Sheet Metal Bend Radii

If these guidelines are not followed, more research and/or, some form of analysis may be requried.

Table 1

Preferred recommended 90 degree bend radii for various sheet metals.

ALUMINUM

Where necessary 5052-H32 may be bent to 1T and 6061-T6 to 1-1/2T

STEEL (American Iron and Steel Institute)

1) See AISI's " Fabrication guidlines for cold bending"

THK 6061-T6 5052-H32 5052-H34
6061-T4
2024-0
3003-0
1100-0
6061-S0
5052-S0
2024-T3 1020
1025
4130
ANN
4130
NORM
18-8
TYPE
304
18-8
TYPE
302
.020 .063 .063 .063 .063 .063 .063 .063 .063 .063
.025 .094 .063 .063 .031 .094 .063 .063 .063 .063
.028 .094 .063 .063 .031 .094 .063 .063 .063 .094
.032 .094 .063 .063 .031 .125 .063 .094 .063 .094
.040 .125 .063 .094 .063 .188 .094 .125 .094 .125
.050 .156 .094 .094 .063 .188 .094 .156 .094 .125
.063 .188 .094 .125 .063 .250 .094 .188 .125 .188
.074 .250 .125 .156 .094 .281 .125 .250 .156 .250
.080 .281 .125 .156 .094 .344 .125 .250 .156 .250
.090 .312 .156 .188 .094 .375 .125 .281 .188 .250
.100 .375 .156 .188 .125 .438 .156 .312 .250 .281
.125 .500 .188 .250 .125 .562 .188 .375 NR NR
.140 .562 .250 .281 .156 .625 .188 .438 NR NR
.188 .625 .312 .375 .188 .875 .375 .500 NR NR
1) Steels with lower carbon content are easier to weld and form. ASTM-A366 (.10 carbon content) may be bent back on itself in any direction without cracking. Typical applications: refrigerators, ranges, washing machines, auto and truck bodies, signs, panels, shelving, furniture, and stamped parts

Table 2

This Table is an excerpt from the Aluminum Association Data Book. You can see a complete list of alloys, along with other very useful aluminum information by purchasing their book, "Aluminum Standards and Data".

ALUMINUM

ALLOY
TEMPER
RADII EXPRESSED IN TERMS OF THICKNESS "T"

1/64
1/32
1/16
1/8
3/16
1/4
3/8
1/2
1100
0
0
0
0
0
1/2T
1T
1T
11/2T
H12
0
0
0
1/2T
1T
1T
11/2T
2T
H14
0
0
0
1T
1T
11/2T
2T
21/2T
H16
0
1/2T
1T
11/2T
11/2T
21/2T
3T
4T
H18
1T
1T
11/2T
21/2T
3T
31/2T
4T
41/2T




















5052
0
0
0
0
1/2T
1T
1T
11/2T
11/2T
H32
0
0
1T
11/2T
11/2T
11/2T
11/2T
2T
H34
0
1T
11/2T
2T
2T
21/2T
21/2T
3T
H36
1T
1T
11/2T
21/2T
3T
31/2T
4T
41/2T
H38
1T
11/2T
21/2T
3T
4T
5T
51/2T
61/2T




















6061
0
0
0
0
1T
1T
1T
11/2T
2T
T4
0
0
1T
11/2T
21/2T
3T
31/2T
4T
T6
1T
1T
11/2T
21/2T
3T
31/2T
41/2T
5T