What equipment is required during sheet metal processing?

The equipment required for sheet metal processing varies depending on the processing technology. The following are some commonly used equipment:

Cutting machine:

Used for cutting sheet metal materials, it can perform both straight and curved cutting.

Bending machine:

Used to bend sheet metal to achieve the desired shape and angle.

Punch press:

Used for punching, stamping, and other processing on the surface of sheet metal.

Welding equipment:

Various welding equipment, including manual welding, gas shielded welding, laser welding, etc., are used for welding sheet metal parts.

Polishing machine:

Used for polishing and polishing the surface of sheet metal to make it flat and smooth.

Spraying equipment:

Used for spraying sheet metal to achieve anti-corrosion, decorative and other purposes.

Laser cutting machine:

Used for high-precision cutting of thinner sheet metal.

CNC bending machine:

Used for high-precision bending of sheet metal.

Machining center:

Used for complex sheet metal processing, it can perform various operations such as milling, drilling, and tapping.

The above are commonly used equipment for sheet metal processing, and the specific selection and combination of equipment need to be determined based on processing requirements and process flow.

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9 GIF dynamic images tell you how sheet metal is processed

In daily life, we see products that use sheet metal, ranging from small iron boxes to large aircraft and ships. The shell of household appliances, mobile phone parts, etc. are all applied to sheet metal technology.

As a product designer, there is no need to visit the factory. Through the following dynamic pictures, you can also have some understanding of sheet metal technology.

Sheet metal stamped circular cover

Bending and forming of stepped parts

Bending and forming of double pendulum block parts

One-time bending forming

Circular parts are formed by pressing and bending

Bending and forming of folded parts

Sheet metal laser cutting forming - can also be stamped and cut

Progressive mold simple stretching forming

Riveting

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What are the processes for sheet metal processing

Sheet metal processing is a manufacturing process widely used in various industrial fields, which involves processing raw materials such as metal sheets, thin plates, and strips into metal products with specific shapes, sizes, and performance requirements through a series of process operations. Sheet metal processing encompasses numerous process steps, each with its unique characteristics and application scope. The following will provide a detailed introduction to the main processes of sheet metal processing.

 

1、 Cutting process

Cutting is one of the most basic processes in sheet metal processing, mainly used to cut raw materials into the desired shape and size. The cutting process includes various methods such as mechanical cutting, laser cutting, plasma cutting, and water jet cutting. Mechanical cutting is suitable for thicker plates, while laser cutting and plasma cutting are suitable for thinner materials, enabling high-precision and high-efficiency cutting.

2、 Stamping process

Stamping is one of the commonly used processes in sheet metal processing, which uses punching machines and molds to stamp raw materials to obtain the desired shape and size. Stamping technology has the advantages of high production efficiency, low cost, and high material utilization, and is widely used in sheet metal processing in industries such as automobiles, electronics, and home appliances.

3、 Bending process

Bending is the process of bending sheet metal materials according to predetermined angles and shapes. The bending process can be achieved through various methods such as mechanical bending, hydraulic bending, and pneumatic bending. The bending process plays an important role in sheet metal processing, as many products require bending to obtain the desired shape and structure.

4、 Welding process

Welding is the process of melting two or more metal components by melting their contact parts, and then cooling and solidifying them into a whole. In sheet metal processing, welding technology is commonly used to connect multiple sheet metal parts together to form a complete product. Welding processes include various methods such as arc welding, gas welding, laser welding, etc. The choice of welding method depends on factors such as material properties, welding requirements, and processing conditions.

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Sheet metal manufacturing process guide: cutting, bending

Sheet metal manufacturing is a valuable prototyping and production method used to manufacture sturdy functional components such as panels, brackets, and casings.

However, unlike other manufacturing technologies, sheet metal manufacturing actually involves many different processes, all of which manipulate sheet metal in different ways. These different processes may involve cutting metal sheets, shaping them, or connecting their different parts together.

This guide focuses on the main sheet metal manufacturing processes and explains their working principles and applications.

What is sheet metal processing?

Sheet metal manufacturing is a set of manufacturing processes that successfully process sheet metal into functional components. For this guide, we divide the process into three categories: cutting, deformation, and assembly.

Common sheet metal materials include steel, stainless steel, aluminum, zinc, and copper, with specifications typically ranging from 0.006 to 0.25 inches (0.015 to 0.635 centimeters). Thin specifications are more ductile, while thicker specifications may be more suitable for heavy-duty parts with severe applications.

For partially flat or hollow parts, sheet metal manufacturing can become an economically efficient alternative to processes such as casting and machining. The process is also fast and generates minimal material waste.

