• Sheet metal Fabrication Services

Sheet metal Fabrication Services

Metal fabrication is the creation of metal structures by cutting, bending and assembling processes. It is a value-added process involving the creation of machines, parts, and structures from various raw materials.


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Sheet metal Fabrication

Sheet Metal fabrication is the creation of metal structures by cutting, bending and assembling processes. It is a value-added process involving the creation of machines, parts, and structures from various raw materials.

Typically, a fabrication shop bids on a job, usually based on engineering drawings, and if awarded the contract, builds the product. Large fab shops employ a multitude of value-added processes, including welding, cutting, forming and machining.

As with other manufacturing processes, both human labor and automation are commonly used. A fabricated product may be called a fabrication, and shops specializing in this type of work are called fab shops. The end products of other common types of metalworking, such as machining, metal stamping, forging, and casting, may be similar in shape and function, but those processes are not classified as fabrication.

Sheet metal materials

Sheet metal processing is a comprehensive cold-worked post-forming process for thin metal sheets (usually below 6mm), including shearing, punching/cutting/compounding, folding, welding, riveting, splicing, forming (such as automobile bodies), etc. Its remarkable feature is that the thickness of the same part is the same. The products processed by the sheet metal process are called sheet metal parts. The sheet metal parts referred to by different industries are generally different, and are mostly used for assembly. Sheet metal processing is called sheet metal processing. Specifically, for example, the use of plates to make chimneys, iron drums, fuel tanks and oil cans, ventilation pipes, elbows and heads, round places, funnels, etc. The main processes include shearing, bending, bending, forming, welding, riveting, etc.

Sheet metal materials

Sheet metal materials

The materials commonly used in sheet metal processing are cold-rolled sheet (SPCC), hot-rolled sheet (SHCC), galvanized sheet (SECC, SGCC), copper (CU) brass, red copper, beryllium copper, aluminum sheet (6061, 5052, 1010, 1060, 6063, duralumin, etc.), stainless steel (mirror surface, brushed surface, matte surface), according to the different functions of the product, different materials are selected, generally need to consider the use and cost of the product.

1. Cold-rolled sheet SPCC, mainly used for electroplating and baking paint, low cost, easy to form, material thickness ≤ 3.2mm.

2. Hot-rolled sheet SHCC, material T≥3.0mm, also uses electroplating and paint parts, low cost, but difficult to form, mainly flat parts.

3. Galvanized sheet SECC, SGCC. The SECC electrolytic plate is divided into N material and P material. The N material is mainly used for surface treatment, and the cost is high. The P material is used for sprayed parts.

4. Copper; mainly used for conductive materials, and its surface treatment is nickel-plated, chrome-plated, or no treatment, and the cost is high.

5. Aluminum plate; generally use surface chromate (J11-A), oxidation (conductive oxidation, chemical oxidation), high cost, silver plating, nickel plating.

6. Aluminum profiles; materials with complex cross-sectional structures, which are widely used in various sub-boxes. The surface treatment is the same as the aluminum plate.

7. Stainless steel; SUS304 is one of the most widely used stainless steels. Because it contains Ni (nickel), it is richer in corrosion resistance and heat resistance than steel containing Cr (chromium). It has very good mechanical properties, no heat treatment hardening phenomenon, no elasticity . The content of SUS301Cr (chromium) is lower than that of SUS304, and the corrosion resistance is poor. However, after cold working, it can obtain good tensile force and hardness in the stamping process, and has good elasticity. It is mostly used for shrapnel springs and anti-EMI.

Sheet metal fabrication technology features

Sheet metal fabrication technology features

Sheet metal has the characteristics of light weight, high strength, electrical conductivity (can be used for electromagnetic shielding), low cost, and good mass production performance. It has been widely used in electronic appliances, communications, automotive industry, medical equipment and other fields. In computer cases, mobile phones, and MP3s, sheet metal is an essential part. As the application of sheet metal becomes more and more extensive, the design of sheet metal parts has become an important part of the product development process. Mechanical engineers must be proficient in the design skills of sheet metal parts, so that the designed sheet metal can meet the requirements of the product. Function and appearance requirements, but also make the stamping die manufacturing simple and low cost

 

Commonly used equipment for sheet metal processing basically includes Shear Machine, CNC Punching Machine/Laser, Plasma, Water Jet Cutting Machine, Bending Machine, Drilling Machine and various auxiliary Equipment such as: uncoiler, leveling machine, deburring machine, spot welding machine, etc.

