Bending a complex shape

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How to bend a complex shape in 1/4" aluminum rod? The process must allow me to make the bends precisely at the right interval and at the right angle, and the steps must be repeatable. A jig with pegs maybe?
 
If you are talking about permanently forming the rod into the bent form, you will need some information about the yield point for the material. Permanent forming involves large deformation, so you will need to determine the amount of strain you wish to create in the rod, and then see where that puts you on the stress--strain diagram. The required force will be that which develops the force for this stress, but you must allow for some amount of spring back. This is essentially a manufacturing engineering problem, one that cannot be entirely calculated but only estimated.


If you apply equal and opposite moments (and no shear forces) at the ends of the rod, the bending moment will be constant along the length and the deformed shape will be (exactly) an arc of a circle. You can find the curvature from beam bending theory.
 
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Aluminum does not bend so well. Be prepared to weld repair. A little heat helps, but too much will work against you.
 
Originally Posted By: Kira
Hello, How complex a shape? Artwork or mechanical part? Kira


5 bends in a mechanical part.
 
Originally Posted By: tig1
Aluminum does not bend so well. Be prepared to weld repair. A little heat helps, but too much will work against you.


That type part is commnonly bent without any breakage occurring. Bent from steel or aluminum.

What is a bending ring? How does it look? I am not talking about a ring bending tool.
 
Originally Posted By: Pop_Rivit
Yes, just a little common sense will tell you that you need to build a jig so you can repeat the process.


Even a compliment from you leaves a sour taste.
 
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