Sheet Metal

Sheet Metal Definition, Types, and Uses
 

This concept can be defined as, according to an article in a scholarly journal:

Punching and cutting, Shearing, riveting, splicing, shaping, folding  (like a car body), etc. are all part of the sheet metal process, which encompasses a wide range of cold working techniques for thin metal sheets (typically below 6mm).

Plate armor worn by cavalry was a significant application of sheet metal in the past, and it continues to see use in various decorative contexts, such as in modern harnesses. 

What is Sheet Metal, Types and Uses
 

In the metalworking industry, "sheet metal" refers to the flat, thin slabs of metal. Metal sheets are typically less than 6 millimeters thick. Metalworkers utilize it because it is one of the most basic shapes and can be shaped in a wide range of ways by cutting and bending.

There's often a wide range of thicknesses possible. The terms "foil" and "leaf" are used to describe extremely thin sheets of metal. The term "plate" is used to describe materials that are more than a quarter of an inch thick. Sheet metal is used in the construction of a wide variety of commonplace items. Sheet metal can be fabricated from a wide variety of metals, including aluminum, brass, copper, cold rolled steel, mild steel, tin, nickel, and titanium. Sheet metal can be found in a wide variety of places, including vehicle bodywork, aviation wings, operating tables, roofs, and more.

Uses 
 

1. Automotive

Sheet metal is widely used in the auto industry to construct vehicle bodywork. Also, this stuff is used to build the bodies of trailers, RVs, and other vehicles.

2. Aerospace

Without sheet metal, airplanes couldn't fly very far. Most of an airplane is sheathed in metal for protection. This is especially crucial for structural components like wings and fuselages.

3. Construction

The construction industry would mostly collapse without the use of sheet metal. This is a crucial component of any structure, from ventilation ducts to roofing flashing and gutters.

4. Equestrian

This Sheet Metal application is purely aesthetic, but it's still cool to look at! Sheet metal is commonly used in the equestrian industry to make ornamental breastplates and other gear for horses.

There are many advantages to using sheet metal. The first is how convenient it is to move around this stuff. It's easy to stack and move around sheet metal because of its lightweight and compact size. That means you may order in bulk with no worries about shipping costs.

Sheet metal is extremely weatherproof because it is coated with a chemical solution after production. This chemical solution is useful for preventing corrosion and increasing resistance to UV rays. Sheet metal is very sturdy for this reason as well. Metal roofing is favored by many families because of its long lifespan.

Metals like aluminum sheets and stainless steel are consistently among the most popular metals to buy. These metal sheet forms have several applications.

Sheet Metal Types
 

1. Pre Plated Steel

These metal sheets are either made of hot-dip galvanized steel or galvannealed steel. The most prevalent types of stainless steel are in the 300 series, and these steels can be non-magnetic in the standard form. It can be manufactured without resorting to hot work or any other form of stress alleviation.

2. Cold Rolled Steel (CRS)

Cold rolling steel is used to improve the surface quality of previously formed hot rolled steel and to maintain a closer dimensional tolerance. It is possible to obtain CRS in both the 1008 and 1018 alloys.

3. Stainless Steel

For objects that will be regularly exposed to moisture, this sheet metal is the best option. Because of the chromium it contains, it greatly inhibits corrosion in salty or moist conditions. From kitchen sinks to office buildings, the use of components made from stainless steel sheet metal fabrication can greatly extend their useful lives.

4. Galvanized Steel

There are two distinct types of galvanized steel on the market today, one that is electro-galvanized and another that is hot-dipped in a metallic coating. Cold-rolled annealed steel is the material used to make the former. It is zinc plating, yet there is no zinc spangle.

The latter is made out of pure zinc and an iron-zinc alloy that has been plated onto cold-rolled strong steel plates. 

Corrosion resistance is improved and costs are reduced in comparison to electro-galvanized sheets when using this galvanized steel.

5. Tool Steel

Tool steel, a hard alloy containing roughly 1% carbon, is incredibly adaptable. Tool steel, like alloy steel, can have a wide variety of element types and proportions depending on its intended use. 

Despite being used in high heat, tool steel retains its durability and effectiveness. This sheet metal's characteristics make it perfect for use in making tools including dies, hammers, punches, and blades.

