Need Help! Bending 1/4" X 1" aluminum bar

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..Get your oxy torch and light up a sooty yellow flame and blacken the aluminium part, now set up the torch a bit better and start to heat it up and when the soot burns off then the temp is about right...
Cheers M

Dan, you sound like you are well on your way. Remember that coining is an area beyond air bending, i.e. the part is bent 90, past 90, the punch penetrates the face of the material, plastically deforms it, and "coins" it back to 90. When you are putting your die set together , make sure you incorporate bolster/shim blocks underneath the actual die former, that way you can shim the bolsters up until you creep up on 90, then approx. 92deg (shouldn't go much beyond 92 if you are using 90deg punch/die combo for this), once you hit 92ish, continue to shim, my guess would be coining would be approx. .004-.006 beyond). A last thought is to incorporate a urethane pad in the die set, to get the tonnage to coin the part, but avoid being so close to the actual bottom of stroke of the press, i.e. risking bottoming/tonnage-spiking/lockups. Good luck in your endeavor.

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