Sheet metal bending is a crucial process in manufacturing, transforming flat sheets into precise shapes for industries such as automotive, aerospace, and HVAC. However, Challenges like springback, cracking, and wrinkling can disrupt production, increase costs, and compromise quality.
As a leading sheet metal machinery manufacturer since 1985, we offer high-quality press brakes and tooling to tackle the bending issues. In this blog, we explore five common sheet metal bending problems and their solutions to help you achieve flawless bends and boost efficiency. Visit our sheet metal brake page to discover our practical solutions.
Bending Issues/Problem: Springback occurs when sheet metal partially returns to its original shape after bending, leading to inaccurate angles and dimensions. This is common in high-strength materials such as stainless steel or thick sheets due to their elasticity.
Causes:
1 ) Insufficient bending force causes incomplete deformation.
2) Small bend radius relative to material thickness.
3) Material properties, such as high yield strength or elasticity.
Benging Solutions:
Pro Tip: Use JSTMT’s CNC press brakes with automatic angle correction for consistent results. Request a quote on our Sheet metal brake.
Bending Issues/Problem: Cracking occurs when the outer surface of the bend is overstretched beyond the material’s tensile limit, especially in brittle materials like hard steel or when the bend radius is too tight.
Causes:
1) Small bend radius causing excessive stress.
2) Bending parallel to the material’s grain direction increases fracture risk.
3) Low ductility in materials like cast iron or high-carbon steel.
Bending Solutions:
Bending Issues/Problems: Wrinkling appears as wave-like formations on the inner side of the bend, often in thin sheets or under excessive compressive stress, affecting appearance and structural integrity.
Causes:
Excessive compressive stress during bending.
Thin material unable to withstand compressive forces.
Improper tooling, such as a die with too small an opening.
Bending Solutions:
Increase Material Thickness: Use thicker sheets (e.g., >1mm) to resist compressive forces.
Use a Larger Bend Radius: A larger radius (e.g., 2x material thickness) allows gradual deformation, reducing wrinkling.
Apply Reinforcement Techniques: Add beading or ribbing to increase sheet stiffness before bending.
Optimize Tooling: Use V-dies with appropriate opening sizes (e.g., 6-8x material thickness) to balance stress distribution.
Pro Tip: JSTMT’s hydraulic small sheet metal brakes ensure precise force application to prevent wrinkling.
Bending issue/Problem: Interference occurs when the workpiece collides with the press brake’s upper die or slider, especially in groove-type parts where the groove width exceeds the leg height, leading to dimensional inaccuracies.
Causes:
1) Improper bend sequence causing earlier bends to obstruct later ones.
2) Groove dimensions (e.g., L-M > 1.5x) causing interference with the die.
3) Complex part geometries not accounting for machine limitations.
Bending Solutions:
Pro Tip: JSTMT’s gooseneck press brake tooling design features customizable tooling that prevents interference. Contact us today for a consultation.
Bending Problem: Surface scarring, which includes scratches, indentations, or marks on the sheet metal after bending, often affects aesthetics and requires costly rework.
Causes:
1) Rough or dirty tooling surfaces cause friction.
2) Improper alignment of the sheet during bending.
3) Lack of protective measures during the bending process.
Bending Solutions:
Pro Tip: JSTMT’s precision-ground tooling ensures smooth, scar-free bends. Request a tooling catalog at Press brake tooling catalogue.
Since 1985, JSTMT has been a trusted manufacturer of press brakes, shearing machines, and press brake tooling in China. Our small sheet metal brakes, with tonnages from 20T to 100T and bending lengths up to 2.5m, are designed to tackle common bending challenges. Features include:
Advanced CNC Controls: DELEM and Estun E21 systems for precise angle correction and bend sequencing.
Custom Tooling: V-dies, gooseneck punches, and quick-change systems to prevent interference and cracking.
Durable Design: All-welded frames with a 10-year warranty for reliability.
Global Support: 24/7 technical assistance, free replacement parts during warranty, and on-site service.
Ready to solve your bending challenges?
Visit sheet metal brake to explore our solutions, request a quote, or contact us at +86 21 5777 3892 . For instant inquiries, WhatsApp us at +86 1500036 5105.
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