Metal Stamping&#;An Overview
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If you require metal in your manufacturing process, then the sheet of metal should conform to your desired shape and design. That is when the element of metal stamping comes in.
Metal stamping will guarantee that you get the exact shapes you want for the metal.
A customer may think, what if I do not form the metals? You don't have to be concerned. Call a top metal stamping firm, and they'll take care of the work for you.
But, even if you opt to outsource the service, you must understand the process. That's why this article will discuss everything you need to know about metal stamping.
Metal stamping is a process used to transform flat metal sheets into specific shapes.
This complicated process involves a range of metal forming methods, such as punching, blanking, cutting, piercing, and bending, to name a few.
These cold-forming methods use stamping presses and dies to ensure that metal sheets are shaped according to the desired specifications.
Metals commonly used in metal stamping are titanium, zinc, aluminum, and nickel.
This procedure requires a lot of force (16 to 500 tons or even more), which mandates special equipment.
The equipment installed in the press is called a stamp. It allows the metal to come into contact with the working tool, resulting in a high-precision part.
Metal stamping has been around since the seventh century B. C. when the Lydians of present day Turkey used a rudimentary form of metal stamping to produce coins.
Since the discovery of metals, there have been many efforts to enhance their utility, which made metal-smithing a highly valued profession.
Although metal stamping dates back to the seventh century, it later became important for weapons production, which required the production of many identical products.
In the 19th century, the active development of stamping production produced household items, for which there was also a need for serial production.
The industrial revolution sped up the development of high-tech metal stamping equipment because manufacturers needed to create products in bulk quantities in order to satisfy market demand. Forging and die casting could not be relied on entirely to complete the task.
Metal stamping has played an essential role in more recent times, with the advent of automobiles and shipbuilding. Metal stamping made it possible to produce products of immense dimensions.
Types of Metal Stamping
There are different types of metal stamping processes, which include progressive die stamping, transfer die stamping, fourslide stamping, fine blanking, deep draw stamping, and short-run stamping.
Let&#;s have a brief look at each type of metal stamping.
Progressive die stamping is a stamping method that is carried out sequentially. It has several stations, and each stage has assigned a function.
There are sequential stages for cutting, bending, and punching.
After the metal sheet has gone through all the sequences, it will be the desired shape and size.
Progressive stamping is suitable for manufacturing large quantities of parts according to strict specifications and tolerances. This method involves feeding a coil of metal through stamping equipment that sequentially stamps, bends, and shapes the parts. The workpiece remains attached to the base strip from start to finish. Separation of the finished parts from the metal strip is the last step in the operation.
The benefits of progressive stamping include:
In short, progressive stamping can repeatedly produce parts with complex geometries quickly and economically.
However, progressive stamping requires an investment in permanent steel tools.
It is also not suitable for parts that require deep pulling. Progressive stamping can use different metals such as steel, aluminum, copper, stainless steel, and copper as primary materials.
Precious metal superalloys, titanium, and Inconel, can also be used. In some cases, non-metallic parts can be progressively stamped.
The method used in the progressive stamping is accomplished by using transfer presses.
These presses transfer components from one place to another with the aid of fingers.
To produce large quantities of stamped components that need intricate in-press processes, it is advised to use progressive presses.
One advantage of this press is the duration of the cycle. Based on the component, the production could easily be over 800 parts per minute.
However, this type of press is not suited for deep drawing with high precision, because the depth of your stamping may be greater than the size of the piece/component.
This procedure is carried out with the help of a transfer press. It operates at a slower speed using mechanical fingers to hold the part in place throughout the forming or shaping process.
The progressive press is just a small part of the forming process that is controlled by sleeves using springs or similar equipment. It can cause issues such as non-uniform thickness of the material.
Another drawback of progressive presses, compared to transfer presses, is the greater amount of raw materials required to transfer the components
The tools cost more because they are built-in blocks. They do not have specific regulations for each station.
Additionally, they can't perform procedures that require components to leave the strip, for instance, beading, necking thread rolling, curling flanges, rotary stamping, etc.
The number of features determines the cost and the tools needed.
It is suggested to make the tools as basic as possible in order to keep tooling costs to a minimum.
Spaced features that are too close together create problems because they may not provide enough space for punch out, which often results in the need for a second station.
There may also be problems with protrusions and narrow cuts.
Dies are usually made of tool steel, which can withstand the high shock load, maintain the sharp edge required, and withstand the force of abrasion.
Transfer die stamping machines treat each part as a single unit, so the first step in the stamping sequence is to separate the part from the metal strip. The fingers then transport it to various stations that perform separate operations.
The most laborious task in creating a process sequence is determining the number of form stations needed, the tool geometry, overall dimensions, tolerances, residual stresses, and surface finish that meet the requirements of the product.
The transfer die stamping process has similarities to progressive stamping, because it uses sequential processing.
The primary difference is the stamping parts are separated from the metal strip at an earlier stage in the process. This process is best suited for large metal parts and/or parts with intricate design elements such as pipes/tubes, grooves, ribs, and threads.
It can also be used to make deep-draw parts, as there is no metal strip attached to the component. The press can punch as deeply as the raw material allows.
Aluminum, brass, copper, Inconel, stainless steel and precious metals are commonly used, although parts can also be manufactured using ferrous and non-ferrous materials.
Fourslide Stamping
Fourslide stamping is a complex metalworking process that incorporates stamping and forming to make tiny, intricate parts/components from wire or metal coils.
This method offers a variety of advantages over traditional pressing methods that include improved flexibility and design versatility, enhanced speed, and lower costs for production.
With these benefits, fourslide stamping has become the preferred manufacturing method for high-precision products and applications in many industries, from automotive to aerospace to medical and electronics.
Metal Stamping, as opposed to the vertical motion of a punch press, A Fourslide metal stamping machine operates at right angles by using four slides that move to carry out the stamping or forming processes.
Fourslide stamping is like multi-slide stamping. However, multi-slide stamping machines have more features than four slides.
Four shafts are linked with a series of bevel gears and driven by a single motor that drives the slides.
Cams connected to each shaft handle the slides which hit the metal workpiece in four orthogonal directions as it feeds through the machine.
This multidirectional method allows you to bend or stamp the workpiece from all four sides simultaneously or sequentially.
A single fourslide operation can produce intricate shapes using many curves, bends, or twists.
