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What is Sheet Metal Fabrication?
Sheet metal fabrication is the process of turning flat sheets of steel or aluminum into metal structures or products by cutting, punching, folding, and assembling. Sheet metal can be cut, bent, or stretched into almost any shape, usually by cutting and burning the metal.
Special tools, such as band saws and chop saws, are also used in the metal fabrication process. These ensure cutting throughout. Cutting torches are capable of cutting large sheet metal with minimal effort.
Sheet metal fabrication uses press brakes to ease the process of metal fabrication by helping to create sharp bends and angles within the metal. There are a variety of different pressure brakes that have different functions and are used for different purposes.
One of the other major elements of metal fabrication is welding. Once all the components are made, they are assembled and soldered into place. Many welding techniques can be used in sheet metal fabrication to prevent warping or any other anomalies. These techniques include covering the metal with sand during cooling, a special straightening process, welding in a staggered pattern, and the use of stout fixtures.
Straightening defective metal can be achieved by using an oxyethylene torch. Heat is applied to the metal in a slow fashion to smooth out any anomalies.
Metal is usually finished by sanding, priming, and painting. This then ensures the metal looks great before it's ready to be sent to the client.
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About Precision Sheet Metal Parts
Roughly divided into steel and non-ferrous metals.
Steel:
Iron plate
SS material (SS400 is mainstream): a kind of hot-rolled steel plate. Since it is a material that is prone to rust, it needs to be protected by surface treatment such as electroplating, painting, and blackening.
SPHC-P (pickling material): also known as pickling steel plate, is to remove the oxide film attached to the surface of the hot-rolled steel plate.
SPCC (Polished Material): A cold-rolled steel plate. It is made by further cold rolling of hot rolled steel plate.
SECC (bonded steel): A type of electro-galvanized steel. It is a cold-rolled steel plate coated with electronic components. The average coating thickness is approximately 2 to 25 µm.
SGCC (galvanized iron): hot-dip galvanized steel sheet. Hot-dip galvanized cold-rolled steel sheet. The average coating thickness is about 50-100 µm.
Stainless steel plate: Stainless steel is a material with excellent mechanical properties, fire resistance, low-temperature characteristics, toughness, machinability, etc., including corrosion resistance.
Non-ferrous metals:
Aluminum: Aluminum alloy with aluminum as the main component.
Copper: Copper has excellent mechanical properties, corrosion resistance, heat transfer, and electrical conductivity, but is expensive.
Uses of sheet metal materials:
SECC: indoors for machine parts, machine housings (control panels), interior parts, and lighting equipment, outdoors for building materials, and transport equipment.
SGCC (galvanized steel): Due to its high rust resistance, it is used outdoors for vending machines, air conditioners, ventilation fans, etc.
SPHC-P (pickling material): There are many electrical equipment housings and automotive parts.
SPCC (Polishing Material): Widely used in thin steel covers, home appliance covers, electrical boxes, Label Printer Sheet Metal Parts, etc. as it is used as a thin material.
Finishing options for Precision Sheet Metal Fabrication:
Anodizing
This finishing process has a smooth and matte finish. Improve the quality and performance of parts such as hardness and wear resistance, corrosion resistance, metal surface, etc. It is done on precision instruments, aircraft parts, and auto parts.
Sandblasting
Pearlizing is done to give the part a smooth finish and a matte feel. It is ideal for vision applications where other treatments will follow.
Powder coating
This coating is done electrostatically and cured with UV light or heat. It is available as a dry, free-flowing powder. It has a glossy or semi-glossy texture.
Plating
Plating is done for added functionality, corrosion resistance, or decoration. It is mainly suitable for the automotive industry and so on. It has a smooth or glossy finish.
Polishing
This process involves physically rubbing or chemically manipulating the physical body of the part to create shine and smoothness. The effect is the reflective part.
Brushing
The brushing process involves using a belt to create marks on the surface of the material, often where there is an aesthetic concern. It has a satin texture. Materials used are stainless steel, ABS, brass, and steel.
Types of Precision Sheet Metal Processes:
Cutting/laser processing
The cutting process is to cut the square tube and angle material into the size specified in the engineering drawing by laser.
Punching
Punching is the process of stamping material according to a die. We primarily use a machine called a turret punch.
Tapping and Deburring
Tapping is to create threads in sheet metal. The flanging is used for threaded pipes, and the screws can be matched. This processing is mainly for processing holes with threads.
Spot facing
Enlarges and bevels the edges of the hole. Enlarges and bevels the edges of the hole. After inserting screws, nails, or bolts, the surface looks perfectly flat.
Forming/bending
Sheet metal forming is done by bending a sheet metal (sheet metal) with two upper and lower dies. There are V bends, L bends, Z bends, etc. We mainly use a machine called a bending machine to bend.
Roll processing
This is the process of rolling metallic material into a cylinder using multiple rollers.
Welding
Welding is the use of heat to melt the joint of two or more components and join them together. Welding types include CO2, argon, and automated fiber laser welding.
Finishing
The welded parts and uneven parts produced by welding can be smoothed with a suitable polishing machine or grinding machine, grinder, precision file, sandpaper, and other finishing tools. In addition, we remove weld seam burn marks produced during the welding process.
Surface treatment
Surface treatment of sheet metal products after welding. We perform processes such as powder coating, electroplating, and silk printing. The purpose is rust prevention and decoration.
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