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Tag: Custom Metal Parts

Metal tube end forming

Metal tube end forming 1

Metal tube end formingMetal Products Fabricate In China  >> Metal Tube Fabrication >> Metal tube end forming

Metal-tube-end-formingService: Metal tube end forming

including tube end single beading, double beads,tube flaring,tube expanding, thread expanding,flanged tubing,tube swaging and reducing.We can process different forms on the tube end.

Materials: carbon steel,stainless,aluminium,copper,brass

Size and Shape: according to drawings

Place of origin: China , Service to worldwide.

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 Experienced Metal tube end beading

Metal-tube-end-forming

 General Knowledge on “Metal tube end beading”

Submit drawings,Let Metalhelper manufacture it for you.

Let Metalhelper to help you process/manufacture Metal tube end forming,Please send us the meassage with drawing or sample photo,and tell us your purchased quantity in first order,and then we`ll quote to you. The more details on product you provide,the more quick we can quote. Procedures of Perforated Metal Tube

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Metal tube end beading

Metal Products Fabricate In China  >> Metal Tube Fabrication >> Metal tube end forming

Metal tube end beading

Metal tube end beading 3

Metal tube end beadingMetal Products Fabricate In China  >> Metal Tube Fabrication >> Metal tube end beading

Metal-tube-end-beadingService: Metal tube end beading

Is a Tube End Forming,it is a metal forming process that forms a bead on the end of a tube. Tube beads can be used to help hold a hose on the end of a tube or to strengthen the end of the tube.There are two forming processes: internal roll forming and ram forming.We can process different beads on the tube end.

Size and Shape: according to drawings

Place of origin: China , Service to worldwide.

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 Experienced Metal tube end beading

Tube-End-Beading-end-Forming

 General Knowledge on “Metal tube end beading”

Submit drawings,Let Metalhelper manufacture it for you.

Let Metalhelper to help you process/manufacture Metal tube end beading,Please send us the meassage with drawing or sample photo,and tell us your purchased quantity in first order,and then we`ll quote to you. The more details on product you provide,the more quick we can quote. Procedures of Perforated Metal Tube

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Metal tube end beading

Metal Products Fabricate In China  >> Metal Tube Fabrication >> Metal tube end beading

Perforated Metal Tube

Perforated Metal Tube 5

Perforated Metal Tube,tube punch holesMetal Products Fabricate In China  >> Metal Tube Fabrication >> Perforated Metal Tube

Perforated-Metal-TubeService: Perforated Metal Tube

Metal tube perforating,also named hole punching,means to perforate or punch,pierce holes on round or rectangle tubes.The materials for perforating includes stainless tube,carbon steel tube, aluminum tube, copper or brass tube. Typical tubes perforated are filtration tubes,exhaust tubes, diffusion tubes,  or manifolds.

Size and Shape: according to drawings

Place of origin: China , Service to worldwide.

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 Experienced Perforated Metal Tube

Metal-Tube-Perforated

 General Knowledge on “Perforated Metal Tube”

Submit drawings,Let Metalhelper manufacture it for you.

Let Metalhelper to help you process/manufacture Perforated Metal Tube,Please send us the meassage with drawing or sample photo,and tell us your purchased quantity in first order,and then we`ll quote to you. The more details on product you provide,the more quick we can quote. Procedures of Perforated Metal Tube

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 hole punching

Metal Products Fabricate In China  >> Metal Tube Fabrication >> Perforated Metal Tube

Dip Tube

Dip Tube 7

dip-tube

Custom: Dip Tube for water heater,metal dip tube with Compression Fitting

Material:Stainless steel tube or copper tube,with copression fittings.Stainless steel or Copper dip tube CUSTOM-BUILT to fit your exact kettle,water heater,keggle, or mash tun.

Custom:accept customized size,Please let us know:
1) Distance (horizontal) from end of coupling to CENTER of your kettle or mash tun;
2) Distance (vertical) from top of coupling to BOTTOM of your kettle or mash tun – at the MIDDLE of the kettle or mash tun;

Place of origin: China , sell to worldwide.

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Models and Details on “Dip Tube”

 

 

General knowledge on “Dip Tube”

 

Custom Manufacturing Products >>Metal Products Fabricate In China  >> Dip Tube

Metal Casting,Custom Casting Metal Parts

Metal Casting,Custom Casting Metal Parts 9

Metal-Casting

Serive: Metal Casting,Custom Casting Metal Parts

Short Description:Die-casting is a metal casting process, which is characterized by using a mold cavity for applying a high pressure molten metal. The mold is usually processed with a higher strength alloy, this process is somewhat similar to injection molding. Most are non-ferrous die-casting, such as zinc, copper, aluminum, magnesium, lead, tin and pewter, and their alloys. Depending on the type of die-casting, requires the use of a cold chamber die casting machine or hot chamber die casting machine.

Material for casting: Aluminium,Zinc,Copper,Brass,Iron

Place of Origin: China, Serve for worldwide customers

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 Experienced products made with technology of Metal Casting

  

  

  

The usual metal for casting mainly include zinc, copper, aluminum, magnesium, lead, tin and pewter, although tpressuring cast iron is very rare, but it is also feasible. Special die-cast metal, including ZAMAK, standard aluminum-zinc alloy and the US Aluminum Association: AA380, AA384, AA386, AA390 and AZ91D magnesium. When various metal casting characteristics are as follows:
Zinc: most likely to die-cast metal, the manufacture of small parts is economical, easy coating, compressive strength, plasticity, long life cast.
Aluminum: light weight, high manufacturing complexity and thin-walled castings dimensional stability, corrosion resistance, good mechanical properties, high thermal and electrical conductivity, high temperature strength remains high.
Magnesium: Easy machining, strength to weight ratio, commonly used in the lightest metal casting.
Copper: high hardness, corrosion resistance, mechanical properties of die-cast metal used best, abrasion resistance, strength close to the steel.
Lead and tin: high density, high dimensional accuracy, corrosion can be used as special parts. Considerations of public health, this alloy can not be used in food processing, storage equipment. Tin antimony alloy (sometimes also contain a little copper) can be used to manufacture handmade type letterpress printing and hot stamping.

  Main Equipments for Custom Metal Casting parts

We specialize in design, research and manufacturing aluminum, copper and zinc alloy casting and forging products, which are  widely used in automotive ,vehicles, ships and machinery, etc.
We have strong techinical force, equipment, testing method and professional personnel . There are chemical element analyzers that can control and analyze product chemical element effectively.
Shot blasting machine,sand blasting machine and vibrative grinder which ensures the quality and surface finish;
Processing center, CNC milling machine,CNC lathe,ordinary lathe and drill press that can strictly control products size and precision.
We are mainly producing according to customer’s drawings or samples,and many thanks for your enquires.

metal-casting-equipments metal-casting-machines

 General Knowledge on “Metal Casting”

Metal Casting Benefits:
1. good quality
High precision casting size, generally the equivalent of 6 to 7, even up to four; good surface finish, usually equivalent to 5 to 8; high strength and hardness, strength than sand casting generally increased by 25 to 30%, but the extension rate reduced by approximately 70%; dimensional stability, good interchangeability; may die casting thin-walled complex castings. For example, the current minimum wall thickness of zinc alloy die castings up to 0.3mm; aluminum alloy castings of up to 0.5mm; the smallest aperture of cast 0.7mm; minimum pitch of 0.75mm.
2. High production efficiency
Machine production rate, such as domestic JⅢ3 horizontal cold air can be die-die-casting machine for eight hours on average 600 to 700, a small hot chamber die-casting machine per eight hours from 3000 to 7000 can; long life type-casting, a pair of die-casting type, bell-casting alloys, life up to hundreds of thousands, or even millions of times; easy mechanization and automation.
3. good economic effect
Because casting precise size, table pan clean and so on. Generally no longer be machined and used directly, or processing capacity is small, so not only improves the metal utilization, and reduces the amount of processing equipment and working hours; casting price will be easy; in combination with other die-cast metal or non-metal materials can be used . Saving metal assembly work and save.