FineBlanking
Fine blanking is also referred to as precision blanking or fine stamping.
The primary goal of fine blanking is to make parts that have an uncluttered, smooth surface.
The distinction between fine and standard blanking is the fact that the material is blanked only by shear. There is no break after clamping across all sides.
There is no snap-thru force in fine blanking. As a result, it is quieter and has less vibration.
The costs for tooling are more than the cost of conventional blanking, and the procedure cannot be performed at extremely high speeds.
Deep DrawStamping
The deep draw stamping process makes the flat metal into a mold/die to create precise, typically cylindrical components.
It is achieved by feeding a flat metal coil through the press, which tools stations then surround. Each station repeats a process on the steel.
The deepdrawstamping process is used to form stamps metal sheets into different hollow axisymmetrical components. Shapes created using this stamping method are cylindrical, however, it can also create box-shaped objects.
Deep draw stamping may be used to make various industrial and household items, such as sinks, baking pans, plumbing fixtures, automobile parts, beverage cans, casings, and much more.
This type of stamping applies a force punch on the sheet of metal, drawing it in a radial direction into the die cavity.
The sheet of metal is first placed on a forming die, and held in place at each end by a compressive force applied by a blank holder.
Second, an axial force is applied to the metal sheet by a mechanical punching tool, causing the piece to deform and flow into the die cavity, forming the desired shape.
"Deep drawing" is so-named because the components contain depths that are greater than their diameter.
Short-Run Stamping
Short-Run metal stamping is a process used to manufacture small numbers of perforated metal parts.
Short-run production can be defined as a run that produces less than 5,000 parts (depends on the manufacturers).
Short-run metal stamping has applications in a wide range of industries. It is suitable for small-volume seasonal products, special products, or other situations where high investment in permanent tools is not workable.
Metal stamping is cost-effective, versatile, quick to set up, and provides precise cuts and shapes.
Short-run metal stamping provides a cost-effective method of producing high-quality, reliable parts with a faster turnaround time.
If you are looking for faster delivery, short-run production may be a good choice for you.
Short-run production has applications in various industries, such as
The short-run metal stamping process creates uniform parts and uses metals such as aluminum, brass, copper, and steel.
Short-run stamping requires a small amount of material, which reduces manufacturing costs.
The Metal Stamping Process&#;A Step-by-Step Procedure
After designing and prototyping, a series of multiple steps are required to create complex metal parts, components, or pieces. It is a much more arduous task than most people think.
Parts, which may seem simple at first glance, rarely require only one stamping step to be considered complete.
Confusion often occurs when trying to determine the best process for metal stamping.
When choosing a metal stamping procedure, you must consider,
&#; How will the process impact the design function?
&#; The design or industry-specific requirements?
&#; Production time and cost-effectiveness?
There are several metal stamping processes. They include blanking, piercing, drawing, bending, air bending, bottoming &coining, forming, pinch trimming, lancing, stretching, ironing, necking/reducing and hemming.
Here is a video that details each process.
Blanking
If needed, the blanking process is the first step in your stamping method.
Blanking refers to the process of cutting large sheets or coils of steel/metal into smaller, easier-to-manage pieces.
This process involves cutting a rough draft of the product's shape you want to get at the end of the entire metal stamping process.
While blanking, major focus points include hole diameter, length, geometry, spacing, and more during the blanking process.
Blanking not only gives you a visual overview of what to expect. It also helps minimize the amount of waste that can appear in later stages.
It also eliminates the problem of wasting time. Blanking usually occurs when a metal object is drawn or shaped.
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Piercing
If the part you are working on requires holes, slots, or other cutouts, the option of piercing is available.
Piercing, which is carried out simultaneously with blanking, creates the required shapes from the sheet of metal or steel.
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Drawing
Drawing is the actual stamping process.
A punch forces a section of metal into the die mold to form the basic shape of the component.
If the depth of the part of a piece is lower than the primary opening, it is considered a shallow drawing.
Parts that have a depth higher than the opening are deep drawn.
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Bending
Bending is an easy-to-understand procedure. The workpiece is placed on a specially designed die and a ram forces the metal into the required bend.
Bending is done after drawing, because punching a bent metal part will cause the entire piece to deform.
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AirBending
Air bending refers to the process by which a punch is used to bend the flat surface of the part into a die (usually V-shaped.)
The distance between the punch and die is greater than the metal's thickness, creating a slightly relaxed bend when the component is removed.
Air bending is less energy intensive in terms of pressure and power than most other bending techniques.
Bottoming and Coining
Bottoming &coining are two bending methods similar to air bending but employ between 2 to 30-times the pressures.
The material is forced into a die that fits tightly, resulting in a more permanent bend.
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Forming
Forming is a bending process that is similar to bottoming, bending, and coining. It is used to make parts that have multiple bends, such as U-bends, in one step.
Pinch Trimming
Pinch trimming involves cutting pieces of a metal sheet and separating them off as scrap metal. It is a novel method, as the metal is pinched against a vertical flat surface.
It is usually, but not always, used to cut deep-drawn round cups from the sheet.
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Lancing
A distinct process, lancing is used to make tabs or vents.
A piece of material is cut across three edges, while simultaneously bent.
This method creates openings or hook-like designs. Expelling scrap is a secondary machining step.
There are various techniques involved in the stamping process, but not every method is effective or even necessary for every component.
When you fully understand of the process, you can create parts that will reduce scrap, reduce costs, and speed up production without sacrificing quality.
Stretching
Here, we increase the surface area of the metal sheet. To achieve this, tension is increased while minimizing the inward movement of the edges. This process also helps to smooth the metal parts.
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Ironing
The metal sheet is squeezed to minimize its thickness. Ironing is vital in applications like making cans for beverages.
Necking or Reducing
The necking or reducing machine is designed to reduce the diameter of a tube.
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Hemming
In the hemming process, the edges of the metal sheet are folded to make them thick, increasing the strength and stability of the shape.
Custom metal stamping is the process of forming metal that requires customized tools and techniques in order to manufacture the parts.
A variety of applications and industries employ custom-designed stamping processes that satisfy high-volume production demands and ensure that every part meets the exact specifications.
Stamping of custom-designed sheet metal can include operations like blanking, cutting, punching, drawing embossing, among others.
Each step is completed with CAD/CAM software-designed tools that offer the accuracy needed for intricate parts.
