Bending & Forming – Sheet & Plate
Bending and forming metal or sheet steel is a process that is used to create duct work as well as metal enclosures such as electrical boxes. If you are looking for a metal manufacturer that can take care of all of your metal bending and metal forming needs, ABT Metals has your back. Our team of knowledgeable and professional engineers and technicians will work with you to help you design, and manufacture the metal parts you need in a timely manner. Whether you need a part mass produced on a regular basis, or just need to place a single metal bending or metal forming order, we can help you. Our engineers will work with you to ensure that we develop an optimized process that will minimize the amount of material wasted and help you reduce costs.
If you are in need of either metal bending services or metal forming services to create the metal part that you require, contact us for a production quote today. ABT Metals is capable of handling all things metal. All of our services are in house which reduces costs and provides an efficient solution to your metal manufacturing needs. We look forward to providing you and your business with high quality metal bending and metal forming services.
Request A Quote
With the rapid advancements in the last few decades, there has been extensive growth in the demand for custom-made products. The sheet metal manufacturing industry is no exception. Since sheet metal is a versatile item that can be easily transformed into various forms, it has brought new techniques that have made metal work more efficient and valuable.
The transformation begins by using sheet metal forming procedures like metal bending to convert sheet metal into the desired shape required for multiple production operations. Whether it is chassis, brackets, cabinets, electrical enclosures, covers, etc., there are endless different sheet metal components that give the impression of being easy to manufacture but attaining its part accuracy includes a complex fabrication process.
In the coming parts of the article, you will come to know about the entire process of sheet metal bending and its intricacies. So, ensure reading it till the end.
Process of sheet metal bending?
When it is about the sheet metal forming, it is a process in which force is applied to a sheet metal piece in order to alter its geometry. The force puts stress on the metal sheet beyond its yield strength that causes the material to plastically deform. The process of sheet metal forming includes bending, wherein the application of force on a sheet metal workpiece results in a bend at a specific angle to create the desired shape.
The process is an efficient way of creating new products, and it also ensures the simplicity of shapes. The external force applied to the workpiece modifies only the external characteristics of the sheet. It means other vital parameters of sheet metal remain unchanged, which includes its length and thickness.
Bending is one of the popular and essential sheet metal fabrication operations in the metal manufacturing industry. For instance, metal bending plays an important role in the automotive business because they use various shapes to have an accurate automobile part that goes perfectly with their design. The process of bending varies in methods that are used to plastically deform the sheet. Size, workpiece material, and thickness are some significant factors that play a vital role in the bending process.
The sheet metal bending process leads to deformation along a single axis. However, a series of different operations can be performed to form a complex part which can be small in size like a bracket or up to 20 feet in length. The bending operation causes compression and tension both in the sheet metal.
What materials can be used in sheet metal bending?
There are some sheet metal materials that are more malleable than others. It simply means that some materials will bend, whereas others might get weakened and crack. When it comes to less malleable materials, it is suggested to heat up the workpiece. It reduces the risk of cracking. Here is a list of several materials that you can use for bending:
Mild Steel: It is very malleable, and there is no problem of cracking in bending mild steel
Spring Steel: It is highly bendable when fully annealed. You may need to heat it often so that it performs like spring steel. It will crack if you’ll try to bend it when it’s completely hardened
Annealed Alloy Steel: Until the exact alloy is known, it is wildly variable. 4140 is quite malleable. Ideally, it should be annealed before bending. Otherwise, it will crack
6061 Aluminum: It is a bit challenging to bend as cracking is extremely prevalent. Cold metal bending will weaken the material. Proper bending is done if you anneal the aluminum. But, it is not an ideal material for creating parts
5052 Aluminum: It is highly formable, making it to be one of the best materials to bend
Copper: It is very easy to bend because it is super malleable
Bronze: It is usually stiffer as compared to other materials. Thus it is more likely to crack. Though heat is used to improve its formability
Brass: The formability of the material depends on the quantity of zinc in the alloy. The more the zinc, the less malleable the brass will be. For complex parts, you may need to heat it to soften it
Titanium: It is a strong material. To prevent snapping, use a large internal bend radius. Since it contains a low modulus of elasticity, over bend it accordingly so as to get the desired shape
Different types of sheet metal bending?
