The processing of raw metal into functional parts can be complex in some cases. This is why it’s important that experts are consulted during the process, from design up to the final powder coating. Each stage of metal fabrication plays an important role in ensuring the end product is accurate and functional. Metal bending is one such stage that needs to be done with precision, as incorrect bending will interfere with the assembly process.
What Is Metal Bending?
Metal bending is usually done following the welding stage of fabrication. During this part of the process, metal is bent in order to comply with the required shape in a project.
In the majority of cases, metal is bent into one of two shapes. These shapes may include a U or a V. The specific shape depends on how the metal parts will be used and what the function will be. Precision plays a big role when it comes to metal bending. Without adequate precision, the final parts will not be able to fit together as expected.
Metal bending can be complex. An example would be a heavy metal assembly with complex bending processes done by VeriForm. We have also performed bending for smaller parts too, which require even more precision and accuracy.
Types of Metal Bending
While the basics of metal bending remain the same, a variety of techniques can be used. Each technique comes with its own benefits and potential drawbacks. Manufacturers need to understand how each metal bending technique works. This ensures the manufacturing process can be matched with the appropriate option, which will ultimately contribute to the final metal parts’ enhanced functionality.
We’ll take a look at the main procedures used for metal bending below.
Mechanical Metal Bending: Mechanical bending procedures are not as commonly used as some of the other techniques. A press brake is used in order to assist with the bending process. The major advantage here is improved accuracy when bending the metal. Speed is another benefit that comes with mechanical bending techniques. There are, however, simpler options available that may deliver similar accuracy and speed.
Hydraulic Metal Bending: The use of a hydraulic press brake system is becoming increasingly popular. This is because more advanced technologies are used in the design of these systems. The technology provides better precision when it comes to bending metal. Hydraulic metal bending is most often used as a method of bending sheets. The precision with sheet bending is superior to many of the alternative techniques.
Pneumatic Metal Bending: With pneumatic bending procedures, an air compressor is needed. This process is ideal for bending metal sheets. Less pressure is needed in the press brake utilized in a pneumatic bending system. This particular type of metal bending procedure is also considered an ideal option when working with smaller parts.
CNC Metal Bending: Also called Computer Numerically Controlled bending, this procedure uses multiple brakes and generally features a high load capacity. Accuracy is the main feature of CNC metal bending procedures. Small and larger parts can be processed with the use of a CNC technique.
Apart from understanding the procedures, there are also specific types of bending procedures utilized in fabrication.
Air bending is a particularly popular option that is widely used in metal fabrication processes. The main reason here is because the technique has the least amount of physical contact with the metal sheet. The procedure will only physically touch the metal sheet at three specific points.
Bottom bending and coin bending are two alternative options. They are not as widely used, but there are certain scenarios where these may prove to be more useful. With bottom bending, it is easier to bend metal when a low tonnage is available – at this stage, the tonnage available may not be high enough to create an imprint. Reduced spring back is another important benefit of bottom bending. Coining is a process that will generally be utilized when there is a need for a specific angle.
VeriForm’s Metal Bending Services
VeriForm has been in the business of metal fabrication for more than 20 years. Our experts are experienced in providing metal bending services and fabrication processes for different types of raw metal. Bending, in particular, is a specialty of VeriForm, with numerous projects already completed.
For information on how VeriForm can be a useful asset to your process, visit our official website. You can find examples of past projects completed, as well as get in touch with an expert at VeriForm.
Metal bending is an important part of fabrication, a process where raw metal is turned into parts used in projects and manufacturing. The bending procedure can make use of several techniques to achieve a final form. Both basic and advanced bending procedures are available, which will often be customized to fit a specific manufacturing project’s needs.
Parts fabrication encompasses the design and production of metal articles and individual components, involving cutting, bending, etc. The techniques are unique yet versatile, but they work towards the same goal— making ready-made parts for various projects and machines.
Are you aware of the many processes that help form the components of fascinating and functional metal structures all around? Or do you have a clue about these perplexing operations but seek more insight? You may even seek parts fabrication services. Whichever category you belong to, you have come to the right place. Read along to learn all you need to know.
