Sheet metal forming is a manufacturing process that fabricates metal parts from thin metal sheets. It is commonly used in everything from aluminum soda cans to aircraft components.
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This article looks at the sheet metal forming process, how it works, where it is used, and its benefits and drawbacks. We also take a look at the sub-processes used to fabricate parts from the metal sheets.
Sheet metal forming, or sheet metal fabrication is the process of using metal sheets to form sheet metal components. This is achieved by forming and cutting sheets into the required shapes and forms using a variety of processes such as: bending, punching, shearing, and hydroforming among others.
Sheet metal forming is extremely common in manufacturing, and sheet metal parts can be found in a wide range of applications, such as: the automotive industry, aerospace industry, consumer goods, and household appliances.
The purpose of sheet metal forming is to create parts made from thin sheet metal for use in a wide range of applications. Sheet metal forming is an extremely versatile process that takes advantage of the strength and malleability of sheet metal to create durable parts that are lower in cost than comparable manufacturing processes such as forging.
Sheet metal forming makes use of a number of processes to transform a flat sheet of metal into metal parts that are durable and lightweight. Bending, shearing, punching, and hydroforming are all examples of processes that are used to form or cut metal sheets into the desired shape.
The tools for these processes will be set up according to the needs of the design, after which the sheet will undergo processing. Finally, a number of finishing steps will be applied. This might include: deburring, surface treatments, or welding.
Sheet metal forming is suitable for metal thicknesses of 0.6 mm to 6.35 mm. This is a general guideline, and the actual suitable thickness will change depending on the type of metal used, the manufacturer's capabilities, and the complexity of the metal part to be fabricated.
Sheet metal forming makes use of a wide range of equipment depending on the design of the part and the process being applied. The following list highlights some of the equipment used in sheet metal forming:
Sheet metal forming involves a number of manufacturing processes. The following list contains some of the primary sheet metal forming operations:
Curling is a process that adds a circular, hollow roll to the edge of sheet metal. This is done to deburr the edges, but also to add strength and make the sheets safer to handle. Metal sheets are usually fed into specialized machines that gradually roll or bend the edges to form a smooth, rounded profile.
Curling is commonly used in HVAC, appliance manufacturing, and architectural applications to create edges on panels, trim, or housings. Most metals can undergo curling, depending on their ductility and thickness, including: steel, aluminum, and brass.
Curling adds strength to the edges of parts and improves rigidity and safety. Complex shapes or tight rolls can be challenging to achieve through curling. Specialized tooling and machinery may also be required to perform curling, depending on the application.
Laser cutting is a process of using a high-powered laser to cut shapes into sheet metal. A sheet metal blank is fastened onto the laser cutter machine bed. A computer numerical control (CNC) system controls the movement of the laser beam, performing precise, clean cuts in a pre-programmed pattern.
Laser cutting is used in applications that require precise shapes, patterns, or holes to be cut into sheet metal. It is commonly used in the automotive, aerospace, and electronics industries. Laser cutting can be applied to many metals, such as: steel, stainless steel, aluminum, or copper. Galvanized steel can be cut with laser cutting, but this is not recommended, as the high heat can lead to the protective coating being damaged, as well as toxic zinc-oxide fumes being released.
Laser cutting offers high accuracy, versatility, and repeatability. Minimal post-processing is needed, and there is minimal material waste. However, the initial equipment cost can be high.
To learn more, see our guide on Sheet Metal Laser Cutting.
Bending involves using bending tools in order to create bends or curves along a straight axis of the metal sheet. Press brakes are commonly used, into which the metal is set or clamped and then bent to the desired angle. Bending is commonly used for making automotive body parts, enclosures, and electrical components. The process is suitable for most types of metals commonly used in sheet metal fabrication, such as: stainless steel, brass, aluminum, and galvanized steel.
Sheet metal bending is quick, accurate, low-cost, and requires fairly simple tooling. Some disadvantages include limitations to the thickness of metal that can be bent, as well as the need for consistent thickness.
To learn more, see our guide on Sheet Metal Bending.
Ironing is a process used to improve the surface finish of sheet metal parts and achieve uniform thickness. A metal part is pressed through a die or series of dies which incrementally reduces clearance. By passing through the die, the walls of the part are thinned and elongated, without altering the shape significantly.
Ironing is used for producing aluminum cans, but also for other applications in which a consistent thickness and a good surface finish are required. Metals with high ductility are suitable candidates for ironing, including steel and aluminum.
Ironing improves dimensional accuracy, surface finish, and thickness uniformity in metal parts, but requires specialized tooling and machinery. It is also unsuited for parts that require significant shape changes.