Sheet metal manufacturing is widely used in industrial and consumer parts, as well as professional industries such as automotive, aerospace, energy, and robotics.

Sheet metal processing: cutting

One of the three main methods of manipulating sheet metal is to cut it. In this sense, sheet metal manufacturing can be considered as a subtractive manufacturing process (such as CNC machining), as usable parts can be manufactured by simply removing material parts.

Manufacturers can use various machines to cut sheet metal, some of which are unique to sheet metal manufacturing.

One of the key methods for sheet metal cutting is laser cutting. Laser cutting machines use powerful lasers enhanced by lenses or mirrors. It is a precise and energy-saving machine suitable for thin or medium-sized metal plates, but may be difficult to penetrate the hardest materials.

Another sheet metal cutting process is water jet cutting. Water jet cutting is a sheet metal manufacturing method that uses high-pressure water jets (mixed with abrasive materials) to cut metal. Water jet cutting machines are particularly suitable for cutting low melting point metal sheets because they do not generate heat that may cause excessive deformation of the metal.

The third sheet metal cutting option is plasma cutting. The plasma cutting machine creates an ionized gas electric channel, forming a hot plasma jet that can even easily penetrate thick metal plates. Although not as accurate as laser or water jet cutting machines, plasma cutting machines are fast, powerful, and have low setup costs.

These three cutting machines can be used for materials other than sheet metal, but there are also some technologies that are only used for sheet metal manufacturing.

For example, the stamping process (sometimes referred to as punching) uses punches and molds to create precise holes on sheet metal. The metal plate is placed between two components, and the punch forces itself through the metal to reach the mold. During the stamping process, the removed material from the stamped circular parts is turned into waste, but these circular parts can also be used as new parts: this is called cutting.

When creating many holes, similar devices can be used to pierce the metal plate.

Sheet metal processing: bending

Another major category of sheet metal manufacturing processes is sheet metal bending. This set of processes involves countless methods to modify and manipulate sheet metal without cutting into it.

One of the main deformation processes is sheet metal bending. Using a machine called a brake, a sheet metal company can bend sheet metal into V-shaped, U-shaped, and channel shapes, with a maximum angle of 120 degrees. Thin sheet metal specifications are more prone to bending. The opposite can also be done: sheet metal manufacturers can remove horizontal bending from strip sheet metal parts through a debending process.

The stamping process is another deformation process, but it can also be considered as a subcategory of its own. It involves the use of hydraulic or mechanical stamping machines equipped with tools and molds, which operate similarly to stamping - although material removal may not necessarily be necessary. Stamping can be used for specific tasks such as curling, drawing, embossing, flanging, and edging.

Spinning is a sheet metal manufacturing process that, unlike other deformation techniques, uses a lathe to rotate the sheet metal while pressing it onto a tool. This process looks similar to CNC turning or even ceramic spinning, and can be used to create circular sheet metal parts such as cones, cylinders, etc.

Less common sheet metal deformation processes include wheel forming, which is used to create composite curves in sheet metal, as well as rolling, where the sheet metal is fed between a pair of rollers to reduce its thickness (and/or increase thickness consistency).

Some processes fall between cutting and deformation. For example, the process of sheet metal expansion involves cutting multiple slits on the metal and then pulling the sheet metal apart like an accordion.

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The advantages of precision sheet metal processing

Precision sheet metal processing is a high-precision and high-quality metal processing technology widely used in various fields, such as electronics, communication, medical, aerospace, etc. The following are some characteristics and advantages of precision sheet metal processing:

High precision: Precision sheet metal processing usually uses advanced CNC machine tools and processing equipment, which can achieve micrometer level machining accuracy, ensuring that the size and shape accuracy of the product meet high standard requirements.

Stable quality: Through precise processing control and quality inspection, precision sheet metal processing can ensure product consistency and stability, reduce scrap and rework rates, and improve production efficiency.

Material diversity: Precision sheet metal processing can handle various metal materials, such as stainless steel, aluminum, copper, titanium, as well as various alloy materials. These materials have different physical and chemical properties and can be selected according to the specific needs of the product.

High processing complexity: Precision sheet metal processing can handle various complex shapes and structures, such as curved surfaces, hollowing, bending, etc. These complex shapes and structures often require high-precision processing equipment and technology to achieve.

Wide applicability: Precision sheet metal processing is not only suitable for mass production, but also for small batch and customized production needs. It can meet the needs of various industries for high-precision and high-quality sheet metal products.

