. When the cuts are made and cleared of chips, you need to carefully begin to bend the pipe;
After the ring is closed, you need to weld the holes that were formed as a result of bending with a welding machine. Some craftsmen use simple soldering irons if the communication has a small diameter;
In order for the bend area to be neat, it will need to be additionally sanded and coated with a protective agent - this will help prevent corrosion or premature failure of the joint.

You can bend the pipe evenly using a spring that fits the size of the profile section:

Communication is locked in a vice;
A spring of the appropriate diameter is inserted into the hole. This will prevent the profile pipe from breaking or taking on an incorrect shape when bent;
To make the work easier, you need to heat the joint and carefully manually bend the communication to the required diameter;
Various metal products suitable for the slope, say, angle grinders, arches, etc., are very helpful here.

In a similar way, you can try to deform communication using sand . How to properly bend a canopy pipe without using a vice or springs:

You need to stop one end of the tube by closing it with a wooden wedge or any other plug;
The closed end of the pipe is fixed in the ground or in a vice (if possible). You can also use any other device that allows you to establish communication;
After this, you need to pour sand into the open end and heat the blowtorch;
The heated lamp needs to be held over the future bend, and then carefully bend the pipe into the desired shape. It is necessary to work quite quickly, because the metal, after it has cooled, will be unsuitable for processing.

training on how to bend a 20 mm pipe without a pipe bender using sand

After bending, it is necessary to leave the pipe in a fixed position for some time - this will help the material consolidate its new shape. If the work is carried out in winter, then the craftsmen expose it even to the cold.

Arch (canopy) without pipe bender

As you know, for a canopy, for example, in the shape of an arch, you need a curved profile pipe. It is important to make sure that the arcs are equally curved, otherwise the canopy will not work. Now we will look at how to do this without using a machine, pipe bender and other aids of this kind.

We will need:

The support on which we will work, for example, a metal table;
As a beam, you can take a pipe 80 by 60 or 50 by 50 mm, 3 meters long. But this method is universal - so it doesn’t matter what kind of support beam you end up with;
A profile pipe 20 by 20 or 20 by 40 mm, which we will bend.

Procedure (step by step instructions):

We divide the support into 6 equal parts. It is very important here - exactly into 6 parts, regardless of how long it is;
At the dividing lines, it is necessary to weld the posts strictly at 90 degrees to the beam. The middle post is 250 mm, the closest to the middle one is 250 mm * 0.8888 = 222.22 mm, and the outermost (smallest post) is 250 mm * 0.5556 = 138.9 mm;
welded posts to the beam
We fix the beam itself to a metal table;
We take the pipe that we will bend, place it on the racks and move it relative to the beam with an allowance of 10-15 cm, so that there is a lever that we can grab and bend it around the racks;
We tie it to the beam with a rope (fix it);
put the profile pipe on the posts and tied it with a rope to the beam
Next, we carefully bend the pipe around the posts and weld it to the ends of the beam with a welding machine.
This is how we get a bent pipe for a canopy
Next, make the required number of such structures (arches), use polycarbonate sheets and your arched canopy is ready!

Important note from an expert:
The length of the posts is the whole secret of bending corrugated pipes into an arch for your canopy. The lengths of the two posts are determined from the length of the middle post (ours is 250 mm - you can take a different length, but no more than 250 mm - otherwise the pipe may break when bent). Coefficients 0.8888 and 0.5556 are valid for any length of support and central post.

Source: https://evroterm32.com/kak-sognut-alyuminievyy-profil-svoimi-rukami/

How to bend an aluminum pipe at home - choosing a method and equipment

Aluminum products are currently very diverse and in demand, which indicates that this material is effective and indispensable in many areas of life. One of the most popular types of products of this type is aluminum pipe.

Features of aluminum pipes

Aluminum pipes are distinguished by their low weight, ductility, resistance to corrosion, chemical and temperature influences (able to withstand temperature fluctuations from +150 to -279 degrees).

In addition, these products have high electrical and thermal conductivity, do not contain harmful toxins and can last for a long time. You can make a variety of designs from aluminum tubes with your own hands.

Aluminum pipes are classified according to the following parameters:

Section shape. They can be round, square, rectangular and shaped.
Manufacturing method. They are cold-deformed, pressed and welded.
Length. Measured, unmeasured, having multiple dimensions and coil packaging.
Chemical composition (grade AI). May be of high or technical purity.

To make the alloy more durable, certain impurities are added to it; however, the degree of its ductility decreases. The plasticity of aluminum products makes them more convenient for machining. Bending an aluminum pipe is very simple and can be done independently. To achieve the integrity and safety of the bent product, it is important to familiarize yourself with the technology of this process in advance.

How to bend an aluminum pipe

By bending a straight aluminum pipe at any angle, we thereby deform the structure of the metal. The inner layer of the profile is compressed and the outer layer is stretched. Aluminum is characterized by a fairly low degree of density, therefore, as a result of bending, these products are injured quite slightly. As for alloyed aluminum, due to its greater density, the procedure for bending pipes made from it is more complex.

Due to their flexibility, aluminum pipes are well suited for the manufacture of the most intricate structures, while maintaining their cross-section and integrity. Such products can be bent manually, for which simple mechanisms or specialized devices are used. The workpiece can warm up or remain cold. Typically, this factor is influenced by the size, type and structure of the pipe being bent, the thickness of its walls and the complexity of the chosen configuration.

Bending of aluminum pipes in one plane can take the form of bends, staples, ducks and rolls. Blanks with two bends of 135 degrees are called weft, three bends are called staples (the central angle parameter is 90 degrees, the extreme angle is 135 degrees). A bend in the form of a semicircle is called a roll, and a bend of 45-135 degrees is called a bend.

