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What is Sheet Metal Parts
Sheet metal parts play a pivotal role in various industries, from construction and automotive to aerospace and electronics. Their versatility, durability, and cost-effectiveness make them an indispensable component in modern manufacturing processes. In this article, we will delve into the world of sheet metal parts, exploring their manufacturing techniques, applications, and the numerous benefits they offer.
Benefits of Sheet Metal Parts
Strength and Durability
Sheet metal parts offer excellent strength and durability, ensuring long-lasting performance even under challenging conditions.
Cost-Effectiveness
Compared to other materials, sheet metal is relatively cost-effective, making it an economical choice for mass production.
Design Flexibility
Manufacturers can easily shape and mold sheet metal parts into complex designs, offering design flexibility and creative freedom.
Recyclability
Sheet metal is highly recyclable, contributing to sustainable and eco-friendly manufacturing practices.
Heat and Electricity Conductivity
Certain sheet metal alloys possess excellent heat and electricity conductivity, making them ideal for specific electronic applications.
Corrosion Resistance
Stainless steel and other corrosion-resistant sheet metals ensure longevity and reduced maintenance requirements.
Welding Equipment Sheet Metal PartsThese are sheet metal parts that are commonly used in welding equipment. These parts are made from sheet metal that has been cut, bent, and possibly welded into specific shapes for functional
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Galvanized Sheet Metal PartsGalvanized sheet metal parts are components made from steel or iron that have undergone a galvanization process to enhance their corrosion resistance.
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Aerospace Sheet Metal PartsAerospace sheet metal parts are critical components used in the aerospace industry, crafted from various metals through precise processes to meet the demanding requirements of aircraft and spacecraft.
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Automotive Sheet Metal PartsAutomotive sheet metal parts are essential components used in the construction of vehicles, providing both structural integrity and aesthetic appeal.
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Bent Sheet Metal PartsBent sheet metal parts are components created by bending flat sheet metal into specific shapes and angles through various forming processes.
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Precision Sheet Metal PartsPrecision sheet metal parts are components manufactured from thin sheets of metal through various processes to achieve high accuracy and specific tolerances.
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Competitive Prices
We offer our products at competitive prices, making them affordable for our customers. We believe that high-quality products should not come at a premium, and we strive to make our products accessible to all.
Rich Experience
Has a long-standing reputation in the industry, which makes it stand out from its competitors. With over many years of experience, they have developed the skills necessary to meet their clients' needs.
Quality Assurance
In terms of quality assurance, the company strictly follows the standards and norms of the industry quality system. Adopt industry-leading testing equipment to ensure product quality and good reputation.
Professional Service
We can accept factory inspection and goods inspection at any time. Technical discussion, research and development of new products, and complete after-sales service.
High Quality Products
We always put customer needs and expectations in the first place, refine on, continuous improvement, to seek every opportunity to do better, to provide customers with their expectations of quality products, to provide customers with the most satisfactory service at anytime.
Customer Satisfaction
Providing after-sales services can enhance customer satisfaction by ensuring that customers' needs are met even after the purchase. This can lead to increased customer loyalty and positive word-of-mouth referrals.
Tips for Designing Sheet Metal Components
Designing sheet metal components requires careful consideration of manufacturability and processing capabilities to ensure successful fabrication. Here are three primary considerations to keep in mind during the design phase:
Ensure Designs can be Unfolded Into a Single Sheet for Processing
Sheet metal components are formed from a single sheet through cutting and bending processes. Designs that cannot be unfolded into a single sheet are impractical for fabrication, highlighting the importance of considering unfolding during the design phase.
Consider Processing Limitations
Sheet metal components are subject to limitations based on bending and forming capabilities, which can vary depending on factors like bending proximity to holes or minimum distances from edges. Consulting processing partners to confirm processing capabilities upfront can help avoid costly rework post-order placement.
Beware of Interference During Bending
Interference between the component and bending tools may occur during processing, especially in cases where bent edges exceed shorter edges. Considering potential interference during the design phase can help prevent processing issues or errors.
Applications of Sheet Metal Parts
Sheet metal parts find application in a wide range of industries and products:
Automotive Industry: From car bodies to exhaust systems, sheet metal parts are extensively used in the automotive sector due to their strength and lightweight characteristics.
Construction Sector: Sheet metal parts are vital in the construction of buildings, bridges, and infrastructure due to their durability and ability to withstand harsh environmental conditions.
Electronics and Appliances: Devices like computers, refrigerators, and air conditioners rely on sheet metal parts for their outer casings and internal components.
Aerospace Industry: Sheet metal parts are crucial in aircraft manufacturing, providing aerodynamic and structural components.
Medical Equipment: Many medical devices and equipment are crafted from sheet metal due to its hygienic properties and ease of cleaning.
Consumer Goods: Various everyday items like metal furniture, kitchenware, and decorative pieces are made using sheet metal.
