Faltungsdefekte

Faltungsdefekte, also known as folding defects, are structural irregularities that can occur during the manufacturing of sheet metal components. These defects arise from the plastic deformation of the material when it is bent or folded. The primary cause is the uneven distribution of stress and strain across the material's thickness during the folding process. When a sheet metal is bent, the outer surface experiences tensile stress and elongates, while the inner surface experiences compressive stress and shortens. If the bending radius is too small or the material properties are not suitable, this differential deformation can lead to localized thinning, wrinkling, cracking, or even complete tearing on the outer surface, and buckling or waviness on the inner surface.

The severity of faltungsdefekte depends on several factors, including the material's ductility, yield strength, and thickness, as well as the bending angle, bending radius, and the tooling used. For instance, materials with lower ductility are more prone to cracking. Similarly, sharper bending radii increase the stress concentration, making defects more likely. Proper process design, including selecting an appropriate minimum bending radius, using lubricants to reduce friction, and employing specialized tooling like pressure pads or strippers, can help mitigate these issues. Understanding and controlling faltungsdefekte is crucial for ensuring the structural integrity and aesthetic quality of folded sheet metal parts used in various industries, such as automotive, aerospace, and consumer goods.