When bending, it is important to adhere to the following recommendations:

If an aluminum pipe has a weld during bending, it should not fall on either a concave or convex bend line, perpendicular to the deformed surface.
On products with a diameter of 15-20 mm, when choosing the bend radius, the outer diameter is taken as a guide, which is doubled.
Workpieces with a diameter of more than 25 mm are equipped with a bend radius equal to the outer diameter multiplied by 3.

Regardless of the bending option chosen, the main task is to prevent any defects from appearing during the bending process. When solving the problem of how to bend an aluminum pipe at home, it is important to understand that in this case everything depends on the correct choice of method and tool, as well as compliance with safety rules.

How to use a pipe bender at home

Pipe benders are special mechanisms that are characterized by different operating principles. With their help, manual and mechanical bending of profile and round pipes is carried out in production conditions or at home.

There are the following types of manual pipe benders suitable for bending plastic thin-walled aluminum products with a small diameter:

Lever . This mechanism is also called the Volnov machine. It has a special form for inserting the workpiece. The bending process itself does not require heating the pipe, and is carried out by lever force. The shape corresponds to a specific diameter.
Crossbow . The structure in which the workpiece is secured is equipped with a bending segment that pushes through the middle of the pipe on the side opposite to the ends.
Spring-loaded . Before bending, the pipe is equipped with a spring, which is placed inside the product. Next, the workpiece can be heated, or a cold bending method can be used. At the end of the procedure, the spring must be removed.

With the help of machine bending, it is possible to solve the problem of how to bend and how to straighten an aluminum tube of various diameters and shapes. The risk of damage is reduced to almost zero.

These mechanisms can have an electromechanical or hydraulic operating principle, which guarantees an accurate result of the work in accordance with the requirements. There are also ways to bend a pipe without a pipe bender, which is very convenient when you don’t have the necessary tool at hand.

Bending methods

The following bending methods can be used in this equipment:

Pushing . In this case, the aluminum pipe is pushed between the rollers of the machine: one of the rollers is assigned the task of deflecting the workpiece. In this way, an arcuate bend is achieved with a very small radius of curvature. The bend radius is determined by multiplying the pipe diameter by 6.
Rental _ An aluminum pipe with a diameter of 10 to 100 mm is rolled through bending rollers, which must strictly correspond to the diameter of the pipe being bent. To carry out this operation, a three-roll pipe bender is used, which is capable of bending in the form of a ring, spiral and arc. It can be used to process both round and rectangular profiles. Rolling is carried out in several passes.
Rolling in . For bending, the rolling head of a pipe bender is used, which bends the workpiece under pressure. In areas without pressure, the pipe bends in the opposite direction. Rolling in is not accompanied by heating. To prevent the workpiece from shrinking, you need to ensure that the minimum bend radius is observed: it is equal to the radius of the pipe multiplied by three.
Pressure bending . Here, for pressing, stamps are used that deform the workpiece from the outside, or hydroforming, when the pipe is filled with water or oil under pressure to bend it from the inside within the boundaries of the mold.

DIY aluminum pipe bending

First, determine what brand of pipe, diameter and wall thickness needs to be bent. If such a procedure needs to be carried out from time to time, then it is better to immediately acquire a manual pipe bender; fortunately, there is a huge selection of different models of this device on sale.

In addition, there are other methods of bending pipes at home, especially when it comes to one-time events:

Before bending an aluminum pipe at home, dry, fine, sifted sand is hammered into it. It is necessary to put plugs in the form of chops on the ends of the workpiece, after which the workpiece is slowly bent. This can even be done manually, but for convenience it is better to secure one end with a clamp. After the workpiece is bent, sand is poured from it: it is necessary to maintain the round shape of the pipe. If the work is carried out in winter, instead of sand, you can use water frozen inside. At the end of the procedure, the part is placed in warm conditions to thaw the ice.
If you need to bend a pipe with a low level of ductility (made of duralumin), then when using the sand method, you will also need a gas burner. In this case, one end of the pipe is clamped in a vice, and the burner serves to uniformly heat the bending area to a temperature of +250 degrees. To check the optimal heating, a piece of paper is brought to the pipe: the appearance of smoke will be a sign that the product is ready for subsequent bending. When carrying out it, it is important not to rush. Repeated heating of the same section of pipe is unacceptable.
In this case, first a semicircular template is made from wood, the thickness of which should exceed the diameter of the workpiece. Having told him the required bending radius, the workpiece is secured to the plane using clamps and bolts. A board of identical thickness and slope is attached close to the template: it is important to achieve a good density of laying the pipe between them. Having laid one end of the pipe to the guide board tangentially relative to the semicircle, with its other end you need to carry out bending movements around the template. In this way, plastic pipes with a diameter of up to 40 mm can be bent to quite significant radii.
After sand is poured into the pipe, it is placed at both ends on two stable supports: the bend should sag. This area is given the required radius using a rubber mallet. It is especially convenient to bend square aluminum pipes in this way.
The area of the workpiece where bending is carried out is equipped from the inside with a steel spring: a wire is tied to its end. After the pipe has acquired the desired shape, the spring is pulled out by this wire. If necessary, the bending area can be warmed up.

THIS IS INTERESTING: Why aluminum does not rust

When carrying out such operations, it is important to remember that bending leads to a change in the length of the pipe, so the required length of the section is set after bending it. In general, it is quite possible to bend an aluminum pipe at home, the main thing is to choose the right tool for this and strictly follow the recommendations.

Source: https://trubaspec.com/montazh-i-remont/kak-sognut-alyuminievuyu-trubu-v-domashnikh-usloviyakh-vybor-sposoba-i-oborudovaniya.html

How to bend an aluminum profile with your own hands - Metalworker's Guide

Add to bookmarksPrint version

Now let's look at how to bend a pipe using a pipe bender

There are two types of pipes:

Profile;
Round section.

Depending on your needs, you need to choose a specific option, but you should remember that working with round reinforcements is much easier than with square ones. The fact is that when bent, the corners can bend or flatten, and there is a high probability of cracks appearing.

