Sheet metal processing is a key process in modern manufacturing, supporting the manufacture of products in various industries. This paper makes an in-depth analysis of its sheet metal process flow, material selection and technical points to show its unique charm.
Basic concepts of sheet metal processing
① What is sheet metal processing
Sheet metal processing involves processes such as cutting, bending, stamping, welding, riveting and surface treatment to work sheet metal into specific switches and dimensions. This processing method is often used to manufacture shell, cover body, bracket and other parts with high precision and appearance requirements.
② Application fields of sheet metal processing
Sheet metal processing is widely used in electronic appliances, automobiles, aerospace, communications, medical, agriculture, construction and other industries. It involves the manufacture of complex components ranging from mobile phone casings to aircraft structures.
Sheet metal processing method:
(1) Non-mold processing: through the number of punching, laser cutting, shearing machine, folding machine, riveting machine and other equipment for sheet metal processing process, generally used for sample production or small batch production, the cost is slightly higher.
(2) Higher processing: through a fixed mold, sheet metal processing, generally have blanking die, forming die, mainly used for mass production, low cost.
Sheet metal processing process
First, the way of cutting materials:
1, cutting material: refers to the material through the shearing machine to obtain a rectangular workpiece process. Using CNC shearing machine for net size machining, this is not a high requirement of workpiece processing, processing cost is low.
2, the number of punching: refers to the use of CNC punching machine for one or more steps in the sheet parts to form various shapes of materials and parts, its advantages are mainly high production efficiency, high precision, low cost, suitable for batch production. The key point of the number of punching is to arrange the material, calculate the material, and process the quantity adequately at one time.
3, laser cutting: refers to the workpiece through the laser cutting process.
4, water jet cutting: it can cut the material into any shape. And there is no heat affected zone in the water jet cutting process, which is mainly used for processing materials that are not suitable for heat treatment.
5, cutting machine cutting: refers to the grinding wheel electric cutting machine for a process of cutting, this is not high requirements, mostly for the profile class of cutting.
6, sawing material: refers to a process of cutting with a sawing machine, which is not high requirements, mostly for the cutting of profiles.
7, blanking: refers to the process of using the mold to process the shape of the product on the ordinary punch or other equipment.
Two, punching and broaching process
Punching: refers to the process in which the workpiece is processed by the ordinary punching machine and the mold. Punch holes or shapes into metal. Tools include automatic punching machines, manual punching machines and CNC machine tools.
Punching types are:
ⅰBlank punching (cut round or non-round blank)
ⅱDie punching (cutting out various shapes)
Ⅲ Advanced die stamping (cutting a variety of shapes)
Broaching is tapping after machining a small base hole into a slightly larger hole, which is often used in sheet metal processing to increase strength and thread count. Thick plate such as 2.0mm or more can be directly tapped.
Three, press the rivets
Press riveting: refers to the process of using a punch or hydraulic press to firmly press riveting nuts, riveting screws or riveting nut columns and other fasteners to the workpiece.
Attached picture (File name: Sheet metal processing bending
Four, sheet metal bending process
Bending: refers to the process of forming the workpiece by the bending machine. Use the corresponding bending mold, first test machine, adjust machine, first check to produce. In the bending process, the principle is that the first bending will not interfere with the part of the next process, and then bend the part that may cause interference.
The following is the general process of bending:
- Positioning: Place the sheet metal on the bending machine, adjust the position, and secure it.
- Adjustment: Adjust the clamping force, bending force and bending Angle of the bending machine according to the requirements of the design drawings.
- Bending: Place the sheet metal material in the bending part of the bending machine and start the machine to bend. Take care to control the bending speed and Angle.
- Check: Each time you bend, you must confirm whether the bending Angle and the height of the straight edge meet the requirements.
5, clean: After the bending is completed, clean the bending machine and sheet metal surface, remove residual impurities and traces.
Five, sheet metal welding
Sheet metal welding: refers to the edge seam welding of a single part, or the connection of multiple parts together to enhance the strength of the part. Common welding methods are TIG welding, MIG/MAG welding, gas shielded welding (such as carbon dioxide welding) and laser welding. The selection method should take into account the material, requirements and equipment conditions.