5 Ways to Strengthen Your Sheet Metal Parts
Avoid the flat design
The flat sheet metal part is not strong enough, as it lacks of the structural integrity. In addition, the flat sheet metal part is easy to bend and deform under pressure. Therefore, the flat sheet metal design should be avoided. Adding ribs, flanges, or hems to sheet metal parts are suggested to bolster the sheet metal parts.
Adding ribs
Ribs are frequently used to improve the strength of sheet metal parts and reduce the deformation. The common shapes of ribs on sheet metal are arch and trapezoid. However, it should be aware that it doesn' t mean the more ribs on the part, the more bolstered the part will be. Too many ribs will also cause the deformation and bending. Meanwhile, ribs should be placed into the sheet metal parts uniformly, otherwise the uneven ribs can lead to part bending as well. The following is the common sizes of ribs.
Adding straight bend, flange or hems
The stretched sheet metal in each groove or line can compound the strength, hold tension in the panel and give it the structural rigidity. Therefore, the sheet metal parts can be bolstered. There are a number of ways to stretch lines or grooves. The following is the common methods to get the sheet metal bent.
Adding triangular ribs to bending place
To ensure the strength and angle of the bent sheet metal parts, the triangular ribs are frequently added to bending place. It' s an easy way to bolster the components.
Connecting the sheet metal parts with hardware
If you need a more robust thread or connection, an inserted hardware would be your preferred choice. Because sheet metal is thin and flat, it' s difficult to thread holes in metals. Integrating hardware into the sheet metal is also key to connect and bolster the parts. Keep in mind that the hardness of the hardware should be equal to or greater than that of sheet metal materials. Available sheet metal hardware are self-clinching nuts, self-clinching standoffs, flush-head stud, thin sheet non-flush stud and more.
Tips for Making Sheet-Metal Parts
Below are some tips and guidelines for designing sheet-metal parts. If you follow the design advice and maintain the tolerances expressed in this article, you are more likely to end up with parts that meet the needs of your designs.
Parts should maintain a uniform wall thickness throughout their entirety, but this should be easy because parts are formed from a single sheet of metal.
Sheet-metal brakes bend sheets into a part' s desired geometry. Bends in the same plane should be designed in the same direction to avoid having to reorient the part during manufacturing, which will save money and time. Another trick is to keep the bend radius consistent to keep parts more cost-effective. Thick parts tend to become inaccurate, so they should be avoided if possible.
To prevent parts from fracturing or distorting, make sure to keep the inside bend radius at least equal to the sheet' s thickness.
Holes should be placed away from the curl at least a distance equal to the radius of the curl plus the material' s thickness. Bends should be at least six times the material' s thickness plus the radius of the curl.
Outside radius of curls must be at least twice the sheet' s thickness.
Countersinks must be separated from each other by a distance of at least 8 times the material thickness, from an edge by at least 4 times the material' s thickness, and from a bend by at least 3 times the material' s thickness.
The maximum depth for a countersink is 3.5 times the material' s thickness.
Hems are folds to the edge of a part that create rounded, safe edges. Hems may be open, flat, or tear-dropped, and tolerances depend on the hem' s radius, material thickness, and features near the hem. It should be noted that flat hems should be avoided because they risk fracturing the material at the bend.
For open hems, the inside diameter should at least equal to the material thickness (larger diameters tend to lose their circular shapes); and the return length should be at least 4 times the material' s thickness. Tear-dropped hems must maintain an inside diameter of at least equal to the material' s thickness, an opening of at least ¼ the material' s thickness, and the return length should also be at least 4 times the material' s thickness.
Holes and slots may become deformed if positioned near a bend. The minimum distance that holes should be placed from a bend is a function of the material thickness, bend radius, and the hole' s diameter. Holes should be at least 2.5 times the material thickness plus the bend radius away from any bends. Slots should be placed 4 times the material' s thickness plus the bend radius away from the bend.
Be sure to put holes and slots at least twice the material' s thickness from an edge to avoid a ‘‘bulging’’ effect. And holes should be separated from each other by at least 6 times the material' s thickness.
Keep hole and slot diameters at least as large as the material' s thickness. Higher-strength materials require larger diameters.
Notches must be at least one-eighth of an inch (3.175 mm) away from each other. For bends, notches must be at least 3 times the material' s thickness plus the bend radius. Tabs must be at least 0.04 inches (1 mm) from one another or the material' s thickness, whichever is greater.
Notches must be at least 0.04 inches (1 mm) thick or as thick as the material, whichever is greater. A tab should not be any longer than 5 times its width. Tabs must be at least 0.126 inches (3.2 mm) thick, or two times the material' s thickness, whichever is greater. Tab length should be no larger than 5 times its width.
Sheet-metal parts may have sharp corners, but designing a fillet of ½ the material' s thickness will make parts more cost-effective.
Relief cuts help parts avoid ‘‘overhangs’’ and tearing at bends. Overhangs become more prominent for thicker parts with smaller bend radii, and may even be as large as one half of the material' s thickness. Bends made too close to an edge may cause tearing.