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Sheet metal workpiece feeding

 After receiving the drawings, different cutting methods are selected based on the unfolded drawings and batch sizes, including laser, CNC punching machine, cutting board, mold, etc. Then, corresponding unfolds are made according to the drawings. CNC punching machines are affected by cutting tools, and for the processing of some irregular workpieces and irregular holes, large burrs may appear at the edges. It is necessary to carry out later deburring treatment, which also has a certain impact on the accuracy of the workpiece; Laser processing has no tool restrictions, a flat cross-section, and is suitable for processing irregular workpieces, but it takes a long time to process small workpieces. Placing workbenches next to CNC and laser is beneficial for placing the sheet metal on the machine for processing, reducing the workload of lifting the sheet metal. Some usable edge materials are placed in designated locations to provide materials for trial molding during bending.

After the workpiece is cut off, necessary trimming (polishing treatment) should be carried out on the edges, burrs, and joints. At the tool joint, a flat file should be used for trimming. For workpieces with larger burrs, a polishing machine should be used for trimming. At the small inner hole joint, a corresponding small file should be used for trimming to ensure the appearance is beautiful. At the same time, the trimming of the shape also ensures the positioning during bending, so that the workpiece is in the same position on the bending machine during bending, ensuring the consistency of the size of the same batch of products.

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Classification of laser cutting processes

1. Vaporization cutting:

Under the heating of a high-power density laser beam, the speed at which the surface temperature of the material rises to the boiling point temperature is fast enough to avoid melting caused by thermal conduction. As a result, some materials vaporize into steam and disappear, while others are blown away as ejecta from the bottom of the slit by auxiliary gas flow.

2. Melting cutting:

When the power density of the incident laser beam exceeds a certain value, the material inside the beam irradiation point begins to evaporate, forming holes. Once this small hole is formed, it will act as a blackbody to absorb all the energy of the incident beam. The small hole is surrounded by a molten metal wall, and then an auxiliary airflow coaxial with the beam takes away the molten material around the hole. As the workpiece moves, the small hole synchronously moves horizontally in the cutting direction to form a cutting seam. The laser beam continues to shine along the front edge of this slit, and the melted material is continuously or pulsatively blown away from inside the slit.

3. Oxidation melting cutting:

Melting cutting generally uses inert gas. If oxygen or other active gases are used instead, the material is ignited under the irradiation of the laser beam, and undergoes a fierce chemical reaction with oxygen to produce another heat source, which is called oxidation melting cutting. The specific description is as follows:

(1) The surface of the material is quickly heated to the ignition point temperature under the irradiation of a laser beam, and then undergoes a fierce combustion reaction with oxygen, releasing a large amount of heat. Under the action of this heat, small pores filled with steam are formed inside the material, surrounded by molten metal walls.

(2) The transfer of combustion materials into slag controls the combustion rate of oxygen and metals, and the speed at which oxygen diffuses through slag to reach the ignition front also has a significant impact on the combustion rate. The higher the oxygen flow rate, the faster the combustion chemical reaction and the removal of slag. Of course, the higher the oxygen flow rate, the better, because too fast a flow rate can lead to rapid cooling of the reaction products, namely metal oxides, at the cutting seam outlet, which is also detrimental to cutting quality.

(3) Obviously, there are two heat sources in the oxidation melting cutting process, namely laser irradiation energy and thermal energy generated by the chemical reaction between oxygen and metal. It is estimated that when cutting steel, the heat released by the oxidation reaction accounts for about 60% of the total energy required for cutting. It is evident that using oxygen as an auxiliary gas can achieve higher cutting speeds compared to inert gases.

(4) In the oxidation melting cutting process with two heat sources, if the combustion speed of oxygen is higher than the movement speed of the laser beam, the cutting seam appears wide and rough. If the laser beam moves faster than the combustion speed of oxygen, the resulting slit is narrow and smooth. 

4. Control fracture cutting:

For brittle materials that are prone to thermal damage, high-speed and controllable cutting through laser beam heating is called controlled fracture cutting. The main content of this cutting process is: the laser beam heats a small area of brittle material, causing a large thermal gradient and severe mechanical deformation in that area, leading to the formation of cracks in the material. As long as a balanced heating gradient is maintained, the laser beam can guide cracks to occur in any desired direction.

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Sheet Metal Welding Process

Sheet metal welding is a fundamental technique in manufacturing and construction, involving the joining of thin metal sheets to form robust structures. This process is pivotal in producing a wide array of products, from automotive bodies and aircraft components to household appliances and electronic enclosures.

The welding process for sheet metal can be executed through various methods, each chosen based on the material properties, thickness, and intended application. Common techniques include Gas Tungsten Arc Welding (GTAW or TIG), Gas Metal Arc Welding (GMAW or MIG), and Resistance Spot Welding. TIG welding is preferred for its precision and control, making it ideal for intricate and delicate work, while MIG welding is known for its speed and efficiency, suitable for larger scale projects. Resistance spot welding, on the other hand, is extensively used in the automotive industry for its ability to create strong welds quickly without the need for filler materials.

