Sheet metal fabrication involves various processes, with welding and bending being common ones. These processes are interconnected in sheet metal fabrication and typically require the selection of appropriate combinations based on specific design requirements and production scale. By precisely controlling the parameters and steps of these processes, sheet metal components that meet various functional requirements can be manufactured. They are widely used in sectors such as automotive, electronics, aerospace, and others.
What is sheet metal fabrication?
Sheet metal fabrication is a manufacturing process that involves transforming metal sheets through a series of operations to create components with specific functionalities. In this guide, we will primarily focus on the three core processes of sheet metal fabrication : welding, bending, and assembly.
Common sheet metal materials include stainless steel, aluminum, alloy steel, etc., with thickness ranging widely from 0.015 to 0.635mm. Different thicknesses of sheet metal materials exhibit different characteristics; for example, thinner sheet metal materials typically have better ductility, while thicker materials are more suitable for manufacturing heavy-duty parts requiring high strength and stability.
In sheet metal fabrication , for certain flat or hollow parts, sheet metal fabrication can serve as an economically efficient alternative. Compared to traditional casting and machining processes, it not only reduces costs but also improves production efficiency. Additionally, the sheet metal fabrication process is relatively fast and generates minimal material waste, giving it a significant advantage in the manufacturing industry.
Sheet metal fabrication finds wide-ranging applications, involving not only the production of industrial and consumer parts but also playing a crucial role in specialized fields such as automotive, aerospace, energy, and robotics. These industries demand high-quality and high-performance parts, and sheet metal fabrication is one of the key manufacturing processes capable of meeting these requirements.
Through precise sheet metal fabrication , Boyi Technology can manufacture metal parts with diverse shapes and functionalities, providing robust support for the development of various industries.
Sheet metal fabrication: Welding
One of the three main methods of working with sheet metal is welding it. It involves joining metal sheets in a specific manner. The principle of welding mainly relies on energy transfer, particularly the process of melting metals to form joints through the heat generated by friction between electrodes and workpieces, also known as heat conduction. Additionally, a strong magnetic field (eddy current) is produced when the current passes through, which aids in the welding process.
In sheet metal welding, there are several common methods, each with its specific applications and advantages.
Manual arc welding uses an arc welding machine and a manual welding gun to feed welding rods or wires into the weld seam, melting the sheet metal and welding material with the high temperature of the arc to form a welded joint.
TIG welding (Tungsten Inert Gas welding) is particularly suitable for welding thin plates and materials such as stainless steel.
MIG/MAG welding is a method of automatic welding using a metal electrode, suitable for scenarios where continuous wire feeding and arc current heating of sheet metal are involved.
Spot welding involves generating high temperatures at the contact points of two sheet metal pieces using electric current, causing the contact points to melt instantly and form weld spots.
During sheet metal welding, it is essential to follow a series of safety and operational procedures to avoid welding defects resulting from operational errors, such as welding undercut, cracks, porosity, and deformation. To prevent these welding defects, precise control of welding parameters, ensuring thorough cleaning and preparation of materials before welding, selecting suitable welding equipment and tools, avoiding welding residues, splashes, and sparks from entering the equipment, regular maintenance and inspection of welding equipment, and ensuring the quality of welding materials are all crucial.
Sheet metal welding finds widespread applications in various fields. In metal sheet fabrication, whether it’s smaller metal sheets or larger panels, efficient and precise processing can be achieved using welding techniques. In steel pipe fabrication, welding technology enables high-speed, high-quality, and large-scale production, and the control of arc energy can achieve precise welding results. In automotive sheet metal fabrication , welding technology plays a crucial role in key aspects such as body manufacturing.
Sheet metal fabrication: Bending
Another major category of sheet metal fabrication processes is sheet metal deformation. It involves shaping metal sheets into specific angles or shapes according to design requirements. This group of processes includes various methods to change and manipulate sheet metal without the need for cutting. It is widely used in fields such as automotive, electronics, aerospace, etc., for manufacturing various functional components and structural parts.
The basic principle of bending processes is to apply external forces to sheet metal to induce plastic deformation, achieving the desired shape and angle. During operations, precise control of bending force, speed, and angle is required to ensure part accuracy and quality.
Common sheet metal bending methods include:
Folding: Bending sheet metal using a folding machine or manual folding tools. Folding machines typically have different molds and fixtures to accommodate sheet metal pieces of various shapes and sizes. This method can achieve high-precision bending and is suitable for large-scale production.
Rolling: Rolling sheet metal into cylindrical or other tubular structures using a rolling machine. During rolling, control of rolling radius, rolling speed, and rolling force is necessary to ensure rolling quality.
Stretch bending: Bending sheet metal into the desired shape using tensile forces. This method is suitable for thicker sheet metal pieces and can achieve larger bending angles.
During bending processes, to avoid the metal protruding on both sides of the bend angle, causing a width larger than the original size, a semicircle can be made on both sides of the bending line before bending, with a diameter of 1.5 times the thickness of the material or more. Bending should be done as perpendicular as possible to the direction of the metal material fibers to avoid cracking at the bend. To ensure bending strength, bending should be attached to the longer edge as much as possible.
Sheet metal fabrication: Assembly
The assembly stage of sheet metal fabrication is the process of assembling sheet metal components that have undergone bending, welding, and other processing according to design requirements.
Sheet metal assembly can utilize various methods and techniques, selecting the appropriate method based on the product’s characteristics and requirements. Common assembly methods include bolt fixation, welding, riveting, etc. For sheet metal components that need to withstand large loads or have special requirements, reinforcement measures are needed to enhance the stability and safety of the assembly. These reinforcement measures may include increasing the number of bolts, using welded reinforcements, adding support structures, etc.
Alternatively, sheet metal parts can also be directly connected together through welding techniques. Common metals such as stainless steel and aluminum have good weldability.
Conclusion
Overall, welding and bending are two crucial process steps in sheet metal fabrication , requiring precise operation and strict control to ensure the quality and performance of the final products. However, regardless of your level of experience, Boyi Technology can provide you with professional sheet metal fabrication services. Additionally, we offer free quotes for sheet metal fabrication and prototype design, allowing you to better understand project costs and expected outcomes. Please feel free to contact us at any time, and let us contribute to your project together.
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