Sheet Metal Fabrication 101: A Basic Knowledge Guide

by Avadhesh Sharma SEO Analyst

When flat steel of metal is turned into various structures and products it is called sheet metal fabrication. This method of processing involves the conversion of different kinds of metal sheets into miscellaneous parts and components of machinery. Hence, this metal forming process deals with a number of forming techniques rather than just a single process manufacturing process. The basic techniques of precision sheet metal fabrication include cutting, punching, bending, welding, stamping and finishing.

Sheet metal fabrication is apt for a broad range of metal materials. There are a number of companies in the world that produce components made from sheets of steel, aluminium, copper, brass and stainless steel. This process of manufacturing, involving steel metal fabrication is one of the most common processes which is used for the most common daily use items.

Designing Process of Sheet Metal Fabrication

The steps involved in the process of sheet metal fabrication is not clear to most people. This leads to difficulty in understanding and having realistic expectations and requirements from a project. The sheet metal processing involves a multi-step process and calls for several skilled and experienced workmen for the completion of the job successfully.

• Each and every process of rapid prototyping starts with an idea. This step involves some basic concepts of what the designer wants. They present these ideas roughly through a 3D model and also to provide the realistic requirements of the project. These three-dimensional models can direct about the needs of wall thickness, hole orientation, bend radii, bend allowance and many more.

• After the 3D model is made, drawings for the purpose of manufacturing are done, which are called blueprints. These blueprints are sent to the machine shops including all information regarding selecting materials, surface finishing etc.

• Along with the other related calculations, the 3D drawings are also checked for manufacturability analysis. This helps the engineers for having insights about the designs to be developed and manufactured. Once this analysis is done, a final shop layout is drawn. The information gained from this leads to determining the sheet metal fabrication.

• A prototype is developed through the methods of cutting, punching, bending, welding, stamping and finishing. The finishings of the surface improves the aesthetics of the prototypes created. And lastly, the prototype is run for evaluating if it meets every kind of requirement. The evaluation is conducted in a real-life condition.

• The prototype creation that passes all the testing and meets every required specification would be forwarded for full-scale production.

Methods of Sheet Metal Fabrication

Sheet metal fabrication in UAE and other countries follows a basic set of techniques of sheet metal fabrication, for transforming a flat metal sheet into three-dimensional functional components. A few procedures of sheet metal fabrication are as follows-

Cutting- Cutting is considered the first step in the process of sheet metal fabrication. It involves cutting the metal sheets. There are a number of ways to cut the metals, for example, using shear force. Few metal cuttings might not include shear which is apt for precision cutting.

Stamping- A cold forming method to transform flat metal blanks into different shapes is called stamping using a tool and die. Stamping encompasses punching, embossing and bending.

Bending- The metal fabricators carry out the bending process of sheet metal fabrication using rolling machines, press brakes and other types of equipment. This equipment creates U shaped or V-shaped bends.

Punching- The technique of creating holes in the metal sheets is called punching. A punch and die is used which is operated using shear force for perforating holes.

Welding- It is the final stage in most sheet metal fabrication processes where the product bears two or more parts. This step involves joining the pieces together, creating a metallurgical bond, into a single piece by melting the edge and by adding filler.

Conclusion

Companies engaged in sheet metal fabrication resort to various advanced technology and practices like computer aided process planning for the designing and production of sheet metal parts. These companies hire a team with a specific skillset for offering sheet metal fabrication services. Premium quality raw materials are used for meeting desired requirements of the buyers through the finished product.