Parts Fabrication: Processes
Since the processes involved in parts fabrication are many rather than few, we will select a few critical ones to educate you on
CNC Laser Cutting
CNC (Computer Numerically Controlled) laser cutting is a fabrication process concerned with the transition (slicing) of metal into sheet metal. This procedure is executed with the specialized use of laser beams. CNC laser cutters are the devices that operators use for the sheet metal manufacturing process. Various cuttable materials with a CNC laser cutter include copper, mild steel, pre-galvanized steel, stainless steel, brass, etc. The CNC cutting process utilizes gases such as nitrogen, O2, and compressed air.
There are hybrid laser cutters, flying optic laser cutters, and moving material laser cutters. Moving material laser cutters work such that the laser beam is in a stationary role while the material that moves beneath it in the X and Y planes. The flying optic laser works very differently. The material is in a fixed position (on the stationary bed), then the laser’s optic head/beam cuts the material in X and Y directions above. The hybrid laser cutter combines the two laser cutters above as it runs the material an X path while it moves the optic beam in the Y (perpendicular) direction.
CNC laser cutting may come in different forms; however, most recognized is the “vaporization cutting” form. In this sheet metal cutting procedure, the metal is melted by laser beams, while a high-pressure gas is consequently expended to remove the molten material. This process is an efficient one. The CNC laser cutting process comprises beam generation, beam focusing, beam movement, localized heating, melting, and material ejection.
The average processing range for CNC laser cutters is 0.3mm to 25mm. The latter is usually for higher-powered machines.
An efficient laser cutter can work on materials measuring ¾in x 80in x 160in with an accuracy of +/- 0.005in.
CNC Bending – Forming
Computer numerically controlled (CNC) bending is a crucial part of the forming process conducted by CNC press brakes. The press brakes can deform sheet metal into an angle within just a few millimeters, while more specialized ones can bend sheet metal across sections several meters long. Press brakes (also called CNC brake presses) bend sheet metal by forcing it between an upper and a lower tool— the Koch being the upper tool and the die being the lower tool.
However, CNC pressing brakes can be diverse in their designs. Down forming is a pressing brake design where the press possesses a stationary bottom bed and V-block tooling, while the top beam is mobile (controlled by the V-blade tools). Up forming has a movable bottom bed and a static head/beam. The two designs provide similar functionality; however, the sheet metal’s absolute bendable length is determined by how long the press brake bed is. In contrast, two factors determine the sheet metal’s thickness: its tensile strength and the machine’s available tonnage. The opening of the V-block is very much related to the usable tonnage.
Computer numerically controlled (CNC) shearing is a cutting material method without heat (melting and burning). Also, there is no formation of chips. Shearing, also known as die-cutting, is a crucial technique of metal parts fabrication. In the real sense, the process is termed “shearing” when the cutting blades are straight, while it is termed a “shearing-type operation” when they are angled.
There are different shearing tool materials, which apply to materials of varying thickness. Low alloy steel works well for low production of materials with up to 0.64 cm thickness. High-carbon, high-chromium steel works well for materials in the same range, albeit for high production purposes. Shock-resistant steel is useful in shearing materials of greater than 0.64 cm thickness.
Welding is another significant metal parts fabrication process. Welding is employed for joining materials with the use of high heat in melting the parts altogether. The welded parts are then fused after cooling. The welding procedure differs from brazen and soldering because it melts the base metal. Sometimes, Pressure is applied in addition to the high heat to give the required results.
Filler materials are an essential aspect of welding. They are added to the joint to enhance the weld pool, giving rise to a stronger weld. You also want to shield the filler/melted metals to prevent either oxidation or contamination. Welders employ destructive or non-destructive methods to test the quality of a weld and mark out possible defects.
A gas flame or electric arc could be used for welding, the former being a chemical energy source, and the latter an electric one. Other energy sources include friction, ultrasounds, lasers, and electric beams. A beneficial aspect of welding is that it can be carried out in virtually all settings. All of these parts fabrication processes are available at VeriForm. We work hard to ensure accuracy and efficiency in every project. For the best of these services and more, visit the VeriForm website today!