Sheet metal stamping is an efficient and effective method of making high-quality, durable parts for various industries, including hardware, electronic, medical, aerospace, industrial lighting, and much more.
When creating and manufacturing precision metal stamped parts, the manufacturing company&#;s engineers and project managers, its suppliers, and the metal stamper need to discuss options for finishing the piece to ensure optimal performance.
In most cases, the end product of the metal stamping process may not be ready to use. Some finishing operations may be required to make it perfect.
The most common post-stamping operations include tapping, cutting, reaming, and deburring. These finishing processes improve the appearance of the product and make it compatible with other machines.
Deburring removes the residues of metallic material that were left after the punching process. Removes sharp burrs and ensures that all metal parts are smooth.
Preventing corrosion, enhancing appearance, or smoothing sharp edges requires metal finishing and this crucial element of the manufacturing process and should be considered from the beginning.
Finishing options include
Sophisticated metal stamping machines can produce quality parts, but it is also crucial to select the right raw materials in the same way the appropriate machining procedure is selected.
Every alloy and metal has unique properties. Based on the component, one may choose a common alloy or a special metal.
Varieties of common alloys are used in metal stamping and are precision engineered across a variety of industries. They include
Engineers and designers must have a basic understanding of the most commonly used, as well as specialty metals, to aid in the selection of materials.
Metal stamping is a well-known manufacturing process because of the advantages it provides.
Mass Production: It encourages bulk production of products and parts.
High Level Precision: If the metal sheet is being cut or bent, the result will bean accurate part/component with the correct measurements. Modern metal stamping equipment is designed to operate with a high level of accuracy.
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Uniformity: In bulk production of products, metal stamping keeps every part uniform, with exact shape, design, and size of every part matching specifications exactly.
Cost Effective: Metal stamping is a cost-effective manufacturing method. Through the use of metal stamping, manufacturing firms can produce products quickly and effectively.
Save Time: Outsourcing the metal stamping process relieves you of all hassles, allowing you to save time and put your skill and effort into other projects.
General Info: It's classified as a cold-working process and, like other cold-working methods, doesn't alter the properties of the metal due to heat-related changes.
Metal stamping doesn't expose parts to extreme temperatures, so there is no danger of changes caused by heat. The Metal parts can be formed by stamping without being exposed to heat.
The effectiveness of metal stamping makes it a preferred option for large manufacturing companies.
There are many things to consider before selecting a reliable metal stamping manufacturer.
Expertise and Experience: Metal stamping uses specialized equipment to form simple to complex patterns. It begins with flat metal sheets which can be shaped and/or perforated. You need to check the experience level of the manufacturer to ensure their proficiency in producing the parts you require.
Cost Effective: The price of the project is a function of the volume. Low volume production will cost you more per piece than high volume production. That&#;s we encourage bulk parts production which takes advantage of the economies of scale.
While cost is certainly a consideration, it is not the only factor to consider once the company's credibility, capacity, and knowledge have been confirmed.
Company Reputation
It shouldn't be difficult to gauge the reputation of the metal stamping producers that are being considered.
Most Original Equipment Manufacturers (OEMs) will choose a stamping firm near important transportation routes and their primary business location to reduce supply chain problems and make logistics simpler to manage.
Check the timely delivery of orders for the business, ensure the company can be ISO registered, and look for companies belonging to the PMA (Precision Metal Forming Association).
Industry Experience
Besides their business name, ensure whether the stamping companies you are considering have proven expertise in your field.
Many leading manufacturers have decades of experience in offering parts for the aerospace, automotive, HVAC, metal construction, building materials, and developing &supplying special parts &components for these sectors.
Capacity for Production
Production capacity is influenced by lead times on orders and the equipment employed.
Modern facilities use state-of-the-art precision equipment that can complete projects according to precise specifications and with tight tolerances that are not achievable using older equipment and systems.
Determining the Cost of a Metal Stamping Project
Stamping tools, also referred to as "hard tools," can be extremely expensive.
For jobs with a small amount (less than 10,000 pieces), the cost of a hard tool is greater than any return that could be possible, so "Metal spinning" is a viable alternative.
Spinning tools are inexpensive. Spinning tools are typically 10-to-20 times cheaper than stamping tools.
Cost is a major consideration, but time is also very important. Along with being costly, stamping machines have longer lead times. Spinning tools and parts are completed in just a few weeks, not months.
Metal stamping has a wide range of industrial applications. Industry applications that require 3D designs usually use metal stamping.
Once you have completed the 3D design of your product, metal stamping machines will consistently produce and re-produce parts in mass volumes.
Industries that use metal stamping firms include (but are not limited to),
Based on Grand View Research, the automotive industry is the leading market for the metal stamping industry, accounting for 34.7 percent of their revenues in .
However, in this technological era, applications for fabricating metals in the consumer electronics sector are booming.
This means that nearly every business using consumer electronic devices in their workplace relies on products made by metal stamping machines.
Smaller industries that create items such as household appliances and jewelry can make their products on a greater scale with a stamping machine.
Gold Precision: Your Reliable Metal Stamping Company
Our company:
Gold Precision offers in-house custom metal stamping, manufacturing & production at reasonable prices.
Our Guarantee:
From the initial prototyping phase until the final product, we will complete your order within four weeks.
Gold Precision is the industry leader in customized metal stamping and manufacturing. From exacting prototyping to final product, we do everything in-house. This gives us greater precision, higher efficiency, and the ability to offer impressive cost advantages.
Our experienced team uses cutting-edge technology for highest quality and rapid 4 week delivery. All at competitive prices that give your business welcome savings and fresh opportunities in the marketplace.
Gold Precision excels at custom metal stamping of parts. Since , we have served countless clients with innovation, improved efficiency, and the exacting, quality parts you need to move your business forward.
Our goal is to ensure your experience is smooth and painless. Expert designers and technicians use the very latest technologies and manufacturing techniques to turn your vision into exciting reality. You get the extensive benefit of our specialized knowledge and decades of experience.
We provide custom metal stamping and related services for consumer electronics, NEV, industrial automation, medical, aerospace, communications and more.
It's easy to work with Gold Precision. Select your material, size, and tolerance. Share your requirements including drawing. Not sure of your product requirements? Send us the information you have in CAD, 3D drawing, or photos. Our team can usually take it from there.
