Sheet Metal

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Sheet metal
From Wikipedia, the free encyclopedia

Sheets of Nirosta stainless steel cover the Chrysler Building

Microscopic close-up of mild steel sheet metal.

Sheet metal is metal formed by an industrial process into thin, flat pieces. It is one of the
fundamental forms used in metalworking and it can be cut and bent into a variety of shapes.
Countless everyday objects are constructed with sheet metal. Thicknesses can vary significantly;
extremely thin thicknesses are considered foil or leaf, and pieces thicker than 6 mm (0.25 in) are
considered plate.
Sheet metal is available in flat pieces or coiled strips. The coils are formed by running a
continuous sheet of metal through a roll slitter.
The thickness of sheet metal is in the USA commonly specified by a traditional, non-linear
measure known as its gauge. The larger the gauge number, the thinner the metal. Commonly
used steel sheet metal ranges from 30 gauge to about 7 gauge. Gauge differs between
ferrous (iron based) metals and nonferrous metals such as aluminum or copper; copper

thickness, for example is measured in ounces (and represents the thickness of 1 ounce of
copper rolled out to an area of 1 square foot). In the rest of the world the sheet metal thickness is
given in millimeters.
There are many different metals that can be made into sheet metal, such
as aluminum, brass, copper, steel, tin, nickel and titanium. For decorative uses, important sheet
metals include silver, gold, and platinum (platinum sheet metal is also utilized as a catalyst.)
Sheet metal is used for car bodies, airplane wings, medical tables, roofs for buildings
(architecture) and many other applications. Sheet metal of iron and other materials with high
magnetic permeability, also known as laminated steel cores, has applications
in transformers and electric machines. Historically, an important use of sheet metal was in plate
armor worn by cavalry, and sheet metal continues to have many decorative uses, including
inhorse tack. Sheet metal workers are also known as "tin bashers" (or "tin knockers"), a name
derived from the hammering of panel seams when installing tin roofs. [1][2]
In 2011, the sheet metal industry was worth almost $20.5 billion in the United States. [3] There
were 4,000 firms employing 106,000 sheet metal workers.
Contents
[hide]



1Materials
o

1.1Stainless steel

o

1.2Aluminium



2Gauge
o



2.1Tolerances
3Forming processes

o

3.1Bending

o

3.2Curling

o

3.3Decambering

o

3.4Deep drawing

o

3.5Expanding

o

3.6Hydroforming

o

3.7Incremental sheet forming

o

3.8Ironing

o

3.9Laser cutting

o

3.10Photochemical machining

o

3.11Perforating

o

3.12Press brake forming

o

3.13Punching

o

3.14Roll forming

o

3.15Rolling

o

3.16Spinning

o

3.17Stamping

o

3.18Water jet cutting

o

3.19Wheeling



4Fasteners



5See also



6References
o



6.1Bibliography
7External links

Materials[edit]
Stainless steel[edit]
Grade 304 is the most common of the three grades. It offers good corrosion resistance while
maintaining formability and weldability. Available finishes are #2B, #3, and #4. Grade 303 is not
available in sheet form.[4]
Grade 316 possesses more corrosion resistance and strength at elevated temperatures than
304. It is commonly used for pumps, valves, chemical equipment, and marine applications.
Available finishes are #2B, #3, and #4.[4]
Grade 410 is a heat treatable stainless steel, but it has a lower corrosion resistance than the
other grades. It is commonly used in cutlery. The only available finish is dull.[4]

Aluminium[edit]
Aluminum is also a popular metal used in sheet metal due to its flexibility, wide range of options,
cost effectiveness, and other properties.[5] The four most common aluminium grades available as
sheet metal are 1100-H14, 3003-H14, 5052-H32, and 6061-T6.[4][6]