Metal Casting Shortcoming
1) Because the liquid metal die-filled cavity high speed, flow regime is unstable, so the use of general-casting method, the casting is easy to produce pores, can not be heat;
2) on the concave complex castings, casting more difficult;
3) melting point alloys (such as copper, ferrous metals), the lower die-type life;
4) should not be small batch production, the main reason is the high cost of die-based manufacturing, die-casting machine production of high efficiency, small batch production uneconomical.

The biggest drawback is the cost of die-cast high. Casting equipment and molds, die casting method relative to other related components for all expensive. So when the production of a large number of products manufactured before casting more economical. Other disadvantages include: This process applies only to the higher mobility of metals and casting quality must be between 30 g and 10 kg.In the conventional die-casting, the casting of the last batch of castings always have pores. Thus any heat treatment or welding can not be performed, because the gas within the gap will be expanded under the action of heat, resulting in the release of micro-defects and internal surfaces.

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order procedures for casting

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Custom Metal bracket,support,mount,shelf

Custom Metal bracket,support,mount,shelf 11

 Custom Metal bracket,support,mount,shelf

Custom Metal bracket,support,mount,shelf,rack for Equipments,Electronic,Lighting,Monitor,Network,Security,Ventilation,etc.

Bracket,also named support,mount,shelf, is a widely supportive role in the architecture.Brackets could mount a plenty of architectural products, including a wall, balcony, parapets, eaves, the spring of an arch, beams, pergola roof, window box, or a shelf.In adjustable shelving systems, the bracket can be seperated into 2 parts, a horizontal arm to bear load weigh and  a vertical wall-mounted arm.Brackets are extremely existing in our life, normally used in electrical appliance installation, building, industrial manufacturing, agriculture, transport, furniture and equipment.Bracket includes hydraulic support, solar bracket, notebook stand, TV stand, air conditioning brackets, pipe supports, greenhouse frame, timber bracket,transmission and distribution of stents, stents, and other cables.

They are usually made from carbon steel plate or tube,and paint with powder coating.Sometimes,also made from stainless steel,in order to get good performance to be anti-rust.

We can custom many types of sheet metal bracket,support,mount,shelves for multi applications. Fabricated metal provides a strong medium that offers superior protection and allows. A variety of options are available for bracket,support,mount,shelf such as doors, drawers, perforated panels, locks, hinges, handles, and much more, which can be made to fit your requirements.

Material Sheet metal can be Carbon Sheet Metal,Stainless Steel Sheet,Aluminium Sheet,Copper Sheet,etc.

With our metal fabrication experience and capabilities to process metal brackets ranging from precision punching and bending to robotic welding and intricate metal perforating, can provide you with quality, finished products, on budget and on time. We have in-house services that move your project along and ensure quality at each stage—engineering support, component assembly, finishing and labeling, as well as storage and fulfillment.

many metal bracketsworkshop to fabricate metal bracketsheet metal automatic cutting hydraulic forming equipment CNC punching stampingMetal sheet CNC bending   metal parts weldingmetal product quality control

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Custom Metal cabinet,enclosure,chassis,box

Custom Metal cabinet,enclosure,chassis,box 13

Custom Metal cabinet,enclosure,chassis,box

Sourcing the right cabinet/enclosure to fit special items? We are your best choice.

Custom Metal cabinet,enclosure,chassis,box in China for Equipments,Electronic,Lighting,Monitor,Network,Security, Ventilation,etc.

The material of Sheet metal can be Carbon Sheet Metal,Stainless Steel Sheet,Aluminium Sheet,Copper Sheet,etc.

Based on the following technology and procedures,Sheet Metal Fabrication is the building of metal structures by stamping,cutting, bending,deforming and assembling processes:

  • Punching or Stamping.Punch hole on the metal material.It is a metal forming process with punch machine.MetalHelper has more than 20sets punch machine with different strength.At present,MetalHepler has been equiped with CNC punch machine.
  • Cutting or shearing.Cutting metal materials with technology shearing or sawing.At present,MetalHelper is equiped with CNC laser cutter,which can provide you products with more accurance.
  • Bending.Bending is to process Sheet Metal Stamping to be bent.It can processed by punch,by Hydraulic machines,or by CNC bending maching.Metalhelper are equiped by all above machines
  • Drawing.It is a metalworking process which uses tensile forces to stretch Sheet Metal Stamping. MetalHelper has different machine to do sheet metal drawing or do drawing or wire, bar, and tube.
  • Hydraulics Deforming.Hydraulics is more better to deforming a metal product,because it put strength on the metal sheet with slow but big strength.MetalHelper has more than 10sets hydraulic machinese,can help you to process different metal products.
  • Welding.Welding is widly used in the field of Sheet Metal Stamping fabrication.MetalHelper has different welding machine,they are Co2 protected welding,Pot Welding,Line Welding.Especially,from 2009,MetalHelper was equiped with automatic welding robot.Its welding quality is more better,more quick.
  • Assembling.Usually,we help our customer to assmble many different components to be a complete product.Now,we owned two assembling line to help you process assemble task.

We have a full service customing cabinet factory, professional in manufacturing Metal cabinet,enclosure,chassis,box for your project in worldwide. We serve in many industries, from light industry to heavy industry,where need to fit the device into a special space. Our customers range from automotive supply, consignment supply, secure with integrated locking mechanisms, pharmaceutical cabinets, printer stand cabinets, and other heavy duty fabricated metal cabinets. Our products are made to order from a variety of metal gauges with full-welded construction. A wide variety of standard security features can be incorporated into the design, such as slide bars and continuous hinges.

With our metal fabrication experience and capabilities to process metal cabinets ranging from precision punching and bending to robotic welding and intricate metal perforating, can provide you with quality, finished products, on budget and on time. We have in-house services that move your project along and ensure quality at each stage—engineering support, component assembly, finishing and labeling, as well as storage and fulfillment.

metal-cabinetssheet metal automatic cutting cabinet forming equipment CNC punching stampingCNC bending   metal welding

 General Knowledge on “Metal cabinet,enclosure,chassis,box”

Sheet metal enclosure (thickness is usually 6mm or less) is processed by the integrated cold working process, after cooling to form the desired enclosure. Its notable feature is consistent with the same part thickness.
Produced using the sheet metal chassis, the chassis can meet the requirements of the various functions and appearance, but also makes the stamping die manufacturing and low cost.

Sheet metal with a light weight, high strength, electrical conductivity (can be used for electromagnetic shielding), low cost, good performance characteristics such as mass production, is currently in the field of electronics, communications, automotive, medical equipment, has been widely used. For example, in the computer chassis, mobile phone, MP3, the sheet metal is an essential component. Common sheet metal chassis: power cabinets, network cabinets, server cabinets, outdoor cabinets, etc.,Main types of precision sheet metal processing and production of products, including sheet metal chassis, cabinets, aluminum system chassis. These are made of sheet metal material.