Once product details are finalized and key components are chosen, we then work closely with your technical team to ensure rapid procurement of materials and components to meet our accelerated production schedule.
With Gold Precision, your product goes to market faster to create fresh opportunities for your sales team. You enjoy increased revenues to power your bottom line. Our greatest reward comes when you shake up your industry with the latest innovation. Please contact Gold Precision to discuss your metal stamping and manufacturing needs. Our team can take your ideas from concept to completion quickly at a cost that will please your budget. Insist on the best with Gold Precision. Proudly made in China.
References
Sheet Metal Forming Processes and Applications by Edited by Taylan Altan and Erman Tekkaya
Sheet metal fabrication is a versatile manufacturing process with an extensive list of techniques and usable metals. Getting familiar with the technology, how it works, and its applications will help you decide if it is the best option for your project. Here is a comprehensive breakdown of this metal fabrication technique and its applications across several industries.
Sheet metal fabrication is essential for various manufacturing processes, ranging from the manufacturing of toys to large-scale airplane parts. Despite its popularity, it is important to know how this manufacturing process works. Here&#;s a detailed overview of sheet metal fabrication.
Sheet metal fabrication is the process of forming flat metal sheets into the desired parts and products by cutting, folding, bending, and assembling.
There is an extensive range of metal materials that are suitable for various sheet metal fabrication processes, including steel, aluminum, stainless steel, brass, copper, and zinc. The sheet metal thickness comes in gauges of about 0.006 to 0.25 inches. Thicker gauges are ideal for heavy-duty applications, while thinner ones offer advantages in terms of malleability.
To create sheet metal parts, professional metal fabricators use various techniques after a thorough design phase to determine product specifications. The combination of methods will depend on the unique specifications of the end product. The basic processes are cutting, forming, joining, and finishing.
There are various techniques available for shaping and manipulating sheet metal. Some of these processes are more suitable for certain applications than others. Thus, an in-depth understanding of the various available process is crucial to making the most efficient designs. It will also help you decide on the best technique for your projects. This section gives you a rundown of the different sheet metal fabrication types.
Cutting techniques are to separate sheet metal material by applying high force to cause the cutting edges to fail. They break into two groups, cutting without shear: laser cutting, plasma cutting, waterjet cutting, and cutting with shear: shearing, blanking, punching, and sawing. This section will discuss each technique in detail.
Laser cutting is a thermal cutting process that involves melting metals in localized areas using focused laser beams.
It involves two simultaneously running sub-processes. The first process involves focusing a high-powered laser beam on the sheet metal material. The laser beam is absorbed onto the material, causing it to vaporize. The second process occurs at the same time, where a cutting nozzle provides the process or blowing gas for laser cutting. This gas is typically nitrogen or oxygen, and it helps protect the processing head from vapors and splashes. It is also important for the removal of excess materials from the kerf.
Laser cutters can cut a wide range of metals, ranging from stainless steel to mild steel and non-ferrous metals. However, more reflective metals such as aluminum may be more challenging to cut. In such cases, fiber lasers are usually the better option. The thickness of the metal can range between 20mm to 40mm, with the maximum thickness depending on the laser&#;s power.
The laser cutting process is best suited to industrial applications. It is highly flexible, time-efficient, and can give a high degree of precision. However, the process has a high energy and gas consumption, translating to high investment costs and strict safety requirements.
It is a thermal cutting process involving the cutting of metal with ionized gas (plasma). As the process takes place, there is a supply of substantial heat on the metal, and it melts away gradually. The final result is a rough cut with large burrs and an oxidized zone around the cut area.
It is important to note that the plasma cutting tool will only work effectively on electrically conductive metals. It is one of the best methods for cutting medium-thickness aluminum and stainless steel, copper, brass, and other conductive materials. You can use this cutting process for thicker pieces of sheet metal (up to 50mm) where there are no strict requirements for surface finish.
Plasma cutting ensures quicker cutting, high precision, and repeatability than many other cutting processes. It also guarantees automation, ensuring the effective cutting of high-strength metals with lower heat input. A downside to this process is that there is relatively high power consumption and possible noise development with dry cutting.
The waterjet cutting process involves using a high-pressure stream of water to cut metal sheets. The pressure is typically around 60,000 psi, supplying a velocity of about 610m/s to cut through almost any kind of metal sheet.
Waterjet cutting is versatile and can cut hard and soft materials with abrasives and pressurized water. To be specific, pure waterjet cutting is best for cutting soft metals like fabrics, rubber, or metal foils. Abrasive waterjet cutting is best suited for hard materials like carbon steel, stainless steel, aluminum, and copper.
Waterjet cutting is a great alternative to the laser cutting process. It gives extremely good surface finishes without burrs or heat distortions. However, high pressures could cause some bending near the cut area, so there is a need for proper support for the component.
Shearing is a metal fabrication process that cuts straight lines on flat metal materials by applying a shearing force, causing the materials to separate at that point of cutting. It is ideal for high-volume applications and for cutting soft materials like aluminum, mild steel, and brass that don&#;t require clean finishes.
If there is a need to get straight edges on metal sheets with rough or uneven edges, shearing is one of the best options. It is cost-effective for high-output operations when you need to produce thousands of parts within a short time. However, the shearing action creates burrs and deformation on the material. As such, it may not be a great choice for applications requiring a clean end finish.
Blanking removes a piece of sheet metal from a larger piece of the stock material with the use of blanking punch and die. The die holds the sheet metal during the process while the punch delivers a &#;blanking force&#; through the metal. The material removed is the desired component, while the material that remains on the die is the blank stock left.
Sheet metal blanking produces economic custom components and it ensures excellent accuracy, dimensional control, and repeatability. However, it is slightly slower and incurs higher tooling costs than the traditional punching operation.
Punching also creates holes in the sheet metal using shear force. However, in this case, the material removed from the hole is the scrap material, while the material left on the die is the final component. Punching helps to create cutouts and holes of various sizes and shapes.
This process is faster than blanking, producing clean and precise parts within a short time. There is also no risk of thermal changes to the workpiece because there is no heat involved. However, preparing for punching can be time-consuming since punching knives and dies need to be precisely matched.
Sawing works by progressively cutting metal materials with a sawtooth tool to make a series of small cuts in the metal. Each saw tooth uses friction and shear force to separate a small material chip from the material body.
