The Inside Workings Of Sheet Metal
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Jeffery Nevil
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Published on 12/12/2011
Sheet metal in lament terms is simply metal formed into thin and flat pieces via a bending process. It is one of the most fundamental forms used in metalworking; it can be cut and bent into a variety of different shapes and dimensions. Countless everyday objects are constructed of the material making it one of the worlds most valued markets.
Sheet metal in lament terms is simply metal formed into thin and flat pieces via a bending process. It is one of the most fundamental forms used in metalworking; it can be cut and bent into a variety of different shapes and dimensions. Countless everyday objects are constructed of the material making it one of the worlds most valued markets. There are many different metals that can be made into sheet metal, such as aluminium, nickel, copper, steel, tin, brass, nickel and titanium and for decorative uses sheet metals like silver, gold, and platinum can be created.
Sheet metal has applications in car builds, airplane wings, medical tables, roofs for buildings, office equipment, even art. Even some sheet metals like iron, copper, gold, with high magnetic permeability or high electrical conductivity, have applications in transformers and electronic machines. Historically the importance of sheet metal was vital for life in the times where plate based armour was worn by cavalry and soldiers without it they were defenceless against such defensive tactics like arrows. From war to art, sheet metal continues to have many decorative uses, from horse tack reigns to creating the Chrysler Building in America.
It's all about thickness and flexibility when it comes to the process of creating the thin metals. Thicknesses can vary significantly although extreme thinness like 0.0060 mm is considered to be in the category of a foil or leaf, and pieces thicker than 6 mm are considered to be plates. The thickness of the sheet metal is called its gauge. The gauge of sheet metal ranges from 3 gauge to about 38 gauge the larger the gauge number the thinner the metal is.
The science behind the formulation to create such thin metals is actually very precise and complicated to work out; how to achieve the maximum bending force which in turn creates the thinness is to use this equation... F(max) equals k with Tlt squared over W. 'k' is a factor taking into account several parameters of friction. 'T' is the ultimate flexible strength of the metal, 'l' and 't' are length and thickness of the sheet metal and the variable 'W' is the open width of a wiping die. So as you can tell, very complicated.
The most common forming process are such techniques as:
Curling:
Used to form the edges into a hollow ring. Other parts are curled to perform their primary function like door hinges.
Decambering:
The process of removing camber, or horizontal bend, from strip shaped materials.
Deep Drawing:
Drawing is a forming procedure in which the metal is stretched over an object. In deep drawing the depth of the part being made is more than half its diameter. Deep drawing is used for making automotive fuel tanks, kitchen sinks and more.
Laser Cutting:
With the advances in technology, sheet metal cutting has turned to computers for precise cutting.
Press Brake:
This is a form of bending, used for long and thin sheet metal parts. Computer controlled to allow the operator to make a series of bends in a component to a high degree of accuracy.
Punching:
Punching is performed by placing the sheet of metal stock between a punch and a die mounted in press. The punch and die are made of hardened steel as well as being the same shape. The punch just barely fits into the die. The press pushes the punch against and into the die with enough force to cut a hole in the metal.
Water Jet Cutting:
The waterjet is a tool capable of slicing into metal or other materials using a jet of water at high velocity and pressure or with a mixture of water and an abrasive element.
Sheet metal has applications in car builds, airplane wings, medical tables, roofs for buildings, office equipment, even art. Even some sheet metals like iron, copper, gold, with high magnetic permeability or high electrical conductivity, have applications in transformers and electronic machines. Historically the importance of sheet metal was vital for life in the times where plate based armour was worn by cavalry and soldiers without it they were defenceless against such defensive tactics like arrows. From war to art, sheet metal continues to have many decorative uses, from horse tack reigns to creating the Chrysler Building in America.
It's all about thickness and flexibility when it comes to the process of creating the thin metals. Thicknesses can vary significantly although extreme thinness like 0.0060 mm is considered to be in the category of a foil or leaf, and pieces thicker than 6 mm are considered to be plates. The thickness of the sheet metal is called its gauge. The gauge of sheet metal ranges from 3 gauge to about 38 gauge the larger the gauge number the thinner the metal is.
The science behind the formulation to create such thin metals is actually very precise and complicated to work out; how to achieve the maximum bending force which in turn creates the thinness is to use this equation... F(max) equals k with Tlt squared over W. 'k' is a factor taking into account several parameters of friction. 'T' is the ultimate flexible strength of the metal, 'l' and 't' are length and thickness of the sheet metal and the variable 'W' is the open width of a wiping die. So as you can tell, very complicated.
The most common forming process are such techniques as:
Curling:
Used to form the edges into a hollow ring. Other parts are curled to perform their primary function like door hinges.
Decambering:
The process of removing camber, or horizontal bend, from strip shaped materials.
Deep Drawing:
Drawing is a forming procedure in which the metal is stretched over an object. In deep drawing the depth of the part being made is more than half its diameter. Deep drawing is used for making automotive fuel tanks, kitchen sinks and more.
Laser Cutting:
With the advances in technology, sheet metal cutting has turned to computers for precise cutting.
Press Brake:
This is a form of bending, used for long and thin sheet metal parts. Computer controlled to allow the operator to make a series of bends in a component to a high degree of accuracy.
Punching:
Punching is performed by placing the sheet of metal stock between a punch and a die mounted in press. The punch and die are made of hardened steel as well as being the same shape. The punch just barely fits into the die. The press pushes the punch against and into the die with enough force to cut a hole in the metal.
Water Jet Cutting:
The waterjet is a tool capable of slicing into metal or other materials using a jet of water at high velocity and pressure or with a mixture of water and an abrasive element.