Thread: Double 45deg bends in an aluminium flat bar...??

How many do you need to make?

Ooh, only about 5 bars or so per month. Each bar is about 2-2.5m long, and will have about four of these tricky Z-bends in it, spaced evenly.

When you say 10-20mm do you mean some times 10 sometimes 20 or some where around 15 will do?
Bearing in mind I am guessing at sizes, a block like this might do the job.
If you leave 30mm of the block at the bottom flat you can do the first fold on the bed of the folder, then flip the bar over, drop it in the slot and do the second fold.

As far as keeping the bar straight you'll just need some adjustable infeed/outfeed supports.

Stuart

If you need sharp bends close to each other . You can hacksaw cut a slot halfway through the bar at the desired location , then bend it , you will have a sharp bend but you will have to tig weld fill the gap to regain the strength and file it down to make it neat . Mike

Press brake with 135-degree dies (plus springback allowance - establish by test).

Also test for consistent location of work points along the raw material.

For AL, you could probably use DIY concrete dies and ordinary hydraulic press.

Cheers,
Joe

Hi,I just tried some 25X3 using a packer behind the second Z. If you wanted to, modify one of the blocks with a slot in it to go over the second Z.
Another you could try using a V block with a type of blade that could be mounted in the vise, I think Carbatec has something similar in their catalog,
(VERITAS Metal Bender cat. 50K08-01) 2010 catalog list price $32.00
If it is to be an on going project, you could get a couple of matching "V" blocks made that put both bends in at once.
Have done this for 50X5 FMS in a 20tonne press (500 off).
Kryn

They are called a joggle. Seaching for making a joggle or bending a joggle will get you started.

Found a short You Tube video that is simple in principle and would work if you have a hydraulic press.
► 0:10► 0:10

Pete