In the process of bending thin square tubes, undesirable phenomena can easily occur. These phenomena include flattening distortion of the cross-section, wrinkling on the compression region and splitting on the tension region. 6063 and 6061 aluminum extruded square tubes containing a center rib, having four kinds of thickness are applied to the rotary bending process. On the section of the square tube, a center rib arranged in the direction of radius of curvature is very effective in preventing splitting and increasing the limit of bending strain, and further, this rib has secondary effect to reduce flattening distortion and wrinkling. In this bending process, applying laminate elastic mandrel and additional axial tension to this workpiece can improve the working limits. As a result of this study, bend degree
H0/
R0 (where
R0 is the radius of curvature on the central plane,
H0 is the height of the square tube) reaches 0.33 without any defects in this bending process for the workpiece of 6063S–O with thickness ratio
H0/
t0 = 40.0.
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