Sheet metal processing allows you to produce different products by combining different techniques and compatible materials. The popularity of sheet metal processing technology therefore shows its importance for a wide range of applications. However, it is important to understand how this process works so that you can use it to your advantage.
This article examines the fundamentals of sheet metal processing and describes the techniques involved and their applications. You will also learn about the many advantages of the process, as well as the materials and surface finishes suitable for the machining process. Read on to expand your knowledge of the sheet metal manufacturing process.
What is sheet metal processing?
Sheet metal fabrication is a manufacturing technique that creates products from flat sheets of metal. Therefore, you can produce sheet metal using various methods that use modern machines to shape, bend, cut and assemble metal into any desired shape.
The various sheet metal processing processes are compatible with many metal materials. These include stainless steel, aluminum, copper, brass, zinc and steel. The thickness of these metal sheets ranges from 0.006 to 0.25 inches. Thinner sheets offer better formability, while thicker sheets are perfect for heavy-duty applications.
Additionally, computer-aided design applications are used in sheet metal processing. They provide a 3D graphical representation of the final product. 3D files are usually converted into machine code (G-Code) that controls the process. This allows the machine to make precise cuts, create joints, and form final products from multiple sheets of metal.
3 Types of Sheet Metal Processing Techniques
Various techniques are used in processing customer-specific sheet metal. Some of these techniques offer more benefits and are more compatible than others. Therefore, it is important to gain a comprehensive knowledge of different processes to achieve more efficient projects. Below is an overview of the three types of sheet metal processing techniques.
- Sheet metal cutting
- Sheet Metal Forming
- Connect sheets
Cutting techniques for sheet metal processing
Cutting is generally the first phase of the sheet metal processing process. You can cut various shapes or structures from rectangular sheets to meet your project needs. The main cutting techniques include two categories: non-shear cutting and shear cutting.
1. Cut without scissors
There are several methods that allow the proper cutting of sheets without shear force. These techniques involve extreme heat, high pressure, evaporation and blasting to shape sheet metal parts. This includes the following:
1.1 Laser cutting
Sheet metal laser cutting uses focused laser beams to melt metals in specific areas. Laser cutters are compatible with a long list of metals, from non-ferrous metals to mild steel and stainless steel.
This technology consists of two subprocesses running in parallel. In the first, a high-power laser beam is concentrated on the sheet. The material absorbs the thermal energy of the laser beam and thus evaporates.
At the same time, the second method uses a cutting nozzle that supplies blowing gas for laser cutting. This gas is usually oxygen or nitrogen. Helps protect the processing head from splashes and vapors when processing sheet metal.
1.2 Plasma cutting
Plasma cutting is a thermal cutting process that cuts metal using ionized gas called plasma. This method uses high temperature to cut the metal, creating large burrs and an oxidized zone near the cutting surface. Furthermore, it allows for faster cutting, high precision and repeatability in sheet metal manufacturing.
The plasma cutting tool only works effectively on electrically conductive sheets. Therefore, it is one of the most suitable methods for cutting conductive materials with medium aluminum thickness.
1.3 Water jet cutting
In this cutting process, metal sheets are cut using a high-pressure water jet. Waterjet cutting is versatile and can cut various hard and soft materials using pressurized water and abrasives. It is ideal for cutting soft materials, metal sheets, fabrics or rubber. At the same time, it is suitable for cutting hard materials such as copper, carbon steel, aluminum and carbon steel.
The pressure is generally around 60,000 psi at a speed of 610 m/s to cut various types of metal sheets. However, waterjet cutting is a better substitute for laser cutting technology.
2. Cut with scissors
Processes in this category cut metallic materials using shear forces to overcome the maximum shear strength of the metal. This typically involves the use of dies, punches, and shear presses to allow for proper cutting of the metal. The techniques described here include the following:
2. 1 scissors
The shears are suitable for large area applications and for cutting soft materials that do not require a clean surface, such as brass, aluminum and carbon steel. Cuts straight lines on sheets with a flat surface. The shear method applies shear force to the surface, splitting the flat metallic material at the interface.
This is generally the ideal method for creating straight edges on a sheet with rough edges. It is economical for large-scale production where thousands of sheet metal parts are produced in a short period of time. However, due to the burrs and material deformation it creates, shearing may not be ideal for applications where a high-quality surface finish is required.
2.2 Drilling
During punching, holes are punched in the sheet metal using shear forces. In this sheet metal processing process, the waste material is the material removed from the hole, while the final product is the material remaining in the die.
Drilling is suitable for making cutouts and holes of various shapes and sizes. However, the drilling process can take a long time. You need to match the dies and punching knives correctly.
2.3 Disappearance
Punching is an ideal process for the economical processing of sheet metal. This involves removing part of the sheet metal from a larger piece of base material using a punch and die. The punch applies a “punching force” to the sheet metal while the die holds it in place during the process.
