How to be an excellent sheet metal fabrication engineer ?
With the rapid development of technology and the constant launch of new products, sheet metal, which serves as the basic structure for various products, has also been widely used.
Due to the ever-increasing demands on product appearance, structural sheet metal processing is also continuously improving.
As an engineer working in the processing and manufacturing of sheet metal, it is necessary to think about how to adapt to the development of the industry and increase competitiveness.
An excellent and competent sheet metal fabrication engineer must possess at least the following skills:
1. Understanding the product, component functions and assembly process, and mastering the main and critical dimensions
First of all, you need to understand what the component is used for, who the customer is, the severity of the customer's quality requirements (for example, some customers focus more on functionality and have less stringent requirements for the appearance of the product, while others have strict requirements for both functionality and appearance), the approximate volume of orders per year, the delivery time of the first batch of orders, etc.
Understanding these aspects is crucial in choosing the right process.
Secondly, it is important to understand the role of the component in the product and what subsequent processes it will undergo (such as electroplating, heat treatment, etc.), and whether the dimensions and functionality will be affected (such as electroplating which often causes the dimension of the shaft increases and the hole size decreases, and heat treatment generally causes deformation of the component).
Thirdly, it is necessary to understand the product assembly process, the interrelationship between components and the main and critical dimensions, which often affect the functionality of the product (such as fitting force, clamping force, service life, etc.) and compatibility with other related components (such as compatibility with plastics, compatibility of male and female components), and whether these critical and important dimensions will vary in the assembly process.
These dimensions must be absolutely guaranteed during production and therefore some measures must be taken in the design to ensure that these dimensions meet the drawings.
2. Ability in mechanical drawing and technical drawing
Mechanical drawing and technical drawing skills are the basic requirements for an engineer. If someone cannot understand orthographic projection, isometric drawing, dimensional tolerances and adjustments, shape and position tolerances, how can they design?
Therefore, mechanical drawing and technical drawing are the basis. Furthermore, it is important to understand the different wordings and standards in different countries and regions and to be able to use them effortlessly.
3. Ability to use engineering computers and related engineering software.
As society progresses, many factories and companies have abandoned their drawings and pencils and adopted CAD/CAM systems. The CAD system not only has high work efficiency and low labor intensity, but also has clear drawings and is less prone to errors.
It is being adopted and promoted by more and more companies. If you are not proficient in using engineering computers and related engineering software, you will become an antiquated relic who will be eliminated by society, just like a farmer using a hoe on a modern farm.
Therefore, a qualified and competent engineer must not only be proficient in using computers and related engineering software, but also have a certain level of foreign language proficiency.
Otherwise, in this information age, they will become the new generation of illiterates who cannot accept new information.
4. Ability to analyze technology.
Because parts are designed by product design engineers, machining is not their specialty. They tend to focus on the function of parts when designing and give less consideration to their machinability. Some parts may have low machinability.
For example,
- The diameter and material proportion of a drilled hole cannot be too small, otherwise it will affect the strength of the drill;
- There must be an adequate fillet to avoid stress concentration;
- The distance between the hole and the bending line should not be too close, otherwise the hole will be stretched when bending;
- The bending height should not be too small, otherwise it will not bend; the cutting burrs must not stick out to avoid side cracks;
- The height of the drawing must not exceed the drawing limit of the material, otherwise it will not be drawn;
- The drawing fillet should not be too small to avoid being unable to reach or having low process capacity.
As a production engineer, when receiving a part drawing, you must first have a concept in mind, where is the most difficult dimension or function to guarantee, what is its machinability and can it be produced most optimally with the current common model ? Is the process stable?
If not, how can it be modified more reasonably without affecting the function?
Only by having a good understanding of machinability will you be able to propose reasonable and optimal improvement plans and coordinate with relevant product design engineers to solve related problems.
5. Have professional knowledge in machining.
Establishing good technology requires detailed knowledge of various processing equipment.
6. Ability to perform feasibility analysis
Feasibility analysis is a critical reflection of a die casting engineer's foundation, capability, practical experience, thoroughness, and breadth and depth of problem solving.
As a die casting engineer, when they start to organize the process, they must consider how the part is molded step by step, what the forming steps are, where the positioning holes are placed, what the shape is, how to organize it. them, how to guarantee the main and critical dimensions, which stations are necessary and whether the operation is convenient.
