I'm working on a project that need me to do a 45 degree forming at the edge of aluminium, 6061-T6 series of thickness 1.88 mm, I tried to do the forming, with a 45 degree form punch with a straight potion at the tip for bottoming effect and followed by another about 10 degree relief, However I'm not allowed to have any bulging effect on the bottom side of the product.

I've tried to notch out the access material and due to the process of notching, the top surface seems to have big die-roll radius.Which of course not allowed by my customer.