An Approach for Designing Out Surface Defects in Metal Stampings

Surface defects occur during forming, material unloading and during further material processing. During forming operations the compressive forming stresses are the cause of defects. During material unloading and further material processing, springback and residual stresses are the major cause of such defects.

The conditions for the occurrence of surface defects at these three stages are examined and discussed. A computer aided methodology is presented for estimation of the residual stresses, application of the approach is given for some practical examples.