Sheet metal shaping is instrumental in the fabrication and assembling of parts and segments for manufacturing. A sheet metal forming process involves reshaping a metal while it is still in its strong solid-state. The versatility of certain metals makes it easier to twist them from a solid piece into an ideal structure without losing the primary structure of the metal. We’ll take a look at the six most common sheet metal forming processes. Each process cycle is refined through cold shaping, without warming or melting the material first to reshape it.

1) Bending

Bending or bowing is a strategy used by manufacturers to frame metal parts and segments into an ideal shape. It is a typical fabrication process where pressure is applied to twist the metal on one of its axes. Plastic deformity changes the workpiece to a desired geometric shape without influencing its volume. Bending changes the shape of the metal without cutting any of the material. Most of the times, it doesn’t even change the thickness of the sheet metal. It is used to give strength and stiffness to the workpiece for utilitarian purposes. It can also be used to take out sharp edges. Bending is performed using a brake press.

2) Curling

Curling sheet metal is a framing process that eliminates burrs to create smooth edges. As a fabrication process, curling adds an empty, roundabout finish to the edge of the workpieces. At the point when the sheet metal is first cut, the stock material often contains sharp burrs along its edges. As a strategy of shaping, curling de-burrs is the best option to avoid sharp and rough edges of sheet metal. Overall, the process of curling improves the strength of the edge and proves to be essential for safe handling.

3) Ironing

Ironing or pressing is another sheet metal forming process done to achieve uniform wall thickness of a workpiece. The most well-known application for pressing is framing the material for aluminium cans. Stock aluminium sheet metal must be thinned to be rolled into cans.  In its crude state, the aluminium sheet metal is too thick for refreshment cans, so it’s pressed to achieve a more slender, and uniform composition. Ironing can be done during deep drawing or performed independently. The process is executed by a punch and die, constraining the metal sheet through a clearance that will act to consistently try to decrease the entire thickness of the piece to a certain value. As with bending, the deformation will not reduce volume. It thins the workpiece and causes the part to extend.

4) Laser Cutting

Laser cutting is a common fabrication strategy that utilises a powerful, engaged laser shaft to cut and take away material from a workpiece into an ideal shape or design. It is used to deliver complex parts and segments without requiring handcrafted tooling. A powerful laser consumes metal effortlessly, quickly, with precision, and leaving smooth-edged finishes. Compared to other conventional cutting methods, parts cut with laser produce less material pollution, waste or physical damage.

5) Hydro-forming

Hydro-forming is a metal shaping process that stretches a blank workpiece over a die using compressed liquid and working at room temperature. Lesser known and considered a special type of die forming metal parts and segments, hydro-forming can make both convex and concave shapes. The method utilises a high-pressure powered liquid to drive a strong metal into a die. This process is best suited to shape flexible metals like aluminium into solid pieces while holding the properties of the original material. Due to the solid underlying integrity of hydro-forming, the automotive industry relies on it for the unibody development of vehicles.

6) Punching

Metal punching is a subtractive fabrication process that structures and cuts metal as it goes through or passes under a punch press. The metal punching apparatus forms custom designs into the metal workpieces. Basically, this process carves a hole through metal by cropping the workpiece. A die set consists of male punches and female dies, and once the workpiece is clasped and set in place, the punch passes through the sheet metal into a die that delivers the desired shape. Even though some punch presses are still manually operated machines, the majority of the present punch presses are industrial-sized CNC (Computer Numerical Control) machines. Punching is a cost-effective and financially savvy strategy for framing metals in medium to high creation volumes.

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