You probably have boarded a car, train, or aircraft today, or you might have used a chair, desk, or any other item made of metal. Have you ever wondered how these metallic equipment are produced from different pieces of metal to give the desired structure? It’s all thanks to welding!
Welding is the act of joining pieces of metal using heat, pressure, or a combination of the two. Unlike brazing and soldering, in welding, the pieces’ of the metal bases are melted and allowed to cool down, therefore getting fused in some instances with a filler’s help.
Ranging from the satellites that are hung beside celestial bodies down to the tiny metal pieces in our mobile phones, the act of welding is deeply interlaced in our lives. Some of the projects that can be done with welding include:
Making the framework for aircrafts
Building of vehicles
Crafting of industrial machinery
Construction of metallic parts of robots and other devices
Creation of scaffoldings
Crafting of tools and furnaces, etc.
Types of Welding
The technology of welding and fabrication has been expanding with the progress in metallurgy, mechanics, and robotic engineering. The need for firm and spatter-free welding increases with the need for perfection hence the evolution of different welding specialties, each with its specification, requirements, and an unmatched advantage over the others.
However, due to the dangerous nature of welding, only professionals must handle any welding operation. This is where VeriForm comes in; we offer welding experts to meet your needs and welding engineers to ensure all specifications are met. Lastly, our in-house certified welding inspector will be present throughout any welding operation to ensure only quality work is produced.
The choice of suitable welding depends on the project’s specifications, type of metals involved, the metal’s size, and aesthetics preferences. Therefore, the available types include the following.
This is of the most popular welding processes today, essentially due to its simplicity and low cost. It requires the use of flux coated consumable electrodes. The electrode is struck at the supposed joint to create the electric arc between the electrode and the metal pieces to be joined. The arc generates a temperature high enough to melt the metal edges and the electrode; in the process, the flux disintegrates to give vapor that shields the weld zone from atmospheric gases; this allows the weld pool to cool firmly with no oxygen interference.
This flux disintegration is what gives shielded metal arc welding the possibility to be performed outdoors. Therefore, it is suitable for big projects of thick iron, steel, stainless steel, and occasionally aluminum.
This type of welding is also referred to as stick welding, or flux shielded welding.
Gas Tungsten Arc Welding (GTAW) or Tungsten Inert Gas (TIG) Welding is the type of welding that requires a non-depleting tungsten electrode to create the arc in the workspace. When the pointed electrode is scratched on the supposed joint, the arc creates a temperature that melts the weld metal at the weld zone, creating a weld pool. This weld pool is shielded from atmospheric gases by an inert gas like argon, a mixture of argon and hydrogen, or helium.
This type of welding is preferred in welding thin sheets of stainless steel, magnesium, aluminum, and copper alloys. TIG welds stand the test of time and wear; it can also be done with various metal types and fillers.
This type of welding is mainly used in nuclear power plants, aircraft, spaceships, and missiles. The main obstacles with GTAW are the requirement of skilled personnel and non-suitability for thick metal pieces.
Gas Metal Arc Welding (GMAW) is classified into Metallic Active Gas (MAG) and Metallic Inert Gas (MIT) Welding, both require the use of electrode filling wire in one hand and shielding gas through a torch in the other hand. The electrode creates the arc between the pieces at the joint, while the high temperature creates the pool, the shielding gas pours out through the torch to prevent atmospheric interference. The gas can be inert (in case of MIG) like argon and helium, or active (in case of MAG) like a mixture of carbon dioxide and argon.
Gas metal arc welding is useful in cracks and breaks repairs, reinforcements, rail lines, coatings, and abrasion proofing of aluminum, bronze, stainless steel, etc.
GMAW is not suitable for outdoor welding, and each type of metal requires a corresponding filler.