By basic sheet metal processing methods, as expected, bending, stretching, forming, welding. This specification describes each of the processing methods to be noted that the process requirements.
Cutting: Depending on the processing methods can be divided into Cape punch, punch a few, is expected to open shears, laser cutting, cutting wind, due to the different processing methods, cutting the process is also different. Sheet metal cutting and punching several main methods of laser cutting.
Bending: When the material is bent on its rounded area, stretching the outer received, inner layer is compressed. When a certain thickness of the material, the smaller the r, the tensile and compressive more serious; when the tensile stress exceeds the ultimate strength of the outer fillet the material, it will crack and break, thus, curved parts of the structure design, to avoid too small bending radius.
Stretching: radius stretching pieces between the bottom and the straight wall thickness should be greater than that r1≥t. In order to make stretching more smoothly, and generally r1 = (3 ~ 5) t, the maximum radius should be less than or equal to the thickness of 8 times, that r1≤8t. Stretching pieces around because of the stress vary in size, and the material thickness will change after stretching. In general, the center of the bottom to keep the original thickness of the bottom fillet material thinning, thickening near the top flange of the material, rectangle stretching pieces material thicken around the fillet.
Forming: beading on the sheet metal parts, helping to increase structural rigidity, blinds typically used to play a role in a variety of ventilation hood or chassis, the molding method is to use the punch to the side of the blade material cut while the remainder of the punch material while for the tensile deformation, to form an undulating shape with one side opened.
Welding: welding methods include arc welding, electroslag welding, gas welding, plasma arc welding, fusion welding, pressure welding, brazing, welding sheet metal products primarily for arc welding, gas welding.
Arc welding with a flexible, mobile, wide applicability, can be all-position welding; the use of simple equipment, durability, and low maintenance costs. But labor-intensive, quality is not stable enough, depending on the operator level. Non-alloy welding flame temperature and nature of the applicable welding than 3mm carbon steel, low alloy steel, stainless steel and copper, aluminum, etc. can be adjusted to the specific heat of welding heat affected zone width, the heat is better concentrated arc, low productivity, used in thin-walled welded structures and small pieces can be welded steel, cast iron, aluminum, copper and its alloys, carbide.

Submit drawings for Custom Metal cabinet,enclosure,chassis,box

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Metal cold heading

Metal cold heading 15

Metal cold heading

Service:Metal cold heading,Metal impact heading

Short Description: Manufacture metal products with cold heading(or named impact heading) technology according to customer`s drawing or sample;

Material: Aluminium,Copper,Brass,Steel,Stainless Steel,etc;

Shape & Size: Customized according to drawing;

Place of Origin: China,Do Metal cold heading to World;

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 What can we do for you?–Metal cold heading

cold-impact-heading-parts cold-heading-machine

 Benefits of Metal cold heading

Most of machined parts could be re-designed and re-manufactured  to be parts made by technology of cold heading,which help you to get significant cost savings.

  • Improve production effience and reduced Production costs:Because of using high speed manufacturing process. The speed reaches range from 10 pieces per minute for low volume large press work to to 450 pieces per minute on the cold heading process.
  • Save material cost: Compared to a traditional machining process, cold forming process  can save up to 70%.
  • Better control product tolerance: compared to more expensive machining processes,less tolerance can be achieved throughout the production process by coldforming
  • Higher and better quality surface: compared to conventional machined surfaces ,cold forming process can get result . The cold forming process can eliminate the need for costly secondary operations, such as welding, machining, etc, with careful product and process design,
  • Improved part performance and characteristics: due to the metal deformation resulting in improved grain structure, while work hardening can yield significantly improved product performance,cold forming process can improve metal part performance and its characteristics.

For many OEMs,cold heading represents clear opportunities for cost savings over traditional large component manufacturing methods.

Material and Process Cost Advantages:

See below charts to check how much you can save if made with cold heading technology:

cold-heading to save material

The Result: Lower Costs of Product to the Customer

Better Quality and Consistency: cold heading is a purely mechanical process that forms metal into net or near net shapes, but unlike traditional alternatives, it is performed at room temperature without using additional heat, providing more precise tolerances and part to part consistency than any other method.

The products made with Cold Forging:

  • Higher Strength: Cold forming work hardens the material raising its yield stress, making it significantly stronger than can be produced through other methods. With these higher strength properties, component design thickness can often be reduced offering further savings on weight, material and clearance.
  • Higher yields for exceptional strength
  • Most precise tolerances available
  • Improved physical properties by refining grain structure
  • Exceptional surface finish no scale
  • Part-to-part uniformity/repeatability
  • Better functional reliability
  • Reduced/eliminated machining & waste
  • May eliminate subsequent heat treating

Advantages of cold heading

SpeedDepending upon the size and complexity of the part and the nature of the equipment of producing them, production rates of 4000 pieces per hour can be achieved.
EconomyWhen compared to casting and machining labor the metal savings alone justify the conversion to an impact extrusion.In some cases when the aluminum slug is sized accurately, little or no trimming or other secondary operations are required.
StrengthThe impact process naturally work hardens non-heat treatable alloys, while the heat treatable alloys can be heat treated in normal fashion after processing.
ToughnessThe impact extruding process produces parts that are dense and porous-free in structure. This condition cannot be obtained in a casting process or by machining of a bar material.
VersatilityAfter impacting, the product can be treated the same as any other piece of material. Secondary operations such as machining, grinding, welding, bending, plating or anodizing can be performed in the same way as any other piece manufactured by a more conventional process.
ConsolidationImpacts can directly replace machined components, or welded or riveted assemblies, in many designs. The process often reduces product costs for secondary machining operations and in many cases increases the strength of a product that was previously an assembly.
 General Knowledge on “Metal Impact Extruding”

cold forging parts

What is Mtal Cold Heading Process?

Cold heading,also named impact heading,is volume specific and the process uses dies and punches to convert a specific “slug” or blank of a given volume into a finished intricately shaped part of the exact same volume.

Cold Heading process means to adopt quick automative “part formers” or “cold-headers” to cut off and push into or transform a metal wire or metal bar into a shaped die, then, in an outward direction,the protruding end is upset. Through the above process, the metal wire(bar) is shaped on the same axis and it always involves to change a diameter from the original wire size as an extrusion.It can do repetitive and tight tolerances by using a special tooling succession at a quick speed up to four hundred times every minute.It is a high efficient technology to manufacture metal fasteners,screws,nuts and custom various of metal parts and components according to your drawings or samples.

