What Kind of Technology Use on Your Sheet Metal Processing Orders?

Normally,There are a lot of kinds of technology used on sheet metal processing parts,just like welding,cutting,bending,punching,forming,rolling and joining and more,but do not worry,Ruitai will make your sheet metal processing parts according to your CAD files and 2D files,we will choose the right and economic way for your sheet metal processing parts.

Another important details is:we can tap threads into the holes and put the pins into the sheet metal processing parts,when welding sheet metal processing parts,we will take the assemble details into consideration.

Just send the emails to us if you have any other questions about your sheet metal processing parts.

Many Surface Treatment We Can Make On Your Sheet Metal Processing Projects

Ruitai can make different kinds of surface treatment on your sheet metal processing orders.Just like passivation;zinc plated,powder coated;painting,Nickel plated,Color plating,Copper plating,black coated and more

If you have more questions about sheet metal processing surface treatment,just let us know

Sheet Metal Processing: The Ultimate FAQ Guide

From the very beginning of the world, human civilization needed metals and metallic products for many purposes. Coins in your hands, furniture in your homes, gates, fans, other household products, kitchen tools, cars, computers, printers, etc., all of these are the end products made of some sheet metal.

What do you think? What has been the process to make end products in your hand? Metals found in the earth are just big or small pieces. There is a large series of processes through which metals are converted into useful sheet metals. These sheets are the primary need for every manufacturer.

There is a big industry that produces metal sheets out of raw materials. Further, many big industries produce useful products through those sheet metals. This FAQ guide will provide you with essential information to understand the major processes, techniques, and operations that are performed to manufacture the desired product or prototype out of those sheets.

How can You Describe Sheet Metal?

It is a shape or a form of metal that is gained after machining operations. It usually refers to thin, flat, smooth, rectangular, uniformly thick pieces of the metal. Those are required for further metalworking. These metallic sheets are further cut and mould according to the need of the product that is being manufactured.

Sheet metals have a thickness ranging from 0.5mm to 6mm. Below this thickness, they are called foils. Whereas if the thickness exceeds 6mm, they are termed metal plates. These metal plates are used I used in the manufacturing procedures and are the basic requirement to produce products through Sheet Metal Processing.

What Is Meant By Sheet Metal Processing?

Sheet metal processing is a series of a mechanical process that is required to manufacture a specific product. These processes can be welding, punching, forming, cutting, bending, glueing, piercing, slitting, joining, etc.

These processes are arranged and carried in a specific order that is tailored according to the need of the product under formation.

Which Materials Do You Think Are Best For Sheet Metal Processing?

Steel, iron, copper, aluminium, gold, silver are good candidates for sheet metal processing. You can also use alloys like brass can process sheet metals.

Your selection criteria of the materials for processing into sheet metals can be: Firstly, materials should be ductile. That is, they should be able to transformable and formable. Secondly, Materials should possess a certain level of rigidity and toughness.

Thirdly, the material should be weldable for you. Fourthly, it must be corrosion resistant; otherwise, all of your efforts will be ruined. On the other hand, extremely stiff and brittle materials cannot be a part of sheet metal processing.

What Are the Shapes Of Sheet Metals?

Usually, you can find two shapes of sheet metals available. One is a flat sheet that is the rectangular shape of a metal sheet that is flat and uniformly thicken. Whereas another shape is coiled sheet metal. A flat sheet is typical, while the coiled sheet metal is formed through roller slitters.

Flat sheet metal	Coiled sheet metal

What Products Can You Make from Sheet Metal?

It is really hard to find out any industry that is not consuming sheet metal. A significant example is the automobile industry that needs sheet metal for car frame formation. Also, trucks, buses, aeroplane bodies are manufactured using these sheet metals.

Another big example that you can find is the body of various computers, laptops, printers, photocopiers, cellular phones, all made of sheet metal. The electrical industry is also dependent on sheet metals. For example, transformers body, main switch bodies, connections, terminals, carriers, etc., are made of sheet metals.

The food industry also uses sheet metal to form food container tins. You can also notice many products like furniture, fences, signs, lamps, vessels all made of sheet metal.

Why Do You Achieve Edge Rounding of Metals in Sheet Metal Processing?

You reduce the sharpness of the edge with edge rounding.  This is important to make sheet metals useful and reliable to make them safe for industrial and other usages in homes. The food and chemical sector also requires edge rounding for lacquering and coating their products.

What Is Sheet Metal Forming in Sheet Metal Processing?

