What is sheet metal processing?

Common materials in sheet metal processing

1. Commonly used sheet metal types in processing

• Characteristics: High mechanical strength, excellent corrosion resistance, and shiny surface, little need for further processing.
• Classification: SUS 304 (most popular, good rust resistance), SUS 201 (lower cost, higher hardness), SUS 316 (excellent corrosion resistance, used in chemical and marine environments).
• Applications: Medical equipment, food, outdoor electrical cabinets.

• Characteristics: Lowest cost, easy to weld and easy to cut. However, it is susceptible to oxidation (rust), requiring surface treatment such as powder coating or galvanizing.
• Classification: SS400, Q235, CT3.
• Application: Machine frame, industrial structure, parts that require high durability but do not require absolute corrosion resistance.

• Characteristics: Light weight, good heat dissipation and electrical conductivity, natural corrosion resistance (due to the creation of a protective oxide layer), easy to finish by anodizing method.
• Disadvantages: Lower hardness than steel, more difficult to weld (usually TIG welding).
• Application: Electronic equipment housing, heat sinks, components in the aviation and transportation industries.

• Characteristics: Excellent electrical and thermal conductivity, highly aesthetic (bronze yellow color).
• Application: Electrical contact parts, conductive busbars, decorative shells.

 

2. Factors affecting the selection of metal processing materials

• Corrosion: If the product is exposed to high humidity, acid, or salt (marine environment), Stainless Steel (316 Stainless Steel) or Aluminum is a mandatory choice.
• Temperature: For heat dissipation applications, Aluminum is the top priority.

• Parts that are subject to strong forces and vibrations require materials with high tensile strength such as Carbon Steel or Stainless Steel.
• High aesthetic factors and durable surface finishes often choose Stainless Steel or Aluminum (Anode).

• Products that need to optimize costs for mass production should use Carbon Steel (plus surface treatment costs).
• Stainless Steel and Copper Have Significantly Higher Input Material Costs

Main techniques of sheet metal processing

1. Cutting - Initial forming

• Laser cutting: is one of the most popular sheet metal cutting methods. Laser cutting machines use laser beams amplified by lenses or mirrors to cut through thin to medium-sized metal sheets but are difficult to cut into the most difficult materials.
• Waterjet cutting: is a technique that uses high-pressure water to cut metal. Waterjets are particularly useful for cutting low-melting-point metals because they do not heat the metal to the point of deformation.
• Plasma cutting: This technique creates an ionized gas channel that can easily cut through thick metal sheets. Plasma cutters are less precise than laser cutters or waterjet cutters, but they are fast, efficient, and have low installation costs.
• CNC Punching: Uses a die and punch to cut (cut, punch) material with great mechanical force.

2. Bending and Forming

• Bending is one of the most important forming processes and can be performed with a bending machine. A sheet metal manufacturing company can use this tool to bend sheet metal into V-shapes, U-shapes, and U-shapes with angles up to 120 degrees.
• Stamping: Hydraulic or mechanical presses with tools and dies are used to deform sheet metal during the stamping process. This process is similar to punching but does not necessarily remove material. Sheet metal stamping can be used for specific tasks such as drawing, edging, etc.

3. Joining - Finishing the structure

• Welding: A permanent joining method.

• Mechanical assembly: Use non-permanent connection methods such as rivets, screws, bolts, or quick-fit parts (rivets, stud welding) for easy disassembly or maintenance later.

Methods to improve the accuracy and efficiency of sheet metal processing

- Using CNC equipment:

• Advantages: CNC bending machines and CNC punching machines can achieve high precision and high processing efficiency.
• Applicable scenarios: Sheet metal parts with complex shapes and high precision requirements.

- Optimizing mold design:

• Method: Reasonable mold design to reduce stress and deformation during processing.
• Effect: Improve processing quality and productivity.

- Strict control of processing parameters:

• Parameters: cutting speed, bending angle, welding current, etc.
• Effect: Ensure the stability and uniformity of the processing process.

- Regular equipment maintenance:

• Method: Regularly check and maintain sheet metal processing equipment to ensure normal operation.
• Effect: Extend equipment life and reduce downtime due to failure.