“All roads lead to Rome”, but the simplest and fastest path may be just one. You have to balance your conditions like finances, time, purpose and various subjective and objective factors to compare, choose the best and avoid the worst through feasibility analysis.
In the same vein, as a cold forging engineer, you must perform feasibility analysis based on existing conditions such as tonnage of various machines, parameters, monthly production of parts, delivery time, cost, existing processing capabilities and other subjective aspects and objective conditions, to achieve the best combination and provide excellent products to meet customer needs.
If abnormal situations occur due to insufficient skills of design personnel, lack of experience, lack of consideration and unscientific organization, the consequences for the production unit are often fatal.
7. Ability to deal with abnormal situations
Dealing with abnormal situations can reflect the overall quality of a person's skills and ability to coordinate and communicate.
Furthermore, dealing with abnormalities, learning from experiences and improving one's skills.
In this complete guide to sheet metal processing, we will delve into various techniques and methods used in the industry.
Chapter 1: Cut
The first chapter focuses on cutting processes, which are essential for shaping sheet metal into desired shapes.
Section 1.1 covers LASER cutting, starting with an explanation of the principles underlying LASER machine tool processing in 1.1.1. We then explore LASER processing techniques in 1.1.2, discussing the advantages and applications of this cutting method.
Next, in section 1.2, we present the NCT (Numerical Control Turret) punching machines. We begin with a detailed introduction to the machine tool in 1.2.1, followed by an examination of processing parameters in 1.2.2. In 1.2.3, we discussed common processing methods and finally delved into NCT processing techniques in 1.2.4.
Section 1.3 is dedicated to wire cutting, a versatile and precise method for cutting complex shapes and contours in sheet metal. We will discuss the process, its benefits and its applications in different sectors.
Lastly, in section 1.4, we discuss cutting machines, which are used for straight line cutting of metal sheets. We will discuss the principles, advantages, and limitations of this cutting method, as well as its role in the overall sheet metal processing workflow.
Read here: Sheet Metal Manufacturing Manual – Cutting
Chapter 2: Training
In the second chapter of our sheet metal processing guide, we explore several forming techniques that are crucial for creating the desired shapes and characteristics in sheet metal components.
Section 2.1 discusses the process of partial shearing, which involves partially cutting sheet metal to create specific shapes or features without completely separating the material. This technique is useful for creating tabs, notches, and other intricate details.
In section 2.2, we looked at the bridge design process, which is used to create raised sections or bridges in sheet metal components. This technique is essential to add structural support and rigidity to the final product.
Section 2.3 delves into the process of creating louvers, also known as slotted holes or vents. These features are commonly found in cabinets, enclosures, and other sheet metal products that require airflow and heat dissipation.
In section 2.4, we explore the extrusion and hole stamping processes. Hole extrusion involves creating holes with a specific shape or profile, while embossing is used to create raised or recessed features on the surface of sheet metal. Both techniques are essential for adding functionality and aesthetics to sheet metal components.
Finally, in section 2.5, we discuss the process of creating corner pads, which are used to provide support and reinforcement to the corners of sheet metal components. This technique is crucial to ensuring the structural integrity and durability of the final product.
Read here: Sheet Metal Manufacturing Manual – Forming
Chapter 3: Bending Machine
In the third chapter of our sheet metal processing guide, we focus on the press brake, a vital tool for bending sheet metal components into their final shapes.
- We begin by discussing the operating principle of the press brake, explaining how it uses force and leverage to bend sheet metal along a predetermined line.
- Next, we examine the structure of the bending machine, detailing its various components and their functions in the bending process.
- In this section, we explore the two types of press brake machine motion, which are essential to understanding the machine's operation and capabilities.
- Next, we will discuss the basic principles of bending sequence, which determine the order in which bends are made to ensure accuracy and prevent warping.
- In this section, we describe the various uses of the press brake, highlighting its versatility and importance in sheet metal processing.
- We provide an overview of basic knowledge about upper and lower dies in the press brake, explaining their functions in the bending process and how they can be customized for specific applications.
- The press brake back gauge is the focus of this section as we discuss its role in ensuring accurate positioning and repeatability during the bending process.
- Finally, we delve into the processing techniques and precautions for folding beds, offering valuable information and tips for achieving optimal results while maintaining safety and efficiency in the workplace.