Photo – Greenhouse made of profile pipes

To bend a profile pipe at home, you need to use a special device - a pipe bender or profile bender. Their feature is the ability to install communication into the device and fix it in a certain position. Due to the pressure that is applied equally to both the external and internal corners, an even bend is formed without sharp changes and cracks.

Photo – mechanical profile bender

There are two types of roll forming equipment :

Manual;
Professional automatic.

The first are a fairly simple device, which consists of a working surface (table) and a number of rollers. Due to the movement of the rollers, the pipe moves along the work table and changes its angle without distorting the desired semicircle.

Professional devices are more convenient to use, but their cost often exceeds 20,000 rubles. They are used for complex work, most often required for the production of complex decorative metal elements.

The advantages of the model include the ideal radius, which will be accurate literally to the tenth. Of course, it is more convenient to work using a machine, but at home it is practically not needed, because...

Designed for processing a large number of pipes per shift.

Photo – manual pipe bender

How to bend a profile pipe for a greenhouse

on this topic:

Let's figure out how to bend pipes for a greenhouse with your own hands at home

How to bend a square pipe

: bend metal profile with square section

Bend the profile rectangular pipe 90 degrees

The advantage of using a pipe bender is that you can very easily and quickly bend a pipe at 90 degrees. Let's see in the video below how to do it correctly:

Source: https://ssk2121.com/kak-sognut-alyuminievyy-profil-svoimi-rukami/

How to bend an aluminum corner?

Today, many DIYers use aluminum for almost everything. Its characteristics allow it to be used without any problems for furniture, for creating garage accessories, etc.

Tsvetprokat aluminum corner offers to purchase on the most favorable terms. This publication will describe various techniques that will make it possible to bend aluminum without damaging it. If you start bending an aluminum part mechanically, cracks may appear in the metal and the part will simply break at the bending point.

Using a homemade rolling machine

A homemade machine can be made from everything you have at hand:

Everything, of course, depends on the dimensions of the aluminum profile itself, as well as on the required bending radius. Such homemade machines allow you to achieve very positive results, in principle, without heating the part.

Success is achieved through gradual, slow bending over a large area. As a result, local stresses do not arise in the metal. You can be sure that cracks will not appear.

However, there is an easier way. All you need is a gas burner and large pieces of wood. Initially, it should be noted that you will not get the expected result the first time. To understand the technique, it is recommended to practice cutting the profile.

Profile bending with a gas torch

Using a gas torch, it is necessary to heat the aluminum profile exactly at the bending point and next to it. The main heat of the flame should be concentrated at the point of bending.

After the required temperature has been reached and the profile has become noticeably more plastic, a steel metal pipe of suitable diameter is applied to the bending metal. Strictly speaking, its outer diameter will be equal to the bending diameter of the aluminum profile.

It is necessary to work with thick gloves, as the metal becomes very hot. Leaning the pipe against the profile, we begin to carefully bend it. Apply jerky, soft movements (you don’t have to constantly pull the profile to bend).

We watch the place of bending. If we see a change in color, continue heating with a gas burner. The final result will be achieved much faster than using homemade rolling machines.

The video demonstrates how you can bend an aluminum profile at home:

Source: http://domkrat.org/kak-sognut-alyuminievyiy-ugolok/

How to bend an aluminum tire

At first glance, there is no more convenient material than aluminum sheet for creating a wide variety of shapes with your own hands. Aluminum is easy to bend, and if you need to heat it up, its melting point is not very high. But it's not that simple. In practice, bending an aluminum sheet has certain specifics both in the bending process itself and in maintaining the integrity of the sheet material at the point of deformation.

What's special about aluminum bending

There are mainly two methods of bending aluminum sheet material:

air or free,
calibration

The free method is when there is an air gap between the punch and the sheet of metal. This method is the most widely used today.

If during the bending process there is no air gap between the punch and the walls of the mold and the aluminum sheet is tightly compressed, then this method is called calibration. This technique is quite old and is used for the softest materials or for the manufacture of complex shapes of products.

Bending aluminum using the free method has a number of advantages compared to the calibration method, namely:

a higher degree of flexibility, so without replacing the punch and mold, you can obtain different bending angles of the sheet profile;
less effort is required to effect deformation;
You can bend sheets of greater thickness;
comparatively lower cost of equipment.

The disadvantages of the free method include:

low accuracy of angles when bending for thin-walled metal sheets;
the accuracy of the repetition of the shape depends on the physical properties of the material;
poor applicability for operations with complex configurations.

Which brands can be bent and which cannot?

First, let's determine what types of rolled aluminum are produced in production.

Thus, we can distinguish several main types of rolled aluminum sheets, which can differ significantly from each other in their physical properties and deformation capabilities. So, the most common types:

Annealed , has the letter M in its designation, is the softest grade, therefore it is perfectly amenable to deformation, but at the same time easily wrinkles and breaks when overextended.
Semi-hardened is designated as H2 and has more rigid properties than grade M; it also deforms well and is able to withstand bending over 90 degrees at a time. At the same time, due to its increased rigidity, it retains its shape well and prevents the formation of dents, therefore it is most often used as a facing material.
Cold-worked , the grade designation contains one letter H. Cold-working is a method of imparting increased strength to sheet metal using cold compaction. To do this, the aluminum sheet is additionally rolled between two shafts on a special machine. This variety bends well at angles up to 90 degrees and is able to withstand significant loads on its surface.
Hardened or naturally aged, as a rule, is marked with the letter T. It is a fairly hard rolled aluminum product, so it is more demanding when processing, since when cold bent at 90 degrees, it cracks at the bend. Used for the manufacture of parts and assemblies operating under increased load.