You can define metal forming as a type of manufacturing technique that has significant importance in all metal processing techniques. In this manufacturing process, you maintain the cohesion that is the attraction among material particles. Plastic deformation is usually used to update the outlook of your workpiece in this process.

During the plastic deforming process, you exert extreme external forces to change the location of the atoms at sliding planes. This results in the modifications of physical and technological properties, which you will call “hardening.”

In general, this process is competitively easy at a specific temperature which you call forming temperature. At that temperature, the resistance to deformation of metals is reduced by many folds. At this temperature, you will notice immediate recrystallization of the microstructure of the metal hence avoids hardening. Thus, plastic forming of steel at forming temperature needs much less work and effort as compared to room temperature.

What Is the Difference Between Cold and Hot Forming during Sheet Metal Processing?

As you can comprehend by the name, cold forming requires less temperature, whereas hot forming is done at high temperatures. Both have their own advantages and disadvantages.

In hot forming, you apply specific techniques under high temperatures to achieve better formability. You might experiences poor dimensional tolerances as well as scored surfaces in the hot forming process, which are probably its major disadvantages.

Whereas you can get precise dimensional tolerances through the cold forming process. You do not have to heat the material, which results in increased strength. But this cold-formed workpiece could only be welded if you soft annealed, thus minimizing stress.

What Are Common Metal Forming Processes in Sheet Metal Processing?

Some of the most common ones are as follows,

· Curling

Smoothing out the edges of sheet metals is termed curling. When you produce sheet metal, they often contain sharp edges with a burr, initially. The main purpose of curling to turn the sharp or rough edges into smooth metal sheets.

· Ironing

To get the required thickness, you can iron the sheet uniformly. For example, the ironed aluminium is the basic element in the manufacturing process of aluminum cans.

Mostly you find aluminum sheet metal thicker enough initially that they are not suitable to transform into food cans. So you need to iron them to get the desired composition. This process uses two dies and punching the sheet among those to achieve the desired result.

· Bending

Other important methods also include bending, in which sheet metals are converted into specific shapes using stress or punch.

What Is Separating Manufacturing Sheet Metal Processing?

Separating the manufacturing process forms a main group among the manufacturing processes. This process explains techniques that you can incorporate to change the shape of a solid body that can also be the workpiece. You need to reduce or completely wipe out the cohesion to make this change happen.

This sheet metal process also allows you to keep the original shape of the product as the final shape too. It dismantles the composite bodies. Thus, Sheet metal processing is super useful when it comes to producing desired designs and products.

What Are Major Separation Processes in Sheet Metal Processing?

The two major and most significant separation processes in Sheet Metal Processing are cutting and punching. These procedures allow you to manufacture products with great precision and accuracy.

· Cutting

Fort cutting you apply shearing force, therefore sometimes called as shearing processes too. If you apply great enough shearing force to exceed the inner shear stress in the material which results in the collapse of the material, and it gets separated at the cutting location.

You can apply this with two tools. These tools can also be called upper and lower blades as one is applied above the sheet and the other below the sheet. The lower tool is used for placing the sheet metal, while the upper tool is used to produce the blow pressure downwards.

Sheet thickness, specific shearing process, and the material itself determine the size of clearance. As sheering goes on, you can notice its effect on the cutting edge of the material. It can deform plastically and “rollover” the edge.

When the blades penetrate into the metal further vertical burnished zone of material appears. Stress gets higher and higher, and finally, material fractures at an angle. You can see some blur, too, at the cutting edges.

· Punching

Another significant separation process is sheet metal punching, in which the substance or the material is removed from a metal’s piece by applying a great force. You can even use CNC Punching to produce desired shapes and sizes by making holes or cutouts in the product.

Punches are of simple geometrical shapes, e.g., circle, square, rectangle, or combinations of these shapes. The punch then presses downward at high speed through the sheet towards the die below. The cut slug is punched out of the sheet falls down through the opening in the die. You can execute punching manually using punch press, or advanced computer numerical controllers can be employed.

What Is Termed as Sheet Metal Joining in Sheet Metal Processing?

You can understand joining as the metal steel process in which numerous solid bodies are attached together permanently. The resulting bodies do get specific geometric shapes via this sheet metal processing.

This process is usually done through a “formless material.” A formless material is one with no proper shape and structure.

What Is Drawing In Sheet Metal Processing?

This is one of the sheet metal processing techniques in which the shape is transformed with material retention. Punching operation is applied to the sheet metal. If the depth of the drawn part exceeds its diameter, it is termed as deep drawing.