Usually, the four most important steps of sheet metal process are shearing, punching/cutting/folding/rolling, welding, surface treatment, etc. The surface treatment of sheet metal parts is also a very important part of the sheet metal processing process, because it can prevent parts from rusting and beautify the appearance of products. The role of the surface pretreatment of sheet metal parts is mainly to remove oil, oxide scale, rust, etc. It prepares for the surface post-treatment, and the post-treatment is mainly spraying (baking) paint, plastic spraying, and anti-rust coating.

Sheet metal fabrication process

Sheet metal fabrication process

1.Cutting 2. Bending 3. Stretching 4. Welding 5. Plastic spraying 6. Inspection 7. Storage.

Definition: It refers to the technology of processing plates of uniform thickness, which does not need to be formed by molds, and the production speed is slow, including blanking, bending, stretching, welding, spraying, assembly, etc., mainly shearing, punching, folding, welding, bonding, etc. step.

Cutting

Cutting

mainly punching and laser cutting. The number of punching means is processed by CNC punching machine, and the thickness of the plate is ≤3mm for cold-rolled sheet and hot-rolled sheet, ≤4mm for aluminum sheet, and ≤2mm for stainless steel. There are minimum size requirements for punching, which is related to the shape of the hole, the properties and thickness of the material. Laser cutting is a laser flying cutting process. The thickness of the plate is ≤20mm for cold-rolled and hot-rolled plates, and ≤10mm for stainless steel. The advantage is that the thickness of the processing plate is large, the cutting speed of the workpiece shape is fast, and the processing is flexible.

Bending

Bending

The bending part has a minimum bending radius. When the material is bent, the outer layer is stretched and the inner layer is compressed in the fillet area. When the thickness of the material is constant, the smaller the inner bending radius, the more serious the tension and compression of the material; when the tensile force of the outer layer exceeds the limit of the material, fracture and fracture will occur.

Stretching

Stretching

The radius of the fillet between the bottom of the drawing piece and the straight wall should be greater than the thickness of the plate. The thickness of the material after stretching will change to a certain extent. The center of the bottom generally maintains the original thickness, and the material at the bottom fillet becomes thinner. , the material at the top near the flange becomes thicker, and the material at the rounded corners of the rectangular stretcher becomes thicker.

Welding

Welding

mainly arc welding and gas welding.

①Arc welding has the advantages of flexibility, maneuverability, wide applicability, and all-position welding; the equipment used is simple, durable, and low maintenance costs. However, the labor intensity is high and the quality is not stable enough, depending on the level of the operator. It is suitable for welding carbon steel, low alloy steel and non-ferrous alloys such as copper and aluminum over 3mm.

②The flame temperature and properties of gas welding can be adjusted. Compared with arc welding, the heat source is wider than the heat affected zone, the heat is not as concentrated as the arc, and the productivity is low. Alloy, cemented carbide, etc.

Plastic spraying

Plastic spraying

The surface of the hardware is automatically sprayed with oil and powder through the oven and other machines to make the product look beautiful and meet the needs of packaging and shipping.

Inspection

Inspection

The production process of the product is controlled by the quality inspection department in real time to reduce the production loss and defective rate and ensure the production quality.

Warehousing

Warehousing

The products that have gone through the above processes have reached the requirements for warehousing and ready to be shipped, and can be packaged and warehousing.

Applications of sheet metal fabrication

Applications of sheet metal fabrication

Computer mainframe chassis, server cabinets, electric control cabinets, TV backplanes, car shells, air conditioner shells, charging pile shells, electrical control cabinets, control boxes, electric boxes, non-standard customized precision CNC sheet metal processing; charging pile boxes, Manufacturing of sheet metal parts for commercial air conditioners and air energy heat pumps; sheet metal processing and spraying for home decoration and display racks; sheet metal processing and spraying for electrical control cabinets, control boxes, and electrical boxes; sheet metal for various electrical and mechanical equipment Processing and spraying of gold shells; design and manufacture of various non-standard sheet metal shells.


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