The main types of rolled aluminum alloys produced can be arranged as follows:

Technical alloys of grades 1105 and VD1 have a relatively low specific weight of the sheet and are easily bent without any problems.
Aluminum-magnesium alloys are marked with the letters AMG. They are made from aluminum alloyed with the addition of magnesium and manganese. The AMG brand has acid-resistant properties and bends well, so it is mainly used for the production of containers and tanks, as well as parts for boats and boats.
Food alloys of grades A5 and AD are produced in cold-worked, semi-hardened or annealed grades.
AMC alloys with increased ductility are specially designed for the manufacture of complexly curved parts, such as car radiators, etc.
Duralumin is marked with the letter D. It is a high-strength grade, the main difference of which is its high resistance to external influences. Duralumin practically does not bend, therefore it is used only in the manufacture of parts by stamping.
Aviation especially strong grade B alloys are bent using a special stamping and pressing technology. They are used in the manufacture of highly loaded parts in the automotive and aircraft industries.

The properties and characteristics of the produced grades and types of rolled aluminum sheets are described in more detail in GOST 21631-76.

Bending aluminum while maintaining integrity

If for some varieties and brands the question of how to bend an aluminum sheet practically does not arise, then for duralumin alloy, as well as sheet metal with clearly hardened and rigid properties, this poses a certain difficulty, since at the point of bending it, as a rule, should burst .

Therefore, bending of sheet aluminum of composite compositions is carried out by cutting a groove at the bending site. To do this, guides are fixed on the sheet and, using a special hand-held milling tool, a groove is cut to at least 2/3 of the depth with a sweep angle of 90 to 110 degrees, which makes it possible to bend the aluminum sheet at an angle of 90 degrees without loss of integrity.

If you have experience on how to bend a rigid aluminum sheet without breaking it, then share it in the comments section.

Source: https://lubimauto.ru/kak-sognut-aljuminievuju-shinu/

How to bend an aluminum corner

(Nobody said)

Today, many home craftsmen use aluminum elements for various purposes, ranging from indoor renovation work to furniture decoration.

The aluminum corner 20x20 is in greatest demand. Let's figure out how to bend this part correctly. After all, if you try to mechanically bend it, the metal may crack, and this component will be irretrievably damaged.

Using a homemade machine for rolling metal

Such a device can be made from available material. For these purposes you can use:

Much will depend on the dimensions and dimensions of the profile itself, as well as on the radius that should be obtained after bending the material. The use of such homemade machines helps to obtain quite good results. In this case, the aluminum corner does not need to be heated.

The effect will be achieved due to the fact that you gradually and slowly bend the element, performing the operation over a large area. As a result, it is possible to avoid local stress in the aluminum alloy. And as a result, cracks will not form on such a product.

Using a gas burner

This method is the most popular among experienced craftsmen.

Please note that the first time you may not be able to bend the aluminum corner using a gas torch, you will have to get used to it a little. To do this, you can practice on some unnecessary piece of aluminum.

The process of bending an aluminum corner will look like this:

Using a gas burner, heat the aluminum profile in the area where the bend will be located. Make sure that the heat of the burner is directed specifically to this area.
As soon as you reach the required temperature and the profile becomes much more flexible, you need to attach a steel pipe that suits your diameter to this area.
Once you have placed the pipe against the aluminum angle, begin to bend it carefully. The procedure should be carried out with soft jerky movements; you should not constantly pull the profile so that it immediately bends.
Pay close attention to the fold. If its color changes, then the part needs to be heated again. Gradually you will notice how the aluminum profile bends at the angle you need.

Wear thick gloves to avoid getting burned by hot metal.

As you can see, bending an aluminum corner is not difficult if you put in a little effort and practice.

Source: http://mrokna.ru/stroit/kak-sognut-alyuminievyiy-ugolok.html

How to bend a profile with your own hands

Purchasing manual pipe benders is only advisable if you intend to bend a small amount of material.

These models cannot be used as a professional tool due to low productivity and the need to approximately adjust the bending radius of each product.

THIS IS INTERESTING: Why you can’t solder copper parts with steel solder

This machine usually comes with several replaceable rollers, through the installation of which the profile pipe is bent depending on the size of its cross-section.

To achieve the desired bending angle, it is necessary to run the pipe through the machine several times.

In this case, each time you have to manually tighten the central roller, lowering it lower and lower. The side rollers remain in a stationary position, so the metal profile bends under the pressure of the central roller.

One of the models of manual profile benders, which allows you to bend a profile pipe on your own in several runs of a metal product between the side and central rollers

When working with a manual pipe bender, a person will have to use physical effort. The equipment cannot be used for bending profile pipes whose cross-section exceeds 40 mm.

Article on the topic: Do-it-yourself profile pipe bender - examples of homemade structures

Option #2 - electric pipe benders for the pros

Unlike manual pipe benders, electric models provide highly precise pipe bending. The fact is that the bending radius is set with an accuracy of 1 degree mechanically or electronically. The use of this expensive, productive equipment allows us to process a large number of profile pipes per shift. Typically, owners of electromechanical pipe benders provide services to the public, which you should use if you are satisfied with their cost.

An electromechanical profile bender, installed permanently in the workshop, ensures precise bending of profile pipes of different sections along a strictly specified radius

The disadvantages of electric profile benders include their heavy weight and high cost, which is inaccessible to the average buyer.

Method #1 - grinder + welding machine

How to bend a profile pipe at the desired angle with your own hands, without using factory machines? If you have an angle grinder and a welding machine, then you can bend according to the following algorithm:

calculate the radius of curvature according to a pre-drawn diagram;
in the place where the pipe is supposed to bend, several transverse cuts are made with a circular saw (grinder);
holding the pipe in a vice, they begin to bend it in the desired direction, applying a little physical force;
then the cuts are welded with a welding machine, not forgetting to comply with safety requirements;

Welding seams are ground.

A circular saw or grinder mounted on a special sole is necessary to make several cuts at the bend of the profile pipe

Method #2 - blank and sand

You can bend a profile pipe along the required radius using another simple method. To do this, prepare sand, which must be sifted and dried, if necessary.