Grade 1100-H14 is commercially pure aluminium, highly chemical and weather resistant. It is
ductile enough for deep drawing and weldable, but has low strength. It is commonly used in
chemical processing equipment, light reflectors, and jewelry.[4]
Grade 3003-H14 is stronger than 1100, while maintaining the same formability and low cost. It is
corrosion resistant and weldable. It is often used in stampings, spun and drawn parts, mail
boxes, cabinets, tanks, and fan blades.[4]
Grade 5052-H32 is much stronger than 3003 while still maintaining good formability. It maintains
high corrosion resistance and weldability. Common applications include electronic chassis, tanks,
and pressure vessels.[4]
Grade 6061-T6 is a common heat-treated structural aluminium alloy. It is weldable, corrosion
resistant, and stronger than 5052, but not as formable. It loses some of its strength when welded.
[4]
It is used in modern aircraft structures.[7]

Gauge[edit]

This article may be confusing or unclear to readers. In particular, it
does not explain the difference between the various gauge standards like
Manufacturers' Standard Gauge, Standard Decimal Gauge, U.S. Standard
Gauge, Birmingham Gage and British Standard Gauge and their
appropriate application. Please help us clarify the article; suggestions
may be found on the talk page. (June 2013)
Use of Gauge to designate sheet metal thickness is discouraged by numerous international
standards organizations. For Example, ASTM states in specification ASTM A480-10a "The use of
gage number is discouraged as being an archaic term of limited usefulness not having general
agreement on meaning." [8]
Manufacturers' Standard Gauge for Sheet Steel is based on an average weight of 41.82 lb
(18.96 kg) per square foot per inch thick.[9] Gauge is defined differently for ferrous (iron-based)
and non-ferrous metals (e.g., aluminium and brass).

Standard sheet metal gauges[10]

Gaug
e

U.S.
standard[11][12]
for sheet
and plate
iron and
steel
decimal inch
(mm)

Steel[13]
inch
(mm)

Galvanized
steel
inch (mm)

Stainless
steel
inch
(mm)

Aluminiu
m
inch
(mm)

Zinc[13]
inch
(mm)

00000
00

0.5000
(12.70)

......

......

......

......

......

00000
0

0.4688
(11.91)

......

......

......

......

......

00000

0.4375
(11.11)

......

......

......

......

......

0000

0.4063
(10.32)

......

......

......

......

......

000

0.3750 (9.53)

......

......

......

......

......

00

0.3438 (8.73)

......

......

......

......

......

0

0.3125 (7.94)

......

......

......

......

......

1

0.2813 (7.15)

......

......

......

......

......

2

0.2656 (6.75)

......

......

......

......

......

3

0.2500 (6.35)

0.2391
(6.07)

......

......

......

0.006
(0.15)

4

0.2344 (5.95)

0.2242
(5.69)

......

......

......

0.008
(0.20)

5

0.2188 (5.56)

0.2092
(5.31)

......

......

......

0.010
(0.25)

6

0.2031 (5.16)

0.1943
(4.94)

......

......

7

0.1875 (4.76)

0.1793

......

0.1875

0.162
(4.1)

0.012
(0.30)

0.1443

0.014

(4.55)

(4.76)

(3.67)

(0.36)

8

0.1719 (4.37)

0.1644
(4.18)

0.1681
(4.27)

0.1719
(4.37)

0.1285
(3.26)

0.016
(0.41)

9

0.1563 (3.97)

0.1495
(3.80)

0.1532
(3.89)

0.1563
(3.97)

0.1144
(2.91)

0.018
(0.46)

10

0.1406 (3.57)

0.1345
(3.42)

0.1382
(3.51)

0.1406
(3.57)

0.1019
(2.59)

0.020
(0.51)

11

0.1250 (3.18)

0.1196
(3.04)

0.1233
(3.13)

0.1250
(3.18)

0.0907
(2.30)

0.024
(0.61)

12

0.1094 (2.78)

0.1046
(2.66)

0.1084
(2.75)

0.1094
(2.78)

0.0808
(2.05)

0.028
(0.71)

13

0.0938 (2.38)

0.0897
(2.28)

0.0934
(2.37)

0.094
(2.4)

0.072
(1.8)

0.032
(0.81)

14

0.0781 (1.98)

0.0747
(1.90)

0.0785
(1.99)

0.0781
(1.98)

0.0641
(1.63)

0.036
(0.91)

