1. Burrs: Rough edges or ridges left on the part after cutting, punching, or shearing. These need to be removed through deburring processes.
2. Wrinkling: Undesired folds or creases in the sheet metal, often occurring during bending or deep drawing processes due to excessive compressive forces.
3. Cracks: Fractures or splits in the material, which can occur during bending, stretching, or forming operations due to excessive tensile stress.
4. Scratches: Surface imperfections caused by improper handling, tooling, or during storage and transportation.
5. Dimensional Inaccuracies: Deviations from specified dimensions, which can result from incorrect tooling, machine setup, or material inconsistencies.
6. Springback: The tendency of metal to return to its original shape after bending, leading to inaccuracies in the final shape.
7. Surface Finish Issues: Inconsistent or poor surface quality due to inadequate finishing processes, tool wear, or material quality.
8. Tool Marks: Imprints or scratches left by tooling, often due to improper or worn-out tools.
9. Warpage: Distortion or bending of the sheet metal part, which can occur due to uneven cooling, improper forming, or residual stresses in the material.
10. Tearing: Rips or tears in the sheet metal, often occurring during stretching or forming operations if the material’s ductility is exceeded.
11. Corrosion: Oxidation or rusting of the metal surface, often due to inadequate protective coatings or exposure to corrosive environments.
12. Punching or Cutting Defects: Issues such as misalignment, incomplete cuts, or excessive tool wear that affect the quality of holes or cut edges.

Managing these defects involves careful process control, regular maintenance of tools and equipment, and using high-quality materials.