In the manufacturing sector, every industry (directly or indirectly) relies on sheet metal fabrication. Whether it is automotive, appliances, energy, or electronics, all these industries need sheet metal to carry on their production. That’s why most manufacturers search for “the best sheet metal industry near me” to get their requirements fulfilled timely and cost-effectively.
Sheet metal is a vital part of everyday products, making sheet metal fabrication a crucial and demanding process among different manufacturing industries in Faridabad.
For meeting the rising demand for fabricated sheet metal, there has been an increase in sheet metal manufacturing companies in Noida. The popularity of sheet metal fabrication is growing every day, making it crucial for manufacturers entering the respective niche to learn the process right from the basics.
If you also want to learn about the different types of sheet metal operations, you’ve landed on the right page. The article will take you through the manufacturing process well to help you find out if it fits your manufacturing needs.
So, let’s begin!
Raw Materials Required
The materials required for manufacturing sheet metal are stainless steel and aluminum. Both the metals are available in different grades, depending on how much resistant and powerful one you want. The stainless steel can be acquired in grades like 304, 316, and 410, in which 304 is mostly used. On the other hand, aluminum is available in four grades, and that is 6061-T6, 5052-H32, 3003-H14, and 1100-H14. The material is used to make several types of machinery, equipment, and weapons, depending on their robustness.
Processes Involved In Sheet Metal Fabrication
The different sheet metal manufacturing companies in Noida uses a distinct set of process to fabricate sheet metal. But there are some common steps that every sheet metal industry near me and far uses. So, here are the steps:
Drawing is a forming process that involves pushing a punch against a flat sheet to force it to attain a required shape. The step turns sheet metal into thin-walled, hollow-shaped parts. The step is usually carried out to manufacture products like cups, household utensils, etc.
The process involves using soft materials that are deformed to acquire the intended shapes. starts with a circular blank of proper size and a die with an ejector system placed below a pad that removes the component after pressing it into shape. Lubricants are used to ensure the smooth flow of the blank over the die/punch.
After the flattening of the sheet metal, another step comes in, and that is cutting. The basic fabrication process involves cutting the metal sheets into half, thirds, or shorter sections. Manual and power tools, like handheld plasma torches, CNC cutters, etc., are used to cut the sturdy metal. The process can be carried out on pre-shaped or freshly cut metals like panels and bars.
It is one of the complicated steps in sheet metal fabrication as it involves the precise folding of metal surfaces at different angles to get the required shape. Attaining the right shape is important to enable the component to function as expected. Although, with the advancement in technology, the step became simpler as the high-tech equipment ironed out all the complexities.
The manufacturing of specific metal components requires passing them through another step called welding. It involves combining two or more pieces of metal using heat and pressure. Welding is used to make components like bars, panels sheets, etc. There are basically four types of welding:
- MIG – Gas Metal Arc Welding (GMAW)
- TIG – Gas Tungsten Arc Welding (GTAW)
- Stick – Shielded Metal Arc Welding (SMAW)
- Flux-cored – Flux-cored Arc Welding (FCAW)
The step involves the removal of excess pieces from the metal. Machining is carried out on a lathe, which rotates the metal at specific angles against trimmers to give it the required shape of accurate measurement. Plus, the step involves forming holes into the metal using a metal drill.
Punching is a step where holes are punched into the metal pieces. First, the metal is kept under a die, and then a fabricator is set cautiously to punch holes of accurate circumference into the metal. Mostly punches are done to fasten latches and other products with the metal pieces or sometimes to form a minor part.
Some manufacturing industries in Faridabad need metal sheets to be cut into longer parts, and that's when shearing helps. It involves a cutting tool placed vertically against the length of the metal sheet, and the sheet is passed horizontally through the cutter. The step can also be carried out by pacing the metal sheet over the edge of a cutter that trims it from one side to another.
When there is a need to raise the metal sheet at certain points, the step of stamping comes into play. It involves the formation of specific shapes, letters, or images on a metal sheet. The step is carried out to form caps, cans, coins, etc.
Casting is done using a mold in which molten metal is poured and allowed to cool down to form a specific shape. It is one of the easiest methods for attaining complex shapes from sheet metal. When any of the other steps in the fabrication process fails to deliver the required shape, casting is used. Different metals can be used for casting, like steel, silver, iron, magnesium, and copper.
Fastening is done on metals that are too thin to be secured. It provides torque resistance to secure metals using nuts, spacers, studs, cable tie mounts, and hooks.
After obtaining the overall metal structure using the above steps, it's time to give it the perfect finishing. The step work of features like appearance, chemical resistance, corrosion resistance, wear & tear, heat & electrical conductivity, surface friction control, and blemish removal.
Metal Fabrication Tools
Metal Cutting Saws
It includes band saws, circular saws, cold saws, and chop saws. Each can be used to cut the metal piece differently, easily, and safely.
Deburring and Bevelling Tools
The tools include bevel mills, grinders, sanders, etc. They are lightweight yet strong enough to be used on sturdy metals like steel. The tools offer a vibration-free performance and help sheet metal manufacturers to attain expected results every time.
Sheet Metal Rolling Equipment
The equipment is available in both manual and automatic operation. It is largely used to bend and roll metal sheets in a simpler way.
As the name says, grinders are used for grinding, cutting, and polishing sheet metal. They are hand-held power tools that can work on various metals of different sizes.
The tools allow the effortless cutting of metal sheets into straight, curved, or irregular lines. They can be used on different metals.
Wire cutters are simple tools used widely in the fabrication industry to carry out multiple tasks ranging from finishing fabrication projects to trimming frayed ends.
Drills bits are another crucial tool used in the sheet metal fabrication process. The tool drills holes in the metal sheets so that they can be fastened or combined together into a component to deliver the required work.
All these tools are used by sheet metal manufacturing companies to make the process efficient and cost-effective.
In addition to the sheet metal fabrication steps mentioned above, there are other steps like honing, broaching, galvanizing, grinding, milling, and roll forming. These steps are carried out to give metal sheets the exact features required for a certain industry. There are many sheet metal manufacturing companies in Noida that uses all the above steps to offer customized fabricated metal to customers and retain them for a lifetime.
We hope that the article has provided you with a vivid view of different types of sheet metal operations used by different industries. If you have any questions or queries, do let us know in the comments.