Then one end of the profile pipe is closed by driving a wooden wedge into it. Sifted sand is poured inside the profile, clogging the entrance to the pipe on the other side. After this, the product begins to be bent around a metal blank having a suitable diameter.

One end of the profile is fixed securely between the pins, and the other is pulled.

Important! To facilitate the process of bending the profile along a small radius, it is necessary to heat the deformation site with a gas burner. The poured sand ensures the integrity of the walls of the metal product during mechanical impact on the pipe.

Having completed the bending process, they begin to remove the clogged wedges by burning or knocking them out. Sand is also completely removed from the pipe cavity. As you can see, homemade methods cause more trouble, so they can be used in practice for one-time bending of pipes.

In winter, sand can be replaced with water, which is poured into a profile pipe and the product is exposed to frost. It is clear that the ends of the profile are plugged with plugs. After the liquid freezes in the pipe, they begin to bend it according to a pre-prepared blank template.

A metal blank used by craftsmen to bend profile pipes with their own hands without the use of special equipment in the form of pipe benders

Method #3 - bending pipes with a square spring

A spring having a cross-section of the same shape, but of a smaller size, prevents the walls of the profile pipe from deforming when bent. The spring is made of steel wire, the diameter of which is selected based on the thickness of the walls. The spring should easily fit inside the pipe.

The planned bend location is heated with a blowtorch or gas burner. Heated profile walls are easier to bend. To prevent burns, you must work in special protective gloves and hold the product with pliers.

A blank or metal pins driven into the ground in a circle helps to achieve the desired bending radius.

Features of different profile bending methods

There are two main methods of bending profile pipes: cold and hot. The first assumes that the bending process is carried out without preliminary temperature exposure to the part.

While the second is carried out only with a preheated pipe. It must be admitted that heating the part significantly increases its ductility and facilitates the bending process.

There are no standards strictly regulating the use of cold and hot bending methods for profile products. They are only available for pipes with a round cross-section. According to these standards, hot bending is used for parts whose diameter is 100 mm or more. For rectangular and square pipes, slightly different rules apply.

If you have a one-time job of bending a pipe, you can buy, but it is better to rent a hydraulic pipe bender with a manual drive:

Plumbers recommend cold bending only all pipes with a profile height of less than 10 mm. Products with a profile height of 40 mm and above are hot bent.

How to bend parts with a profile height from 10 to 40 mm is up to the performer to decide. To avoid mistakes, you can perform a trial bending. In general, if you have a pipe bender, you can use it to bend the pipe without any heat.

If there is no special tool, it is worth performing a trial bending of the profile pipe. To do this, one edge of the part is firmly clamped in a vice. A pipe with a diameter larger than that of the product being bent is put on the other end.

The resulting “shoulder” should be pulled strongly, bending the product. If the part bends, you can use the cold bending method. If not, bending with preheating is used.

Brief summary

As you can see, all the artisanal methods invented by craftsmen for bending profile pipes require time and effort. However, obtaining an even bend is not guaranteed one hundred percent. The quality of the metal frame directly affects the strength and beauty of the structure being erected.

Therefore, you should not neglect the services of professionals who have special equipment for bending pipes.

Buying a manual machine for bending profile pipes will allow you not to spend money on paying for third-party services. The purchase will quickly pay for itself if you start bending custom pipes yourself.

Source: https://the-master.ru/profili/kak-sognut-profil-svoimi-rukami

How to bend an aluminum pipe professionally: tips and solutions

Today, the production of aluminum products is extremely diverse and all of them are in demand. This indicates the effectiveness and indispensability of this type of material in most areas of application. Let's focus on the most popular type of aluminum product - pipes.

You can bend an aluminum pipe using different methods, with or without the help of technology.

Characteristics of aluminum pipe products

Aluminum pipe is lightweight (one-third the weight of steel), ductile, non-corrosive, resistant to chemical and temperature influences (operating temperature from +150°C to -270°C), with high electrical and thermal conductivity, environmentally friendly and durable type of product. They differ:

according to the cross-sectional shape into round, square, rectangular and shaped;
by production method into cold-deformed, pressed and welded;
along the length into measured, unmeasured, with multiple measurements, coil packaging;
by chemical composition (Al grade) for high purity and technical purity.

Information about wrought alloys with markings and characteristics of properties is presented in the table.

Table 1

Strengthening method	Wrought alloys	Brand	Impurities
Pressure	Low strength	BP 0	1050 A	Aluminum without impurity
AD 1	1230
High strength	AMts	3003	Al+Mn manganese impurities
D 12	3004
Medium-strength and highly plastic	AMg 2	5251	Al+Mg magnesium impurities
AMG 3	5754
AMG 5	5056
AMG 6	—
Temperature	Medium-strength and highly plastic	AD 31	6063	Al+Mg+Si magnesium and silicon impurities (avial)
AD 33	6061
BP 35	6082
Normal strength	D 1	2017	Al+Cu+Mg admixtures of magnesium and copper (duralumin)
D 16	2024
D 18	2117
Normal strength	1915	7005	Al+Zn+Mg impurities of magnesium and zinc
1925	—
High strength	At 95	—	Al+Zn+Mg+Cu admixtures of magnesium, copper and zinc
Heat resistant	AK 4-1	—	Al+Ni+Fe+Mg+Cu impurities of nickel, iron, magnesium, copper and zinc
1201	2219	Al+Mn+Cu admixtures of manganese and copper
For forging	AK 6	—	Al+Mg+Cu+Si impurities of magnesium, copper and silicon
AK 8	2014

Important! As the degree of impurities increases, the ductility of the alloy decreases and the strength increases.

The range of aluminum pipes includes products with different technical characteristics

Aluminum products, due to their plasticity, are malleable to any mechanical stress. It is quite easy to bend an aluminum pipe even at home, and it will remain safe and sound. It is enough just to observe some features of this operation.