Metal band saws have several fines, and marginally bent teeth ideal for cutting aluminum, brass, copper, and other non-ferrous metals. Horizontal band saws are configured to cut longer bar stock to meet sizing requirements. On the other hand, vertical band saws help complete more complex cuttings requiring precise contours in the metal part.
Band saws have the ability to create accurate straight cuts. They also come with advanced features such as dual-bearing, blade-tracking adjustments, and blade-guided rollers. These features further ensure consistently precise cutting. Band saws generate smaller kerfs than many other cutting processes, substantially reducing waste. Therefore, it is a great option for lowering fabrication costs. However, it is difficult to maintain the required contact between the surface of flat workpieces and the cutting tool. This may cause material instability and cutting inconsistencies.
Sheet metal forming involves reshaping metal materials while they are still in their solid states. This section will cover the most important forming processes for sheet metal. These processes are varied in their applications for making custom fabricated parts.
Bending is the process that deforms metal with force and bends the metal at the desired angle to form the required shape. It is carried out with press brakes and rolling machines. A press brake uses a punch and a die to bend sheet metal. There are different kinds of rolling machines, and they can roll sheet metal into various shapes within specific ranges.
There are various sheet metal bending methods, and the most common ones include:
Generally, bending is ideal for metals that are malleable but not brittle. They include mild and spring steel, aluminum , and copper. Materials like aluminum , brass, bronze, and titanium are more difficult to bend.
Bending is cost-effective when used for low to medium-volume productions, giving parts with excellent mechanical properties. However, there is a high possibility of springback affecting the resulting bend angle.
Hemming involves rolling over a sheet metal edge onto itself to create an area with two layers. It often occurs in two stages. The first stage involves bending the sheet metal and bottoming it out into a V-die. The second stage involves the removal of the material and its placement into a flattening die. This process flattens the hem to give the desired shape.
Hemming is effective for reinforcing part edges and improving parts&#; appearance. The accuracy of the process helps to get components with superior surface qualities. However, material deformation occurs during this process, leading to dimensional variations.
Sheet metal rolling is the process in which a metal piece passes through a pair of rollers to reduce the material&#;s thickness or get a uniform thickness. The rollers are constantly spinning to create compressive forces that plastically deform the workpiece. If the rollers are directly perpendicular to the piece of sheet metal, flattening occurs.
There are two major rolling processes &#; hot rolling and cold rolling. Hot rolling occurs above the material&#;s recrystallization temperature, while cold rolling usually occurs at room temperature. The common applications of rolled sheet metal are found in pipes and tubes, stampings, discs, wheels and wheel rims, etc.
Rolling is a fast process with high efficiency, making it suitable for mass production. The process can be designed to create parts with tight tolerances and complex cross-section profiles. But metal rolling requires high initial investment, so it&#;s more suitable for mass production.
Sheet metal stamping is a cold-forming technique that uses stamping presses and dies to transform raw materials into various shapes. This process is compatible with a wide range of sheet metal materials, including stainless steel, low- and high-carbon steel, aluminum, brass, copper, etc.
Stamping can generally be a combination of complex cutting and forming techniques to obtain complex components with shorter operations. It encompasses bending, punching, embossing, and flanging to create an extensive range of products.
Metal stamping is cost-effective. The process is fast, requires lesser tools and reduced labor time, and it&#;s relatively cheap to maintain the stamping dies, which contributes to an overall drop in expenses. Automating metal stamping is also easy. Therefore, proper programming of metal stamping machines will ensure consistent delivery of high-quality precision parts and repeatability. But the disadvantage of stamping is the increased cost of presses. If there is a need to alter the design during production, it may be difficult to change dies.
Sheet metal curling is the process of adding circular, hollow rolls to sheet metal edges. Most curling processes occur in three stages; the first two stages create the curves for the curl, while the third stage closes up the curl.
Curls help to remove sharp untreated edges from a workpiece to make it safer for handing. A curled edge also provides strength to the edge. Curling can also lead to burrs and material deformations, so care must be taken during the process.
Spinning involves forming metal discs into rotationally symmetrical hollows. During the process, the material is placed between the tailstock of the machine and a shaped spinning mandrel. Upon rotation, the spinning roller helps shape the sheet into the shape of the mandrel.
Metal spinning is ideal for mild metal plates, including stainless steel, copper, brass, aluminum, etc. Metal spinning can produce several hollow parts of various shapes without compromising their quality. Other sheet metal forming processes like bending and punching can be incorporated into a spinning cycle, making it highly flexible for both small batch and large volume production. Size and shape limitations are the major downside to this process. It produces only parts with concentric, symmetric shapes.
Welding is a process that joins two pieces of metal sheets together using heat, pressure or both. It is a high heat process that melts the base metal, typically adding filler material.
There are various welding techniques available for sheet metal fabrication, which function to join metal together through a melting process and the addition of a filler. These welding techniques include the following:
Riveting is a non-thermal, semi-permanent method of joining sheet metal pieces using different types of rivets or mechanical fasteners. The process begins by drilling a hole in the pieces of sheet metal to be joined, followed by the installation of the rivet. After installation, the rivet&#;s tail is deformed by smashing or pounding it. Flattening the rivet&#;s bottom will prevent it from removing.
Riveting can occur in two ways &#; hot riveting or cold riveting. Hot riveting involves applying heat of -°C to steel rivets of diameters greater than 10mm. The hammering force per area in this process is usually 650 to 800 MPa. On the other hand, cold riveting is excellent for non-ferrous and light metals with diameters less than 10mm.
The process is more suitable for non-ferrous metal parts such as copper and aluminum. Besides, it is efficient, cost-effective, and reliable, making it easy to perform quality inspections. However, rivets increase the overall weight of the component. The riveted joints also create more noise and cause plates to become weak due to created holes.
Sheet metal fabrication tolerances refer to the acceptable deviations for features of sheet metal parts required for accurate and consistent installation and integration.
For sheet metal parts, ISO -mk is usually used to ensure proper control of the elements of geometry and size. The following will show you 7 tolerance standards range of linear and angular dimensions, flatness & straightness, cylindricity, and circularity.
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Get it TodayThe following sheet metal design tips should serve as a guide towards ensuring the efficient design of sheet metal parts. These tips have been developed based on standard DfM practices, changing industrial requirements, and analysis of metal fabricated products.