15

0.0703 (1.79)

0.0673
(1.71)

0.0710
(1.80)

0.07 (1.8)

0.057
(1.4)

0.040
(1.0)

16

0.0625 (1.59)

0.0598
(1.52)

0.0635
(1.61)

0.0625
(1.59)

0.0508
(1.29)

0.045
(1.1)

17

0.0563 (1.43)

0.0538
(1.37)

0.0575
(1.46)

0.056
(1.4)

0.045
(1.1)

0.050
(1.3)

18

0.0500 (1.27)

0.0478
(1.21)

0.0516
(1.31)

0.0500
(1.27)

0.0403
(1.02)

0.055
(1.4)

19

0.0438 (1.11)

0.0418

0.0456

0.044

0.036

0.060

(1.06)

(1.16)

(1.1)

(0.91)

(1.5)

20

0.0375 (0.95)

0.0359
(0.91)

0.0396
(1.01)

0.0375
(0.95)

0.0320
(0.81)

0.070
(1.8)

21

0.0344 (0.87)

0.0329
(0.84)

0.0366
(0.93)

0.034
(0.86)

0.028
(0.71)

0.080
(2.0)

22

0.0313 (0.80)

0.0299
(0.76)

0.0336
(0.85)

0.031
(0.79)

0.025
(0.64)

0.090
(2.3)

23

0.0281 (0.71)

0.0269
(0.68)

0.0306
(0.78)

0.028
(0.71)

0.023
(0.58)

0.100
(2.5)

24

0.0250 (0.64)

0.0239
(0.61)

0.0276
(0.70)

0.025
(0.64)

0.02
(0.51)

0.125
(3.2)

25

0.0219 (0.56)

0.0209
(0.53)

0.0247
(0.63)

0.022
(0.56)

0.018
(0.46)

......

26

0.0188 (0.48)

0.0179
(0.45)

0.0217
(0.55)

0.019
(0.48)

0.017
(0.43)

......

27

0.0172 (0.44)

0.0164
(0.42)

0.0202
(0.51)

0.017
(0.43)

0.014
(0.36)

......

28

0.0156 (0.40)

0.0149
(0.38)

0.0187
(0.47)

0.016
(0.41)

0.0126
(0.32)

......

29

0.0141 (0.36)

0.0135
(0.34)

0.0172
(0.44)

0.014
(0.36)

0.0113
(0.29)

......

30

0.0125 (0.32)

0.0120
(0.30)

0.0157
(0.40)

0.013
(0.33)

0.0100
(0.25)

......

31

0.0109 (0.28)

0.0105

0.0142

0.011

0.0089

......

(0.27)

(0.36)

(0.28)

(0.23)

32

0.0102 (0.26)

0.0097
(0.25)

......

......

......

......

33

0.0094 (0.24)

0.0090
(0.23)

......

......

......

......

34

0.0086 (0.22)

0.0082
(0.21)

......

......

......

......

35

0.0078 (0.20)

0.0075
(0.19)

......

......

......

......

36

0.0070 (0.18)

0.0067
(0.17)

......

......

......

......

37

0.0066 (0.17)

0.0064
(0.16)

......

......

......

......

38

0.0063 (0.16)

0.0060
(0.15)

......

......

......

......

Tolerances[edit]
During the rolling process the rollers bow slightly, which results in the sheets being thinner on the
edges.[4] The tolerances in the table and attachments reflect current manufacturing practices and
commercial standards and are not representative of the Manufacturer's Standard Gauge, which
has no inherent tolerances.