What is the bending process and how to bend an aluminum pipe

When a straight aluminum pipe is bent at any angle, the metal structure is deformed, namely, the inner layer of the profile is compressed, and the outer one is stretched. Since aluminum has a fairly low density, bending causes the least damage to the product. Alloyed aluminum acquires greater density during the production process, so these brands of pipe products do not bend so easily.

Flexibility allows you to install structures of the most intricate shapes from aluminum pipes, maintaining the cross-section and integrity of the workpieces. The bending process itself occurs manually, using simple devices, or using specialized mechanisms, using heating of the workpiece or in a cold state. It all depends on the size, type and structure of the product, wall thickness, and complexity of the curved shapes.

There are 4 main types of aluminum pipe bending (one plane): bend, bracket, weft, roll. Blank with two bends at 135 degrees. - this is a duck, with three folds - this is a staple (the angle in the center is 90 degrees, at the edges 135 degrees), with a bend in a semicircle - a roll, with a bend of 45-135 degrees. - this is a withdrawal. When bending you need to follow these rules:

if the aluminum pipe has a welded seam, then it must be bent so that the seam does not pass along either a concave or convex bend line (perpendicular to the surface being bent);
if the diameter of the product is 15-20 mm, then the bend radius must be no less than the outer diameter multiplied by 2;
if the diameter of the workpiece is more than 25 mm, then the bend radius must be no less than the outer diameter multiplied by 3.

Aluminum is a very soft metal, and failure to bend properly will result in pipe rupture

Advice! Whatever bending option is chosen, the main task is to avoid cracks, breaks, flattening, and wrinkling of the concave part. This means choosing the right method and tool, following safety rules when bending at home.

How a pipe bender can help

Pipe bender is the general name for special devices with different principles of operation, used for manual or machine bending of pipes, both profile and round, both at home and in professional workshops.

Using a manual pipe bender, aluminum plastic thin-walled products with a small diameter are bent. Among them:

lever pipe bender (Volnov machine) - the workpiece is placed in a mold, where, under the influence of lever force, it bends without heating. The mold is made to a specific diameter;
crossbow pipe bender - the workpiece is fixed in a structure where the bending segment pushes the middle of the pipe in the direction opposite to the ends;
spring pipe bender - a spring of the required diameter is placed in the pipe, and after heating the workpiece, or using a cold method, bending is performed, after which the spring is removed.

Machine bending is designed to bend workpieces of various diameters and shapes with minimal risk of damage. These are electromechanical and hydraulic mechanisms that provide precise bending results according to the specified parameters. Such equipment provides the following bending methods:

pushing method - bending by pushing an aluminum pipe (Ø up to 100 mm) between the rollers of a pipe bender, where one of the rollers performs the deflection function. The bend is arc-shaped with a minimum radius of curvature (the bending radius is equal to the diameter of the pipe multiplied by 6);
rolling method - bending by rolling an aluminum pipe (Ø from 10mm to 100mm) through bending rollers, which are selected strictly to the diameter of the product being bent. This operation can be performed using a three-roll pipe bender, which performs ring, spiral, and arc bending. Can be used for both round and rectangular profiles. Rolling is done several times;
rolling method - bending by impact of the rolling head of a pipe bender. The head ball bends the pipe under pressure, and where there is no pressure, the pipe bends in the opposite direction. No heat is applied. To avoid compression of the workpiece, the minimum bending radius must be equal to 3 pipe radii ;
pressure bending method - bending by pressing with stamps (deformation from the outside) or hydroforming (deformation from the inside by supplying water or oil into a pipe under pressure, the product is bent within the boundaries of the form).

A pipe bender of even the simplest design significantly reduces the risk of damage to the workpiece during bending

How to bend an aluminum pipe at home

First you need to determine the brand of pipe, diameter and wall thickness. If you decide to bend aluminum structures at home more than once, then you cannot do without a manual pipe bender. Buying such a device now will not be difficult, there is a very large selection. It is also possible to build a basic pipe bending machine or stand.

There are also several ways to bend an aluminum pipe without a pipe bender at home. Such methods are suitable for small volumes of work.

Method 1. Fill the pipe with sifted, dry, fine sand, plug the ends with choppers, slowly bend the workpiece (you can even do it manually), securing one end into a clamp. Bend the workpiece and pour out the sand. Sand will help maintain the roundness of the cross-section, and in sub-zero temperatures it can be replaced by water that freezes in the pipe. After bending, you need to place the finished part in heat so that the ice melts.

Method 2. If the pipe is not plastic (duralumin), then we use method 1 with sand and a gas burner. Secure the pipe at one end in a vice, heat the bend area evenly (250°C). Bring a piece of paper to the heated area; if it smokes, the product is ready to be folded. Bend slowly. Repeated heating of the same area of the workpiece should not be allowed.

Method 3. Make a flat semicircular template from wood (thickness greater than the diameter of the workpiece) with the desired bend radius, secure it to the plane with clamps or bolts.

Next to the template, a board of the same thickness is attached with a slope, so that the pipe fits tightly between them. Lay the pipe with one end to the guide board tangent to the semicircle, bend its other end along the template.

This method can be used for plastic pipes of any section Ø up to 40 mm. The method is applicable for bending with a large radius.

Filling the pipe with ordinary sand allows you to bend it by hand without the risk of damaging or breaking the workpiece

Method 4. Fill the pipe with sand according to method 1, place the ends of the workpiece on two supporting, stable planes, so that the bend point is suspended. Using a rubber mallet, we form the desired bend in a place that is not adjacent to the supports. The method is well suited for square-section products.

THIS IS INTERESTING: What is the strongest metal

Method 5. Place a steel spring of a smaller diameter in the bend area of the workpiece, and tie a wire to the end of it. Bend the pipe to the desired shape and remove the spring by pulling the wire. The bend area can be heated if necessary.