Every component must maintain uniform wall thicknesses throughout. Generally, 0.9 to 20 mm thickness can be manufactured from sheets (<3mm). The recommended thickness range for sheet metal laser cutting is between 0.5 to 10 mm. On the other hand, 0.5 to 6 mm is recommended for sheet metal bending.
Bends in sheet metal fabrication are characterized by the following critical parameters. These parameters must be consistent with tooling for effective machining.
K-factor considerations are important to avoid tearing and deformation. The ideal range should be between 0.3 and 0.5mm, while the average used for bending operations is 0.mm. Calculating the k-factor will help find the neutral axis along a bend. This will ensure the correct designing of flat patterns and finding the right bend allowance.
K-factor is calculated as the ratio of neutral axis (t) to material thickness (Mt):
K-factor = t/Mt
Material thickness, bending method, and bend angle often influence the k-factor. These variables may make it difficult to calculate k-factor accurately.
The bend radius refers to the distance between the bend axis and the material&#;s internal surface. The smaller the bend radius, the higher the strain on the workpiece. Bends in the same plane should be designed to go in the same direction. This will help avoid the need for part re-orientation.
For ductile materials like stainless steel, the interior bend radii of a component should be at least the same size as the metal thickness. Larger bend radii are ideal for brittle metals. This will help prevent distortions around the bend.
It is important to keep bend orientation consistent to reduce the number of component re-orientations. This will help save manufacturing costs and reduce lead times.
Having bends close to the edge of sheet metal materials often increase the risks of tearing and deformation. Adding bend reliefs to sheet metal design helps prevent tearing of the material. Bend reliefs also add stiffness to the metal, reducing the level of springback.
The depths of bend reliefs should be greater than the bend radius. The width of the bend relief should also be at least equal to the material thickness.
Bend height should be at least two times the material thickness plus bend radius. Having a bend height that is too small often makes it difficult to form and position the material in press brakes. This may lead to low bend quality and deformation.
Flat hems should be avoided as much as possible in sheet metal designs. Open or tear-dropped hems are usually preferable because there is a lesser risk of fractures.
The inside diameters of open or tear-dropped hems should be at least the same as the sheet metal thickness. The length of the hem should also be at least four times the material thickness.
The diameter of holes in a sheet metal design should be at least equal to the material thickness. It is even best to have hole diameters that are larger than the thickness of the metal sheet, which will reduce the chances of tooling damage, thus minimizing production costs and times.
Hole spacing should be at least two times the sheet metal thickness. Having holes at very close proximities can cause breakage or deformation during bending or forming. Holes should be placed away from the edges using at least the thickness of the sheet to prevent tearing and deformation.
The outside radius for any curl should be at least two times the thickness of the material. Curling sheet metal involves the addition of a hollow roll to the sheet&#;s edge. This curled edge aims at providing strength and making the component safe for handling. Therefore, the hole size should not be lesser than the curl&#;s radius plus material thickness.
Likewise, countersink depths should not be more than 0.6 mm of the material thickness. The distance between the centers of the countersink should be at least eight times the material thickness. In addition, the distance between the countersunk center and the bend line should be at least three times the thickness of the material.
Tabs should be no longer than five times their width. They should also be at least twice as wide as the material&#;s thickness.
On the other hand, notches should at least have the same width as the material&#;s thickness. It is also best to place them at least &#; of one-inch distance from each other. If the design requires tabs and notches near a bend, they should be kept away from the bend at least three times the metal thickness plus bend radius. This will reduce the risks of warpage and deformation.
Sheet metal gauge is among the most vital design tips for sheet metal fabrication. The thickness of the metal material will depend on the part&#;s geometry and its intended applications. However, using sheet metals that are too thick may limit the bend angle achievable on press brakes.
Sharp bends are often difficult on press brakes and may cause microscopic cracks in the material. This may result in costly and long production runs. Unless required, it is best to stay away from sheet metals that are too thick. Thinner and more pliable metals are the best options.
Sheet metal fabrication ensures the wide availability of materials and surface finishing options. Here is a detailed guide through the available sheet metal materials and surface finishes and their applications.
With several materials available for sheet metal projects, it is important to make the best decision. Choosing the best material includes decisions about the metal type and physical properties. Each material has its unique characteristics and offers unique benefits. Thus, the desired end products and applications will determine the right sheet metal material selection.
This includes various sheet metal materials containing at least 10.5% of chromium. The chromium content in stainless steel makes it more resistant to corrosion than other steel materials. This makes it popular in metal fabrication projects.
Other important properties of stainless steel are its high durability and strength, temperature resistance, ease of fabrication, and increased formability. Some grades of stainless steel are also preferred for decorative and non-structural purposes.
Stainless steel is an ideal option for:
Hot rolled steel is best for metal fabrication projects where dimensional tolerances and surface finish are not key concerns. Its flexibility and malleability also make this material ideal for structural applications.
The common applications of hot-rolled steel include:
Comparing the strength of cold rolled steel and hot rolled steel, cold rolled steel is about 20% stronger. Its strength makes it suitable for processes where the quality of the final product depends on the quality of the steel material. It also has a smooth and shiny finish, making it ideal for aesthetic purposes.
The most common applications of this steel type are:
Pre-plated steel is galvanized sheet metal material with zinc coating to prevent corrosion. The coating offers barrier and galvanic protection to extend the product&#;s life. Pre-plated steel ensure easy sheet metal manufacturing due to increased formability and weldability. This sheet metal material is suitable for equipment bodies.
Aluminum is a pure, lightweight metal that can be combined with other metals like copper, magnesium, and manganese to form alloys. However, it must be noted that not all aluminum alloys work well for sheet metal fabrication. The most notable aluminum alloy for this manufacturing process is aluminum and aluminum .
Aluminum&#;s lightweight and excellent strength-to-weight ratio make it suitable for sheet metal applications. It also offers great resistance to corrosion and easy machinability.
Aluminum is also an excellent conductor of heat and electricity, making it a top choice for various applications like:
Copper is another good option for sheet metal fabrication because it is easy to bend. Its malleability allows easy rolling and hammering into different shapes and sizes without breaking. Copper is also highly resistant to corrosion, making it suitable for components that may be exposed to corrosive agents.
Brass sheet metal also has a high resistance to corrosion, which is why it is popular among aviation engineers and industrial designers. Being a combination of zinc and copper, brass also has excellent electrical conductivity and high-temperature resistance, so it is suitable for electrical components.