Stainless steel sheet metal tolerances[4]
Sheet width
Thickness
[in (mm)]

36 (914.4)
[in (mm)]

48 (1,219)
[in (mm)]

0.017–0.030 (0.43–0.76)

0.0015 (0.038)

0.002 (0.051)

0.031–0.041 (0.79–1.04)

0.002 (0.051)

0.003 (0.076)

0.042–0.059 (1.1–1.5)

0.003 (0.076)

0.004 (0.10)

0.060–0.073 (1.5–1.9)

0.003 (0.076)

0.0045 (0.11)

0.074–0.084 (1.9–2.1)

0.004 (0.10)

0.0055 (0.14)

0.085–0.099 (2.2–2.5)

0.004 (0.10)

0.006 (0.15)

0.100–0.115 (2.5–2.9)

0.005 (0.13)

0.007 (0.18)

0.116–0.131 (2.9–3.3)

0.005 (0.13)

0.0075 (0.19)

0.132–0.146 (3.4–3.7)

0.006 (0.15)

0.009 (0.23)

0.147–0.187 (3.7–4.7)

0.007 (0.18)

0.0105 (0.27)

Forming processes[edit]
Bending[edit]
Main article: Bending
The equation for estimating the maximum bending force is,

,
where k is a factor taking into account several parameters including friction. T is the ultimate
tensile strength of the metal. L and t are the length and thickness of the sheet metal, respectively.
The variable W is the open width of a V-die or wiping die.

Curling[edit]
Main article: Curling

Decambering[edit]
Main article: Decambering

Deep drawing[edit]
Main article: Deep drawing

Example of deep drawn part

Drawing is a forming process in which the metal is stretched over a form or die.[15] In deep
drawing the depth of the part being made is more than half its diameter. Deep drawing is used for
making automotive fuel tanks, kitchen sinks, two-piece aluminum cans, etc. Deep drawing is
generally done in multiple steps called draw reductions. The greater the depth the more
reductions are required. Deep drawing may also be accomplished with fewer reductions by
heating the workpiece, for example in sink manufacture.
In many cases, material is rolled at the mill in both directions to aid in deep drawing. This leads to
a more uniform grain structure which limits tearing and is referred to as "draw quality" material.

Expanding[edit]
Main article: Expanded sheet metal
Expanding is a process of cutting or stamping slits in alternating pattern much like the stretcher
bond in brickwork and then stretching the sheet open in accordion-like fashion. It is used in
applications where air and water flow are desired as well as when light weight is desired at cost
of a solid flat surface. A similar process is used in other materials such as paper to create a low
cost packing paper with better supportive properties than flat paper alone.

Hydroforming[edit]
Main article: Hydroforming
Hydroforming is a process that is analogous to deep drawing, in that the part is formed by
stretching the blank over a stationary die. The force required to do so is generated by the direct
application of extremely high hydrostatic pressure to the workpiece or to a bladder that is in
contact with the workpiece, rather than by the movable part of a die in a mechanical or hydraulic
press. Unlike deep drawing, hydroforming usually does not involve draw reductions—the piece is
formed in a single step.

Incremental sheet forming[edit]
Main article: Incremental sheet forming

Ironing[edit]

Main article: Ironing

Laser cutting[edit]
Main article: Laser cutting
Sheet metal can be cut in various ways, from hand tools called tin snips up to very large powered
shears. With the advances in technology, sheet metal cutting has turned to computers for precise
cutting. Many sheet metal cutting operations are based on computer numerically controlled
(CNC) laser cutting or multi-tool CNC punch press.
CNC laser involves moving a lens assembly carrying a beam of laser light over the surface of the
metal. Oxygen, nitrogen or air is fed through the same nozzle from which the laser beam exits.
The metal is heated and burnt by the laser beam, cutting the metal sheet. The quality of the edge
can be mirror smooth and a precision of around 0.1 mm (0.0039 in) can be obtained. Cutting
speeds on thin 1.2 mm (0.047 in) sheet can be as high as 25 m (82 ft) a minute. Most of the laser
cutting systems use a CO2 based laser source with a wavelength of around 10 µm; some more
recent systems use a YAG based laser with a wavelength of around 1 µm.

Photochemical machining[edit]
Main article: Photochemical machining
Photochemical machining, also known as photo etching, is a tightly controlled corrosion process
which is used to produce complex metal parts from sheet metal with very fine detail. The photo
etching process involves photo sensitive polymer being applied to a raw metal sheet. Using CAD
designed photo-tools as stencils, the metal is exposed to UV light to leave a design pattern,
which is developed and etched from the metal sheet.

