Sheet metal manufacturing: Technical analysis and in-depth guide to industry applications

Sheet metal manufacturing, as a basic process of modern industry, runs through many fields such as construction, automobiles, aerospace, and medical equipment. From the steel structure of skyscrapers to the precision shell of smartphones, this technology continues to promote the progress of human industrial civilization by converting two-dimensional metal sheets into three-dimensional functional components. This article will deeply analyze the process system of sheet metal manufacturing, explore its technical advantages, and reveal its innovative applications in various industries.

Process definition and core characteristics

Sheet metal manufacturing is a manufacturing process that converts metal sheets (usually with a thickness of 0.5-6mm) into a specific shape through systematic processing. Its technical characteristics are reflected in three dimensions.

Material ductility uses the plastic deformation characteristics of metal to achieve complex shapes, process integration, and integrates cutting, forming, connection, surface treatment and other processes. Dimensional accuracy, modern CNC technology can achieve ±0.1mm tolerance control

Core technology process flow, CAD modeling, using SolidWorks, AutoCAD and other software for three-dimensional modeling, DFM analysis optimizes parameters such as bending radius and opening position through manufacturability design analysis, and generates unfolded drawings. Expand the 3D model into a 2D cutting path and calculate the material utilization rate.

Key processing procedures Precision cutting, laser cutting, CO2/fiber laser achieves 0.1mm accuracy, applicable thickness 0.5-25mm, die cutting and stamping high-speed punch press with progressive die to achieve mass production

Forming process Bending forming, CNC bending machine with multi-station mold, angle accuracy ±0.5°. Roll forming Continuous rolling forms complex curved surfaces for pipe and profile manufacturing. Deep stamping multi-pass stretching process manufactures deep cavity parts.

Connection technology Resistance welding, spot welding efficiency reaches 600 points/minute, the main connection method for automobile bodies. TIG welding: 0.8mm thin plate welding, beautiful weld formation. Riveting assembly: SPR self-piercing riveting technology realizes the connection of dissimilar materials

Surface treatment

Powder spraying: Electrostatic spraying uses the principle of high-voltage electrostatic corona electric field. The metal guide cup on the spray gun head is connected to the high-voltage negative charge, and the coated workpiece is grounded to form a positive pole. A strong electrostatic field is formed between the spray gun and the workpiece. When the carrier gas (compressed air) delivers the powder coating from the powder supply barrel to the guide cup of the spray gun through the powder delivery pipe, dense charges are generated around it, and the powder is negatively charged. Under the action of electrostatic force and compressed air, the powder is uniformly adsorbed on the workpiece, and after heating, the powder melts and solidifies (or plasticizes) into a uniform, continuous, flat and smooth coating.

Anodic oxidation: Anodic oxidation is an electrochemical oxidation process. Aluminum or aluminum alloy is used as the anode and placed in a specific electrolyte (such as sulfuric acid, oxalic acid, etc.). A dense layer of aluminum oxide (Al2O3) film is generated on its surface by applying an external current. The core principle of this process is electrolytic reaction

Electroplating: Electroplating is an electrolytic process. The metal sheet that provides the plating metal acts as the anode. The electrolyte is usually an ionic solution of the metal, and the plated object acts as the cathode. After the voltage is input between the anode and the cathode, the metal ions in the electrolyte are attracted to swim to the cathode, and after reduction, they are plated on it. At the same time, the metal of the anode is dissolved again, providing more metal ions to the electrolyte. In some cases, insoluble anodes are used, and new electrolytes need to be added during electroplating to supplement the plated metal ions.

Stainless steel polishing: Stainless steel polishing processes are divided into two categories: electrolytic and mechanical, and the internal and external finish is achieved through fine cutting. Common grades such as #400, #600 and matte treatment, 304 series is particularly suitable for decorative applications, dry grinding wire drawing costs are low, oil grinding wire drawing has good effect, 8K processing has outstanding mirror texture, and titanium decoration is more high-end. Generally, the most commonly used stainless steel surface processes are stainless steel brushing and stainless steel polishing mirror.

Material Performance Comparison

The above are the commonly used sheet metal materials. Different materials are selected according to different structural requirements. The materials are selected according to actual needs. The materials are not limited to the above. The above are the more commonly used and cost-effective materials.

Compound processing technology, integrated equipment for laser cutting + bending + tapping. Green manufacturing water-soluble coatings replace traditional solvent-based coatings. Microstructure regulation, optimizing material grain orientation through forming process.

The global sheet metal processing market has a compound annual growth rate of 6.2% and will reach US$483 billion in 2028. The demand in the field of new energy vehicles has surged, the power battery housing market has grown by 21% annually, and the penetration rate of smart factories will increase from 38% in 2023 to 72% in 2030.

As the cornerstone technology of modern manufacturing, sheet metal manufacturing is undergoing a profound transformation from traditional processes to smart manufacturing. With the continuous breakthroughs in new materials and new processes, this technology will continue to expand its application boundaries and play a key role in precision medical equipment, new energy systems, space exploration equipment and other fields. In the future, smart sheet metal factories that integrate technologies such as artificial intelligence and digital twins will achieve closed-loop optimization of the entire process of design-manufacturing-testing, and promote the manufacturing industry into a new era of dual improvement in quality and efficiency.