Copper and brass give desirable, aesthetically pleasing products, and they are useful in:
Adding surface finishes to sheet metal parts often makes them last longer and perform better. When deciding the best sheet metal finishing solution for sheet metal components, it is essential to understand the available options. Below are some of the major surface finishes available:
This finishing process involves using tiny abrasives (sand or glass beads). These abrasive particles are shot at the sheet metal component surface with compressed air. The impact of these beads on the surface gives a smooth sheet metal finish with a matte texture.
Bead blasting gives an accurate, smooth finish to sheet metal parts without hindering their dimensions. It works well for materials such as steel, aluminum, and copper, making it suitable for sheet metal fabrication, and it improves the durability of components.
This is another aesthetic surface finish involving spraying powdered paint on the component&#;s surface. This is followed by baking of the sheet metal to create strong layers on the material, impacting wear and corrosion resistance.
Powder coating is suitable for sheet metal fabricated parts because it creates hard, long-lasting finishes for these parts. It also offers solid resistance to chemicals and heat, adequately protecting the components from extreme weather and corrosion.
While many metals can take powder coating, it is more suitable for sheet metal products made from stainless steel and aluminum. These metals are good candidates for powder coating because of their ability to hold electromagnetic charges and tolerate high temperatures.
Anodizing involves the conversion of the surface layer of sheet metal products into an oxide layer. Anodizing finish is majorly compatible with aluminum and titanium, and it is available as:
Type I &#; involves the creation of a thin layer on the metal surface with the use of chromic acid.
Type II &#; this amortization uses sulfuric acid to produce a strong and corrosion-resistant layer on the product&#;s surface.
Type III &#; hard-coat anodization gives thicker finishes with wear and corrosion resistance.
The common applications of anodizing finishes are in automotive and aircraft parts, mechanical components, precision instruments, etc. This versatile finishing process helps impact aesthetic, corrosion-resistant finish on the sheet metal parts.
Laser engraving allows the engraving of desired text or images on a sheet metal product. Its application ensures labeling for traceability or personalization of products.
In this process, the laser fuses the desired coating to the sheet metal component, resulting in a durable marking on the metal surface. Laser engraving is compatible with standard aluminum, stainless steel, carbon steel, etc. It is even possible to create corrosion-resistant laser marks on parts made from steel sheets without damaging the surface.
This surface finishing process uses filamentary brushes to improve the surface quality of sheet metal parts. Brushing helps to remove burrs that may have occurred during the various sheet metal processes without causing secondary defects to the component.
It is also suitable for removing weld slag, paint, rusts, and dirt from sheet metal fabricated parts. The right brush will also help create well-rounded corners where two surfaces meet while keeping tolerances intact.
Screen printing, also known as silk-screening, employs fine polyester mesh and a blade to apply the ink to specific sections of the metal component. During the process, stencils help to guard the areas where ink should not reach. The stencils are carefully placed to achieve exact design features.
Screen printing is a simple, cost-effective method of adding custom designs to sheet metal parts. It is a good alternative to engraving and painting, and there are no color or size restrictions. This finishing technique is ideal for applications such as company logos, part labels, nameplates, and safety instructions.
Other
The table below summarizes other finishing techniques suitable for sheet metal fabrication.
FinishDescriptionApplicationsProsConsApproximate Increase PricePassivationThe sheet metal material is immersed in an acid bath of citric or nitric acid. The acid dissolves the iron but leaves the chromium to form a thick, protective chromium oxide layer.It is used mainly to prevent corrosion on stainless steel materials by creating a protective oxide layer that won&#;t react with the environment.a. It prevents chemical degradation of the materialA wide range of industries out there uses sheet metal fabrication products in their everyday operations. This section discusses the applications of this manufacturing process in various industries.
Components of the aerospace industry require high precision and tolerances. Sheet metal fabrication helps to create various lightweight and space-ready components. Materials like steel and aluminum can be combined with improved processes to produce complex spacecraft and aircraft designs.
Sheet metal fabrication can also be a low-cost option for the fabrication of custom interface panels and specific aerospace fasteners. Sheet metal fabricated parts are ideal for aerodynamic applications and airfoils because of their ability to create big, smooth contoured parts. Other applications include assembly tooling and fixtures, sensor enclosures, and avionics.
The possibility of designing automobiles came into existence mainly due to the availability of sheet metal materials. This is true because of sheet metal forming capabilities and how it can make very solid frames from thin sheets of metals.
The fender, hood, roof, and side panels of most vehicles are all products of sheet metal manufacturing. These parts passed through laser and punching operations. The exhaust and frame of vehicles also undergo roll forming before bending into the desired shape using CNC tube benders.
There are many constraints and demands in the healthcare sector when it comes to the selection of materials. However, sheet metal materials are always readily available in most cases. Since medical tools require high accuracy and quality, sheet metal technologies can help identify flaws in designs and make necessary changes.
Also, most metal fabrication techniques are now automated, reducing human error while improving accuracy. This process also provides the opportunity to order specially designed medical instruments needed for specific functions.
The properties of sheet metals also make them suitable for the healthcare sector. Aluminum and stainless steel are ideal for MRI applications because they do not get affected by magnetic fields. High precision tools like scalpels and surgical tools can also be made from sheet metal. The chemically inert nature of these materials also makes them valuable, so they can be easily sterilized and cleaned.
There is hardly any appliance in a hardware store that is not made of sheet metal or enclosed with sheet metal. The wide availability of sheet metal materials and advanced fabrication processes enables the design of high-quality products for the appliance industry.
Sheet metal fabrication helps to create both the enclosures and inner parts of appliances, ensuring adherence to specifications and tolerances. Some examples of the appliances include capillary tubes, blender and mixer housings, kitchen appliances, dispensing equipment, etc.
Several sheet metal fabrication applications are found in the electronics industry. Sheet metal fabrication helps in the prototyping of electronic components, including computers, cell phones, tablets, LED lighting, audiovisual equipment, drones, telecommunications equipment, etc.
Laser cutting, waterjet cutting, CNC sheet metal turret punch presses, and press brakes make electronics sheet metal fabrication less expensive. The process is also very fast, meaning that you can examine prototypes faster and get products to market quickly.