Hydroforming is a process of shaping metals into complex forms by using high-pressure fluid. A metal blank is placed within a die cavity, whereafter high-pressure fluid is pumped onto the blank, forcing it into the shape of the die.
Hydroforming is commonly used in the automotive, medical, and aerospace industries, for which complex shapes are often required. Metals with high ductility are suitable for hydroforming, like: aluminum, stainless steel, and brass.
Hydroforming can create complex shapes with uniform wall thickness, with reduced waste and relatively low cost compared to other forming methods. Disadvantages of hydroforming include the specialized equipment that is needed, which requires a high initial investment, as well as the specialized expertise needed to perform hydroforming.
Deep drawing is a process used to create hollow cylindrical shapes. It works by placing sheet metal over a die and pressing the metal blank into the die cavity using a punch, resulting in a hollow cylindrical shape with no reduction in the thickness of the sheet metal.
Deep drawing is used for creating containers, beverage cans, and automotive parts such as door panels. The process can be suitable with any metals with high ductility and malleability. Aluminum, stainless steel, copper, and brass are commonly used in deep drawing.
Deep drawing allows for the creation of complex hollow shapes with consistent wall thickness and precise dimensions. It requires minimal labor and is cost-effective at high production volumes.
Shearing is a cutting process used to cut sheet metal along a straight line. The sheet metal blank is positioned on a shearing machine, which has two blades that slide past each other to cut the metal. The blank is clamped in place, and the upper blade of the shearing machine is lowered onto the blank to make the cut.
Shearing is used to cut metal sheets into smaller pieces or to trim edges. It is widely used in the manufacturing, construction, and automotive industries. Steel, aluminum, and stainless steel, along with most other metals can be sheared. The thickness of the metal and the capability of the shearing machine are the limiting factors as to what can be sheared.
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Shearing is a rapid process, produces minimal waste, and is cost-effective at high volumes, but can cause edge deformation and burrs, especially in thicker materials. Shearing only cuts along a straight line, and must be combined with other processes to produce complex shapes.
Punching is the process of removing material from sheet metal to create holes, slots, or specific shapes. Sheet metal is placed between a punch and a die. The die supports the sheet metal, while the punch is forced through the sheet metal into the die to create the hole or shape.
Punching is also used for creating enclosures, brackets, and panels. Most metals can be used for punching, with the thickness of the sheet and the capabilities of the punching machine being the limiting factor.
Punching is an automated, rapid process. It has good repeatability and is a highly efficient process, especially for high-volume production. On the other hand, tooling costs can be high, especially for custom shapes. Some post-processing may also be required, especially for intricate designs.
Sheet metal forming can be applied to a wide variety of metals, depending on the application and specific properties required from the sheet metal part. Some common metals used in sheet metal forming are:
Yes, galvanized steel can be used in sheet metal forming. It is commonly selected for its high durability and corrosion resistance, as well as its relatively low cost of production. Some common applications of galvanized steel parts include: roofing applications, air conditioning, refrigeration, and industrial machinery.
No, tool steel is simply not suitable for sheet metal forming. Tool steel is extremely hard and brittle, and it would break if subjected to the common metal-forming processes. Sheet metal forming relies on the ductility and malleability of metal sheets to form them into metal parts. Tool steels are generally hard with low ductility and malleability. This makes them less than ideal for sheet metal forming.
Sheet metal fabrication is extremely useful for a wide range of applications, as evidenced by how commonly the manufacturing process is used. Sheet metal forming is a relatively low-cost, extremely versatile process that can produce an almost limitless variety of parts.
Products made by sheet metal forming can be seen all around, in everything from beverage cans, household appliances, and metal furniture, to HVAC systems, structural components, and components for the aerospace industry.
Sheet metal forming is used in an incredibly wide range of industries, thanks to its versatility, relatively low cost, and the durability of the produced parts. Some industries that commonly use sheet metal forming are:
Yes. The construction industry uses sheet metal forming for a wide range of applications. The relatively low cost and versatility of sheet metal forming, combined with the durability of sheet metal components make it an obvious choice for use in the construction industry.
Structural components such as: beams, columns, and brackets are made using sheet metal forming processes and are used for their high strength and load-bearing capabilities. Roofing sheets fabricated via sheet metal forming are used for their longevity and weather resistance. Ductwork for HVAC systems is commonly made using sheet metal forming.
Sheet metal forming has a number of advantages and benefits. Here are some advantages of sheet metal forming:
Sheet metal forming does have some drawbacks. Here are some disadvantages of sheet metal forming:
No. Sheet metal forming is relatively inexpensive and is known as a low-cost manufacturing process. The cost of sheet metal forming will change depending on the design of the part, the material used, and the number of processing steps involved. Fabrication costs can be kept low by sticking to fairly simple design elements and using standard sizes and options.