The secondary process after Metal cold heading:

Though metal parts coming from cold heading process are usually complete or near to be finished with very small minimal scrap, generating significant raw material savings compared to traditional screw machining process,it always still is used as the primary manufacturing process which produce as simple as a screw/nut blank. The part then always comes with secondary process including polishing,maching,etc to achieve more high precision part configuration with good tolerances grade.The best commen secondary process are:

  1. Heat Treatment. To achieve a desired result such as hardening or softening of a material. Heat Sometimes,heating and cooling are done for the specific purpose of altering properties intentionally, they often occur incidentally during forming.
  2. Polished.To polish the cold forming product,usually,they will be sprayed with mini stainless steel ball in a closed room,then all scraps,oils,burrs will be removed.
  3. machined or lathing.Machining process is usually to make screw thread or make a horizontal hole on the cold forming product.As cold forming process itself is diffcult to make thread or horizontal hole.
  4. Anodic oxidation or electroplating.After all processes are finished,some products are required to do electroplating.If the product is made from aluminium,it is always required to do anodic oxidation

Typical Design Considerations for Cold Heading Parts

cold-form-designs

The below designs are some typical metal part which are always to manufactured by the cold heading process :

  • Metal Hexagonal Head
  • Metal Round Head&Square Head
  • Round Head with Slit
  • Radial Slot & Recessed Drive
  • Double Reverse Extrusion
  • Diameter Reduction
  • Cylindrical Extrusion
  • Offset, Pierced and Embossed
  • Multi-Diameter Extrusion
  • Carriage Bolt
  •   Offset Head
  • Lugs&Collar

Material for cold heading process

Usually,the following metal are always to do cold heading processs:

  • Brass or Bronze
  • Copper
  • All kinds of Aluminum
  • Carbon Steels wire or bar
  • Stainless steel
  • Alloy Steel
  • Nickle Alloys
  • ……

With the development of computer and cold heading process machines, cold heading design capabilities will be more and more and “endless.”

Cold heading`s metallic materials requirements

1, the mechanical properties of metallic materials for cold heading request
According to metal cold heading process characteristics,here is the requirement on the mechanical properties of the steel:
1) Yield strength Re and deformation resistance should be as low as possible, it let the unit deformation force to be reduced accordingly, to extend the life of the die;
2) cold deformation performance of meterial should be good, that means the materials should have good plasticity performance, lower hardness, which can let product avoid cracking in a large degree of deformation . For example,when you are going to cold head high strength bolts ,you can use carbon steel which has higher carbon content, also can use low carbon steel, low alloy steel. If increase carbon content in the metal, it will increase the hardness, decrease plasticity performance, to let cold deformation performance reduce. But if you add a small amount of alloying elements (such as adding a small amount of boron 10B21,10B33 steel) in low carbon steel, the steel can significantly be improved the strength to meet the performance requirements of the product ,and without compromising its cold deformation properties;
3) It`s better to have the lower sensitivity of the work-hardening materials, so that it can avoid too large deformation force. The work hardening sensitivity of the available material can be reflected by the deformation resistance – strain curve slope. The larger the slope, the higher the hardening sensitivity. Such as stainless steel 0Cr18Ni9 (SUS304),it has the maximum slope of the curve. The hardening sensitivity of this material is more intense, as the deformation increases, the deformation resistance rise sharply.
The performance of the mechanical properties of steel not only t billets original Rm, Re, A, Z and hardness and other indicators, affected not only by the chemical composition of raw materials, macroscopic tissue microstructure, etc., but also by the material preparation process drawing various channels and also affect by heat treatment process between.

2,Requirements on chemical constituents.
⑴ carbon (C) is the most important element to effect carbon steel`s cold plastic deformation . The more carbon content, the higher the strength of steel,but the lower plasticity performance. Each carbon content increased by 0.1%, the yield strength Re improve 27.4MPa, tensile strength Rm increase (58.8-78.4MPa), while the lower elongation A 4.3% reduction of Z 7.3% lower. When the carbon content of steel <0.5%, manganese content of <1.2%, reduction of Z = 80%, the unit is cold deformation force P and the steel containing C, Mn approximate relationship between the amount as follows:
P = 1950C + 500Mn + 1860 (MPa) …………………… (1)
You can see, the carbon content of the steel for cold plastic deformation properties is significant. In the actual process,the metal cold heading extruding steel carbon content is greater than 0.25%, it is required to have the best annealing steel plastic tissue – a spherical pearlitic structure. For the degree of deformation of 65% -85% of the cold heading fasteners without intermediate heat treatment is performed three times upsetting deformation, the carbon content should not exceed 0.4%. When the carbon content exceeds 0.3% -0.5% in the carbon steel, it is necessary to increase the use of intermediate or adopt process of full annealing,or use warm heading.
⑵ The role of manganese (Mn) steel with iron smelting .
(Mn + FeO + MnO + Fe) mainly for steel deoxidation to join. Manganese in steel acts with iron sulfide (Mn + FeS + MnS + Fe), can reduce harmful sulfur to steel performance. The Manganese sulfide formed can improve the machinability of steel/metal. Manganese let steel strength increase, decrease plasticity,it is unfavorable for cold plastic deformation properties , but the impact of manganese on the deforming force is only about a quarter of carbon. Due to the special performance requirements of the finished product, allowing for the sulfur content of manganese five times. In addition to the special requirements of the finished product, but should not exceed 0.9%.
⑶ silicon (Si)
silicon is the deoxidizer`s residues in steel smelting . When the silicon content in steel increased by 0.1%, the increase 13.7mpa. Experience has shown that when the silicon content of more than 0.17%, and greater carbon content, has a great influence on the plasticity of lower steel. Appropriate increase in silicon content in the steel, mechanical properties of steel, especially advantageous elastic limit, can also enhance corrosion resistance of steel. But when silicon steel exceeds 0.15%, so that the formation of non-metallic inclusions sharp steel, high silicon steel annealing does not even soften dramatically reduced cold plastic deformation properties of steel. If silicon is present in the steel in the form of silicic acid, the dispersion of the fine particles in the steel will be too worn mold. Therefore, in addition to product performance requirements of high-strength, cold heading steel always try to reduce the content of silicon.
⑷ sulfur (S)
Sulfur are harmful impurities. The sulfur in steel causes cold heading separated from each other at the time caused the crack. The presence of sulfur has also prompted to produce hot brittle and rusted steel. Thus the sulfur content should be less than 0.06%. When heading high-strength fasteners, should be controlled within 0.04%. Since the compounds of sulfur, phosphorus and manganese can improve cutting performance, the sulfur content of cold heading steel nut can be raised to 0.08% -0.12%, to facilitate for tapping.
⑸ phosphorus (P)
Phosphorus to solution strengthening and work hardening is very good.Severe segregation in the steel, increasing cold brittleness and temper brittleness of steel,to let the steel erodible acid. phosphorus will worsen cold plastic deformation properties in the drawing manipulation wire breakage, cracking in cold heading workpiece manipulation. Phosphorus content of the steel should desirably be controlled 0.045% or less.
⑹The effect from other alloying elements chromium (Cr), molybdenum (Mo), nickel (Ni), vanadium (V), tungsten (W) and other alloying elements on the cold deformation properties of steel is lower than carbon. In general, increases in steel alloying elements, mechanical strength index steel hardenability increases, performance decreases cold deformation.