The extracted material is the preferred component, while the remaining material in the matrix is the leftover black material. This process is suitable for the economical production of special parts due to its high repeatability, dimensional control and excellent precision.
2.4 Saws
Sawing involves cutting metal materials using a sawtooth tool to create a series of small cuts in the metal. A sawtooth uses shear force and friction to tear off a small portion of metallic material. Bandsaws have several fine, slightly curved teeth suitable for cutting brass, aluminum and other non-ferrous sheets.
Horizontal band saws help you cut longer bars to the desired size. Vertical band saws help you make complex cuts that require precise contours on metal parts.
Forming techniques for sheet metal processing
Sheet metal forming techniques can be used to shape materials while maintaining their solid state. However, these techniques differ in their application to producing custom sheet metal parts. This section explains the main forming techniques used in sheet metal processing.
To bend
Bending sheet metal is extremely economical for small to medium quantities. The metal surface is forcefully deformed and bent at the required angle to obtain the desired shape. You can use press brakes and a laminator for this process. This technique is suitable for spring steel, copper and 5052 aluminum.
to roll
Rolling involves passing a piece of metal through a pair of rollers to gradually reduce the thickness of the metal or achieve a balanced thickness. These rollers rotate constantly with high efficiency to generate compression forces. Consequently, the forces plastically change the shape of the part.
Cold rolling and hot rolling are the two most important rolling processes. Cold rolling generally occurs at room temperature, while hot rolling occurs at a temperature above the recrystallization temperature of the material. Discs, stamped parts, rims, tubes and cables are typical parts of rolled sheets.
Stamp
Stamping combines complex cutting and forming processes with shorter sheet metal processing operations to produce complex parts. Sheet metal stamping is a typical cold forming technique that uses punching machines and dies to shape raw materials into various shapes. It is compatible with many sheet metal materials – copper, aluminum, low and high carbon steel and brass.
Metal stamping technology is typically cheap, fast, and requires few tools and labor time. Additionally, you can automate the stamping process to achieve high-quality precision and repeatability parts. However, it is more expensive to operate and design changes during production are difficult.
sheath
Folding is a custom sheet metal manufacturing process in which the edge of a sheet metal is rolled around itself to form a two-layer area. This usually happens in two different steps. The first step involves bending the sheet metal and lowering it into a V-die. The second step, on the other hand, involves removing the material and placing it into a flattening die. This helps to flatten the hem while giving it the desired shape.
Bending is often effective in strengthening the edges of parts and improving their appearance. The process is characterized by high precision, which contributes to the production of components with high quality surfaces. However, this process usually results in deformation of the material, which leads to dimensional deviations.
Curling
Lamination involves adding round, hollow rollers to the edges of the sheets. The process generally takes place in three steps. The first two steps form the curves of the roll, while the third step closes the roll.
Bending effectively removes sharp, unfinished edges from a workpiece to make handling safer. Folding strengthens the edge even more. However, bending can cause burrs and deformation of the material. Therefore, this procedure requires extreme care to be carried out correctly.
Joining techniques for sheet metal processing
The following joining techniques are used in the sheet metal processing process:
Welding
Welding is a standard process for joining pieces of sheet metal into a single piece by heating them to their melting point and holding them in place with a torch. It is one of the basic processes in the final stage of sheet metal processing. There are several sheet metal welding techniques, including:
- Covered Metal Arc Welding (SMAW)
- Metal Inert Gas (MIG) Welding
- Tungsten Inert Gas (TIG) Welding
These three techniques have different approaches. However, they all have the purpose of joining metals by fusing the edges of the pieces and adding fillers. As a result, they form a metallurgical bond between the parts to firmly join them together.
Rivets
In riveting, a hole is made in the sheets to be connected and the rivet is then inserted. After inserting the rivet, deform the end of the rivet by tightening it. This flattens the end of the rivet and prevents it from falling out. Riveting is also suitable for parts made of non-ferrous metals such as aluminum and copper.
There are two types: cold riveting and hot riveting. Cold riveting is ideal for non-ferrous metals and light metals with diameters less than 10 mm. During hot riveting, however, steel rivets longer than 10 mm are exposed to heat of 1000 – 1100 °C.
Advantages of Sheet Metal Processing
Sheet metal processing includes various techniques for producing components for many industries. The main advantages of sheet metal processing include:
Production of lightweight components
Sheet metal processing is ideal for the production of lightweight components. Industries that require lightweight engine parts, such as aerospace and automotive, rely on custom sheet metal fabrication for its high-quality materials and techniques.
Additionally, this manufacturing process allows for the production of sheet metal parts that reduce aircraft and automobile fuel consumption while increasing efficiency.
Extensive techniques and materials
As explained in this article, there are several techniques associated with the sheet metal manufacturing process. Therefore, there is no shortage of techniques to choose from for your project.
