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Home » Metal Profile Bend Radius Calculator | Aluminum & Steel (Q235, Q345, A588) | Free Online Tool

Metal Profile Bend Radius Calculator | Aluminum & Steel (Q235, Q345, A588) | Free Online Tool

Our Metal Extrusion Minimum Bend Radius Calculator is an essential tool for engineers, fabricators, and designers working with aluminum and steel extrusions. This advanced calculator helps determine safe bending parameters for various materials including aluminum alloys 6061/6063 and structural steels Q235, Q345, and A588 in different processing conditions. Get accurate bending radius calculations instantly to optimize your metal forming processes.

Metal Profile Minimum Bend Radius Calculator

Minimum Bending Radius Calculation Results

Material Condition Allowed Elongation Conservative (Min ε) Recommended (Avg ε) Risky (Max ε)

Note on Elongation and Bending Radius Calculation:

This calculator provides estimated minimum bending radius values based on the elongation range of various metals. For aluminum alloys, we consider T4, T5 and T6 tempers. For steels, we consider hot-rolled, normalized and quenched & tempered conditions.

In actual production, bending at the higher end of the elongation range often produces better results. However, please be aware that elongation values can vary depending on the manufacturer, specific profile design, and quality control. Always refer to the material test report (MTR) or consult your supplier for precise data before finalizing a bending process.

These values are for reference only. For critical applications, we strongly recommend validating the material’s properties through actual testing.

Material Properties:

Material-Condition Tensile Strength (UTS) Yield Strength (YS) Elongation (%) Characteristics

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Key Features:

✔ Multi-Material Support: Works with aluminum (6061, 6063) and steel (Q235, Q345, A588)
✔ Condition-Specific Calculations: Accounts for different tempers (T4/T5/T6) and treatments (Hot-rolled/Normalized/Q&T)
✔ Three Safety Levels: Provides conservative, recommended, and maximum bend radius values
✔ Comprehensive Material Data: Includes tensile strength, yield strength, and elongation ranges
✔ Responsive Design: Works perfectly on desktop and mobile devices
✔ Engineering-Grade Accuracy: Based on standard material properties and formulas

How to Use:

  1. Enter Extrusion Width: Input your profile width in millimeters
  2. Select Material: Choose from aluminum alloys or structural steels
  3. Choose Condition: Select appropriate material treatment (auto-updates based on material)
  4. Calculate: Get instant bending radius results for different safety levels
  5. Review Material Properties: Check detailed specs for your selected material-condition combination

FAQ Section:

Q: What's the difference between conservative and risky bend radius values?
A: Conservative values use minimum elongation for maximum safety, while risky values use maximum elongation for tighter bends - choose based on your application's criticality.

Q: Can I use this for non-standard extrusion profiles?
A: The calculator works best for standard profiles. For complex shapes, consider adding a safety factor of 10-15% to the results.

Q: Why are steel elongation values higher than aluminum?
A: Structural steels generally have better ductility than aluminum alloys, allowing tighter bends relative to their thickness.

Q: How accurate are these calculations?
A: Results are based on standard material properties. For production applications, always validate with actual material tests.

Q: What does Q&T mean for steel conditions?
A: Q&T stands for Quenched & Tempered - a heat treatment that increases strength while maintaining some ductility.

Q: Can I save my calculation results?
A: Currently the tool doesn't save data - we recommend screenshotting or noting down your results.

Technical Notes:

• All calculations assume uniform material properties and standard bending practices
• Aluminum results are based on ASTM standards, steel results on GB/T and ASTM specifications
• For critical applications, always consult with your material supplier
• "Risky" values represent maximum theoretical bends - actual production may require adjustments

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