3, microstructure request
In order to better adapt to the cold steel forging process, for the distribution of steel structure and the size and form of non-metallic inclusions has certain requirements.
⑴ steel structure
In addition to the ferritic steels in vitro, as well as pearlite. The higher the carbon content, the more the number of pearlite. Soft ferrite matrix, in the soft matrix embedded with hard pearlite particles. Piles of pearlite distribution is disadvantageous for cold deformation, will be the formation of cracks. Organization of steel should be closely uniform, so. Cold heading steel use as uniformly distributed spherical grain structure.
⑵ grain size
Deformation of the metal is due to the deformation of crystal grains and grain itself slip occurs. Within a certain volume, the number of fine grains of metal grains more inevitable than coarse grains of metal, plastic deformation position when slip of the grain to the benefit is greater, distortion can be uniformly dispersed in each grain. Corresponding to the fine-grained metal deformation inhomogeneity and unevenness due to deformation caused by stress concentration are small, so the chance of cracking is also small, appear to increase the amount of plastic deformation can withstand before cracking, plastic is better reflects foreign . The smaller the grains, the grains produced by excitation of adjacent slip stress is smaller. For the deformation continues, the applied stress must be increased, reflecting a larger external deformation resistance. Therefore should not be used for cold heading steel too small grains. Grains too, will make the surface rough, resulting in significant scars and cracks. Coarse grained steel work hardening sensitivity than fine grain steels, and less plastic, cold deformation performance is poor. Cold heading steel grain size requirements for the 4-6 grade, grain size specification is as follows: the average grain diameter of about (0.02-0.06) mm; the number of grains per mm2 of about 250-2300 months; average grain an area of about (400-4000) μm2.
⑶ nonmetallic inclusions
Regardless of the method of smelting steel, there will always be more or less non-metallic inclusions. An oxide or sulfide inclusions, causes the crystal structure of the metal close intermittently. In the form of inclusions, the number and distribution of different properties of steel for cold deformation effects are different. Cold heading wire is a hot-rolled steel products for use after cold drawing, rolling and cold drawing process, these inclusions have been elongated along the direction of deformation. In general, fine, uniform distribution of inclusions little damage. Small and scattered sulfide inclusions can be better with the deformation direction deformation, thus representing a number of other inclusions smaller damage resulting deformation. Particularly harmful alumina inclusions. Alumina fine particles not only extremely hard, it will damage the mold; and hard to combine with the steel substrate, often tearing manipulation in severe cold deformation of the workpiece. Thick or thin and local concentration of inclusions, for cold heading steel properties influence.

4, the requirement of surface quality
Surface condition of the majority of ordinary hot-rolled steel is not good enough. Hot-rolled steel surface defects after cold drawing (if the compression ratio is too small) can not be eliminated, resulting in cold heading product surface defects and waste, will be unable to produce serious.
⑴ billet surface defects
Steel smelting, steel ingot leaving bubbles, shrinkage and other defects. After hot-rolled and cold drawn, the wire with a more serious penetrating longitudinal, upsetting significantly when exposed to the product surface. Defects folded ears, segregation, cracks and other raw materials in the rolling, cold heading will cause serious harm. Such as: bolts breakage, cracking nuts; workpiece while rubbing and thread, screw blanks crushed in half and so on. Improper handling of raw materials in pickling, the steel surface pitting, corrosion. If pitting, corrosion minor, after cold drawing, is elongated pits on the surface is basically not show signs of cold heading in Buzhi Yu therefore cracks. If the pits will form a serious gap; the gap is presented in more corners of the large deformation of the workpiece. Cracks and other surface defects deeper, cold deformation performance worse. Experiments show: Whether cold-drawn or cold heading, shape deformation degree for cracks little effect, but the impact is great crack depth. For larger deformation cold heading materials, critical depth of surface defects is 0.04-0.10mm, deeper defects must be avoided.
In the low-carbon steel is heated atmosphere will cause decarbonization. Although the quality of the products from the appearance of decarbonization not see anything, but any change in the carbon content of the surface have a significant effect on the mechanical properties of the workpiece. Especially on the carbon content of more than 0.30% of the steel, the surface of the workpiece decarbonization fatigue strength and wear resistance obviously harmful. Material in order to prevent decarburization annealing, the protective gas should be used.
Contrary to carburization and decarburization. High carbon steel in high temperature environments will produce carburizing. While the finished product is equivalent to the carburizing for hard shell is acceptable, sometimes need to adopt a method of producing the soft-core, but for the cold heading process is quite harmful. There carburizing steel surface layer as thin as eggshells hard. When the material restructuring or cold heading, the surface will produce cracks or peeling, reduce cold deformation properties of steel. Therefore, cold heading steel should completely avoid decarbonization and carburizing. Decarbonization and carburizing steel case can be microscope examination.
⑵ dimensional accuracy requirements
The dimensional accuracy of the wire for cold heading has a great influence on product quality and process. Cold heading wire and molds are usually processed separately specialization. If the wire diameter exceeds the maximum allowable value, when the upsetting piece of metal on the head too, will have adverse burrs or workpiece curving bar. Or because the wire diameter is larger than the diameter of the die hole leaving the die hard feed. And the stem portion of the workpiece to be brushed die hole, the hole in the mold to form a sharp metal tumors. If the wire diameter is less than the minimum allowable value, while not upsetting the metal mold cavity is completely filled, causing the workpiece edges unclear. So cold heading material to be sufficiently close to the true circle, uniform diameter. Cold heading wire diameter tolerance is generally 0.20-0.35mm, roundness tolerance of 1/2 of the diameter tolerance.

 Contact MetalHelper to Customize Metal cold heading Products

Submit drawings for Metal cold heading,Let Metalhelper manufacture it for you.

Let Metalhelper to help you process/manufacture Metal cold heading,Please send us the meassage with drawing or sample photo,and tell us your purchased quantity in first order,and then we`ll quote to you. The more details on product you provide,the more quick we can quote. You also can visit  http://www.metalhelper.com to contact Metalhelper company directly for Metal Extrusion Fabrication business

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Metal Products Fabricate In China  >> Metal cold heading

Metal Cold Forging

Metal Cold Forging 17

metal cold forging

Service: Custom Metal Cold Forging Products,Save material,Improve performance

Short Description:Cold forging use compressive force to manufacture and form metal parts,including to forge metal screws,sockets, bolts, power nuts, non-standard hardware parts, machinery parts, auto parts, construction parts,ground pins,sleeve bushing, rivets,ring gear,housing,etc.Adopting technology of cold forging/cold heading,not only save materials,but also increase density,and improve item`s performance.

Material: Aluminium,Copper,Brass,Carbon Steel,Stainless Steel,Zinc,etc;

Shape & Size: Customized according to drawing;

Place of Origin: China,Service to World;

Want “Metal Cold Forging Items”? Inquiry or Order it!
 Experienced products made with technology of Metal Cold Forging

Metal Cold Forging, also named cold extrusion, cold heading, is cold working, a process of metal defroming working and material forming, is carried out at a normal temperature. The material for cold forging are mostly small, better deforming ,mainly are aluminum alloys, copper and some alloys, low carbon steel, carbon steel, low alloy steel. The product surface with cold forging manufacturing is high quality, high dimensional accuracy, can replace some of the cutting. It makes material strengthen and improve the strength of the parts.

experienced cold forging metal parts cold-forming-parts-2 Metal Cold Forging Fabrication equipments fabricate Cold Forging metal parts manufacture cold forged parts

  • Aluminium cold forging parts
  • Copper cold forging parts
  • Brass cold forging parts
  • Carbon steel cold forging parts
  • … …
 Popular Metal parts made with metal cold forging/heading technology

The following metal parts are popular to be made with cold forging technology.Not only can save materials,save cost,but also can improve item`s strength density and production effience.

custom cold forged bushing- cold heading metal sleeve bushing

Custom cold forged nuts cold heading metal nuts

cold-forged-bolts-cold-heading

Custom cold forged pins cold heading pinston pins

custom cold forged socket cold heading metal housing socket

custom-cold-heading-rivets

Custom-cold-forged-terminal

Ring-Gears

  • Other non-standard parts

metal-cold-forging

 Benefits of metal cold forging

Most of machined parts could be re-designed and re-manufactured  to be parts made by technology of cold forming,which help you to get significant cost savings.