The high temperature used in welding causes damages and discoloration in the heat-affected zones (HAZ) of the metals, which are aesthetically displeasing. To reduce this effect, the Pulsed Gas Metal Arc Welding (GMAWP) is developed; it is just like gas metal arc welding, but with a low temperature, which reduces the spatter on the weld zone. As stated, every project has its specifications, and each needs a different treatment to reach fruition. Therefore each project requires the expertise of veteran welders, which you can find at VeriForm for your welding, rolling, iron bending, and other metal fabrication projects.
Sheet metal fabrication refers to the development of parts from sheet metal. A large number of industries around the globe rely heavily on sheet metal fabrication. Railroad, aerospace, automobile, oil and gas, electronics, military, and HVAC are some of the leading industries that use CNC sheet metal fabrication to produce a variety of different products; for example, roofing, electronics closure, drainage equipment, pipes, tanks, and ventilation systems.
The production of custom parts using CNC laser cutting machine sheet metal has given birth to remarkable opportunities for manufacturers. At VeriForm, we are unlocking new possibilities through state-of-the-art machining capabilities and craftsmanship.
New technologies are continuously reshaping the way metal fabrication companies develop unique parts and meet the growing demand for high-quality products. With time, the sheet metal fabrication process has been developed into a form of art that requires sophisticated machines and skills. For example, precision sheet metal fabrication has become a common manufacturing process.
The Popularity of CNC Laser Cutting Machines for Sheet Metal
CNC metal cutting technology enables manufacturing processes in which pre-programmed software is used to automate and control the movement of various metal fabrication equipment. CNC capabilities can be used to automate a variety of complex manufacturing devices ranging from cutting and drilling to bending and rolling. Sheet metal fabrication is one of the many applications of CNC systems.
The growing need for accuracy, speed, and cost-effectiveness has led manufacturers to employ CNC machines to deliver a high degree of precision as compared to old-fashioned cutting machines.
Materials used in sheet metal fabrication vary in terms of hardness, strength, resistance to corrosion, and conductivity. However, CNC laser cutting machines are ideal for sheet metal fabrication.
How Sheet Metal Cutting Works
CNC laser cutting utilizes a high powered laser to cut through sheet metal. A combination of lenses and mirrors directs a high-energy beam of light onto the surface of the sheet. The power of the beam melts and vaporizes the metal. CO2 is a common laser used to cut sheet metal. The diameter of the beam at the cutting surface is usually around 0.008 inches. While the table moves, the cutting head remains stationary. Besides, pressurized gas blows away the molten metal.
Laser cutting machines can be used to cut both ferrous and non-ferrous sheet metals. However, materials with low conductivity and reflectivity (carbon steel, titanium, stainless steel) allow the laser beam to deliver better results.
Sheet Metal Fabrication Services in Ontario
VeriForm is one of the innovative metal fabrication companies in Canada where they take full advantage of CNC laser cutting to meet the growing needs of their customers. Since the sheet metal fabrication processes demand high precision from skilled fabricators, VeriForm hires highly experienced and skilled operators to ensure consistent quality. A mix of skilled labor and advanced CNC machines enable VeriForm to ensure accelerated and cost-effective production processes.
When it comes to precision and energy conversion, the CNC laser machine has the advantage over plasma cutting systems when cutting sheet metal. However, most laser cutting machines can’t cut through the greater metal thickness. This is where you can consider employing plasma cutting machines. The latest laser machines operating at higher power are competing with plasma systems in their ability to cut thick materials.
Categories of Sheet Metal Fabrication
CNC laser cutting machine sheet metal falls into 3 major categories: industrial, structural, and commercial. While sheet metal fabrication helps businesses create common consumer products such as electronics, appliances, and cars, industries use the process to create parts in the production of equipment that is used to manufacture consumer products. Manufacturers are leading buyers of products produced through CNC machining.
Fabrication shops often use large-scale CNC sheet metal fabrication to create components for many industries: construction, manufacturing, roofing, and more. With so many industries relying on sheet metal fabrication, it’s easy to comprehend the large consumer base for sheet metal products.