6. Carbon Steel

Sheet metal made from an iron-carbon alloy is a very sturdy alternative. Steel with low, medium or high carbon content can be selected by the producer depending on the final product's intended use. 

As a result of its low carbon content, this material is extremely adaptable and is used in a wide variety of commonplace products. 

Medium carbon steel is frequently used in the production of cars, trucks, and home appliances. Carbon content above a certain point makes the material significantly more brittle, making it suitable for use in extremely fine applications like wires.

7. Alloy Steel

Alloy steel, as its name implies, is created by combining various components to achieve a wide range of desirable characteristics. 

The primary element here is carbon steel. Metals like tungsten, chromium, and manganese, or vanadium and nickel, are frequently added to improve the material's stiffness and strength, respectively. Alloy steel's affordability and adaptability make it a popular choice.

8. Aluminum 

Aluminum is a great lightweight material choice for uses like these. Without a coating, this metal sheet has exceptional resistance to corrosion. Aluminum is a versatile metal that can be machined, welded, and sliced with a laser. 

Aluminum, a reasonably priced material, comes in numerous grades with varying qualities to satisfy specialized needs. Although it has a low strength, Grade 1100 steel is durable against the elements, can be welded, is ductile enough for deep drawing, and is resistant to chemicals. Strength, formability, weldability, corrosion resistance, and low cost all characterize Grade 3003. While Grade 5052 is considerably stronger, it can still be formed, welded, and is resistant to corrosion. 

This structural alloy, grade 6061, is strong and resistant to corrosion, but it cannot be shaped. It can be welded, however the process weakens it slightly.

Sheet Metal Forming
 

Let’s review the top 6 common sheet metal forming process:

1. Curling

A sheet metal forming method, curling is used to soften the edges of a sheet metal piece. After being manufactured, sheet metal frequently has rough, jagged edges called "burrs." Curling is a method of metal forming that involves de-burring the edges of the metal to create a finished product with rounded corners.

2. Bending 

Bending is another typical method of sheet metal fabrication. A brake press or equivalent machine press is primarily used by businesses for sheet metal bending. When the sheet metal is in place over the die block, a punch is used to strike the metal. Holes aren't actually formed in the metal when it's bent. Instead, it "bends" sheet metal to fit the form of a die, living up to its moniker.

3. Ironing 

Ironing sheet metal can also help bring it to a consistent thickness. For instance, most aluminum cans are produced from aluminum that has been ironed. Aluminum sheet metal is too thick in its natural state to be used for beverage cans, therefore it is ironed to obtain a thinner, more homogeneous composition. Punching sheet metal between dies is the key step in the ironing process.

4. Laser Cutting

In recent years, laser cutting has replaced several other methods for producing sheet metal. In laser cutting, a powerful laser is used to melt holes in a metal sheet. With the use of computer numerically controlled (CNC) laser cutting equipment, this cutting technology is both quicker and more precise than conventional methods.

5. Hydroforming

Hydroforming is an alternative method for shaping sheets of metal. Similar to deep drawing, hydroforming entails extending the blank over a die. I'm confused; please explain the distinction between hydroforming and deep sketching. The primary distinction between deep drawing and hydroforming is that the latter only involves a single stage of lowering the material's volume.

6. Punching 

Last but not least, punching is a method of sheet metal formation in which holes are cut out using a punch and die set. After positioning the punch and die, the sheet metal is fed in between them. After positioning the sheet metal, the punch is pressed down into it to make a hole.

FAQs: Sheet Metal
 

Q. What is the thickness of sheet metal?
Ans. Sheet metal thicknesses range from 0.5 mm all the way up to 6 mm.

Q. What are the grades of sheet metal?
Ans. The most common grades of sheet metal are 1100-H14, 6061-T6, 5052-H32, and 3003-H14.

Q. What are the standard sheet metal sizes?
Ans. The standard sheet metal sizes include 36” x 96”, 36”x 120”, 36” x 144” and 48” x 96”

Q. What are the properties of sheet metal?
Ans. Yield Strength, Compressive Strength, Bending Strength, Tensile Strength, and Fracture Surface Shrinking Percentage are some mechanical properties of sheet metal.