Common Problems in Sheet Metal Fabrication

Last Updated on December 23, 2022 by Leizi

Sheet metal processing has a wide range of applications, from prototype to mass production. It is also one of the top choices for most people. At the same time, some errors are inevitable in processing. It’s common to rework the sheet metal parts. In this article, we will discuss what are the common problems in sheet metal processing, and how to solve them.

Sheet Metal Cutting

1. Splitting

Although sheet metal materials are of certain machinability, they may also be easily split during processing. There are two cases: Metal parts will crack if the quality of the metal used is not superior, or when the metal is stressed beyond its processing limit strength.

Solution: To avoid its splitting during processing, the best way is to use simulation software to test the degree of cracking in advance. By simulating and testing the material, shape, thickness, and forming radius of metal parts, the problem of splitting can be effectively analyzed and solved at a lower cost.

Sheet Metal Splitting

2. Extra Burrs

During punching, excess burrs may be generated on the surface of the sheet metal material. When the burr has a certain height, it is easy to scratch the mold. It may affect its accuracy.

Solution: It requires the production staff to remove the extra burrs in time to avoid scratches.


3. Springback

During bending, the metal material may not be able to achieve the expected bending radius due to insufficient elasticity, which is a common springback problem in high-strength metal sheets. And this tends to lead to inaccuracies in metal parts.

Solution: To solve this problem, we will adjust by positive stretching to increase the strength of the part.


4.Hole Deformation

If there is not enough space between the hole and the bending position, it is easy to deform the hole of the plate during the bending process.

Hole Distortion of the Sheet Metal Parts

Solution: Reserve a certain position for the hole and bending position in the sheet metal processing design. Before processing, we will conduct a DFM report. If similar problems are found in the drawings, our engineers will provide suggestions for modification of the drawings to avoid the problem of hole deformation as much as possible.


5. Uneven Bending Angle

Uneven Surface of Sheet Metal Parts

When the rounded corners of the mold are uneven, or the strength of the material is not enough, these will easily lead to instability during bending. Then the bending angle of the metal parts will deviate.

Solution: Test whether the rounded corners of the mold are balanced before processing, and increase the jacking force.


6. Wrinkles

If an inappropriate process is chosen to process the material, it may result in stacking and wrinkling of the material. In general, thinner sheet metal materials are more prone to wrinkling.

Solution: This is one of the serious processing defects. We need tools to stretch the wrinkled part and cut it off.


7. Surface Scratches

Several situations are prone to surface scratches on sheet metal parts. The first is the problem of packaging. If you do not choose suitable packaging for them, it is easy to cause pressure loss between metal parts and scratches on the surface. The second case is surface scratches caused during the handling of parts.

Solution: Scratches on sheet metal parts are one of the common problems. To avoid this situation, we usually require the production department to use customized packaging for the parts and check the mold regularly.

sheet metal processing samples

Sheet metal processing has always been one of the important metal processing ways in the manufacturing industry. If you are worried about any of the above problems in your sheet metal processing project, we will be your reliable partner.

Ruitai focuses on customized sheet metal processing, from small batch to large batch processing. Our processing

capabilities include stamping, cutting, welding, bending, and more. If you need any machining support, we are always here to support your sheet metal fabrication project.

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