CNC Aluminum Profile Bending: How Rise Error Moves the Radius
With a fixed 1,600 mm chord, a 98–102 mm rise window corresponds to a radius of roughly 3,188–3,314 mm.
This application example uses public references and explicitly stated planning inputs. Figures derived from assumptions are estimates for evaluation, not measured customer results.
Production question
How sensitive is the inferred radius to small rise changes on a shallow arch?
Worked calculation
For a 1,600 mm chord and 100 mm nominal rise, R = 3,250 mm. At 98 mm rise, R ≈ 3,314 mm. At 102 mm rise, R ≈ 3,188 mm. A ±2 mm rise window maps to an asymmetric interval of roughly −62 to +64 mm in radius.
How to validate it on the shop floor
Measure at the specified chord after the profile is unloaded. Record free-state rise, twist and cross-section changes for each coupon. Compare trial bends by alloy, temper, section orientation and batch.
What to do with the result
The shallow shape amplifies measurement error. Near the example’s nominal point, a 1 mm error in rise changes the inferred radius by about 31.5 mm. Use a rigid chord reference with repeatable end contact before attributing the whole variation to the bender. If only the crown is checked, a locally flat zone or asymmetric bend can pass unnoticed, so inspect several stations against a template.
Practical follow-up
Can the calculated radius predict springback? The geometry describes the shape after bending. The roller setting requires trials with the actual alloy, temper and cross-section.