Sheet Metal Fabrication
Definition of sheet metal fabrication
Sheet Metal fabrication is the creation of useful metallic parts and structures by the application of multiple fabrication processes. Sheet metal fabrication is basically a broad term that involves various complex processes like cutting, forming, bending, welding, machining, and assembling. The instructions include below: materials, processes, and tools required for sheet metal fabrication.
Types of Sheet Metal Fabrication Materials
The choice of metal depends on the final use of the fabricated parts.
Common fabrication processes:
· Carbon Steel
· Stainless Steel
· Aluminum
· Bronze
· Copper
· Brass
· Aluminized steel
· Galvanized steel
Types of Metal Fabrication Processes
The journey to the final product from raw sheet metals proceeds through various sheet metal fabrication processes. All the sheet metal fabrication processes can be grouped into the following three categories:
· Cutting
· Deformation
· Assembly
Sheet metal fabrication: Cutting
ii. Water jet cutting
iii. Plasma cutting
Sheet metal fabrication: Forming or Deformation
Bending: Sheet metal bending is one of the most popular deformation processes. A machine known as a Press brake is used to bend sheet metals into V, U, or other complex shapes. With an increase in gauge thicknesses of sheet metals the force required to bend increases.
Stamping: In the stamping process, a hydraulic or mechanical stamping press equipped with a tool and die is used to perform specific tasks like curling, drawing, embossing, flanging, etc
Hemming: Hemming is a process by which the edges of sheet metal are folded over itself or another piece of sheet metal to create a rounded edge. In the sheet metal fabrication process, two types of hemming processes are widely involved. They are roll hemming and conventional die hemming. Conventional hemming is used for mass production. A hemming roller is used for roll hemming.
Spinning: Spinning is a metal fabrication process where a lathe machine is used to rotate the sheet metal against a tool to produce conical or cylindrical shapes.
Sheet metal fabrication: Assembly
Assembly is basically joining Sheet Metal Components produced using above mentioned cutting or bending processes. The common sheet metal assembly process consists of joining by Welding and joining using fasteners.
Welding: In the welding process, sheet metal components are joined together by melting sections with the application of heat to form a solid connection. There are various processes available that are used to weld sheet metals.
Joining using Fasteners: Similar or dissimilar sheet metal parts can easily be joined using fasteners like bolts, screws, rivets, etc.
Brazing: Brazing is a process similar to welding that operates by melting a filler without melting the sheet metals.
Adhesives: Adhesives can be used to hold metal sheets together in conjunction with other joining methods
Advantages and Disadvantages of Sheet Metal Fabrication
As sheet metal fabrication covers a wide area of techniques and methods, the advantages and limitations will vary depending on the process used during fabrication.
Benefits:
i. Sheet metal fabrication is fast and can produce high-quality components.
i. A large number of processes are available with wide range of materials
ii. High strength to weight ratio for sheet metal fabricated parts.
Disadvantage:
i. Each fabrication process has their own limitations.
ii. High initial cost for set up of equipment and tools.
iii. Requirement of skilled labors for each process.
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Recently, the GCS600 gearbox independently developed by Hangzhou Gear Research Institute has successfully adapted to the 1,500-ton sea surveillance ship of Zhejiang Fisheries Law Enforcement Corps. Its superior performance has laid a solid foundation for this type of gearbox to enter the sea surveillance ship market.
The 21st century is an era of human marine economy. Countries are strengthening the maintenance of marine rights and interests, the development of marine resources, and marine environmental protection. Since 2012, the “Diaoyu Island Incident†and the “China-Philippines Huangyan Island Incident†have further prompted China to accelerate the development and production of sea surveillance vessels. The Hangzhou Gear Group is aiming at the forefront of the market and is actively developing new high-speed marine gearboxes that are suitable for sea surveillance vessels.
After a period of research and development and trial production, the GCS600 marine gearbox was officially put on the market not long ago, and it is suitable for the seafaring ship of 1,500 tons of Zhejiang Provincial Fisheries Law Enforcement Corps and a ship speed of up to 20. The gearbox was tested at full load by the 6.4 MW test platform of Hangzhou Lianjiang Base. The technical indicators met the functional requirements of the product. Successfully passed the joint acceptance of 711 and Zhejiang Fisheries Law Enforcement Brigade, and received high praise from relevant experts.
The GCS600 marine gearbox adopts the clutch speed reducer CPP (adjustable propeller) to form the ship propulsion system, and the auxiliary power output drives the fire water cannon and generator, which not only makes all the automatic control meet the relevant requirements of the sea surveillance law enforcement ship, but also can use the power generation. The remaining power of the machine continues to generate electricity, achieving the effect of energy saving and emission reduction.
Although the Hangzhou Gear GCS600 marine gearbox has entered the field of high-power, large-tonage marine law enforcement vessels for the first time, its high standard, high performance and high quality have won a good reputation in the industry, winning for the subsequent development of the 3,000-ton sea surveillance ship. A precious opportunity.