  • Metal Cold Forging improve production effience and reduced Production costs:Because of using high speed manufacturing process. The speed reaches range from 10 pieces per minute for low volume large press work to to 450 pieces per minute on the cold heading process.
  • Metal Cold Forging save material cost: Compared to a traditional machining process, cold forming process  can save up to 70%.
  • Better control product tolerance: compared to more expensive machining processes,less tolerance can be achieved throughout the production process by coldforming
  • Higher and better quality surface: compared to conventional machined surfaces ,cold forming process can get result . The cold forming process can eliminate the need for costly secondary operations, such as welding, machining, etc, with careful product and process design,
  • Metal Cold Forging improve part performance and characteristics: due to the metal deformation resulting in improved grain structure, while work hardening can yield significantly improved product performance,cold forming process can improve metal part performance and its characteristics.

For many OEMs,Cold Forging represents clear opportunities for cost savings over traditional large component manufacturing methods.

Material and Process Cost Advantages:

See below charts to check how much you can save if made with cold forging technology:

cold forging save materials

The Result: Metal Cold Forging can be lower Costs of Product to the Customer

Better Quality and Consistency: Cold Forming/Forging is a purely mechanical process that forms metal into net or near net shapes, but unlike traditional alternatives, it is performed at room temperature without using additional heat, providing more precise tolerances and part to part consistency than any other method.

The products made with Cold Forging:

  • Higher Strength: Cold forming work hardens the material raising its yield stress, making it significantly stronger than can be produced through other methods. With these higher strength properties, component design thickness can often be reduced offering further savings on weight, material and clearance.
  • Higher yields for exceptional strength
  • Most precise tolerances available
  • Improved physical properties by refining grain structure
  • Exceptional surface finish no scale
  • Part-to-part uniformity/repeatability
  • Better functional reliability
  • Reduced/eliminated machining & waste
  • May eliminate subsequent heat treating
 General Knowledge on “Metal Cold Forging”

What is Metal Cold Forging?

Cold forging,also named cold forming.In Japan ,called cold forging, In China, called cold heading,is a process descripted as a technology process with high speed manufacturing to let metal block(including steel,aluminium,brass,copper,etc) formed and shaped at normal circumstance temperature,the process ofen doesn`t require to remove the scrap of material..it is a manufacturing process,and also is a processing method. Same as cold stamping process,cold forging has basically same procedures . Cold forging process is composed by materia, molds, and equipment. The difference is that in cold stamping, the material is primarily sheet metal, but in the cold forging, the material is mainly discs or solid wire.

Basic concepts:
Metal Cold forging refers to the various volumes of metal carried below the recrystallization temperature of the molding.
Shapes of cold forging parts become more and more complex, from the initial stepped shaft, screws, bolts, nuts and catheters, etc., to the more complex shape parts. The typical process of spline shaft is: being extruded rod Department – upsetting the middle of the first part – extruded spline; splined sleeve main process is as follows: anti-extrusion cup – made of red bottom ring member – positive squeeze bushings. Cold cylindrical gear extrusion technology also successfully used in the production. In addition to black metal, the copper alloy, magnesium alloy and aluminum alloy cold extrusion applications are increasingly widespread.
Technology Advantages
Cold forging process is a precision plastic forming technology with cutting unparalleled advantages, such as good mechanical properties of products, high productivity and high utilization of materials, particularly suitable for mass production.It is adopted as a method of manufacturing the final product (Net-shape Forming), means of transportation in the aerospace and machine tool industry and other industries with a wide range of applications.

Process shortcomings
It has high requirement on Materials; not suitable for a small amount of processing; mold cost is high.

Technical Requirements
Cold forging technology is more diffcult than the warm forging and hot forging, It has unique advantages in the field of precision forming . It increased bore finishing, dimensional accuracy, surface strength, extending the life of the barrel.

Applications of metal cold forging
The current rapid development of automobile industry, motorcycle industry and the machine tool industry for the development of the traditional cold forging technology to provide a driving force. For example, China’s national output in 1999 had more than 11.26 million units of motorcycles, according to preliminary estimates of 2000, China’s total demand for cars to 2005 will reach 3.3 million, of which 130 to 1.4 million cars only forging needs of the automotive industry in 50 to 60 tons. Cold forging technology in China, although not too late to start, but the pace of development, but there is a big gap with the developed countries, so far, China’s production of cold forging weight of cars on the lack of 20kg, equivalent to half of the developed countries, developing great potential to strengthen and promote the use of cold forging technology development is an urgent task of our country.

Metal Cold Forging Die

Cold forging can be divided to being squeezed, anti-extrusion and coextrusion. Cold forging punch stands greater dynamic loads, to prevent fatigue failure die early, avoid excessive stress concentration, and should pay attention to the stability of the punch, punch the aspect ratio (L:D) is not too large when pressed steel, L:D≤3:1, extruded copper and its alloys L:D≤5:1, extruded aluminum and its alloys L:D≤10:1. When the stress exceeds the mold material σ0.2 / 2, the die need to be added with prestressing ring which can taper between the die and the prestressing ring (0.5 ° ~ 1 °) fit or shrink-fit (red jacket) .

Materials for Cold Forging

Currently,the available materials for cold forging and cold extrusion are: lead, tin, silver, aluminum (L1 ~ L5), aluminum (LF21, LY11, LY12, LD 10, etc.), copper and oxygen-free copper (T1, T2, T3 , TU1, TU2, etc.), brass (H62, H68, etc.), bronze (QSn6.5 a 0.1, etc.), nickel (N1, N2, etc.), cadmium zinc and zinc alloy, iron, carbon steel (Q195, Q215, Q235, Q255, 08, 10, 15 20, 25 30, 35, 40, 45, 50 numbers, steel, etc.), low-alloy steel (15Cr, 20Cr, 20MnB, 16Mn, 30CrMnSiA, 12CrNiTi, 35CrMnSi etc. ) and stainless steel (1Cr13, 2Cr13, 1Cr18Ni9Ti, etc.). In addition, for some titanium and titanium alloys, tantalum, zirconium, and Kovar alloy, also can be cold extrusion, even bearing steel GCr9, GCr15 and HSS W6Mo5Cr4V2 also can be a certain amount of deformation of cold forging and cold extrusion.

Low carbon steel cold forging dies require high hardness (59 ~ 66HRC), high compressive yield strength and toughness appropriate. Commonly used mold materials Cr12MoV, Cr12Mo1V1, W6Mo5Cr4V2 steel and base steel, prestressed ring often used 4Cr5MoVSi, 4Cr5MoV1Si steel (46 ~ 48HRC), prestressing steel outer ring usually 4Cr5MoVSi, 5CrNiMo so on.

Aluminum cold forging die

Carbon Steel can be T7A, T10A, Cr12, Cr12MoV, GCr15,9SiCr and CrWMn so on.

The mold with Excellent material, design right, good hot and cold processing, good heat treatment,though due to improper use of the machine adjustment and operation, it may still be invalid during the early failure. Machine adjustments and operational factors, including the accuracy, rigidity, gap adjustment machine, positioning allowed and occasional overload. Seriously these factors will help to identify the real cause of die failure, the greater volatility in the life of the mold production, often with the machine to adjust and use the operating factors, must be given adequate attention.

