Methods and tools for bending Aluminum Tubes

Aluminum tubing is a very versatile material that can be used for a variety of purposes such as construction projects, automotive frames and energy transportation. However, in order to be these need to bend the aluminum tubes.

How to bend aluminum tubes can be tricky because aluminum is a soft metal that can be easily damaged. So, in this article, we will discuss the different methods of bending aluminum tubes and the tools needed. If you want to bend aluminum tubes, then bear with us and read on.

Bending of aluminum tubes using the cold forming method

Bending aluminum tubes or tubes with small dimensions can be achieved by cold forming methods. This bending method is also known as “cold bending” because the process does not require very high temperatures.

The tools required are:

• Fixtures and molds
• Measuring and angle gauges
• Manual or mechanical tube bender (for bending aluminum tubes with small angles and diameters)
• Hydraulic bending machines
• Lubricants or bending mandrels

 

Steps in cold forming bending:

1. Adjust the die or fixture of the tube bender according to the angle and radius of the bend required.

2. Place the aluminum tube into the bender to ensure that the tube is correctly positioned. Use the clamps to hold the aluminum tube in place to prevent it from moving during the bending process.

3. Start the bender and perform the bending operation. During the bending process, it is necessary to pay close attention to the changes in the bending angle and radius to avoid excessive bending resulting in tube deformation or rupture.

 

 

 

Here are some tips for bending aluminum tube：

Use the correct size bending mandrel. The mandrel should be the same diameter as the pipe you are bending.

Bend the pipe slowly and evenly. Do not bend the tube hard as this can cause the tube to kink or break. There may even be safety concerns.
When you use a pipe bender, use a clamp to hold the pipe in place. This will help prevent the pipe from slipping out of the bender.

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Bending aluminum tubes: using thermoforming methods

 

When you want to bend large sizes of aluminum tubing, or when you want to bend aluminum tubing to larger angles. Cold forming methods would be difficult and fail because of the soft nature of the aluminum metal. Therefore, we can take advantage of this property by heating the aluminum tube or profile to a temperature close to the deformation and then bending it. This method is capable of handling complex bends and changing the bending diameter of the tube.

 

 

This method requires these tools below:

• Flame gun for heating aluminum tubes
• Bending machines
• Clamps or tables for fixing
• Large pliers
• Thermometers
• Goniometers

 

step of bending tube：thermoforming methods

1. Heat the aluminium tube to a suitable temperature so that it softens and bends easily. The heating temperature needs to be determined according to the material and thickness of the aluminum tube.

2. Moves heated tube or aluminium section into bending machine and holds it in place using clamps.

3. The machine tool performs the bending operation. During the bending process, it is necessary to keep the tube heated evenly and control the bending speed and strength.

4. After bending, the aluminum tube is allowed to cool naturally to room temperature. Then pack it or process it further.

Note: This method requires a specialized manufacturer or engineer to complete. This is because heated aluminum tubes can be dangerous, and temperatures in excess of 800 degrees Celsius can burn everything they touch.

 

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Properties of bent aluminum tubes

We already know the two methods of bending aluminum tubing and the tools needed. So why do people want to bend them? These following characteristics about bending tubes can help you understand better.

1. Light weight and high strength

Compared with steel or copper metal, aluminum is less dense but stronger. This means that the bends are able to perform well in specific building structures. For example, roofs of houses and door frames of shopping malls that require low weight but high load-bearing capacity.

2. Excellent flexibility

Bent aluminum tubes still have excellent flexibility, and they can be further processed to obtain different shapes. For example, it can be CNC machined or welded, so it can be used as a part of a car or boat.

3. Environmentally friendly and recyclable

Aluminum metal is a completely recyclable metal, even the recycling process does not produce waste. Therefore, you will not have to worry about how to dispose of the damaged aluminum bends when you use them.

4. Excellent corrosion resistance

Aluminum tubing itself has excellent corrosion resistance, and the aluminum oxide film on its surface can resist corrosion. Even in the resistance to a variety of acidic and alkaline substances, this feature makes it a chemical raw materials transportation tube.

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Application of bent aluminum tubing:

Since aluminium tubing has so many advantages, what are its applications in our lives?

Its applications includes:

• led lamp housing
• Architectural frames
• Chairs or tables
• Staircase handrail
• Bicycle frame
• Car door handle
• Transportation pipes
• Bus handrail

 

 

 

 

Choosing the right bent aluminum tubing!

Finally, if you want to do this job DIY by yourself, then you can only excel in smaller aluminum tubes or aluminum sections. because larger sizes of aluminum tubes or aluminum profiles require professional equipment and personnel to carry out the job, so in order for you to be able to get satisfactory bends.

You can contact Hugh Aluminum —– We are a large aluminum extrusion manufacturer and we are equipped to extrude and bend all types of aluminum tubes. Over the past 14 years, we have excelled in completing over 600+ construction projects from 43 countries.

Don’t hesitate to contact us! Our team is friendly and professional.