Perforating[edit]
Main article: Perforating
Perforating is a cutting process that punches multiple small holes close together in a flat
workpiece. Perforated sheet metal is used to make a wide variety of surface cutting tools, such
as thesurform.

Press brake forming[edit]

Forming metal on a pressbrake

This is a form of bending used to produce long, thin sheet metal parts. The machine that bends
the metal is called a press brake. The lower part of the press contains a V-shaped groove called
the die. The upper part of the press contains a punch that presses the sheet metal down into the
v-shaped die, causing it to bend.[16] There are several techniques used, but the most common
modern method is "air bending". Here, the die has a sharper angle than the required bend
(typically 85 degrees for a 90 degree bend) and the upper tool is precisely controlled in its stroke
to push the metal down the required amount to bend it through 90 degrees. Typically, a general
purpose machine has an available bending force of around 25 tonnes per metre of length. The
opening width of the lower die is typically 8 to 10 times the thickness of the metal to be bent (for
example, 5 mm material could be bent in a 40 mm die). The inner radius of the bend formed in
the metal is determined not by the radius of the upper tool, but by the lower die width. Typically,
the inner radius is equal to 1/6 of the V-width used in the forming process.
The press usually has some sort of back gauge to position depth of the bend along the
workpiece. The backgauge can be computer controlled to allow the operator to make a series of
bends in a component to a high degree of accuracy. Simple machines control only the backstop,
more advanced machines control the position and angle of the stop, its height and the position of
the two reference pegs used to locate the material. The machine can also record the exact
position and pressure required for each bending operation to allow the operator to achieve a
perfect 90 degree bend across a variety of operations on the part.

Punching[edit]
Main article: Punching
Punching is performed by placing the sheet of metal stock between a punch and a die mounted
in a press. The punch and die are made of hardened steel and are the same shape. The punch
is sized to be a very close fit in the die. The press pushes the punch against and into the die with
enough force to cut a hole in the stock. In some cases the punch and die "nest" together to
create a depression in the stock. In progressive stamping a coil of stock is fed into a long
die/punch set with many stages. Multiple simple shaped holes may be produced in one stage,
but complex holes are created in multiple stages. In the final stage, the part is punched free from
the "web".
A typical CNC turret punch has a choice of up to 60 tools in a "turret" that can be rotated to bring
any tool to the punching position. A simple shape (e.g., a square, circle, or hexagon) is cut
directly from the sheet. A complex shape can be cut out by making many square or rounded cuts
around the perimeter. A punch is less flexible than a laser for cutting compound shapes, but
faster for repetitive shapes (for example, the grille of an air-conditioning unit). A CNC punch can
achieve 600 strokes per minute.
A typical component (such as the side of a computer case) can be cut to high precision from a
blank sheet in under 15 seconds by either a press or a laser CNC machine..

Roll forming[edit]
Main article: Roll forming
A continuous bending operation for producing open profiles or welded tubes with long lengths or
in large quantities.

Rolling[edit]

Bending sheet metal with rollers

Main article: Rolling
[17]

Spinning[edit]
Main article: Metal spinning
Spinning is used to make tubular (axis-symmetric) parts by fixing a piece of sheet stock to a
rotating form (mandrel). Rollers or rigid tools press the stock against the form, stretching it until
the stock takes the shape of the form. Spinning is used to make rocket motor casings, missile
nose cones, satellite dishes and metal kitchen funnels.

Stamping[edit]
Main article: Stamping
Stamping includes a variety of operations such as punching, blanking, embossing, bending,
flanging, and coining; simple or complex shapes can be formed at high production rates; tooling
and equipment costs can be high, but labor costs are low.
Alternatively, the related techniques repoussé and chasing have low tooling and equipment
costs, but high labor costs..

Water jet cutting[edit]
Main article: Water jet cutting
A water jet cutter, also known as a waterjet, is a tool capable of a controlled erosion into metal or
other materials using a jet of water at high velocity and pressure, or a mixture of water and an
abrasive substance.