Important! The length of the pipe after bending may change, so the required length of pipe should be formed after bending.

Today, at home or in specialized workshops, bending an aluminum pipe with your own hands or using a pipe bender will not cause any difficulties. The main thing is to carry out the bending process professionally, and for this you need to make the right choice of method and device, know the material and measurable data of the pipe.

Source: http://TrubaMaster.ru/sgibanie/kak-sognut-alyuminievuyu-trubu.html

How to bend a corner into a semicircle

Angle bending is a technological process for obtaining various products of given parameters and required shapes by mechanical action, including on special profile bending equipment.

The products obtained by bending a metal corner are widely used in various fields of construction. They allow you to create reliable frames and various metal structures that, despite their external lightness, can withstand significant loads.

Corner bending methods

Several basic methods are used to obtain structures of a given shape and profile from a metal corner, namely:

cold bending,
hot bending,
shaping by cutting, bending and welding the finished product.

Cold bending of a metal corner, in turn, is divided into:

free bending is when the corner is bent without the use of special equipment;
bending using a rolling mechanism on a specialized profile bending machine.

The use of cold bending of a metal corner, unlike other methods, has certain advantages, namely:

this is the least expensive method of giving metal a given shape, and does not require the use of additional equipment for heating, cutting, welding and subsequent processing of the metal;
the resulting frame has greater strength, since it eliminates possible defects characteristic of heating, cutting and welding;
finished structures are guaranteed to last longer due to the fact that the integrity of the metal profile structure is preserved during processing;
the likelihood of metal corrosion occurring over time is reduced.

Bend a corner radius

Bending a metal corner along a radius is a rather complex technological operation, since any bending is a simultaneous compression of the inner and stretching of the outer layer of metal, and, in the case of a profile in the form of a corner, such processes cannot proceed evenly, which will be accompanied by an attempt to longitudinally displace one from these layers.

Directly for a metal corner, two main methods of bending in the profile plane are used - this is when one of the shelves lies in a vertical plane, and the other in a horizontal one, and its bending will be:

inside the radius of curvature of the deformation, in which case it will be greatly compressed,
outside the radius of curvature of the deformation, accordingly, it will stretch.

Cold bending of a metal corner using the rolling method on special profile bending equipment allows you to bend both a steel corner and an aluminum profile, thereby obtaining products of almost any radius with an ideal shape.

You can see how to bend a corner along a radius with your own hands in this video.

Source: https://moreremonta.info/strojka/kak-sognut-ugolok-polukrugom/

Aluminum profile bending technology. Aluminum profile bending

ProfileBending aluminum profile

Aluminum profile bending machine: types, design, video

Aluminum profiles are widely used in the manufacture of sliding wardrobes and other structures. It can be processed during the production process. For it, benders use various settings. Unfortunately, not everyone can afford to purchase such equipment. First of all, this is due to its high cost. The only way out of this situation is to make a machine for bending aluminum profiles with your own hands.

Industrial aluminum profile bending machine

Purpose

The bending machine is widely used in the production of various materials. Thus, it is used to process pipes, aluminum profiles and other materials. In this case, the workpieces can have different cross-sections. With the help of such a device, metal rods and channels are even processed. Depending on the design features, the installation can simultaneously process the entire part or only a certain part of it.

CNC machine for bending aluminum profile

At home, homemade equipment is used to process materials. Its peculiarity is that it can bend the material without preheating. The operating principle is based on cold rolling, which significantly simplifies and speeds up the processing of parts.

Modern units allow processing materials of any complexity. So, you can easily make a spiral or a closed loop from the material. You can also adjust the bending angle. Using the unit, the workpiece is rolled at one time. All work is carried out using special rollers, which are located on the working surface according to the established pattern.

Type of designs

The machine for bending aluminum profiles of sliding wardrobes and cornices is divided into several types. Yes, they are:

Electric. Often the unit is large. Therefore, it is most often used for industrial purposes. Small home installations are no less popular. This is explained by the fact that they are used to process workpieces with a small cross-section. It is used to perform high precision bending.
Hydraulic. Used for rolling metal products on an industrial scale. It is often used in the construction of pipelines.
Manual. Widely used at home. They are often made by hand. The disadvantage is its simple design and low functionality. A manual machine is used for bending aluminum profiles of small-section wardrobes and cornices.

Manual machine for bending aluminum profiles Electric model of the machine Horizontal version of the machine for bending profiles

Despite some disadvantages, manual installations are the most acceptable option for use at home.

Therefore, it is worth taking a closer look at how to make such equipment at home.

Principle of operation

The operating principle of the device is based on the fact that the workpiece is rolled, resulting in bends. Before starting work, it is necessary to ground the equipment. This is especially true for structures equipped with an electric drive.

Before use, the rollers and workpiece are wiped with a dry cloth, and the installation itself is started and idles for half an hour. If any deviations occur during the running process, the equipment is stopped and appropriate adjustment work is performed. If this is provided for by the design features, then the rollers are adjusted.

At the initial stage, the profile is clamped between the shafts, after which it is rolled. The radius of curvature is adjusted by lowering and raising the operating shaft.

Making a device yourself

If the device will be used for bending workpieces of various sizes, then you should pay attention to professional models that have high functionality and productivity. In other cases, it is rational to use a machine made by yourself. We are talking about manual equipment here.

Before making a machine for bending an aluminum coupe profile with your own hands, you need to determine the cross-section of the parts. If the diameter of the workpiece is less than 2 cm, then a concrete slab will be needed for production. Holes are made in it for metal rods. These rods will serve as those same rollers. If the diameter of the workpiece is 2 cm or more, then the do-it-yourself bending machine has a somewhat complex design.

