Types of Metal Fabrications

Selecting the metal fabrication technique that's appropriate for a given project depends on the shape of the component and its intended use and the materials employed in the process of making it. Common metal fabrication techniques are like this:

Casting

Casting refers to the process where the molten metal is poured into a mold or die and allowed to cool and harden to shapes that are desired. The metal fabrication process is perfect to mass-produce parts by reuse of the same molds to create similar products. There are various kinds of casting. Die-casting is when liquid metal is forced into a die , instead of a mold, and there the pressure that is applied holds it in place until it is able to harden. This technique is well-known for the speedy applications it can support. The process involves pouring melting metal into a mold.

There are many kinds of casting techniques. Sometimes, a vacuum is also utilized in this method. Permanent mold casting can result in more durable castings than die casting, however, they are difficult to get out of the final product. Therefore, semi-permanent mold castings are also readily available. They have cores that can be expended which make them more manageable and less expensive to clean. The final process for casting is using sand casting. With sand casting, castings are created by pressing a design into the fine sand mixture. This creates a mold for the infusion of metal to pour into. This isn't the fastest method, however it is usually more cost-effective than other forms of casting. It is also a good option to make use of for intricate designs as well as for large metal fabrication.

Cutting

This is a very popular type of Metal Fabricating Manufacturing is the cutting of a piece of workpiece to break it up into smaller sections. Sawing is the most traditional method of cutting, modern methods include laser cutting, waterjet cutting, power cutters and plasma arc cutting. There are numerous cutting methods, from manual and power tools as well as computer numerical (CNC) cutters. Cutting could be the initial phase of a long fabrication process or even the only process used.

Die cutting is another cutting method that utilizes a die to slice metal. Rotary die cutting uses a spinning cylindrical die to cut through the material that is fed through the press. Flatbed die cutting is employed for thicker metal materials and uses a die on a press to cut out shapes while the die presses down on the metal.

Drawing

Drawing employs tensile force to pull metal into and through a tapered. The die expands the metal into a thinner form. Usually drawing is performed at room temperature and is known as cold drawing however, the metal workpiece may be heated in order to lessen the force.

The process is referred to as deep drawing when the end product has a depth more or less than its radius. It is commonly used in the sheet metal fabrication to make pieces into cylindrical hollow or box-shaped vessels.

Folding

The metal fabrication process is achieved by manipulating metal to bend at an angle. The most commonly used method is to use a brake press that causes creases to the metal by pressing it. The workpiece is held between a punch and an die and is then it is forced to fold under tension from the die. This process is usually used to cut sheets of metal. Folding can also be done by hammering the metal until it bends, or by using the folding machine which is also known as the word "folder. The machine is equipped with a flat surface on which the flat sheet of metal is set, a clamping bar that holds the workpiece in its place, and a back panel that raises up and then forces the metal stretched over it to fold.

Forging

Forging uses compressive force to shape metal. A hammer or die strikes the workpiece to create the design achieved. This manufacturing process is possible with the metal at room temperature, and is called cold forging. Forging is also possible by having the metal being heated to a temperature of temperatures that are above or below the temperature of recrystallization and can be referred to as warm or warm forging. If the metal gets heated up to its recrystallization temperature which is dependent on the metal and type, the process is referred to as hotforging. Forging is among the oldest types of metal fabrication which blacksmiths employed forging many centuries ago.

Extrusion

When using an extrusion manufacturing procedure, the piece of work is pushed through or around an closed or open die. When forced through an open or closed die, the diameter of the workpiece is reduced to the cross-sectional area of the die. When pressed around a die, a cavity is formed within the workpiece. Both of these processes generally use the same metal either a slug, or even a cylinder (a billet) as the workpiece, and a ram to perform the impact operation. The product that results from the impact typically consists of piping or wiring. The cross-section of the die can be various shapes, resulting in different formed components. Extrusion can be continuous in order to make very long pieces or semi-continuous in order to make smaller pieces.

Also called cold extrusion, impact extrusion is performed at room temperature , and it increases its strength part that makes it stronger than the initial material. If sufficient pressure is applied to proper metal it begins to flow into the available shape, similar to the motion of viscous fluid. Cold extrusion is commonly used to make metal metal fabrication.

Extrusion that is hot takes place at a higher temperature to stop the metal from hardening and to enable it to move in the die. It's commonly used to fabricate copper, and also to make custom aluminum parts.

Machining

The metal fabrication method called machining refers to the method of shaping metal by removing the unwanted material from it. The process can be carried out in a variety of ways. There are several different methods of machining, such as turning, drilling or milling.

Drilling utilizes a rotary cutting tool, the drill bit, to create a hole into the material. The drill bit presses against the metal while rotating quickly in order to create a circular hole.

Turning is the use of a lathe that rotates the metal in a cut tool is moved in a linear manner to cut away metal from the diameter of the cylindrical form. The cutting tools can be adjusted to create various designs. It can be done manually or by using an CNC rotating machine. CNC machining is typically used for parts that require measurements to be precise.

Milling makes use of rotating multi-point cutting tools to gradually remove material from the workpiece until the desired form is achieved. The metal is slowly inserted into the machine, or the tool is moved across the stationary metal or both the workpiece as well as the tool are moved with respect to one another. This process can be done by hand or using the aid of a CNC milling machine. Milling is typically a secondary or finishing procedure, however it can be used as the sole method for metal manufacturing from start to end. Milling methods include face milling, plain milling, climbing milling, angular milling as well as form milling.

Custom Metal Fabrication - A Summary

This guide provides a basic knowledge about metal fabrication, the various methodsused, as well as the factors to consider when selecting a fabricator. For more information on related services consult our other product guides or go to our Super Eagle Supplier Discovery Platform to discover potential suppliers or get more information on specific products.