Due to the sudden change in thickness, when we form the bracelet
on the mandrel, we are getting rather sharp buckles and crimps
instead of a smooth contour, especially at either end where the
original thickness suddenly changes at the first cut-out section.
Other than using expensive forming dies or a hydraulic press,
either of which would evenly distribute the load over the entire
bracelet during forming, is there a way to prevent the buckling at
these stress points? The triangular shape precludes using round
There are several ways to deal with that. The easiest is to form the
bracelet and than remove the metal.
If it is not possible, the bending should be done in swage block
using punch with triangular groove and face curvature fitting the
swage. The force must be applied to avoid sections where metal was
removed. Flat sections where metal was removed can be cajoled into
shape by burnishing from inside after the shaping is completed.
If you do not have swage block, a groove in a piece of hardwood will
do, and pulley of the right diameter will serve as a punch nicely.
Select the pulley so grove would match wire profile and use wood
mallet to strike the pulley.
Another way is to remove the metal leaving corners rounded. In
another words, the profile of removed section is not rectangular, but
like a segment cut out of an ellipse (looking from the side ). You
should be able to shape such wire on a mandrel without any kinks.
After shaping is done, you can refine the profiles to required