When we talk about fabrication, we are usually thinking about the metal industry. Metal fabrication is important for the construction industry, as it helps to make heavy machinery components, bridge skeletons, and structural supports. Fabrication is also vital in industries such as aerospace and computing, where the products of fabrication services range from computer hardware to small electronics. A good example of what this type of fabrication can do is make parts shaped like a heart or a robot arm.
Common Methods or Types of Fabrication
Cutting
There are many ways to cut metal. Steel and aluminum are strong and lightweight, and aluminum is formable at low temperatures. Copper is a decorative metal that has useful properties for forming. In fabrication, cutting removes sections of the metal. There are several types of cutting, including plasma and shear. Shear cutting is the most common method for nonindustrial products, while non shear cutting uses a laser or water jet. Other cutting methods use a combination of processes, including waterjet and plasma.
Another common fabrication technique is hole punching. Hole punching involves removing material. The punch comes down onto the die, which changes the geometrics of the sheet metal. Calculating the bend is an important part of the process. The material’s thickness, force, and die must be considered. Some common forms of cutting are:
Laser cutting and oxy-gas cutting are both good options for low-cost fabrication but require considerable capital investment. These methods are also not the best choice for cutting flammable or heat-sensitive materials. In such cases, a dedicated machine is required. Waterbed cutting is an option for smaller fabrications and offers advantages in terms of noise and fumes. Aside from this, laser cutting systems are very accurate and produce sharp edges.
When choosing a metal fabricator, look for one that is ISO-certified. It should be ISO 9001:2015-certified and can cater to customers in northern Illinois and Wisconsin. You can also find a metal fabricator on the Internet. You can look for a metal fabricator based on their industry experience and expertise. These companies will have a wide variety of skills, including cutting, bending, and stamping.
Forming
Forming refers to a variety of manufacturing processes that involve the physical deformation of a material. It is used to shape an object to a specific size or shape by applying suitable stress to the material. Metal deformation requires forces that are greater than the material’s yield strength. In this process, big, heavy machinery is used to apply high loads and create a complex shape. Economies of scale are facilitated by the use of machines that can form large volumes of materials quickly and easily.
Besides the automotive industry, forming is used to create a variety of metal parts. Metal forming can be used on a wide range of materials, including stainless steel, aluminum, brass, copper, and galvanized steel. The type of metal used will depend on its strength and mechanical properties. Depending on the application, this process can be used to create a variety of complex shapes. Forming techniques also can produce smaller pieces, such as hinges and bolts.
While traditional forming techniques are effective in many cases, the process is more complex and requires much more input data than a conventional approach. Metals that can resist high shear stress are best suited for this technique. However, when a complex shape needs to be created, the forming process must be optimized for high-quality precision. To meet these requirements, the design must take into account the limiting factor. The limiting factor determines the maximum pressure that can be applied without causing the metal to fracture.
Punching
Punching is a type of fabrication process that creates multiple holes through a sheet of raw material. This method is commonly used in sheet metal fabrication processes and is particularly effective when working with thinner materials. The material to be punched must be large enough to accommodate the diameter of the hole. Punching is generally used on high-production sheet metal fabrication projects. The process is often accompanied by blanking, which is a similar process.
The first step in the punching process is to cut the piece into the required shape. This is done with a punch press that changes the shape of the workpiece. The metal may be cut into a number of pre-set shapes. Sometimes, sheet metal forming is performed with two parts: the punch and the die block. During the process, multiple punches can be used to cut a sheet into a variety of shapes.
Another common type of fabrication process is punching. This technique creates a hole in a surface by forcing a punch through a workpiece. A punching tool can be made from a variety of different materials, including steel, aluminum, and iron. Punching can also be combined with existing dies to meet a particular need. In addition, punching allows for very precise hole size and shape requirements.
Shearing
Shearing is a process used to cut unwanted metal material. Two blades are placed over and beneath the metal to produce a long straight cut. The upper blade applies pressure to the metal until the edge breaks, while the lower blade presses on the bottom edge and fractures it. The two tools are used in conjunction to produce various types of metal fabrication. In addition, they can be mounted at an angle to reduce the amount of force applied during shearing.
The process of shearing is relatively simple and inexpensive. However, it does have its disadvantages. It is prone to causing defects on workpieces, and it cannot process very hard metal. It is also not appropriate for low-volume manufacturing applications. Shearing is an excellent choice for a wide variety of materials, but not all metals are suitable for it. To learn more, read the following article:
Shearing machines are powered by hand or electricity. Unlike hand shears, power shears can cut larger sheets of metal. The upper blade pushes against the lower fixed blade, exerting tension on the material. The machine can cut straight lines, but can also cut curves up to a large radius. Moreover, power shears are flexible and have high precision. A common type of power shear is throatless shear.
Stamping
The primary advantage of stamping over fabrication is the reduction in labor. These processes can be used in production runs that are high in volume. A progressive tool that feeds a coil produces parts at a rate of 20 to 100 parts per minute. The rates of high-speed applications are even higher. Hand-fed tools produce 80 to 180 parts per hour and are suitable for smaller jobs and assemblies. Press brake operations can be eliminated entirely in high-volume applications.
The process begins with the design of tooling. The tool design must be accurate and precise to ensure optimal part quality. A progressive die consists of several stations arranged according to the fabrication sequence. During the process, a metal sheet is fed into a metal stamper. When the die opens, the metal sheet proceeds horizontally on a conveyor system. Once the die is open, the metal sheet stops at a different station. The distance between each station is equal. The stamped part is usually ejected after the process is complete.
The application of stamping varies depending on the industry and the materials that are being used. This process is particularly useful for lettering, surface engraving, and three-dimensional designs. It is widely used in home appliances, automobiles, lighting, telecommunications services, and medical equipment manufacturing. This process can be used to create the smallest parts of electronics. It can also be used to manufacture engine parts and airplane components in large quantities.
Welding
Welding is a common process for assembling different metals and materials. A fillet weld, for example, joins two overlapping components by filling in a hole in one of the components. Filler metal is then inserted into the hole, which is usually circular or oval, and a process is performed to fuse the metal together. This process is known as a complete joint penetration weld, and in the United States, it is often referred to as “complete joint penetration welding”.
Throughout the fabrication process, raw materials emerge from normal or unusual sources. After picking out the raw materials, the metals are cut to size. Cutting may involve basic or advanced equipment. Then, they are assembled using welding. While welding is only one step in the fabrication process, it is an essential component. It is essential to follow certain steps in a process of fabrication to create quality results. In addition to using the proper equipment and materials, welders must understand how to properly maintain and clean a welding area.
In fabrication, preparation is an essential phase. This phase includes shaping, cutting, and other processes to prepare the metal. As the saying goes, “failing to plan is planning to fail.” The preparation stage paves the way for the next steps. During this phase, engineers work closely with designers and customers to create the right combination of techniques and materials to produce the final product. The end result is an intricate, useful product.
