An aluminium extrusion can be given the desired form through bending. One of the great advantages of this method is the ability to create a finished component from a single extrusion instead of joining together several parts.

Extrusions up to seven metres long can be machined using a number of different methods. The method that is used in each individual case is determined by the size of the production run, radii, force of bending and tolerances. At ProfilGruppen are we working with this methods:

Tensile bending is a method that provides great accuracy of radii and bend angle. Tensile bending is a CNC controlled process that is often suitable for medium-sized and large runs. Tooling investment is required for each extrusion section and there is often a great deal of opportunity for automation.

Roller-bending is suitable for components with large radii and which do not require precise form tolerances. The tooling investment is relatively low.

Press bending is a cost-effective method for large runs and provides good accuracy. The investments in tools is relatively high and they are dedicated to each individual extrusion. Depending on the curvature, both T4 and T6 tempered materials can be used.

Stretch bending stretches the material over the stretch limit. The method provides high accuracy. However, expensive tools and high set-up costs make the method relatively expensive.

Things to think about when choosing a bending method:

  • Minimum bend radius 3 x d
  • Seeks symmetrical profile
  • Buck operation in T4
  • Think about surface changes – “orange peel surface”