Whenever there is a need to enclose electronic mechanisms, sheet metal fabrication can meet this need. It ensures economical housing and enclosures to protect sensitive electrical equipment and gearboxes. Sheet metal fabricated parts also protect the equipment from the environment, preventing dirt from entering the equipment. Also, a series of cutouts can be produced for cable connections like LED panels, HDMI, light pipes, and glass windows.
Sheet metal fabrication involves several techniques and processes. Therefore, the benefits and limitations vary based on the process chosen. This section highlights the advantages and disadvantages of sheet metal part manufacturing.
Sheet metal technologies have improved significantly in recent years to create products faster and more efficiently. It can produce prototypes faster with the same speed and precision it can give in production. For instance, laser beams can cut through 1mm thick steel at a speed of 18m/min. It is also possible to optimize the power and speed of the nozzle, depending on your project.
In addition, most sheet metal techniques are automated. After entering codes on the computer, the machines will begin work with the required precision. The resulting component tends to have very little or no defects. Limiting human error in the process further ensures the accuracy of results.
There are several techniques used to bring a sheet metal fabricated part to life. These techniques include cutting, bending, punching, stamping, rolling, etc. Each of the processes has its distinct purpose for creating different shapes and sizes of components. There are also many surface finishing options to choose from whenever a component requires additional finishing.
Similarly, you can choose from a wide range of sheet metal materials, including stainless steel, aluminum, copper, steel, and other custom metals. Your choice of material will depend on the final application of your product.
Sheet metal fabrication is an excellent manufacturing process for lightweight projects. Industries such as the aerospace and automotive industries rely on sheet metal fabrication for advanced materials and techniques. This manufacturing technique helps produce components that improve automobile and aircraft fuel economy while ensuring efficiency. Lightweight constructions from sheet metal manufacturing are also key to the success of architecture, machine tools, and general engineering.
Sheet metal fabrication requires high initial capital for tools and equipment employed. Processes like roll forming and stamping need custom equipment and tooling. Custom equipment can be quite expensive and only profitable when manufactured in large quantities. This technique may also require manual labor, and it can increase production costs. Automation can help reduce labor costs, but it is only feasible when producing large quantities.
Bending operations can be complicated due to the trial and error aspects and calculations required in the design cycle. It becomes even more challenging when a shaft alignment and hole are necessary. Using thick metals will make the process more challenging and may cause the final product to fail eventually.
Despite the flexibility of many metals, transforming them into highly complex designs and shapes with the sheet metal fabrication process is almost impossible. Unlike the injection molding process, which can produce complex shapes, sheet metal fabrication produces boxy end-products with a basic appearance.
Sheet metal fabrication can be labor-intensive, which may drive up manufacturing costs. Therefore, it makes sense to choose simple design solutions whenever specifications permit it. This section provides you with eight effective tips for reducing sheet metal fabrication costs.
Choosing the appropriate raw materials for production will assist in reducing the cost of fabrication. It is preferable to choose low-cost materials such as low carbon steel and hot-rolled steel during the prototyping stage.
Also, it is best to use the most affordable metal material that can effectively perform the parts&#; functions for the final production parts. For instance, you can consider aluminum over stainless steel. Aluminum is less expensive than stainless steel, but it can also offer similar properties you will expect from the latter. Doing this will help you save overall manufacturing costs.
If your component will be in a hostel environment, you should choose pre-plated metals. These metals are less likely to rust, so they will save you the costs of additional finishes.
Standard sheet size and gauge are ideal for design. Ordering unique gauges of metal sheets can increase production costs. Standard gauges are often readily available, and there will be no need for a lengthy ordering process. Therefore, choosing metal grades according to the current market condition and using the common gauge will help reduce costs associated with variable gauges.
Another way to reduce sheet metal fabrication costs is to avoid plating and welding. Welding of pre-plated metal sheets is not so safe; it releases toxic zinc oxide into the environment. The risk of welding tends to increase manufacturing costs, especially when using pre-plated metal sheets.
For instance, uncoated cold-rolled steel will also need plating to enhance its corrosion resistance properties. The overall plating process increases lead time and manufacturing costs. Thus, it is best to avoid anything that has to do with plating and welding.
Although complex designs are of aesthetic value, they tend to increase the cost of manufacturing. For example, adding too many cuts and small bends with thick metals will cause difficulties during manufacturing. They will require several different fabrication tools and also increase the risks of getting inaccurate results during the process, thus increasing costs.
Therefore, designs should have simple angle bends that follow the design tips discussed earlier. Another way to reduce sheet metal fabrication costs is by keeping the bend radius steady. Features like chamfered edges, blind holes, and machined pockets should be avoided if not compulsory. All these additional features increase lead time and production costs.
Using optimal geometrics in the part&#;s design is another way to reduce metal fabrication costs. The internal bend radius must be between 0.030 inches (0.762mm) and the material thickness. Following this will enable manufacturers to form the radii with tools specifically for those geometries. There will be no need for a specialized toolset or other alternatives that may increase manufacturing costs.
Every zero added to tolerance will increase the cost of manufacturing. Tighter tolerance features are often more challenging to manufacture, requiring specialty toolings placed under great strain. Such tools also require constant replacement. All these combine to drive up sheet metal fabrication costs.
Just a few parts of the surface play a vital role in the functioning, so it is better to allocate critical tolerances to such surfaces. This allows you to reduce tight tolerances while maintaining components&#; essential performance needs and saving costs.
Fancy, custom-designed fasteners drive up manufacturing costs and slow down the manufacturing process. Therefore, it is best to stick with readily available, fast, and frugal fasteners.
The choice of finishing process will depend on several factors, including the aesthetic requirements and applications of the parts. For example, if the operation of the component is in an unfriendly environment, using a pre-plated metal will be better. Delaying finishes such as silk screening and engraving till the last stage of production can also help reduce costs.
Some materials do not require a specialized finish because they are naturally resistant to corrosion. Adding specialized finishes to such materials adds to the manufacturing costs and increases the lead time. Standard finishes like passivation, chrome plating, etc., are pretty cheap and faster.
Considering sheet metal for manufacturing applications is a great choice. In this paper, we discussed sheet metal fabrication in detail, covering everything you need to get started with your project.
It is crucial to understand the various processes, basic design guidelines, materials and finishes involved in sheet metal fabrication. Each of these factors plays an important role in bringing out the best of your project. The information provided in this paper will guide you make the best decision for your project.
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