Relief cuts for bends must be at least one sheet' s thickness in width, and be longer than the bend radius.
Custom sheet metal parts are fabricated from various materials, each possessing distinct features and characteristics. The choice of material will rely on the product’s intended application and aspects such as cost, durability, and strength. Among the most often employed materials for custom sheet metal products are:
Steel: Due to its strength and durability, steel is a common material for custom sheet metal goods. Additionally, it is quite affordable, making it a cost-effective choice for various applications. There are numerous ways to finish steel, including painting, powder coating, and galvanizing.
Aluminum: It is a lightweight and corrosion-resistant material frequently used to fabricate sheet metal products. It is also an excellent conductor of both electricity and heat, making it a perfect material for goods requiring both characteristics. Anodizing is one of the various coatings that may be applied on aluminum to create an attractive, corrosion-resistant surface.
Copper: Copper is a soft and pliable metal frequently used for sheet metal goods requiring electrical conductivity. It is also highly corrosion-resistant and can be coated with various finishes, such as tin plating and nickel plating, for increased durability and protection.
Stainless Steel: Stainless steel is a highly corrosion-resistant material frequently utilized for sheet metal items exposed to hostile conditions. It is also a sturdy and durable material that can be coated in various ways, including polishing, to provide a sleek and contemporary look.
5 Ways to Reduce Costs on Sheet Metal Fabrication
Choose the Appropriate Material
Material cost is one of the most significant drivers of part costs. Be sure to choose your material carefully and use stock sizes. If you are prototyping, consider using Aluminum 5052 versus 304 stainless steel or other less expensive material.
Design to a Common Gauge
When designing your part, remember to use standard sheet metal gauges. Generally, Xometry is capable of manufacturing sheet metal parts up to ¼” (6.35mm) in thickness, but this constraint mainly depends on the geometry of the part. Thicker metals may restrict what bends are achievable for your part.
Simplify Your Folds
In general, the more complicated your part is, the more expensive it will be. To cut down on your costs, design for simple angled bends, with a radius equal to or greater than the thickness of the sheet. Small bends on large, thick parts tend to become inaccurate, so they should be avoided if possible. Our Design Guide on sheet metal gives some great best practices for designing sheet metal pieces.
Limit the Use of Tight Tolerances
Typically, only a few surfaces of a part are critical to its function. The more features with tolerance callouts in the design (e.g., radii, hole diameters, and distances), the more expensive a part becomes to manufacture. In order to eliminate unnecessary costs, the key is to only assign tolerances to mission critical features and surfaces.
Maintain Uniform Bend Orientation
Bends in the same plane should be designed in the same direction to avoid part reorientation, which will save both money and time. Keeping a consistent bend radius will also make parts more cost-effective. For more information check out our blog post on the basics of bending sheet metal.
How to Avoid Hole Distortion in Sheet Metal Parts
Sheet metal fabrication is an excellent method of making mechanical parts, especially support brackets. They tend to be cheap, light, strong, and easy to pack and ship. In this article, I explain how to avoid hole distortion in sheet metal parts.
Ideally, when sheet metal is bent, the entire length of the bend gets pressed into the die by a punch. The resulting bend smoothly and accurately matches the bend radius of the punch and die. It is common to have holes designed into sheet metal parts for various reasons. A hole located near the punch is likely to be distorted and warped during the bending process.
To determine whether a hole is at risk for distortion depends on the bend radius, bending method, and tool size. Generally a hole is at risk for distortion if it is within a distance equal to 3 or 4x the sheet metal thickness from the bend line. This rule also applies to slots, punch-outs, louvres, dimples and other features that may be distorted by bending.
If the hole and bend can’t be moved farther apart, add a relief to the area roughly as long as the diameter of the hole. This will reduce the possibility of the hole being distorted. The image below shows a support bracket with these reliefs designed in. A section cut has been made to show internal details.
By adding the reliefs, the hole should avoid becoming distorted. However, a possible trade-off is that the flange-bend might become disrupted. If the part is not specifically required to have a continuous bend (e.g., to be liquid tight or visually homogenous), then this is a good trade-off to ensure a round and appropriately sized hole for the fastener to pass through. This also particularly important when the hole is for a self-clinching insert. The insert requires a predictable profile for reliable installation. Issues could arise with the anvil and punch if the hole is too close to the flange.
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Mechanic Machining (Shenzhen) Co., Ltd, which was establish in 2004, is professionally engaged in the manufacturing and sales of various precision tooling fixtures and mechanic parts and accessories.
The factory covers an area of 4,000 square meters and has more than 80 employees. The company fully applies the ERP system and is managed in accordance with the ISO9001 and ISO14001 systems.
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As one of the leading sheet metal parts manufacturers and suppliers in China, we warmly welcome you to wholesale high quality sheet metal parts made in China here from our factory. For customized service, contact us now.
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