Sheet metal fabrication is an essential component of modern manufacturing, playing a pivotal role in various industries, from automotive to aerospace, electronics to construction. The process involves cutting, bending, welding, and assembling metal sheets to create custom parts and products.
The materials generally used in sheet metal processing include cold-rolled sheet (SPCC), hot-rolled sheet (SHCC), galvanized sheet (SECC, SGCC), copper (CU) brass, copper, beryllium copper, aluminum sheet (6061, 5052, 1010, 1060, 6063, hard aluminum, etc.), stainless steel (mirror, brushed, matte), and different materials are selected according to the different functions of the products. Generally, the use and cost of the products need to be considered.
1. Cold-rolled sheet SPCC, mainly electroplated and painted parts, low cost, easy to form, material thickness ≤3.2mm.
2. Hot-rolled sheet SHCC, material T≥3.0mm, also electroplated, painted parts, low cost, but difficult to form, mainly flat parts.
3. Galvanized sheet SECC, SGCC. SECC electrolytic sheet is divided into N material and P material. N material is mainly not surface treated and has high cost. P material is used for spraying parts.
4. Copper: mainly used for conductive materials, its surface treatment is nickel plating, chrome plating, or no treatment, high cost.
5. Aluminum: generally uses surface chromate (J11-A), oxidation (conductive oxidation, chemical oxidation), high cost, silver plating, nickel plating.
6. Aluminum profile: materials with complex cross-sectional structures, widely used in various plug-in boxes. Surface treatment is the same as aluminum plate.
7. Stainless steel: mainly used without any surface treatment, high cost.
Cutting
Once the material is selected, the first physical step in the fabrication process is cutting. Here are some of the typical cutting methods:
Laser Cutting: A high-precision technique that uses a laser beam to cut through metal with extreme accuracy. It is suitable for intricate designs and thin to medium thickness materials.
Water Jet Cutting: Uses a high-pressure stream of water mixed with abrasive materials to cut through metal. This method is ideal for thicker materials and can be used with a variety of metals.
Shearing: A mechanical process where the metal is cut with a pair of sharp blades, similar to using scissors. It is typically used for straight cuts and works best with thinner materials.
Plasma Cutting: A process that uses an ionized gas (plasma) to melt and cut metal. It is generally used for cutting thicker sheets of metal and is less precise than laser cutting.
Bending is a critical process in sheet metal fabrication, where the metal sheet is deformed along a straight axis to create angles or curves. Here are some of the bending methods:
Air Bending: Involves applying force to the metal sheet using a punch and die to create a bend at a specific angle. It’s versatile and suitable for a wide range of materials and thicknesses.
Bottoming: This is a more precise method where the metal is forced into a die to create a more accurate bend.
Coining: A highly precise bending process where the material is compressed between a punch and die to form a more defined angle, typically used for intricate designs.
Punching and stamping are processes used to create holes, slots, or other shapes in the metal sheet. These processes are typically performed using a punch press, which drives a punch through the metal sheet.
Punching: A punch tool is used to pierce holes or shapes in the metal. This method is ideal for creating holes for fasteners, rivets, or other connections.
Stamping: Involves using a die to press the metal into a specific shape or pattern. It can be used for creating logos, detailed designs, or texture on the surface.
In many cases, multiple pieces of sheet metal need to be joined together to create a single part. Welding is the most common method for joining metal sheets. Various welding techniques can be used depending on the material and thickness of the metal:
MIG (Metal Inert Gas) Welding: A versatile and commonly used welding process for joining metals like steel and aluminum.
TIG (Tungsten Inert Gas) Welding: Offers higher precision and is often used for thinner materials or when a clean, high-quality weld is required.
Spot Welding: Frequently used in automotive manufacturing and involves applying pressure and heat to weld specific points on the metal sheets.
After the metal parts are fabricated, they often undergo finishing processes to improve their appearance, durability, and corrosion resistance. Common finishing processes include:
Powder Coating: A dry powder is applied electrostatically and then cured, providing a durable and even finish.
Plating: Metal parts can be plated with materials such as chrome or nickel to enhance durability and provide a sleek finish.
Deburring: The process of removing sharp edges or burrs left over from cutting, punching, or welding. This helps to improve the safety and appearance of the part.
Anodizing: A process often used with aluminum to increase corrosion resistance and create a colored finish.
The final step in sheet metal fabrication is assembly. After all individual parts are fabricated and finished, they are assembled into the final product. This might involve attaching additional components, such as fasteners, hinges, or handles.
Once the assembly is complete, a thorough inspection is carried out to ensure that the parts meet the required specifications and quality standards. This includes checking for dimensional accuracy, weld quality, surface finish, and overall functionality.
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