There are different methods of sheet metal bending, but they are similar in terms of their end objective, i.e., to alter sheet metal structures into the desired form. As mentioned earlier, to determine the bending method, it is important for you to have a sound understanding of the thickness, size, bend radius, and intended purpose of the material.
Following are some methods which you can use to get the best outcome. Each of these has its merits. However, the dilemma lies between selecting the simplicity or accuracy of the method. Have a look at the different bending methods:
It is the most popular sheet bending method because it is used for all the major bending tasks. It uses equipment called a punch and a V-shaped die to form a bend in the sheet metals at the desired angle. During the procedure, the bending punch applies force on the sheet metal that is placed over the die. The angle created by the material is dependent on the pressure of the punch. It is an easy and efficient method because it is used for bending steel plates.
It is a procedure that is used to bend sheet metals to form curved shapes or rolls. Roll bending utilizes a press brake, hydraulic press, and three sets of rollers to form various bends. This method is useful for forming tubes, cones, and other hollow shapes.
In terms of technique, U-bending is similar to V-bending. The equipment is the same except that of a U-shaped die. The shape formed using this method is U.
It is yet another common method used for sheet metal edges. In this method, it is vital to ensure that the sheet is accurately pushed onto the wipe die. The wipe determines the inner radius of the bend.
Rotary bending has merit as compared to V-bending and wipe bending. It doesn’t scratch the surface of the sheet metal. Moreover, it can be used to bend different materials into sharp edges.
What machines are used for sheet metal bending?
It is possible to bend some kinds of sheet metals without using any machinery. But using tools for bending enhances the precision and productivity of the process. Although, it is vital to employ all the safety measures while using the machines. Here are some machines that are used to bend sheet metals:
- Box and Pan Folders
- Steelworkers/ Ironworkers
- Roll Benders
Some Closing Words:
With this, you’ll have a fair understanding of sheet metal bending. The requirement for customized products will not going to reduce in the coming future. Thus, this article will help you in getting to know about metal bending.
Metal Bending Service
Metal bending is a process that is used to deform metal into the desired shape using a piece of equipment called a press brake. Here at ABT Metals we utilize a variety of different types of press brakes that allow us to perform any type of bend you may need. In addition to manual and mechanical press brake metal bending equipment, we offer CNC press brake services that will create accurate bends in your material.
Metal Forming Service
If you need a sheet of metal formed into a custom shape ABT Metals offers metal forming services that can help you. Our engineers will develop a system that will efficiently form metal into whatever shape you require. Allow us to help you form your metal material using our presses, benders, dies and extruders. If you need your metal sheet formed into a custom shape, we will be happy to help you.
Metal Bending and Forming Equipment
ABT Metals offers both CNC and manual press brake services to our customers. Our team designs tooling for customer products to be used in our presses. We are capable of air bending, bottom bending, and coining parts up to 14′ long, with our machines rated up to 240 tons. Unlimited possibilities and configurations allow us to cost-effectively produce the most demanding parts with our CNC Press Brakes.
Metal Bending and Forming at ABT Metals
The knowledgeable and helpful team here at ABT Metals is here to help you produce your metal parts and components in an efficient, cost effective manner. Our engineers will work hard to ensure that we produce high quality metal parts. You can rely on ABT Metals to deliver your metal parts quickly with short lead times. If you have any questions about the capabilities of metal bending and metal forming services, or would like to request a quote for production of your metal part, please contact us today. Give us a call or fill out the online contact form below. One of our knowledgeable team members will be more than happy to assist you.