Metal fabrication workshops offer sheet metal punching services to customise various metal products. Among the sectors relying on this service are farming, aerospace, energy, construction, automobile, architecture, railroad, electronics, and several others.
After taking a quick look at sheet metal basics, let’s learn more about the benefits of sheet metal punching and the processes involved through this article.
Sheet Metal: What You Need to Know
Metalwork is said to trace its way back to 10,000 to 4,500 BCE, with copper being the first metal discovered. The Bronze and Iron Ages even attributed their breakthroughs to the discovery of metal, which prehistoric individuals widely took advantage of. They used it for forging tools and weapons. In the present era, structural steel fabrication continuously evolves and aids metal processes for various sectors, including sheet metal fabrication.
Sheet metal is a fundamental component in metalwork. It refers to various metal types formed into flat or coiled, uniform workpieces in assorted sizes and chemical assemblies. Sheet metal fabricators shear, punch, roll, bend, and shape these materials to produce numerous items and meet varying project requirements. And unlike base metal, sheet metal is more durable and has higher tensile strength, making it suitable for construction and machinery equipment.
Some of the most common metals used today are cold rolled steel, mild steel, tin, galvanised steel, stainless steel, aluminium, and copper.
Meanwhile, sheet metal thickness varies from 0.55 up to 6 mm. The type that exceeds this range is called “metal plate.” The measurement units used to categorise its thickness include gauges, millimetres, and mils. A larger measurement is equivalent to a thinner metal.
Sheet metal is widely used for structural and aesthetic purposes. Its application will also vary based on the metal type since it dictates what a sheet is used for. When we care to observe our surroundings, we will realise that numerous fabricated metal sheets are literally everywhere, from small to large items.
Sheet Metal Production
Sheet metal is produced in two ways—hot rolling and cold rolling. The processes are dependent on the mill production, not on the product grade. Here are the primary differences:
- Hot-rolled sheet metal. This sheet metal production generates roll-pressed sheet metal through an extremely high temperature (over 1700° F)—above recrystallisation for most steel. This process also makes steel easier to form. In addition, it is cheaper than cold-rolled sheet metal because it is quicker, avoiding potential delays in the milling process. Moreover, reheating is not required.
- Cold-rolled sheet metal. This is another sheet metal production method, essentially a hot-rolled sheet metal that underwent further processing. Once the material has cooled, it is re-rolled at room temperature. This is done to achieve more precise proportions and achieve higher surface quality. Afterwards, an annealing or temper metal rolling is done.
Sheet Metal Cutting Operations
Experts categorise sheet metal cutting operations into forming and cutting processes.
Cutting operations: This involves stressing the metal sheet’s ultimate strength, thus breaking its structure. The following are some of them:
- Shearing
- Blanking
- Slotting
- Piercing
- Perforating
- Slotting
- Notching
Forming operations: This is the process of distorting metal parts by causing stress below the sheet metal’s ultimate strength. The following are under this process:
- Bending
- Ironing
- Curling
- Hydroforming
- Laser cutting
- Punching
The subsequent discussions will focus on the last type of metal forming operation—sheet metal punching.
Sheet Metal Punching
Back then, sheet metal shops perform the sheet metal punching process manually. With the technological advancements today comes automated punching machines, allowing faster operations and more precise results for fabricators and manufacturers.
Sheet metal punching is a common metal cutting procedure sought by several industries since it is a cheap alternative to laser cutting. This involves the application of sufficient shearing force to remove material. But how does this fabrication process work?
How It Works
Most metal workshops use a CNC (computer numerically controlled) punching press machine to generate various customised holes and specially designed shapes. Regardless of whether you use a machine-assisted or manual technique, the entire process is straightforward:
- The sheet metal or workpiece, made of hardened metal, is inserted between the machine’s punch and die tools. The die is located underneath the material while the punch is placed over it. The die supports the sheet and cuts the workpiece to achieve the desired forms.
- The punch moves downward with extreme force, hitting the workpiece and the die.
- Afterwards, metal scraps (also referred to as plug) are removed from the material. These are often recycled into a container.
- The metal workpiece is left with a hole or shape desired.
Sheet Metal Punching Advantages
The following are the benefits that various fabrication and manufacturing industries get from sheet metal punching services:
- Metal punching is cost-effective. The metal punching cost is relatively low compared to other punching processes. With sheet metal punching, fabricators find it quick to combine dies. They have to complement a specific mould, allowing their customers to save more. This is in addition to the requirements—whether simple or intricate—being met.
- Metal punching is flexible. Fabricators consider this as their go-to punching technique because it is versatile. It can handle just about any material type, from aluminium to galvanised steel and more.
- Metal punching guarantees speed and accuracy. Modern machinery makes the metal punching process quick and easy, ensuring efficient results and reducing the labour required from fabricators and manufacturers. It also allows them to achieve a high production level since they can create more parts in a short period. It is easier to set up and more reliable than traditional punching techniques. Moreover, this is ideal for workshops catering to several orders from different clients.
- Metal punching scraps are recyclable. Conventional machines produce a vast amount of scrap material, while modern sheet metal punching machines generate lower scrap volume. This is also because of its versatile characteristics that help modify vast metal types. Plus, the shed material can be recycled, again depending on the material scrap type.
- Metal punching yields precise results. Summing up their beneficial features, sheet metal punching machines increase the production of precise items in a single operation. Not only is this economical, but it exceeds or meets customers’ desired results. Depending on the residential or project requirements, it can cater to several material specifications.
Work with Special Build for Your Sheet Metal Punching Requirements
If you seek excellent sheet metal punching services in Sydney, look no further than Special Build!
Our 11,000 square metre facility can cater to your metalwork’s requirements, especially sheet metal punching. We have been proud of having an excellent track record of meeting or exceeding our customers’ expectations for three decades.
We guarantee you that we can accommodate your project specifications with expertise and professionalism. We invest so much in generating top-tier residential and commercial designs with our world-best equipment here at Special Build.
Be inspired and look through our metal processing services. Contact us for your enquiries on +61 2 9616 7444.