Read here: Sheet Metal Manufacturing Manual – Folding
Chapter 4: Union and Fixation
In the fourth chapter of our sheet metal processing guide, we discuss various methods of joining and fastening sheet metal components to create a cohesive final product.
4.1 In section 4.1, we explored TOX riveting, a mechanical joining technique that uses a specialized rivet to create a strong, reliable connection between sheet metal parts.
4.2 Section 4.2 is dedicated to welding, a widely used method for joining sheet metal components. We cover the following topics in this section:
4.2.1 Definition: We provide a clear and concise definition of welding and its role in sheet metal processing.
4.2.2 Welding methods and classification: We discuss various welding methods and their classifications, highlighting the differences and applications of each technique.
4.2.3 Composition and capabilities of existing welding equipment: We examine the components and capabilities of modern welding equipment, emphasizing their importance in achieving high-quality welds.
4.2.4 Welding Representation Methods: We explain how welding symbols and notations are used to convey essential information about the welding process.
4.2.5 Welding manufacturing processes: We investigate the various welding manufacturing processes, discussing their advantages, limitations and applications in sheet metal processing.
4.3 In section 4.3, we discussed hole extrusion riveting, a technique that involves creating a hole in sheet metal and inserting a rivet to securely join components together.
4.4 Finally, in section 4.4, we explore blind rivet fastening, a versatile and efficient method for joining sheet metal components in situations where access to both sides of the material is limited.
Read here: Sheet Metal Manufacturing Manual – Joining and Fixing
Chapter 5: Surface Treatment
In the fifth and final chapter of our sheet metal processing guide, we explore various surface treatments that improve the appearance, functionality and durability of sheet metal components.
5.1 Section 5.1 discusses brushing, a technique used to create a uniform, directional finish on the surface of sheet metal, improving its appearance and reducing surface imperfections.
5.2 In section 5.2, we discuss blasting and sandblasting, processes that clean and prepare the surface of sheet metal by removing contaminants, rust and scale.
5.3 Section 5.3 delves into metal coating and chemical treatments, which protect and improve the surface of sheet metal. We cover the following topics in this section:
5.3.1 Galvanizing Methods: We have discussed various galvanizing techniques and their applications in sheet metal processing.
5.3.2 Pre- and post-galvanization treatments: We explore the importance of appropriate preparation and finishing steps in the galvanization process.
5.3.3 Representation methods for metallurgy and chemical treatments: We explain how to convey essential information about these processes using symbols and notation.
5.3.4 Electroplating and chemical galvanizing processes: We discuss the differences, advantages and applications of these two galvanizing techniques.
5.3.5 Chemical Treatments for Metals: We explore various chemical treatments used to improve the properties and appearance of sheet metal components.
5.3.6 Aluminum Surface Treatments: We discuss specific surface treatments for aluminum sheet metal components.
5.3.7 Metallization and chemical treatments in sheet metal fabrication: We examine the role of these processes in the overall sheet metal fabrication workflow.
5.4 In section 5.4, we discussed painting (baking paint), a process that applies a protective and decorative coating to sheet metal components.
5.5 Section 5.5 covers screen printing and pad printing, techniques used to apply logos, labels, and other graphics to sheet metal components.
5.6 In section 5.6, we explored polishing, a process that improves the appearance and smoothness of sheet metal surfaces.
5.7 Finally, in section 5.7, we discuss grinding, a technique used to remove imperfections and obtain a smooth, uniform surface on sheet metal components.
Read here: Sheet Metal Manufacturing Manual – Surface Treatment
Conclusion
In conclusion, this comprehensive guide to sheet metal processing covers a wide range of techniques and methods essential for creating high-quality sheet metal components. We explore various stages of the process, including cutting, forming, bending, joining and surface treatments.
Throughout the guide, we discuss the principles, advantages and applications of each technique, providing valuable information about the sheet metal processing industry. From LASER cutting and NCT punching to metal welding and galvanizing, we delve into the intricacies of each process, highlighting their importance in achieving the desired functionality and aesthetics of sheet metal products.
By understanding the various processes and techniques involved in sheet metal processing, professionals in the field can make informed decisions about the best methods to use for their specific applications. This knowledge is crucial to ensuring the production of high-quality, durable and functional sheet metal components that meet the demands of diverse industries.
Overall, this guide serves as a valuable resource for anyone involved in sheet metal processing, offering a comprehensive overview of the techniques and methods that are essential to success in this dynamic and constantly evolving field.
