Can sheet metal parts be bent and formed into various shapes without breaking?

Sheet metal parts can indeed form various shapes through bending, but whether they will break depends on multiple factors.
Firstly, the selection of materials is crucial. If the strength of the selected material is not high enough, or if there are internal defects in the material, it is easy to bend during the processing and may lead to fracture. Meanwhile, the thickness of the material also affects its bending performance. Materials that are too thin or too thick are prone to bending problems. Materials that are too thin may fracture due to insufficient stress during bending, while materials that are too thick may be damaged due to difficulty in effectively bending.
Secondly, the setting of processing parameters is also crucial. If the cutting speed of the tool is too fast or the feed rate is too high, the sheet metal part may be subjected to excessive force during processing and may bend or even fracture. Unreasonable fixture design and uneven distribution of cutting forces may also cause bending and fracture problems.
Furthermore, the bending radius of sheet metal parts is also an important factor affecting whether they break. A small bending radius may lead to a high ratio of tension and compression in the material. When the tensile stress of the outer fillet exceeds the ultimate strength of the material, cracks or fractures may occur. Therefore, when designing curved parts, it is necessary to avoid excessively small bending fillet radii.
In addition, thermal stress during the processing may also cause bending or even fracture of sheet metal parts. For example, the thermal stress generated during welding and heat treatment in high-temperature environments, if not effectively controlled, may lead to bending and fracture of sheet metal parts.
In summary, although sheet metal parts can form various shapes through bending, whether they will fracture depends on multiple factors such as material selection, machining parameter settings, bending radius, and thermal stress during the machining process. Therefore, in practical operation, it is necessary to comprehensively consider these factors to ensure that the sheet metal parts will not break during the bending process.