Sheet metal fabrication is a big business. In fact, it is a huge industry with a valuation of $3,165 billion in 2022, and the growth is relatively healthy. This massive growth and market value owes itself to the fact that sheet metal is used in virtually every industry and engineering project across the globe. From construction to aircraft engineering and even spacecraft, sheet metal forms an integral part of human civilization.
However, fabricating sheet metal is not quite as easy as it seems. Due to its volatile nature, sheet metal might have a lot of deformation during the production process, which can put a dent in your production plans. This article will provide some practical tips to help you prevent the deformation with ease.
Why Deformation Happens During the Sheet Metal Fabrication Process
Sheet metal will be bent and worked on in various ways during the fabrication process. Deformation refers to unintended bends as well as distortion that happens during the process. There are numerous ways why these unintended deformations occur, but most will have to do with a poor sheet metal design.
Here are some top reasons why deformation could occur:
- Unsupported flanges
- Unrelieved bends
- Having holes or cuts too close to the bending areas
The reasons above illustrate that a bad design that does not put thought into the bends will be the primary reason for deformation in the sheet metal fabrication process. Thus, the key to preventing deformation lies in creating better designs.
Tools for Preventing Deformation in Sheet Metal Fabrication
To build better designs, you will need specialized tools that work specifically with sheet metal fabrication. The first tool you need is the appropriate software that enables you to draw complex and detailed designs that allow bends as well as other features on your sheet metal. You simply cannot create a reliable design for sheet metal without this software, as it enables you to put the specifications into the drawing plan, ensuring that the fabrication engineers down the line understand the instructions clearly.
You will also need a specialized sheet rolling machine to work with the sheet metal. It would be prudent to choose a sheet rolling machine that does not apply too much force on the sheet metal, a principal factor that contributes to sheet metal deformation. This sheet rolling machine will also have to accommodate different materials so that you will have a more flexible range of materials in your portfolio.
Finally, invest in a tube bender if you have the opportunity. While you would need a fully automated system for the most part, having a manual tool to bend your sheet metal whenever necessary will not hurt. It might be a last-minute lifesaver!
Practical Tips to Prevent Deformation in Sheet Metal Fabrication
The sheet metal fabrication process is a difficult one, but there are some neat practical tips that you could follow to create a smooth production line of sheet metal for your profits.
Choose the Correct Materials
The material you use for your sheet metal plays a central role in its properties. For example, if you choose soft materials such as aluminium or soft steel, you will have a much easier time bending them, reducing the risks of deformation. Meanwhile, if you have to work with hard steel materials or other hard metals, bending is noticeably much harder, so you will likely struggle with these materials. Review the requirements set out by your customers first so that you have a clear understanding of what they need to pick the perfect materials.
Determine the Correct Bend Allowance
The bend allowance is a hard limit to the bend angle of your sheet metal, and it should serve as a great stop sign to let you know when you are stretching a bit too far. The bend allowance should be set according to the project’s requirements as well as the material’s own properties as well.
Support Your Flanges
Some sheet metal designs require flanges, and these are the designs that need your attention the most. Flanges need to be properly supported, or else they will be deformed the moment the sheet rolling machine applies pressure to them. A rule of thumb when designing sheet metal with flanges is to provide adequate length to cover the bottom die and be sure to take into account the press brake’s back gauge.
Add Bends Space or Relief
Bends space and relief are tiny spaces that relieve the stress on the bends, reducing the chance of warpage or deformation. The size of bend spaces and reliefs will have to depend on the type of material used for the sheet metal as well. As a rule of thumb, the thicker and tougher the material, the more support it needs to prevent deformation.
Control Bending Force
When rolling your sheet metal, avoid using sudden excessive force. This will certainly cause deformation or even breakage in some cases. Apply force slowly and surely using the appropriate intensity to make sure that the sheet metal is bent in the manner you prefer.
Control the Temperature
Temperature is another factor to take into consideration. Sheet metal becomes much more malleable and flexible when heated, so you could try this method to get the bends you aim for. Avoid rolling or bending the sheet metal in a cold environment, as it will vastly increase the chances of deformation.
The best tools and techniques to prevent deformation in sheet metal fabrication are to improve the sheet metal design as well as to choose the correct material that fits the project’s requirements. You can also consider heating up the metal sheet first before working with them for more malleability and flexibility. Utilizing advanced techniques as well as in-depth industry knowledge, ArtTangent is fully capable of providing top-notch machining products such as control boxes. We also offer custom dies and gaskets
Reference:
https://www.linkedin.com/pulse/sheet-metal-fabrication-services-market-global-outlook-mblbf