Surface treatment and finishing of processed sheet metal

1. Cleaning and preparation

• Degreasing: Completely remove lubricants, coolants and organic contaminants that adhere to the metal during processing. This is done with specialized chemicals or electrochemical methods.
• Pickling: Using acid or chemical solutions to remove metal oxides (rust) and inorganic impurities on the surface, leaving the metal bare and ready for further processing.
• Grinding and polishing: Using a grinder or sandpaper to smooth cuts, remove sharp edges and smooth the surface.
• Sandblasting: Shooting sand, steel balls or glass beads at high pressure onto the surface to remove impurities, roughen and prepare for the next coating.

2. Finishing the surface of sheet metal

• Principle: Spraying dry paint powder with a negative charge onto a metal surface with a positive charge. The paint powder adheres tightly and is heated (curing) to melt, forming a hard, even coating.
• Advantages: Creating an extremely durable coating, good impact and scratch resistance, diverse colors and environmentally friendly.

• Principle: Using electrolysis or hot-dip method to coat another layer of metal on the surface of the detail.
• Zinc Plating: The main purpose is to prevent corrosion (Anode Sacrifice), protect the inner metal core, very important for outdoor applications.
• Chromium/Nickel Plating: Increases surface hardness, abrasion resistance, and creates a shiny, high-class appearance.

• Principle: The electrochemical process is only applied to Aluminum. It creates a thicker and harder aluminum oxide layer, integrated into the surface structure.
• Advantages: Increases outstanding corrosion and abrasion resistance. The Anode layer has the ability to absorb color, creating diverse and durable decorative colors.

Quality control in sheet metal processing

1. Accuracy and Tolerance

• Importance of Tolerance: In KLT machining, Tolerance is the allowable error range in size, shape and position of the part. Strict control of tolerances at each stage (from laser cutting, punching to bending) is extremely important to ensure the interchangeability of the parts. If the tolerance is exceeded, the part cannot fit, causing waste of materials and repair time, directly affecting production efficiency.
• Deformation control: Cutting and welding processes generate large amounts of heat that can cause warping of thin metal sheets. QC must measure and correct flatness/straightness to ensure the final product maintains the geometry as drawn.

2. Measuring Equipment

• Coordinate Measuring Machine (CMM): This is the most advanced 3D measuring equipment. CMM is capable of measuring and mapping complex details with micron accuracy, which is extremely important for products requiring high precision such as aerospace and telecommunications components.
• Electronic rulers and Micrometers: Basic measuring tools commonly used in the workshop to quickly check linear dimensions, hole diameters, and material thickness.
• Go/No-Go Gauge and Standard Template: Mainly used in large-scale mass production. Gauges help to quickly check a specific dimension or tolerance, ensuring high QC speed while maintaining reliability.

Practical applications of sheet metal processing

1. Electrical - Electronics and Telecommunications Industry

• Industrial electrical cabinets and protective enclosures: Creating electrical cabinets, control cabinets, server racks (for data centers), and telecommunications equipment enclosures. These products require tightness, good heat dissipation, and corrosion resistance (usually stainless steel or powder-coated steel).
• Internal components: Chassis frames, electromagnetic interference shields (shielding), and heat sinks are made of aluminum or copper to ensure the performance of the equipment.

2. Furniture, decoration and construction industry

• Modern furniture: Production of metal tables and chairs (table legs, chair frames), display shelves, and decorative components with high aesthetics (usually using stainless steel or painted steel).
• Facades and partitions: Metal panels are cut with laser patterns or CNC punched to make facades for buildings, office partitions, creating an industrial or modern architectural style.

3. Transportation and Heavy Industry

• Automotive and Shipbuilding: Production of chassis, engine covers, car bodies and non-load-bearing interior parts of cars and trucks. KLT processing provides lightweight but sturdy parts.
• Machine tool housings: CNC machine housings, presses, stamping machines, etc. are processed with KLT. These parts require high durability, vibration resistance and often have to be powder coated to protect against grease and chemicals.

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