Deep drawing is achieved by punching between a series of dies over and over again. The metal area under the die experiences compression of tangential and radial draw type. At times you may notice flange wrinkles as a stress result. But you can use a blank holder to avoid wrinkles.

What Are Joining Processes of Sheet Metal processing?

Some of the most common joining processes are discussed below,

· Soldering

You can define soldering as a joining process that joins different types of metals using a melting solder. Solder is usually made of metal alloy, for example, tin and lead that is melted using a hot iron. The solder is heated above 600 degrees Fahrenheit which then cools down to make a strong electrical bond.

· Welding

You can join two metal sheet parts together with a welding torch. This torch increases the temperature of the specific portion and turns it into the melted form. Then the melting parts are combined and fused together and get permanently join when they get cool.

You can find different types of welding that can be melt welding or pressure welding. Other types can be arc welding and spot welding, TIC, and MIG welding.

· Screwing

You can tap the thread of screws for quick and strong assembling and joining. These can easily be disassembled.

· Riveting

You just rivet the crimp nut on the sheet metal, which joins with the corresponding outer nut. This gives strong joining of the sheet metal as required.

· Folding

Two sheet metals are joined by folding and bending tabs. This can be in the form of clamps or buckles. This rapidly assembles the required portions conveniently, but it can be poorly précised.

· Glueing

You can join metals together or metal to other materials using metal glue. There are different types of glue available to join metals. The right type of glue at the right place in the right amount can be not less than any other joining technique. But it has its own limitations like every other technique.

What Is Surface Technology in Context of Sheet Metal Processing?

Different processes and techniques that you use to enhance surface properties are termed surface technologies. You can supplement the primary function of sheet metals through surface treatment.

You coat the surface with paint or warmish-type materials. You can remove a layer of the surface through burnishing or electropolishing. Other several mechanical and chemical surface treatments are also available that you can choose according to your need.

What Are the Significant Advantages of Surface Treatment During Sheet Metal Processing?

You can enhance the mechanical and physical characteristics of the metals to make your product make more resistant, so the overall performance gets improved. That’s why during sheet metal processing, metal treatment is considered highly essential before the end product is going to be shipped to market.

What Surface Characteristics Can You Improve in Sheet Metal Processing?

The surface treatment enhances these features of sheet metal products.
· Aesthetics
Mostly surface treatments allow the sheet metal products to become more attractive. For the car sector, home appliance and medical purpose metal treatments have become mandatory to make products more appealing and successful to market.

· Duration

You can delay the metal oxidation process using Surface treatment techniques. That, in turn, will hinder rust, so the duration will prolong.

· Durability

Surface treatment helps you to increase the surface hardness of the single sheet metal products. They become more resistant to mechanical stress.

 What Are Common Processes of Metal Surface Treatment during Sheet Metal Processing?

Many processes are used for surface treatment in sheet metal processing. The most significant of those are described here. These processes are applied to iron, copper, aluminum, stainless steel. It is also useful for alloys. They not only improve the resistance of metal sheets but also helps to attain better finishing quality.

· Metal painting

You can coat acrylic or epoxy resin type of paint to increase the resistance towards corrosion by coating—this technique is mostly used by automotive field and household objects like furniture, etc.

· Metal plating

You can coast the sheet metal products using a layer of some other metal or alloy. Mostly zinc, nickel, silver, or chrome layer is deposited using electroplating techniques. This process will preserve the products from any external agents.

· Metal burnishing

During Burnishing, you rub a smooth, hard tool with sufficient pressure on the metal surface. This causes the plastic flow of the metal, which flattens the high surface spots. It is done with a live flame to improve the appearance of the steel.

· Metal polishing

You can obtain polished products by grinding them with an abrasive paste. This process will make an impressive and smooth final effect.

· Metal sanding

With the help of a jet of sand and air, you remove the corroded and damaged parts from a metal object.

· Metal anodizing

In this process, you form a thin protective layer of oxide to aluminum, zinc, and magnesium sheet metals.

What Are Significant Tools That You Need for Sheet Metal Processing?

The list of tools for sheet metal processing goes on and on. However, you can divide them into two major categories. One is hand tools while the other being power tools.

Hand tools are supposed to be working with manual power. These tolls are only useful for a small level of work. These can include hammers, files, piston files, file drawing pins, iron saws, pliers blind riveting pliers, shell irons, ejector pistols, file pistons, and so on. On the other hand, you can define power tolls as tools working with electric power.

How Can You Differentiate Between Metal Stamping and Metal Fabrication in Sheet Metal Processing?