The secondary process after metal cold forging:

Though metal parts coming from cold forming process are usually complete or near to be finished with very small minimal scrap, generating significant raw material savings compared to traditional screw machining process,it always still is used as the primary manufacturing process which produce as simple as a screw/nut blank. The part then always comes with secondary process including polishing,maching,etc to achieve more high precision part configuration with good tolerances grade.The best commen secondary process are:

  1. Heat Treatment. To achieve a desired result such as hardening or softening of a material. Heat Sometimes,heating and cooling are done for the specific purpose of altering properties intentionally, they often occur incidentally during forming.
  2. Polished.To polish the cold forming product,usually,they will be sprayed with mini stainless steel ball in a closed room,then all scraps,oils,burrs will be removed.
  3. machined or lathing.Machining process is usually to make screw thread or make a horizontal hole on the cold forming product.As cold forming process itself is diffcult to make thread or horizontal hole.
  4. Anodic oxidation or electroplating.After all processes are finished,some products are required to do electroplating.If the product is made from aluminium,it is always required to do anodic oxidation

Cold forging,same as cold extrusion, due to friction,maybe cause cracks in the surface of the metal extrusion attached under the influence of tensile stress. Therefore, the better the metal material`s plastic performance, the lower the hardness, the lower the carbon content and the less fit sulfur, phosphorus and other inclusions, the weaker of work hardening sensitivity,then it is more favorable to cold forging/cold extrusion, the process quality of forging and extrusion will be better.

 Contact us to Customize Metal Cold Forging Products

 Submit drawings for Metal Cold forging,Let Metalhelper manufacture it for you.

Let Metalhelper to help you process/manufacture Metal Cold forming,Please send us the meassage with drawing or sample photo,and tell us your purchased quantity in first order,and then we`ll quote to you. The more details on product you provide,the more quick we can quote. You also can visit  http://www.metalhelper.com to contact Metalhelper company directly for Metal Extrusion Fabrication business

procedures for metal cold forging parts

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application of Metal cold forging

Home >>Custom & OEM >> Metal Products Fabricate In China  >> Metal Cold Forging

Sheet Metal Fabrication

Sheet Metal Fabrication 19

sheet-metal-fabrication
Custom-Sheet-Metal-products

Sheet Metal Fabrication,Stamping, Shearing, Cutting,Bending,Deforming, Welding…

Short Description:  Sheet metal fabrication means to use pressing equipments to either coin or air-bend metal sheet into different forms.The sheet can be carbon steel sheet,stainless sheet,aluminium sheet and copper sheet.
-Laser Metal Cutting
-Sheet Metal Punching&Stamping
-Fastener Standing&Insertion
-Metal Sheet folding,bending and deforming
-CNC Lathing&Machining
-MIG and TIG welding of aluminium, mild steel and stainless steel
-Anodizing, Powder Painting Coating and electric-plating
-Associated Assembly work, including electrical assembly

Place of Origin: China, Service to worldwide customers.

Want “Sheet Metal Fabrication”? Inquiry or Order it!
 Experienced products made with technology of Sheet Metal Fabrication

Our service is based on the following technology and procedures,Sheet Metal Fabrication is the building of metal structures by staming,cutting, bending,deforming and assembling processes:

  • Cutting or shearing.Cutting metal materials with technology shearing or sawing.At present,MetalHelper is equiped with CNC laser cutter,which can provide you products with more accurance.
  • Extrusion.It is a process that the material is pushed or drawn through a die of the desired cross-section.MetalHelper has the machine to extrude steel bar,brass bar,or aluminium bar.
  • Punching(or we names it stamping).Punch hole on the metal material.It is a metal forming process with punch machine.MetalHelper has more than 20sets punch machine with different strength.At present,MetalHepler has been equiped with CNC punch machine.
  • Bending.Bending is to process Sheet Metal Stamping to be bent.It can processed by punch,by Hydraulic machines,or by CNC bending maching.Metalhelper are equiped by all above machines
  • Deep Drawing.It is a metalworking process which uses tensile forces to stretch Sheet Metal Stamping. MetalHelper has different machine to do sheet metal drawing or do drawing or wire, bar, and tube.
  • Lathing.Lathes are used in metal spinning, it can be used to shape pottery.At pressent,MetalHelper are equiped with CNC lathe to provide better service for high accurance.
  • Hydraulics Deforming.Hydraulics is more better to deforming a metal product,because it put strength on the metal sheet with slow but big strength.MetalHelper has more than 10sets hydraulic machinese,can help you to process different metal products.
  • Welding.Welding is widly used in the field of Sheet Metal Stamping fabrication.MetalHelper has different welding machine,they are Co2 protected welding,Pot Welding,Line Welding.Especially,from 2009,MetalHelper was equiped with automatic welding robot.Its welding quality is more better,more quick.
  • Metal product Powder Painting,anodic oxidation or electricplating.Most of mild steel priducts and some aluminium items need to be painted with plastic powder in order to protect it from corrosionm,and some sheet metallic products will require anodic oxidation or electricplating.All these surface process can be done in Smartclima.We have a fully automatic powder painting line to fabricate powder painting on metal products.
  • Assembling.Usually,we help our customer to assmble many different components to be a complete product.Now,we owned two assembling line to help you process assemble task.

The following photos show you a SMALL PART of Metal Sheet Fabrication samples which we did ago.

Sheet Metal Stamping parts Sheet Metal bending parts CNC Punching sheet

hardware parts metal bracket mount metal sheet deep-drawing products

Sheet Metal Stamping partssheet metal deforming part stainless steel flanges and stamping

stainless steel deep drawing perforated sheet metal Sheet Metal Fabrication

sheet-metal-products1 galvanized sheet metal stamping and bending sheet shell for home appliance

Sheet Metal bending Sheet Metal case and cabinetsSheet Metal assembled

The most popular metal product made with sheet metal technology are:Metal Cabinet,Enclosure,Chassis,Box;Metal Bracket,Support,Mount,Shelf;Perforating metal panel, Piercing metal plate;Flanges,Connecting pieces… …

  Main Equipments for Sheet Metal Fabrication


Laser Cutting Service

Metalhelper is equiped with laser cutting machine. Coupled with heavy plate capabilities and certified welding services, we are proud to bring you good service to custom sheet metal fabrication. From high volume production to prototypes, no job is too big or too small. If you have sample or drawing which want to be customed to produce metal products,just send it to us,we`ll study it and quote to you.Providing complete solution for high quality custom sheet metal fabrication, assembly and finishing. We take pride in working closely with our customers in order to provide the highest level of service.


Sheel metal laser custting

Metalhelper is equiped with laser cutting machine. Coupled with heavy plate capabilities and certified welding services, we are proud to bring you good service to custom sheet metal fabrication. From high volume production to prototypes, no job is too big or too small. If you have sample or drawing which want to be customed to produce metal products,just send it to us,we`ll study it and quote to you.Providing complete solution for high quality custom sheet metal fabrication, assembly and finishing. We take pride in working closely with our customers in order to provide the highest level of service.


CNC Sheet Metal Fabrication

Metalhelper is equiped with CNC punching machine which is utilizing computer to control machine to process stamping on workpiece.CNC is the latest equipment available in the industry, such as water jet, laser and other cutting edge technology. Coupled with heavy plate capabilities and certified welding services, we are proud to bring you good service to custom sheet metal fabrication. From high volume production to prototypes, no job is too big or too small. If you have sample or drawing which want to be customed to produce metal products,just send it to us,we`ll study it and quote to you.Providing complete solution for high quality custom sheet metal fabrication, assembly and finishing. We take pride in working closely with our customers in order to provide the highest level of service.

