1. Blanking: Blanking refers to the process in precision sheet metal fabrication where materials are cut into the required shapes according to the developed design. There are various blanking methods, which can be classified by machine type and working principle, including shearing, punching, and laser cutting.
2. Flanging: Also known as hole flanging or hole drawing, this process involves forming a slightly larger hole from a smaller base hole, followed by tapping. It is mainly used for thin sheet metal to increase strength and the number of thread turns and to prevent thread stripping. It is typically applied to thin sheets where shallow flanges are formed around holes with minimal thickness change. When thinning of 30–40% is allowed, a flange height 40–60% higher than normal can be achieved. With 50% thinning, even greater flange height can be obtained. For thicker materials (e.g., 2.0 mm, 2.5 mm or above), direct tapping can be performed.
3. Punching: This is a forming process using dies. Common punching operations include hole punching, corner cutting, blanking, embossing, tearing, hole drawing, and forming. Each process requires corresponding dies such as punching dies, blanking dies, embossing dies, tearing dies, hole-drawing dies, and forming dies. Key operational considerations include positioning accuracy and directional control.
4. Rivet Pressing: Rivet pressing includes components such as press-fit nuts, screws, and self-clinching fasteners. It is performed using a hydraulic riveting machine or a press machine to fasten components onto sheet metal parts. Clinching methods are also used, with attention required for correct orientation.
5. Bending: Bending refers to the process of transforming 2D flat sheets into 3D components. It is carried out using a press brake and corresponding bending dies. Bending sequence must be properly arranged; the general principle is to perform bends that do not interfere with subsequent operations first, and those that may cause interference later.
6. Welding: Welding is a process in which atoms and molecules of the base materials are brought to atomic lattice distances to form a unified structure.