In this case, the unit consists of a solid base on which the rollers are fixed. The side edges of the rollers have a circular cross-section. The radius of the edge is identical to the diameter of the part that can be bent. It is passed through rollers. Its movement is carried out using a winch. After the material acquires the desired bends, the winch stops.

Assembly of the structure

The unit consists of certain components. Each unit is manufactured separately, after which the structure is assembled. First of all, the frame is assembled. Here they use a workbench or a regular table. To ensure that the machine stands firmly and reliably, it is recommended to use pipes of a specified diameter or channel to make the legs. The parts are fastened using welding or bolts.

The next step is to assemble the conveyor. The unit consists of two rollers, which are located opposite each other. Particular attention is paid here to chain sprockets. They are securely attached to the shafts. After this, a tensioning mechanism is installed, the design of which has an asterisk. It is used to regulate chain tension.

An important component is the clamping mechanism. To make it, use an ordinary clamp. After all components and parts have been manufactured, the unit is assembled.

Here the device for processing an aluminum coupe profile with your own hands can be considered ready. To avoid any problems in the process of making the unit with your own hands, you must follow the drawing exactly.

At the final stage, it is checked in operation, which makes it possible to determine the quality and accuracy of the assembly.

When performing work on the installation, do not forget about safety precautions. Careless movements can lead to situations dangerous to human health and life. This also often causes damage to parts that can be rolled. As a result, they are unsuitable for further use.

Source: https://xn-----6kcbbajywdipdcf3bggdl8bw5s.xn--p1ai/profil/gnute-profilya-alyuminievogo.html

As indicated in explanatory dictionaries and encyclopedias, bending is giving something a curved shape. In our case, bending is understood as a metalworking operation of bending workpieces from profile materials. Under the influence of a bending moment, the workpiece is deformed, its outer layers are stretched, and its inner layers are compressed.

We carry out bending using three-roll machines produced by the Swiss company Profilbiegetechnic AG, which is a generally recognized world leader in the production of bending machines.

Bending process

Bending is carried out as follows.

To avoid collapse, the profile chambers are filled with special sand, it is compacted, then the profile is inserted into rollers between two front and one central. The rollers are synchronized and rotate in one direction until the profile is rolled along the entire length of the workpiece, then in the other direction.

One profile rolling is called one pass. With each pass, the central roller approaches the front ones, due to this a bending moment arises. The force during bending can reach 30 tons. Rollers are manufactured for each type of profile.

The number of passes is set by the machine operator and adjusted during the bending process depending on the required radius and other assigned tasks.

What is technological allowance

The landing diameter of the rollers is 105 mm, the diameter of the pressing surface is 130/140 mm. The outer diameter of the rollers can reach 160/220 mm. Experience has shown that such roller parameters are optimal for radius bending of both aluminum and steel system profiles. Due to the external dimensions of the rollers, a technological allowance is formed. Because

the central roller presses in the middle of the front ones, and the profile is clamped in them, the bending moment occurs at some distance from the edge of the profile. Therefore, the bent profile has straight, unbent edges. On average, the technological allowance is 300 mm on each side or 600 mm in the workpiece.

It also depends on the dimensions of the profile section and can reach 1000 mm in the workpiece.

What is the output of straight parts

Sometimes the task is to make a smooth transition from the radius to the straight part. The task is complicated by the fact that during the bending process the profile is always deformed and excess material is driven to the edges, therefore, on the straight part, at the transition point, a thickening often appears, visible to the naked eye.

In order to eliminate this thickening, there is a special rolling operation, which allows for a smooth transition from an arc to a straight line.

When designing such parts, it should be taken into account that the output of the straight part is possible only tangent to the arc (which means the radius drawn at the transition point is perpendicular to the straight output).

What are the different bending directions?

If you draw a section of a profile, for example a crossbar, and draw the X and Y axes, then when bending for flat (arched) glazing, the bending radius will be directed to the side wall (Rx) - this is bending along the X axis; and when bending for molded (bent) glazing, the direction of the bending radius will be towards the end of the profile (Ry). These are the two most common bending directions.

When glazing domes, sometimes there is a need to bend the crossbar, which lies in the horizontal plane, but is turned to it at an angle, the bending radius will then be directed between the X and Y axes (Rxy), such bending is called two-plane.

Our company developed its own two-plane bending technology back in 2006, and is so far the only one in the Russian Federation offering such a service.

In 2015, the task arose to bend an arch from a facade profile on a radius wall. Our company was also the first in the Russian Federation to successfully cope with this task. Because As a result of bending, a spatial curve is obtained; we called this bending (X,Y,Z).

Arch types:

simple arch with one radius;
arch with several radii on one workpiece.

How bending radius is measured and controlled

The bending radius can be measured mechanically and electronically. The mechanical method is considered more reliable, but also longer. When using a mechanical measurement method, the principle described in the section “Bending calculator” is applied, i.e. according to two parameters: H (chord) and h (chord height). The role of the chord is usually played by a specially made measuring ruler, and the height of the chord can be measured with a caliper.

With what precision is bending performed?

The bending accuracy depends on the tools used, the quality of the profile and other parameters, such as the length of the arc in relation to the radius. In addition, due to poor quality material, sometimes an effect such as radius dispersion is observed, i.e. spread of radii along the entire length.

This leads to the need for careful control of the overall dimensions of the arc. There is no ideal material (profiles), and the radius is always measured with some accuracy, the main thing is that this accuracy satisfies the assigned tasks. For each bending task, you can calculate your measurement accuracy, i.e. limits of deviations.

For example, in mechanical measurements, the measurement accuracy with a caliper is up to 0.1 mm; for the measuring ruler used, the deviation limits can be calculated. They always turn out below the profiles required for processing.

When bending façade profiles in the direction for molded (bent) glazing, the manufacturing accuracy of double-glazed windows is always lower than our bending accuracy, our tests have shown this.

Source: https://MyTooling.ru/instrumenty/kak-gnut-aljuminievyj-profil