 

 

Mechanical automatic Sheet Metal Stamping

Metalhelper is equiped with Mechanical automatic Stamping machine which is utilizing fixed program to process sheet metal punching or deep drawing or forming on metal workpiece.Mechanical automatic Stamping  is the updated  technology from traditional punching technology.Automatic Stamping is more widely used in todays industrybecause of its high effience and less worker cost.Usually,it can save 80% worker cost,compared with traditional punching machine. Coupled with heavy plate capabilities and certified welding services, we are proud to bring you good service to custom sheet metal fabrication. From high volume production to prototypes, no job is too big or too small. If you have sample or drawing which want to be customed to produce metal products,just send it to us,we`ll study it and quote to you.Providing complete solution for high quality custom sheet metal fabrication, assembly and finishing. We take pride in working closely with our customers in order to provide the highest level of service.

 

develop sheet metal product mold traditional stamping equipment mechanical Punching machine

laser-cutting sheet metal CNC-Punching steel plate CNC-bending sheet metal products

automatic punching and stamping Sheet Metal Fabrication spreading and cutting sheet deep drawing and deforming

welding robot is working automatic powder painting line powder painting on metal products

pulling-test rust corrosion performance test electric plate thickness-test

 General Knowledge on “Sheet Metal Fabrication”

Sheet Metal Fabrication is based on the difference sheetmetal structure, process may vary, but the total does not exceed the following points.

1, Sheet Metal Fabrication–cutting: cutting a variety of ways, there are several ways
①. Scissors: Scissors cut using a simple strip materials and parts, it is primarily for blanking forming mold preparation and processing, low cost, accuracy of less than 0.2, but can only process nonporous no chamfered strip or block material.
②. Punch: Punch is the use of one or more steps in the flat pieces of sheet metal stamping parts will commence after forming various shapes of materials and parts, the advantage of cost and shorter, high efficiency, high precision, low cost, suitable for mass production, but to design the mold.
③. NC CNC cutting, the first to be prepared when cutting CNC machining NC program, use programming software, an expanded view of the preparation will be drawn into the NC machine tools pull a few recognizable program, let knife punching each step on the plate according to these programs Frame shape flat pieces, but its structure by the tool structure actions, low cost, precision 0.15.
④. Under the laser material, the use of laser-cut way, in large flat shape of the structure will be cut out of their flat, with NC laser cutting, like the need to write programs that can be flat pieces of a variety of complex shapes, high cost, accuracy to 0.1 .
⑤. Sawing: mainly used under aluminum, square tube, showing the pipe, rod material and the like, low cost, low accuracy.
2. Sheet Metal Fabrication–Fitter: sink hole, tapping, reaming, drilling
Countersink angle is generally 120 ℃, for pop rivets, 90 ℃ for countersunk screws, tapping Inch Bottom.
3.Sheet Metal Fabrication– Flanging: also known as pumping hole, turn the hole is on a smaller base hole pumped into a slightly larger hole, and then tapping, mainly with relatively thin thickness of sheet metal processing, increase its strength and number of threads avoid slip teeth, generally used for relatively thin thickness, its shallow hole flanging normal week, unchanged thickness, allowing a thinner thickness of 30-40% higher than the normal height and large available flanging 40- 60% of the height, with extruded thin 50%, may be the largest flange height, when the plate thickness is large, such as 2.0, 2.5, and above the plate thickness, can be directly tapping.
4. Sheet Metal Fabrication–Punch: The use of mold forming manufacturing processes, there are punching, Cutaway, blanking, punching convex hull (bump), red tear, pumping holes, forming presses and other processing methods are generally processed, the processing need to have appropriate mold to complete the operation, such as punching blanking die, the convex hull mold, tearing mode, pumping hole mold, molding, etc., the main attention to the location of the operation, direction.
5. Sheet Metal Fabrication–Clinching: riveted on this company, there are rivet nuts, screws, captive, etc., which are riveted by a hydraulic press machine, or to complete the operation, which was riveted to the sheet metal parts, as well as up riveting way, the need to pay attention to direction.
6. Sheet Metal Fabrication–Bending and Deforming; bending the plate member is a 2D, 3D folded parts. Its processing requires folding bed and the corresponding bending mold is completed, it also has some bending sequence, the principle is under the knife does not interfere in the first fold, will produce interference after the break.
7.Sheet Metal Fabrication– Welding:
① classification:  fusion welding: welding, CO2 welding, gas welding, manual welding;pressure welding: welding, butt welding, soldering hit;Brazing: electric welding chromium, copper
② welding:  CO2 gas shielded arc welding;TIG welding; spot welding;robot welding
Selection of welding methods are based on actual requirements and the material may be, in general, CO2 gas shielded arc welding classes for welding iron daub; welding for stainless steel, the aluminum type welding, robotic welding, can save time, improve efficiency and welding quality, reduce the intensity.
③ welding symbols: Δ fillet, Д, I type welding, V-weld, unilateral V-weld (V) with a blunt edge V-weld (V), spot welding (O), plug welding or groove weld (Π) curling welding (χ), with a blunt edge unilateral V-weld (V), U type of ribbon blunt with blunt J-welding, welding back, every weld
④ arrow lines and connectors
⑤ welding deletion and its preventive measures fail
Spot welding: strong enough to play bump imposed welding area
CO2 welding: high productivity, low energy consumption, low cost, strong anti-rust capability
TIG: melting depth, welding speed is slow, inefficient, high production costs, with the clip tungsten defects, but with the advantage of a better quality of welding can weld metals, such as aluminum, copper and magnesium.
⑥ welding deformation reasons: lack of preparation prior to welding, an additional clamp
Adverse improve the process of welding jig
Welding sequence bad
⑦ welding deformation effect Dharma:
Flame effect Dhamma
Vibration Method
Hammer

Commen steel sheet for Sheet Metal Fabrication:

1. Galvanized steel SPCC
SECC substrates for general cold rolled steel coils, galvanized in a continuous production line after degreasing, pickling, electroplating and various post-treatment process, it becomes galvanized products. SECC only has the mechanical properties of cold-rolled steel sheet and approximate general workability, and has excellent corrosion resistance and decorative appearance. Has great competitive and substitutes on electronics, home appliances and furniture markets. For example, the widespread use of computer chassis is SPCC.
2. Ordinary SPCC cold rolled sheet
SPCC refers to the continuous cold rolling mill rolling ingot through a desired thickness steel roll or sheet material. SPCC surface without any protection, exposure to easily oxidized in air, oxidation speed, especially in humid environments, appear dark red rust, in the use of the surface to be painted, plated, or other protection.
⒊ hot-dip galvanized steel SGCC
Hot-dip galvanized steel coil refers to semi-finished products after the hot pickling or cold, after cleaning, annealing temperature of about 460 ° C immersed in molten zinc bath, leaving the steel coated with zinc layer, and then quenched leveling and chemical treatment is made. SGCC material material harder than the SECC, ductility (avoid deep drawing design), zinc layer is thick, welded poor.
4. Stainless steel SUS304
One of the most widely used stainless steel, because it contains Ni (nickel) so than containing Cr (chromium) steel richer corrosion resistance, heat resistance, and has a very good mechanical properties, non-hardening heat treatment, there is no flexibility.
5. Stainless steel SUS301
(Cr) Cr content lower than the SUS304, corrosion resistance is poor, but after punching in the cold to get a good tension and hardness, good elasticity, and more for shrapnel springs and anti-EMI.

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