You do metal stamping with the help of punch presses with specific tools and dies to produce the required shape or pattern. It is used when metal parts are to be produced in bulk. With large quantity production, this method is highly cost-effective. It includes basic metal forming operations like bending, pressing, stamping, folding, etc.

For Metal fabrication, you use specialized equipment, for example, CNC laser cutters and press brakes, welding, and CNC turret presses. You can utilize it for the manufacturing of three-dimensional metal parts. The major operation involved here is bending, cutting and other assembly processes. As compare to stamping, it provides more design flexibility.

How to Choose Among Stamping and Metal Fabrication during Sheet Metal Processing?

You should choose fabrication if you are producing complex parts that can be three-dimensional. Whereas stamping is used to produce simple and two-dimensional parts. The main selection criteria further can be manufacturability of the part and its quantities required. Manufacturability here means that the part you are producing is complex or simple? Will be manufactured through stamping, or will fabrication be better?

Moreover, the material underuse can be a deciding factor. Since stamping produces less scrap than fabrication, so with expensive material, you are more likely to choose to stamp over fabrication.

How Blanking and Piercing are used in Sheet Metal Processing?

These both are shearing processes and utilize the punch and die to produce required parts from steel metal.

In the blanking process, the metal sheet piece is placed between punch and die. The blanking cutout part, which is cut in a die’s shape, is the required part, whereas the leftover sheet metal piece is the scrap.

In contrast, piercing is a type of punching operation that produces an extruded hole in the workpiece. It can further be explained as the punched-out part is just scrap and the desired product is the sheet metal.

What Is Laser Cutting in Sheet Metal Processing?

Laser cutting is an advanced cutting technology. It is a thermal process in which cutting is done by directing a high-power laser beam that melts the material in that specific area on the metal sheet.

One of the basic processes in metal fabrication is cutting. Laser cutting is just the go-to technology to perform those cutting jobs because of its being so advanced. Since laser cutting does not apply any force, so the threat of metal deformation flies away. Furthermore, it is fast, highly précised, allows narrow cutting slots, fatly. Because of such advantages, most of the manufacturers in china prefer laser cutting over other traditional methods. China produces WSX laser along with Raycus laser to offer the most economical cuttings.

What Are the Benefits Of Laser Cuttings in Sheet Metal Processing?

Although advantages of laser cutting are countless. You can describe Major advantages as under:

· Fastness

You will find Laser cutting a lot quicker than the traditional mechanical cutting method. During more complex cuts, this fastness is more noticeable.

· Quality

You will find a really small burr in laser cutting. This will be small enough to remove. But this quantity of burr is dependent on the material type and other factors like sheet metal thickness.

· Precision

Laser cutting is supposed to be highly precise since laser cutting is highly accurate as compared to other thermal cutting techniques. You won’t need any added tolerances since the accuracy meets its highest standard, being +/-0.1 mm without any after treatment.

· Flexibility

You will find the same setup of laser cutting suitable for the same material thickness. Even the intricate cuts are managed easily. You will not require any exchange of the tools as long as the sheet metal does not changes its width, length or thickness.

· Automation

Most of the laser cutting machines come with feeding systems, so they offer high precision. They need only a little manpower to be highly automated. Labor hiring cost cuts down by many folds. High speed is another big advantage, so more work is done in the given time with a smaller number of laborers.

What Are the Main Drawbacks of Laser Cutting?

As you know, everything on the earth offers a lit bit of disadvantages, no matter how much useful it be. The same is the case with laser cutting. Here are major disadvantages that you may find with laser cutting.

· Expensive

Laser-cutting machines are expensive. You can find their prices as high as £1,000,000. That is almost double as compare to waterjet or plasma cuttings.

· Metal Thickness Limitations

You will find laser cutting not suitable with the high thickness of the sheet. Mostly the laser cutters are suitable for maximum thickness being up to 15 or 20 mm. Anyhow the available machinery, along with the expertise to use it, are the main deciding factors of the highest suitable thickness.

· Environment unfriendly

One of the disadvantages of laser cutting is, it melts the material for fine cutting. This melting metal produces several types of gases and dangerous fumes. So advance ventilation is highly required to make the working environment safe.

So here you read the ultimate guide for sheet metal processing. Hope all of your queries are resolved to know. You would have become a good knowledgeable person in this field.  You are now familiar with nearly all major sheet metal processes. It is easy for you now to choose the best suitable process among all processes according to the product you are going to make.

For further understanding, this video is supposed to be helpful for you.

https://www.youtube.com/watch?v=L0YgSmfwzWYs