A critical aspect of sheet metal welding is the preparation of the metal surfaces. Cleaning and aligning the sheets are essential steps to ensure strong, defect-free welds. Contaminants like oil, rust, or paint can significantly compromise the weld quality. Proper fixturing and clamping techniques are also employed to maintain alignment and minimize warping during the welding process.

Safety is paramount in sheet metal welding. Welders must use protective gear, including gloves, helmets with face shields, and appropriate clothing, to protect against sparks, UV radiation, and harmful fumes.

Advancements in welding technology, such as automated welding systems and advanced robotics, have enhanced precision, speed, and safety, making sheet metal welding a continually evolving and indispensable process in modern manufacturing and construction.

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What is the laser cutting process?

The laser cutting process uses the energy released when the laser beam is irradiated on the surface of the steel plate to melt and evaporate the stainless steel. Laser sources generally use carbon dioxide laser beams with a working power of 500-2500 watts. The power level is lower than the power required by many household electric heaters, but through lenses and reflectors, the laser beam is concentrated in a very small area. The high concentration of energy enables rapid local heating, causing stainless steel to evaporate.

In addition, due to the high concentration of energy, only a small amount of heat is transferred to other parts of the steel, resulting in minimal or no deformation. Laser can accurately cut complex shaped billets without the need for further processing.

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The advantages and disadvantages of stamping

Compared with other processing methods, stamping forming has many unique advantages in both technical and economic aspects, mainly manifested in the following aspects:

(1) The dimensional accuracy is guaranteed by the mold, so the processed parts have stable quality, good consistency, and the characteristics of "identical"

(2) Stamping forming can obtain parts with thin walls, light weight, good rigidity, high surface quality, and complex shapes that other processing methods cannot or are difficult to manufacture;

(3) High material utilization rate, belonging to low and chip free processing;

(4) High efficiency, easy operation, and low technical level of required workers;

(5) The mold has a long service life and low production cost.

However, stamping processing also has the following drawbacks:

(1) High noise and vibration;

(2) High precision requirements for molds, complex manufacturing, long cycles, and expensive manufacturing costs limit small-scale production;

(3) If the precision requirements of the parts are too high, it is difficult for stamping production to meet the requirements.

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Common materials of sheet metal

 1. Galvanized steel sheet SECC

The base material of SECC is a general cold-rolled steel coil. After degreasing, pickling, electroplating and various post-treatment processes in the continuous electrogalvanizing production line, it becomes an electrogalvanized product. SECC not only has the mechanical properties and similar processability of general cold-rolled steel sheets, but also has superior corrosion resistance and decorative appearance. It has great competitiveness and substitutability in the market of electronic products, home appliances and furniture. For example, SECC is commonly used in computer cases.

2. Ordinary cold-rolled sheet SPCC

SPCC refers to steel ingots that are continuously rolled into steel coils or sheets of required thickness by cold rolling mills. The surface of SPCC has no protection and is easily oxidized when exposed to the air. Especially in a humid environment, the oxidation speed is accelerated, and dark red rust appears. When in use, the surface must be sprayed with paint, electroplated or otherwise protected.

⒊ Hot-dip galvanized steel sheet SGCC

Hot-dip galvanized steel coil refers to the semi-finished product after hot-rolled pickling or cold-rolled, which is washed, annealed, immersed in a molten zinc bath at a temperature of about 460°C, and the steel sheet is coated with a zinc layer, and then tempered, leveled and chemically treated. SGCC material is harder than SECC material, has poor ductility (avoid deep drawing design), thicker zinc layer, and poor electric weldability.

4. Stainless steel SUS304

One of the most widely used stainless steels, because it contains Ni (nickel), it is more corrosion-resistant and heat-resistant than steel containing Cr (chromium), has very good mechanical properties, no heat treatment hardening phenomenon, and no elasticity.

5. Stainless steel SUS301

The Cr (chromium) content is lower than SUS304, and the corrosion resistance is poor, but after cold processing, it can obtain good tensile force and hardness in stamping processing, and has good elasticity. It is mostly used for springs and EMI protection.

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What is sheet metal processing?

 The processing of metal sheets for parts is called sheet metal processing.

Sheet metal processing is a key technology that sheet metal technicians need to master, and it is also an important process for the formation of sheet metal products. Sheet metal processing includes traditional cutting, punching, bending and pressing methods and process parameters, various cold stamping die structures and process parameters, various equipment working principles and operation methods, and new stamping technologies and new processes.

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