Metal bending is a complex fabrication process with many variables that can lead to defects if improperly controlled. When working with metal bending services, being aware of potential flaws in the finished product and their causes is essential for achieving quality results. Common bending defects, their appearance, causes, prevention, and remedies are detailed below. Wavy Edges Wavy or rippled edges on the outer bend radius indicate inconsistent bending. This results from improper punch and die clearance, worn or chipped tooling, or trying to bend with too large of a radius. It can be prevented using proper tooling tolerances and radii for the material thickness. Wavy edges can only be remedied by re-bending or scrapping the part. Twisting The finished bend has an undesired twist along the bend axis. The punch causes it and the die's non-parallel alignment or the grain direction in the metal sheet. It can be prevented by realigning the tools or changing grain direction. Severe ...
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