Six, polishing and polishing
Polishing: mainly refers to the use of grinding machine, file and other tools to make the workpiece welding scar smooth, smooth process. After welding, it is necessary to polish and check, and use emery cloth to remove the edges, welding slag, etc., so that the weld is smooth. Avoid edges and corners to prevent cracks, check the weld to ensure quality, and provide guarantee for subsequent use and installatio
Seven, surface treatment
Surface treatment: refers to the surface treatment of sheet metal parts after processing to play a role in anti-corrosion protection and decoration, improve its appearance and service life. Common surface treatments are: powder spraying, galvanizing, hot dipping zinc, surface oxidation, surface drawing, screen printing and so on.
Powder spraying: Sheet metal commonly used surface treatment, through powder spraying, electrostatic adsorption and high temperature baking, the formation of a colorful coating on the sheet metal, both beautify the appearance and enhance corrosion resistance.
Electrogalvanizing: refers to the process of plating a layer of metal on the surface of the workpiece for the protection or aesthetics of the workpiece. Thin zinc layer, good decorative, suitable for light anti-corrosion occasions.
Hot dip zinc: thick zinc layer, strong corrosion resistance, suitable for outdoor heavy corrosion protection environment.
Surface oxidation: refers to the process of forming an oxide film on the surface of the workpiece in order to protect or beautify the workpiece.
Surface drawing: under normal circumstances, aluminum profiles do this surface treatment, through the motor driven wire drawing machine, under the action of sand belt to form a trace of different thickness, beautify the appearance.
Screen printing: refers to the process of using special ink to penetrate a special grid to form text or patterns on the surface of the workpiece.
Assembly: refers to the process of assembling more than two workpieces together. The assembly of sheet metal structural parts, in principle, the large parts sprayed and the tapping of the cabinet are responsible for assembly.
Packaging: refers to the process of protecting the workpiece and facilitating transportation.
Attached figure (file name: Aluminium sheet metal parts
Sheet metal manufacturing materials and applications
Common materials for sheet metal processing include cold-rolled plate (SPCC), hot-rolled plate (SHCC), aluminum plate (such as 6061, 6063 and duralumin), galvanized plate (SECC/SGCC), copper, copper, bronze, brass, stainless steel, etc. Use and cost should be considered when choosing.
Cold-rolled steel (SPCC) : low cost, easy to form, high strength, but toughness, poor weldability, suitable for electroplating, painting parts, smooth surface, no additional finishing.
Galvanized sheet (SECC, SGCC) : Galvanized sheet refers to a layer of metal zinc plated on the surface of the steel plate to prevent surface corrosion of the steel plate and extend its service life.
Aluminum plate (6061, 6063) : good corrosion resistance, light weight, good heat dissipation, easy to rapid prototyping process. Stainless steel: It is an easy to process corrosion resistant alloy, with good heat resistance and processing properties. The cost of stainless steel is higher than that of aluminum.
Copper: holds good electrical conductivity, thermal conductivity, corrosion resistance and ductility. Simple manufacturing process, beautiful appearance.
Brass: an alloy of copper and zinc. Corrosion resistance, no stress deformation, high strength, good machinability.
Copper: has excellent electrical and thermal conductivity. Copper is often used in copper because it does not corrode in air or water.
Advantages of sheet metal processing
Sheet metal processing is an economical and efficient metal parts production method, compared with the traditional method, its cost is lower, the processing process is simple. Its parts are characterized by high strength, high precision, durability and lightweight, suitable for various environments and working conditions. In addition, sheet metal processing can also achieve rapid production to meet the various needs of the market.
Sheet metal manufacturing applications
Sheet metal manufacturing is suitable for a variety of industries, including: aviation, automotive, construction, chemical, medical, telecommunications, energy, furniture, home appliances, food, decoration, ships, electronic appliances, hardware and other industries.
Conclusion: The above is the complete guide to sheet metal machining, and wherever you are, you can get our 24/7 engineering support all year round. Our team provides you with the most suitable solution, including part design, material selection, surface treatment and fast delivery. Contact the Futai manufacturer Learn more about sheet metal manufacturing or request a free quote.