Wheeling[edit]
Main article: Wheeling
[18]

Fasteners[edit]
Fasteners that are commonly used on sheet metal include:


Clekos[19]



Rivets[20]



Sheet metal screws

See also[edit]


Circle grid analysis



Corrugated galvanised iron, also known as Corrugated Sheet Metal



Diamond plate



Forming limit diagram



Strip steel



Temper mill

References[edit]
1.

Jump up^ Lodhi, Veerendra Singh; Jain, Prof. A.K. (30 April 2014). "A Review of
Experimental Study of Spring Back Effect of Aluminum Sheet Metal". International Journal of
Engineering Research and Science & Technology (IJERST)(College Jabalpur (M P), India:
Academia.edu) 3 (4): 2.doi:10.7763/IJET. ISSN 2277-9655. Retrieved 14 July2015.

2.

Jump up^ Green, Archie (1993). Wobblies, pile butts, and other heroes : laborlore
explorations. Urbana u.a.: Univ. of Illinois Press. p. 20. ISBN 9780252019630. Retrieved 14
July 2015.

3.

Jump up^ Pell Research - Sheet Metal Industry Statistics Report

4.

^ Jump up to:a b c d e f g h i j k l "Sheet metal material". Retrieved2009-07-26.

5.

Jump up^ "Sustainability of Aluminium in Buildings" (PDF). European Aluminium
Association. Retrieved 20 June 2013.

6.

Jump up^ "Central Steel & Wire Company Catalog" (2006-2008 ed.): 151.

7.

Jump up^ All Metal Construction Made Easy

8.

9.

Jump up^ "ASTM A480/A480M-13b Standard Specification for General Requirements for
Flat-Rolled Stainless and Heat-Resisting Steel Plate, Sheet, and Strip". ASTM International.
Jump up^ Oberg, p. 2522.

10.

Jump up^ Rowlett, Ross (26 July 2002). "Sheet Metal Thickness Gauges". University of
North Carolina at Chapel Hill. Retrieved 21 June 2013.

11.

Jump up^ Oberg, p. 387.

12.

Jump up^ 15 U.S.C. § 206: Standard gauge for sheet and plate iron and steel

13.

^ Jump up to:a b Oberg, p. 2502.

14.

Jump up^ "ASTM-AISI Thickness Tolerance Ranges" (PDF). CoyoteSteel.com.
Retrieved 20 June 2013.

15.

Jump up^ Parker, Dana T. Building Victory: Aircraft Manufacturing in the Los Angeles
Area in World War II, p. 20, 85, Cypress, CA, 2013. ISBN 978-0-9897906-0-4.

16.

Jump up^ Parker, Dana T. Building Victory: Aircraft Manufacturing in the Los Angeles
Area in World War II, pp. 29, 83, Cypress, CA, 2013. ISBN 978-0-9897906-0-4.

17.

Jump up^ Parker, Dana T. Building Victory: Aircraft Manufacturing in the Los Angeles
Area in World War II, p. 115, Cypress, CA, 2013. ISBN 978-0-9897906-0-4.

18.

Jump up^ Parker, Dana T. Building Victory: Aircraft Manufacturing in the Los Angeles
Area in World War II, p. 89, Cypress, CA, 2013. ISBN 978-0-9897906-0-4.

19.

Jump up^ Parker, Dana T. Building Victory: Aircraft Manufacturing in the Los Angeles
Area in World War II, p. 70, Cypress, CA, 2013. ISBN 978-0-9897906-0-4.

20.

Jump up^ Parker, Dana T. Building Victory: Aircraft Manufacturing in the Los Angeles
Area in World War II, pp. 17, 22, 29-30, 117, Cypress, CA, 2013. ISBN 978-0-9897906-0-4.

Bibliography[edit]


Oberg; et al. (2004). Machinery's Handbook (27th ed.). New York: Industrial
Press. ISBN 0-8311-2700-7.

External links[edit]
Wikimedia Commons
has media related
to Sheet metal.




"Manufacturers Standard Gauge History". Steel Market Update.
"Sheet Steel Gauges and Thicknesses" (PDF). Sheet Steel Facts. Canadian Sheet Steel
Building Institute. April 2009.
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This page was last modified on 22 April 2016, at 08:29.



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