In my experience with metal fabrication, I have encountered various bending problems that can hinder productivity and quality. Over the years, I’ve identified seven major solutions to flexion problems that can help optimize the process and improve results. Understanding these solutions has allowed me to troubleshoot effectively and enhance the performance of bending operations. In this article, I will share these seven major solutions to bending problems, providing insights that can assist both beginners and seasoned professionals in overcoming challenges and achieving precise bends in their projects.

1. On both sides of the corner of the sheet metal after flexion, the metal material will protrude due to the extrusion. The width is larger than the original size, and the protrusion size is related to the thickness of the material used. The thicker the material, the larger the protrusion point. To avoid this phenomenon, you can make a semicircle on both sides of the bending line beforehand. The diameter of the semicircle is preferably more than 1.5 times the thickness of the material. When the edge material is designed to be folded back, the same method is used.

2. When the sheet metal is bent, the inner R angle is preferably greater than or equal to 1/2 of the material thickness. If you don’t do R angle. After several times of punching, the right angle will gradually disappear and the R angle will naturally form. After that, the length of the R angle on one or both sides of the R angle will be slightly longer.

3. The sheet metal is easily deformed under force after bending. To avoid deformation, an appropriate amount of reinforcing ribs with a 45-degree angle can be added at the bending position, and the strength is increased based on the principle of not interfering with other parts.

4. Generally, sheet metal parts are not easy to maintain their straightness when they are long and narrow, and they are more likely to deform after being stressed. Therefore, we fold one edge into an L shape or two edges into a round shape to maintain its strength and straightness, but often the L and round shapes cannot be connected from beginning to end. What should we do when they are interrupted due to some factors? The right amount of ribs to increase its strength.

5. It is better to have a narrow hole in the transition between the flat surface and the bending surface or to retract the edge of the opening after the bending. Otherwise, burrs will be produced. The width of the narrow hole is preferably greater than 1.5 times the thickness of the meat. When drawing, don’t forget or be lazy without marking the R angle. The male and female molds of right-angle or acute-angle molds are easy to crack. In the future, the suspension and grinding will be additional losses.

6. If there is no special requirement for the corner of the metal sheet to be at a 90-degree angle, be sure to treat it as an appropriate R angle. Because the right angle on the edge of the metal sheet is easy to cause sharp points and cut the staff. In the case of the female mold, the right-angled tip is prone to cracks due to stress concentration. The male mold is easy to crack at the tip so that the mold must be repaired and mass production is delayed. Even if it does not crack, it will form an R angle due to wear over time, which will cause the product to produce burrs and cause defective products.

7. Hem

It can be divided into unilateral discount and bilateral discount. If precision is required, it is best to use the bilateral discount, which has better accuracy.

The height of the folded edge should preferably be greater than 3mm. (T: 1.0~1.2mm) Otherwise, the size will be unstable due to too small clamping size.

● l When folding the edge, the parts on the side wall or the internal protrusions should not be too close to the bottom surface, preferably more than 10mm, otherwise the corners below the protrusions will be larger than the R angles on the left and right sides without a male die. The R angle is not continuous, which will affect the appearance. The solution can be to punch out an indentation of an appropriate length on the fold line before bending, which will improve its appearance.

● l When folding the edge, the opening on the side wall should not be too close to the bottom surface, preferably more than 3mm, otherwise the opening will be deformed due to bending. The solution can be to punch out a long hole with a length equal to the opening and 1.5 times the thickness of the material on the folding line before bending. Its function can cut off the involvement without affecting the appearance of the opening.

Bending problems pose significant challenges across various industries, impacting the performance and longevity of structures and components. By implementing the 7 solutions majeures aux problèmes de flexion—including careful material selection, design optimization, strengthening techniques, proper support systems, advanced manufacturing processes, regular maintenance, and the use of Finite Element Analysis—engineers and designers can effectively mitigate these issues. Embracing these strategies not only ensures structural integrity but also enhances overall efficiency and safety, paving the way for more resilient and reliable applications.