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In the manufacturing industry, sheet metal fabrication is a crucial process that involves the creation of quality parts. There are various machines designed to produce these parts, and one such machine is the sheet metal folding machine. This article will explore the importance and benefits of using sheet metal folding machines in the manufacturing industry.
A sheet metal folding machine is a tool used to form sheet metal into desired shapes and angles. Unlike a press brake, which gauges the flange and rotates the part up, a sheet metal folding machine gauges the entire section and turns the flange up. This key difference provides several advantages for operators. The folding machine boasts an integrated support back gauge, which holds up the weight of the items, making it easier for operators to work. Additionally, the folding machine's ergonomic design eliminates the need to push massive sheets from the front, enhancing efficiency and reducing strain on the operator.
Bending accuracy is a crucial factor in sheet metal fabrication. Sheet metal folding machines offer remarkable bending accuracy, ensuring that the final product meets precise specifications. The compression and tension techniques employed by these machines result in minimal deformation along a single axis. This means that sheet metal can be bent without stretching, tearing, or cutting. Moreover, the absence of tool wear and the ability to handle a wide range of parts with complicated bends without tooling changeouts make sheet metal folding machines highly efficient and cost-effective.
Setup time is a significant consideration in any manufacturing process. Sheet metal folding machines excel in reducing setup time due to their unique design and features. Unlike other machines that require tooling changeouts, sheet metal folding machines eliminate the need for such time-consuming processes. With the table supporting and guiding the material, setup can be easily performed by a single operator. This not only saves time but also increases overall productivity and efficiency.
Achieving consistent accuracy in part fabrication is crucial for manufacturing companies. Sheet metal folding machines excel in providing exceptional part accuracy. By clamping and forming the sheet metal while being held on the worktable, the initial bend eliminates any inaccuracy in the sheet size. This ensures that every subsequent bend is exact in angle and length, resulting in precise and consistent parts. The CNC-controlled gripping fingers/pushers affixed to the table further enhance accuracy and repeatability, providing a definite advantage to fabricators.
Cosmetics play a significant role in the manufacturing industry, especially when it comes to the final appearance of the products. Sheet metal folding machines offer a distinct advantage in terms of cosmetics. Unlike press brake bending, where scratches may be left on the outside corner of formed pieces, sheet metal folding machines create scratch-free forms. By simply pushing the flange against the clamping tool, the folding machine eliminates the risk of scratches, resulting in a clean and visually appealing finish.
Labor efficiency is a key consideration in any manufacturing process, and sheet metal folding machines contribute significantly to labour reduction. Large parts on a press brake often require two or more operators to hold and move the material in synchrony with the ram. This not only increases labour costs but also requires additional foot pedals for safe engagement. In contrast, sheet metal folding machines allow the material to rest safely on the bed of the gauging table, where the operator can easily spin and position it for clamping and bending. This labour-saving feature not only reduces costs but also saves time, improving overall productivity.
Sheet metal folding machines offer manufacturers the ability to produce a diverse range of products. From custom rain gutters to electrical cabinets and panels, the possibilities are vast. The flexibility and versatility of sheet metal folding machines make them an essential tool for fabrication shops and manufacturing companies of all sizes. By having a sheet metal folding machine in their arsenal, businesses can cater to a wide range of customer needs and expand their market potential.
With the ability to produce a diverse range of products, businesses that utilise sheet metal folding machines can enhance their market potential. The manufacturing industry is highly competitive, and the ability to offer custom and high-quality sheet metal products sets businesses apart from their competitors. By investing in sheet metal folding machines, companies can meet the demands of various industries and expand their customer base, ultimately leading to increased profitability and success.
Selecting the right bending system for your needs and budget can be a daunting task. However, companies like Southern Fabricating Machinery Sales specialise in metal forming and sheet metal folding machines. With their expertise and knowledge, they can assist businesses in choosing the most suitable machine for their specific requirements. Whether you are a small fabrication shop or a multinational manufacturing company, expert assistance ensures that you make an informed decision and maximize the benefits of sheet metal folding machines.
In conclusion, sheet metal folding machines are essential tools in the manufacturing industry. They offer numerous benefits, including bending accuracy, reduced setup time, overall part accuracy, improved cosmetics, labour reduction, and the ability to produce a diverse range of products. By investing in sheet metal folding machines, businesses can enhance their market potential, meet customer demands, and ultimately increase profitability. With expert assistance and support, companies can make informed decisions and choose the right machine for their specific needs. Embrace the power of sheet metal folding machines and elevate your manufacturing capabilities today.
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