At VeriForm, we have a smart team of sheet metal fabricators that leverage CNC capabilities to meet your manufacturing needs–whatever they may be. With our broad range of CNC machining and metal fabrication services, our experts are happy to take on complex projects and are committed to your success.
What started as a simple technique to cut metals has now developed into a highly efficient and productive tool for fabrication shops. Built off of plasma welding in the 1960s, plasma cutting is a widely used method to carefully cut metals. While early cutting technology was slow, expensive, and large, precision plasma cutting now offers greater flexibility and speed in cutting various shapes based on instructions programmed into the CNC machine.
Plasma cutting is widely employed in the construction and fabrication industries due to its high speed, precision, and cost-effectiveness. Whether you want to create artwork or manufacture finished products, precision plasma cutting provides you with unlimited possibilities for cutting stainless steel, aluminum, and other metals.
This article will talk about how precision plasma cutting works, its benefits, applications, and recommended solutions.
How Precision Plasma Cutting Works
Simply put, an accelerated jet of hot plasma cuts through workpieces made of electrically conductive materials. Conductive gas with a temperature of up to 30,000 C turns precision plasma into an effective cutting tool. Steel, aluminum, brass, copper, and stainless steel are typical materials that are cut using this technique.
The fundamental function in plasma cutting is the creation of an electrical channel of electrically ionized, highly heated gas from the cutter. High-speed plasma and compressed gas blow the workpiece away and cut it with great precision.
A high-precision plasma cutting machine concentrates more energy in a smaller area, which helps fabricators produce precision cuts with less top-edge rounding, less bevel, and a narrow kerf. Such precision tools can play a central role in many manufacturers’ success.
The Increasing Popularity of Precision Plasma Cutting
The demand for extremely accurate and high-quality products in a short time led to a surge in demand for precision plasma cutting and other advanced metal fabrication techniques. If you want to cut materials of different thicknesses and shapes with high accuracy and speed, you should consider using precision plasma cutting. Let’s take a look at some of the benefits of plasma cutting:
Ease of use
Plasma cutters are often designed in a way that makes it easier for fabricators to move them wherever the job demands. Thus, they help fabricators accelerate productivity and operational efficiency.
A diverse range of metals can be cut using plasma cutting. This cutting technique is also effective when a fabricator has to cut several materials stacked on top of one another.
If we make a comparison between traditional and plasma cutting tools, the latter clearly wins the race in terms of speed and time-saving. To be more precise, a plasma cutter can get the job done one-fourth the time of a traditional cutting tool. You don’t have to preheat a plasma cutter before cutting metal.
When it comes down to cutting different shapes or angles with sheet metal, plasma cutting should be your first choice. A traditional cutter can’t produce such precision even when an experienced operator with a steady hand is operating it.
Customers demand high-quality products at a lower price. It’s not possible to meet these expectations with old-fashioned machines. Precision plasma cutters not only cut things faster but also produce less waste, which leads to cost-effective metal fabrication processes. Less time spent on piercing means less money charged to customers.
Moreover, high-end plasma technology dramatically reduces the amount of heat. It avoids plate wrapping of thin materials. Safety is an additional feature of modern CNC cutting processes.
Applications of Precision Plasma Cutting
While manual plasma cutters are used for thin metal processing, scrap welding, trailer production, artworks, welding repair, and maintenance, CNC plasma cutting is used for more sophisticated jobs. Automotive repair and restoration, industrial construction, manufacturing, and scrapping industries widely use plasma cutting to process materials.
Types of Precision Plasma Cutting Offered by VeriForm,
At VeriForm, fabricators use high-definition plasma cutters that increase productivity and quality in cutting non ferrous and ferrous materials. New plasma cutting technology enables them to produce improved cut quality than what had been previously possible with plasma cutting.
VeriForm is a one-stop fabrication shop for customers looking for metal fabrication services in Canada. The company offers CNC precision cutting, bending, rolling, welding, and machining services to a broad range of industries. Ready to take advantage of precision plasma cutting capabilities? Contact VeriForm to get a Free quote!
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