The sheet metal stamping process is a cold forming manufacturing process in which a mold is used on a press to press on the shape of a metal blank, thereby forming plastic deformation. This process can also be accompanied by other forming tools to obtain a complete part or as an intermediate step.

1. Crack

Sometimes, when metal layers exceed their machinability limits, they begin to thin until the flat layer tears along the weakest region. This defect is referred to as "necking" or "cracking" during the sheet metal stamping process. To ensure that this does not occur, the sheet should be analyzed using forming simulation software before the operation begins. In addition, checking the setting of the forming radius and depth, the type and thickness of material, and heat treatment techniques can also help to avoid these defects.

2. Fold

When the compression strain conditions applied by the processing equipment push the metal plate against itself, the linear force presses inward, forming a wrinkled flange, and the internal geometry is destroyed. This defect can be solved by stretching the sheet rather than forming it. In addition, when the plate has a complex geometric profile, wire drawing beads, wire drawing clips, and pads can be used. Drawn beads help control the flow of metal into the mold cavity.

3. Rebound

When the bending radius is lower than the set value set by the bending device, the desired shape cannot be achieved. This is referred to as rebound, or final part deviation due to incorrect workmanship. To correct these defects, adjustments can be made through excessive bending or overcompensation. However, doing so does not eliminate elastic deformation errors, but rather increases the stiffness of the part through positive stretching.

In addition to the sheet metal forming process, other common problems may arise during the manufacturing process. For example, some common surface scratches, contamination, dents, and pinholes. In addition, during plate manufacturing, uneven surfaces may occur due to high tensile stress or compressive buckling.