Bending metal might look simple, but it’s actually a detailed process. If the tools or setup aren’t just right, you can end up with bends that don’t look good or parts that don’t work properly. Knowing what can go wrong and how to prevent it helps get better results.

Wavy Edges

Wavy or uneven edges happen when the bend is not smooth. This is often caused by tools that are too worn or not set up correctly. It can also happen if the bend is too wide for the type of metal. Using the right tools and bend size for the metal, as well as bending machines like the examples seen at cotswold-machinery-sales.co.uk/euromac-bending-machines/horizontal-bending-machines, can stop this from happening.

Twisting and Flat Spots

Twisting means the metal turns slightly along the bend. It’s usually caused by the tools not being lined up or the grain of the metal pulling it. Flat spots show up as flat sections on the bend instead of a smooth curve. These can be avoided by using lubrication and making sure the tools are aligned.

Overbending and Under Bending

Sometimes the metal bends too much or too little and this happens if the tools are worn or not set deep enough. These issues can sometimes be fixed by re-bending, but it’s better to avoid them by using well-maintained tools and the right settings.

Springback

After bending, some metals try to go back to their original shape. This is called springback. You can plan for this by bending the metal a little more than needed.

Surface Problems

Scratches and gouges are caused by dirty or damaged tools. Cracks, thinning and thick areas happen when the wrong bend size or too much pressure is used. These issues often mean the part has to be thrown away. Keeping tools clean and using the right bend size helps avoid this.

Many bending problems come from using the wrong tools, not enough pressure or not planning ahead. Working with skilled metal fabricators and checking the setup before starting can help avoid these mistakes and lead to better, stronger parts.