In the electrical industry, there is an increasing demand for lightweight and strong components. These parts must be affordable and perform optimally to ensure the safety of end users. Sheet metal fabrication plays a critical role in manufacturing electrical components. From electrical enclosures and housings to connectors and support structures, there are a thousand and one benefits of sheet metal fabrication.
However, is sheet metal fabrication compulsory when manufacturing electrical components? Are there other alternatives that can serve similar functions? This article will take you through the use of sheet metal fabrication for electrical companies. It will explain what sheet metal fabrication is, reasons why sheet metal fabrication is suitable for electrical components, and the most common metals you can use.
What is Sheet Metal Fabrication
Sheet metal fabrication is an important manufacturing technique in the electrical sector. It involves everything from cutting and bending to assembling and finishing sheets of metals with thicknesses ranging from 0.005 to 0.20 inches. The end product of the metal manipulation process is strong and durable components of varying shapes and sizes. There are different techniques you can use to alter metal sheets. They come in three main categories; cutting, joining, and forming.
Cutting Sheet Metal
Cutting is the first and arguably the most important step in sheet metal fabrication. You can use the cutting techniques alone or in conjunction with other operations. Cutting involves dividing large metal sheets into smaller parts or removing unwanted material to get the desired size. You can carry out cutting with or without a shear force.
- Cutting with shearing uses tools and equipment to slice through materials. Before the workpiece can split, the shear force you use must be greater than the shear strength of the metal. Techniques such as punching, sawing, and blanking come under cutting with shear.
- In cutting without shear, you do not use shear force. Rather, heat, pressure, and abrasives serve as that cutting tool. They are noncontact processes that preserve the quality of the base metal. Examples of these techniques include waterjet cutting, laser cutting, and plasma cutting.
Forming Sheet Metal
Most times, forming comes after cutting operations. In forming sheet metal, you do not add or subtract any material. What you do is to shape the metal sheets in their solid state. Different techniques involving bending, rolling, hemming, and stamping come under sheet metal forming.
- Bending involves using press brakes to produce a U-shape or V-shape.
- Rolling can either be with or without the application of heat. Rolling aims to reduce thickness and produce curved metal sheets.
- When using the hemming technique, you fold the edge of the metal sheet onto itself. This will help conceal burrs and make them safer for handling.
- To carry out stamping, you have to place the sheet metal in a stamping press to create the desired shape.
Joining Sheet Metal
Joining is usually the last step in sheet metal fabrication. It entails using various techniques to assemble previously fabricated parts to make a whole. You can join sheet metal either by welding or with the use of fasteners.
- Welding uses heat, pressure, or both to fuse parts. Common welding techniques include laser welding, TIG welding, and MIG welding.
- Mechanical fastening describes the use of nuts, bolts, screws, and rivets for part assembly.
Why Use Sheet Metal Fabrication for Electrical Components
Sheet metal fabrication is usually the first choice for many electrical components. The various techniques offer unique benefits that make them appealing in product development.
Lightweight
Sheet metal parts are lightweight and easy to handle. When compared to blocks of metals, using metal sheets helps to reduce the overall weight of the final part. This lightweight feature is important not just for consumer electronics. It also plays a huge role when manufacturing electrical components for cars and aircraft. Using lightweight parts in the automotive and aerospace sectors improves fuel efficiency and lower transportation costs.
Design Versatility
Sheet metal fabrication brings out the creativity in you. You can use various techniques to bend, cut, roll, or join metal sheets as you want. From prototyping to mass production, there is no limit to the designs you can create. Furthermore, sheet metal fabrication allows for easy customization. You can manufacture electrical parts that meet the specific needs of individual clients.
High Precision
The accuracy and precision of sheet metal fabrication are second to none. Many of the techniques are automated and function using CNC technology. This ensures that parts are manufactured exactly to specifications without errors. Furthermore, the absence of human intervention ensures that the electrical components are identical when produced in large quantities.
Durability
Though lightweight, sheet metal fabricated parts come with remarkable strength. They are durable and suitable in a high-stress environment. These components will not break down easily as a result of temperature changes or physical impacts. They save costs and help your company’s finances in the long run as they do not need frequent replacement.
Types of Sheet Metal Used for Electrical and Electronics
There are many types of metals and alloys suitable for manufacturing electrical and electronic components. They have unique properties and you use them in different ways. The following are the common electrical and electronic metals.
Aluminum Alloys
Aluminum alloys are widely used in electrical and electronic part manufacturing. They are lightweight and conduct electricity readily. Furthermore, aluminum reflects electromagnetic waves and is corrosion-resistant. The most common aluminum alloys for electrical applications include 6061-T6, 6063-T5, 5052-H32, and 6101-T6.
Applications: Heat sinks, electrical connectors, enclosures, and switches.
Stainless Steel Alloys
Stainless steel alloys are another popular electrical and electronic material. There are different grades of stainless steel you can use including SS304, SS316, SS410, and 17-7PH. Stainless steel alloys are durable and have a high strength-to-weight ratio. They can withstand high temperatures which prevents overheating when you use them for electrical appliances. Furthermore, they are corrosion and wear-resistant.
Applications: Terminals, PCB chassis, electrical enclosures, connectors, and structural components.
Copper Alloys
You can also use copper alloys for electrical applications. One of the most important properties of copper is its remarkable electrical and thermal conductivity. They conduct electricity readily and dissipate heat properly. Furthermore, copper is malleable and you can easily shape it into different structures. They have antimicrobial properties which makes it easy to clean copper components.
Applications: Electrical wiring, printed circuit boards, connectors, and switches.
Galvanized Steel
A galvanized steel is one where the steel base metal has been coated with zinc. This additional layer of metal helps to protect the steel and enhance performance. Galvanized steel has remarkable corrosion resistance properties. It does not break down even after prolonged contact in a corrosive environment. Furthermore, they are magnetic. For this reason, you should use galvanized steel in applications where magnetism will not cause problems.
Applications: Support structures, wire ducts, enclosures, and cable trays.
Mild Steel
Mild steel is a type of steel that has a low carbon content usually between 0.05 to 0.25%. You can also refer to it as low-carbon steel. Mild steel has high ductility and you can easily bend and roll it to get the desired form. Furthermore, they have a low cost and are weldable. Note that mild steel is susceptible to corrosion attacks. Hence, you should consider painting or coating the fabricated sheet metal before using it.
Applications: Mounting electrical structures, control panels, and transformer cores.
Conclusion
Is sheet metal fabrication necessary for electrical companies? The answer to this question is a big YES. Though there are alternatives like 3D printing, the role of sheet metal fabrication in electrical components manufacturing cannot be overemphasized. Sheet metal fabrication produces parts that are strong, durable, and easy to handle. They are of high quality and meet the rigorous standards of the electrical industry. Looking to use the service of a reliable sheet metal fabricator? Reach out to Zintilon today for the best manufacturing experience.
