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Sheet Metal Fabrication Guide

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CUSTOM MECHANICAL SOLUTIONS TENERE.COM A STARTER GUIDE TO SHEET METAL FABRICATION An introduction to basic sheet metal fabrication terms and definitions INTRODUCTION Whether you’re liking a photo on social media or making the switch to a solar powered home, sheet metal is everywhere. And because its uses are so varied - from the servers that run social media platforms to in-home intelligent energy storage systems - we’ve put together a guide to help you understand the ins and outs of sheet metal fabrication. Sheet Metal Fabrication Defined nearly any shape or size. Sheet metal fabrication is the process of Depending on the process and the engineering transforming sheet metal into specific shapes, required, sheet metal fabrication often involves usually by bending, punching, or cutting. Metal varying levels of human interaction, but all involve sheets of various gauges can be manipulated into some form of heavy machinery and equipment. LASER CUTTING - an extremely precise method SET-UP TIME - the amount of time it takes to set METAL FORMING AND STAMPING of cutting that uses a concentrated beam of light. up the proper dies and punches for a job. This Also used by evil geniuses. time varies depending on the complexity of the Press Brakes Turrets and Lasers part and machine. MACHINING/MILLING - the controlled removal A press brake squeezes a single sheet of metal When it comes to cutting sheet metal, turret of material using a cutting tool or lathe. SHEARING - a form of cutting in which downward between two plates or dies to bend the metal to punches and laser cutters are common options. force is applied to sheet metal, causing it to break predefined specifications. The force (or tonnage) NESTING - strategically fitting multiple parts on a cleanly. needed to bend the metal is often determined by Turret punches hold a variety of standard tools to single sheet of metal to reduce waste. Commonly the type of metal, gauge, and geometry of the punch shapes into sheet metal. The sheet is laid arranged automatically by nesting software. SOFT TOOLING - the sheet metal fabrication bend. Press brakes offer two types of dies: flat and clamped into the turret, which is processes that include laser cutting, turret standard and custom. programmed to move the sheet metal across the PEMMING - the installation of threaded hardware punches, and press brake forming. machine bed and make a series of punches to (usually a specific set of threaded fasteners) to Standard dies produce simple bends based on achieve the desired part. The rotating turret allow for assembly; includes nuts, studs, and STAMPING - accomplished using steel dies - straight-forward geometry. But when products changes the tool based on which feature it needs standoffs. progressive and stage - that are designed to call for a more creative approach—like 3D to punch. GLOSSARY stamp, bend, and form sheet metal. shapes—a custom die must be developed. COINING - a different design is created on each PLASMA CUTTING - the use of concentrated Laser cutting utilizes laser technology to cut ASSEMBLY - the action of putting together side of the metal or on just the top layer and not ionized gas (plasma) to melt away portions of TONNAGE - the amount of pressure applied by a individual or partially assembled units to build a throughout - usually used for fine detail. sheet metal. Less precise than laser cutting. press. complete product. CUTTING - the use of blades, torches, lasers, and POWDER COATING - a dry powder surface TURRET - a type of punch press used to punch BASE METAL - the sheet of metal that is to be other means to remove pieces of sheet metal. coating that’s applied to final metal pieces. When sheet metal. Named after the rotating turret head cut, bent, or punched. heated, it forms a bond with the metal, ensuring a above the metal that rotates to change tools. DIE (PRESS BRAKE) - the cavity below a piece of lasting finish and color. BENDING - the process of applying pressure to sheet metal that allows the punch to pierce the WELDING - the joining together of two or more specific areas of the base metal to achieve a metal. PRESS BRAKE - a machine that forms pieces of metal by melting or soldering them desired shape. predetermined angles, or bends, by squeezing a together. Types include TIG, MIG, projection, and EMBOSSING - one side of the material is raised sheet of metal between a matching punch and a spot welding. BLANKING - removing a piece from the entirety while the other is depressed. die. of the base metal, where the piece is kept and the remaining metal around it is discarded. Like a FORMING - the process of cutting, punching, or PUNCH (PRESS BRAKE) - the tool above a die cookie-cutter. Blanking typically occurs prior to bending sheet metal to create a desired shape. that uses compression