Sheet Metal: The Art of Metal Shaping in Industrial Manufacturing

Sheet Metal: The Art of Metal Shaping in Industrial Manufacturing

Sheet metal fabrication is a comprehensive technology that integrates engineering design, materials science, and manufacturing processes. Through processes such as shearing, bending, stamping, welding, forming, and surface treatment, sheet metal is transformed into three-dimensional components or structures with specific shapes and functions. This process requires both precise mechanical calculations and experienced manual skills. It is widely used in industries such as aerospace, automotive manufacturing, electronic equipment, architectural decoration, and medical devices, earning it the status of the "metal shaper" of modern industry.

I. Sheet Metal's Core Process: The Transformation from Flat to Three-Dimensional

The essence of sheet metal fabrication is to change the geometric form of sheet metal through physical deformation while ensuring that its mechanical properties meet design requirements. Its core process encompasses the following key steps:

1. Material Selection and Pretreatment

Material Types: Common metals include mild steel (such as Q235), stainless steel (such as 304 and 316), aluminum alloys (such as 6061 and 5052), and copper alloys. Materials with compatible corrosion resistance, strength, and conductivity should be selected based on the intended use.

Sheet Material Specifications: Thickness typically ranges from 0.5 to 6 mm (sheet thickness exceeding 6 mm is considered "thick sheet processing," and the process varies significantly). Width and length are determined by the processing equipment's capabilities (e.g., a standard sheet of 1.25 m x 2.5 m is common).

Pretreatment: This includes surface degreasing, rust removal, and leveling (to eliminate internal stress and deformation). Some high-precision parts require coating before laser cutting to reduce thermal deformation.

2. Blanking and Cutting

Common methods for processing large sheet metal into the desired part blank shape include:

Shearing: Using a shearing machine (mechanical or CNC) to cut sheet metal along straight lines, this method is suitable for mass production of regular shapes.

Laser Cutting: Using a high-power laser beam to precisely cut complex contours with an accuracy of ±0.1mm, this method is particularly suitable for small-batch, high-precision, or special-shaped parts (such as porous plates and curved parts).

Stamping: Using a die to punch out the part shape in a single operation on a punch press. This method is highly efficient but carries high die costs, making it suitable for large-scale production (such as automotive panels).

Water Jet Cutting: Using a high-pressure water jet mixed with abrasives to cut, this method eliminates thermal deformation and is suitable for cutting hard or heat-sensitive materials such as stainless steel and aluminum.