Processing method
ALUBOND u.s.a panels
can be shaped with ordinary aluminum processing
and woodworking machines and tools:
Saw
cutting
Running saws and panel saws for woodworking
can cut panels easily. We recommend the carbide
tip blade made for aluminum and plastic.
Shear
cutting
A square shear is the most efficient method
for sizing a large quantity of panels. Some
shear droop may occur at the cut edge. The appropriate
clearance and rake angle are:
Panel Thickness
Clearance
Rake Angle
3mm
0.04mm
1°
4mm
0.04mm
1°30´
Grooving
It is important to leave 0.2 to 0.4mm of core
material in U-grooving. We recommend 110° of
a grooving angle for 90° bends. Panel saw or
NC routing machine is suitable for mass grooving
production.
Router
and Trimmer:
Use a modified router bit as shown in the drawing.
[Example
of router bit]
Number
of teeth
2-4
Number
of rotations
20,000-30,000
rpm
Feeding
speed
8-12
m/min.
Material
Solid
carbide or carbide tip
Groove
Cutter:
When processing a large quantity of panels,
use a circular saw or panel saw equipped with
a groove cutter.
[Example of groove cutter]
Material
Carbide
tip
Outside
diameter
220mm
Number
of teeth
18
Number
of rotations
3,000
to 5,000rpm
Feeding
speed
10-15m/min.
Folding
Fold U-grooved panels with a folding jig, press
brake or plate punch. To ensure a straight line
on folded corners, fold the grooved panel on
a flat table. To prevent the coating from cracking,
we recommend that you do the folding at a temperature
of 10°C or higher.
Rout and return system
Locate the rout 25-50mm from the sheet edge,
and fold it to form a tray type panel. After
assembling, seal the corner with sealant to
prevent water leaks, if you notch the end of
corner out with 90°C square.
Bending with press brake
In case of bending ALUBOND
u.s.a panel with a press brake, use a top die
with the desired radius. The minimum internal
bending radius is:
Thickness
Minimum Bendable Radius (mm)
Alubond u.s.a
Traverse
Parallel
Traverse
Parallel
3mm
40
55
4mm
80
100
40
55
Bending with Three-Roll Bender
For a larger bending radius, use a three-roll
bender. Groove and slit the curving edge before
bending, as shown below:
Rivet & Bolt
Use an aluminum blind rivet for your junction.
Do your fixing work from the same direction,
and use a stainless steel bolt/nut. When panels
are connected with a junction hole, make sure
the distance from the hole center to the panel
end (e) is larger than twice the hole's diameter
(D) to ensure that the hole has sufficient tensile
strength (e >2D).
Welding
The core of Alubond u.s.a panel can be welded
with a hot air gun. Use a low-density polyethylene
rod for a welding rod, or substitute a scrap
piece of the panel. Reinforce it after welding.