This manufacturing process also allows you to choose from a wide variety of sheet materials, including copper, stainless steel, steel, aluminum and other custom sheets. The material you choose determines the application of your final product.
Efficiency and precision
Sheet metal processing technology offers greater efficiency and precise manufacturing capabilities. It helps you create prototypes faster with high precision and accuracy. For example, some laser cutters can cut about 0.0005 inches.
Additionally, it is important to understand that most sheet metal processing techniques are automated. So the machines start working as soon as you enter the codes into the computer. The process avoids human errors. Therefore, the final products usually show very little or no deformation.
Available materials for sheet metal processing
There is a long list of materials compatible with sheet metal construction. Here are some common sheet metal fabrication materials:
- stainless steel
- Hot rolled steel
- Cold rolled steel
- Pre-coated steel
- Carbon steel
- aluminum
- copper
- Brass
Surface refinements for sheet metal processing
Surface finishing is a fundamental aspect of custom sheet metal processing. It offers manufactured parts functional and aesthetic advantages. These are some of the surface finishes for sheet metal parts:
- Powder coating
- Glass bead blasting
- to brush
- Electroplating
- Anodizing
- Laser engraving
- screen printing
Industrial applications of sheet metal processing parts
Sheet metal parts are used in daily work in various industries. Here are some of these industries:
Auto Industry
The sheet metal manufacturing process paved the way for innovative automobile design because production-ready materials were available. The metal forming capabilities of this technology help create perfect frames from thin sheets.
Therefore, most auto parts are laser stamped and processed. For example, hoods, fenders, side panels, and roofs of most vehicles are sheet metal products.
Aerospace
Customized sheet metal processing facilitates the production of various space-consuming components and lightweight parts. Components used in the aerospace industry typically require tighter tolerances and high precision. Therefore, you can combine sheet metals like aluminum and steel with improved methods to create complex spacecraft and aircraft designs.
Health care
Sheet metal processing helps detect design defects and provides reliable solutions to the quality and accuracy requirements of medical instruments. Sheet metal prototyping and fabrication are ideal for MRI applications and for manufacturing scalpels and surgical instruments. You can automate these processes to eliminate human errors and improve precision in medical device manufacturing.
Housing
Sheet metal fabrication can be used to create cost-effective enclosures to protect sensitive gears and equipment. Furthermore, the manufactured parts protect the tools from the environment and prevent dust from entering. You can also use sheet metal fabrication techniques to create various cutouts for cable connections such as glass windows, LED panels, light guides, and HDMI.
Construction Tips for Sheet Metal Processing
Here are some important sheet metal design tips for manufacturability:
Wall thickness
The geometry of each component must have a uniform thickness because sheet metal parts are made from a single sheet of metal. In general, you can produce sheet metal parts with a thickness of at least 0.9mm to 20mm.
However, various custom sheet metal processing techniques are compatible with different thicknesses. For example, laser cutting is suitable for metals with thicknesses between 0.5 mm and 10 mm. In contrast, sheet metal bending can work with sheets between 0.5mm and 6mm thick.
Alignment of holes and slots
When modeling parts in custom sheet metal fabrication, hole and slot diameters are important factors to consider. The diameter of the holes and slots must be as large as the thickness of the material. You must also leave enough space between the holes. You should never place the holes too close to the edge of the material.
Flexion and deduction allowance
The bend allowance is the additional length of material you need to add to the actual dimension of the parts to create a level pattern. The flexure cut is the material that must be cut to the length of the flanges to obtain a balanced design.
Curvature radii
It is very important to keep the internal radius of curvature of the sheet equal to its thickness. This prevents sheet metal defects and deformations in the final products. Consequently, maintaining consistent bend radii throughout the part helps ensure excellent alignment and savings in sheet metal processing.
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Concluding
Manufacturing parts using sheet metal processing is an excellent option. It offers several advantages, from efficiency and precision to the production of lightweight parts and compatibility with different materials and techniques. Therefore, understanding the various methods, applications and design tips involved in this process is crucial to the success of your project.
Common questions
How does the sheet metal processing process work?
Sheet metal processing involves processing or converting sheet metal materials into various geometries through cutting, shaping, or joining. The process begins with developing the concept and creating technical drawings.
Engineers then use various processes to develop prototypes according to the design model. After prototype development, product testing and design changes, series production of the intended products can then begin.
What are the main sheet metal processing techniques?
The main sheet metal working techniques are generally divided into three categories. This includes cutting, shaping and joining. Each category includes a variety of unique processes that are useful for different applications.
What is the maximum thickness for sheet metal processing?
The thickness of the sheets is generally between 0.5 mm and 6 mm. Due to their small thickness, the sheets are very easy to process and at the same time offer sufficient strength for their intended purpose.