to create a bend or pierce a bending but can happen while forming, piece of sheet metal. depending on the machine. HARD TOOLING - sheet metal stamping RIVETING - the installation of a mechanical CAD - short for “computer-aided design,” LANCING - a slice or slit made in a piece of metal fastener, or rivet, through a hole in the material to engineers use CAD software to design 2D and 3D to free it up without separating it from the main hold two or more pieces of sheet metal together. models. piece. through sheet metal. The sheet is placed into the the overall cost of the part long-term and Spot – Two pieces of metal are placed under insertion machine. They’re made up of a shaft and perform with uniform precision every time, Machine Automation from one hole to another is dependent primarily whenever possible, engineers should allow machine and the laser cutting head moves to increasing part consistency. Parts are produced pressure between two copper alloy tips which head that become deformed during insertion. reducing potential ergonomic and safety hazards upon the machinery used to process the sheet. +/-.010” hole-to-edge. Tolerances of +/-.005” make the desired cuts to the part, as much quicker and require less labor, which can be apply an electrical current, welding the pieces Solid rivets are very strong but require access to to human operators. For example, some Automatic Tool Changing - Whether working Some equipment will hold better than +/-.005” should be used only when absolutely necessary. programmed. Laser cutting offers geometry highly beneficial as a product becomes a staple in together. Welds are flush to the surface and no both sides of the sheet metal, as well as an programs require extremely repetitive motion with press brakes or turrets, automatic tool with little difficulty. flexibility since the cut options aren’t limited to a the market and demand increases. fluxes or fillers are required, allowing for a clean overlapping joint. that can injure a person over time. Robotic changers (ATCs) are fast, reliable, and accurate. Hole to Bend +/- .015” - Several factors have standard tool. appearance. operators eliminate that risk. Once it receives a command, the changer However, all holes and features punched through been introduced leading up to this stage in the Most sheet metal assemblies are a mix of soft and Semi-Tubular Rivets - These rivets are also mechanism will remove an old tool and replace it the sheet can introduce stress into the sheet fabrication process. Features and parts have been Where laser cutters can cut thicker metal types, hard tool parts. Riveting composed of a shaft and a head, the difference Robotics can also be quickly reprogrammed to with a new one. Manual set-up time for a press metal. If the part has a closely spaced perforated punched on a CNC turret press, line sanded or turret punches have the capability to work with being in the partial hole at the tip. This small hole accommodate last-minute engineering changes, brake can take 1-4 hours, depending on the pattern or formed features such as dimples or tumbled to remove burrs, and is now being more types of metals. Turrets also have more TYPES OF METAL STAMPING MOLDS Rivets are used to fasten two or more pieces of reduces the amount of force required to install. small batch runs, and line change-overs. number of bends, where ATCs can reduce that counter sinks, the result can cause the sheet to formed on a press brake. The deburring process capabilities such as coining and bending, which metal together and can be purchased in steel, Similar to a solid rivet, access to both sides of the time to 20-30 minutes, no matter how complex warp and distort. This can cause unwanted may remove .003” when cosmetic appearance is a reduces the manual labor required to complete Progressive Dies stainless steel, and aluminum. The advantages of sheet metal and an overlapping joint are required. Machine Robot - Machine manufacturers are now the program. variation between holes or features. If this priority. the part. riveting over welding include their ability to incorporating robotics directly into their condition exists, a greater tolerance should be A progressive die is made up of a series of fasten dissimilar materials together or their ability Blind Rivets - These rivets have an integrated technology. These robots are built specifically for Material Load/Unload Systems - Turret presses applied to certain areas surrounding this Precision press brakes will position and repeat Metal Stamping progressions in a process where, when advanced to fasten areas that are not accessible to other mandrel running through them. When pulled out each machine and can perform duties based on can now be purchased with automated sheet characteristic. within the +/- .002” range. Skilled brake operators through the mold, each piece is further bent or processes.
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