Sheet metal bending is a versatile and effective method of transforming sheets of metal into desired shapes, an important production method used in a variety of industries. In this guide, we will explore the different types of metal bending and when and how each method should be used. We will also discover sheet metal bending’s relationship with various different metals, to help you determine if sheet metal bending is the right method for you.
Types of Sheet Metal Bending
Air Bending
Air Bending is a common sheet metal bending process that utilises a press brake using a technique which means only a section of the tool touches the metal. The press brake bends the metal into a v-shape whilst putting less stress on the machine. Air bending is a great technique which can produce a wide variety of angles and metal shapes.
Coining
Coining is a bending process where the metal sheet is pressed into the die with force to create the specific shape of the die. This produces reliably consistent and very accurate bends. The process is called coining due to its accuracy and consistency, similar to how coins are always produced accurately and consistently in design.
Roll Bending
Roll bending is a great technique for producing curved shapes from sheet metal. The metal is put through a series of pressurised rollers which bend even thick metal to the desired shape and angle.
Wipe Bending
Wipe bending is used on the edges of metal sheets to create precise bends. The punch presses down along the edge of the sheet to bend it to the desired angle. This is a very accurate process that is used to create flanges and hems for larger sheet metal parts.
U-Bending
As the name suggests, U-bending creates U-shaped profiles in metal sheets. The metal sheet is pressed down into the U-shaped groove.
Rotary Bending
This process utilises a rotating die to create precise bends. The die has a curved surface, which the sheet metal rotates around to create the desired bend. This technique reduces friction and pressure, leading to less damage to the sheet metal.
Materials used in Sheet Metal Bending
Different sheet metal techniques work better with different types of metal. The metal you choose may impact the bending process, as some techniques will be less efficient at bending thicker materials. The most common metals for sheet metal bending are steel and aluminium, but other metals are also used:
Steel
Magnesium
Aluminium
Copper
Titanium
Alloys
Steel Sheet Bending
Steel is the most common metal used in sheet metal bending, due to its low cost and durability. It is also relatively easy to bend, meaning less power and strain is put on the sheet metal bending tool. Bending steel sheet is a process used in the creation of everything from car parts, and construction beams, to road signs.
Aluminium Sheet Bending
Aluminium is significantly lighter than other metals, making it a popular choice when creating products where weight is a big consideration, such as aerospace parts and portable consumer products. Due to its low density, aluminium is easily bent and shaped using little force, making it a great metal to make complex shapes and precise bends, this does, however, mean it may not be the most suitable metal for applications requiring extreme strength.
Auditoria offers steel sheet metal bending and aluminium sheet metal bending services for projects of all sizes. Contact us today to get started.
What industries use Sheet Metal Bending?
Sheet metal bending can be used in a variety of industries. Auditoria supplies sheet metal bending services for projects of all sizes, from one-off bespoke prototypes to large multi-part batch design. Industries that utilise sheet metal bending include:
Construction – Structure beams, cladding, and roofing.
Aerospace – Wing structures, brackets, interior components.
Agricultural – Storage tanks, machinery components
Renewable Energy – Solar panel frames, wind turbines
Consumer Goods – Furniture frames, toolboxes, home decor
Retail – Shelving, Display racks, signs
Advantages of Sheet Metal Bending
Sheet metal bending can be a beneficial technique depending on your desired result and application purpose. The main advantages of sheet metal bending are.
Aesthetic Appeal – Bending metal produces smoother and cleaner results than other methods, making it a good choice for results that require a smooth and clean finish.
Versatility – As stated above, there are a variety of methods and techniques in sheet metal bending, which can create a variety of shapes and designs.
Precision – Highly precise pieces can be made using methods such as rotary bending and wipe bending, which are crucial for making automotive parts and electronic components.
Cost Effective – Sheet metal bending naturally produces a low amount of waste, meaning less money spent on materials.
Quick Production – The process of sheet metal bending can be automated, making it time-efficient in mass producing projects, with little need for manual labour.
Disadvantages of Sheet Metal Bending
Springback – After bending, the metal can return to their original shape, or not hold the desired shape, due to their elasticity. This can be an issue with metal such as aluminium, where you will have to factor in springback in the bending process. This can also result in inconsistencies within batches.
Tool cost – Although the production cost in sheet metal bending is relatively low, the initial cost of custom dies and punches can be expensive, especially for custom or one-off designs.
Design Restrictions – Whilst complex shapes can be made using sheet metal bending, additional processes such as welding and cutting may also be needed to achieve the desired result.
Maintenance – Sheet metal bending tools require regular maintenance and calibration to maintain consistent results and prevent wear to the machine.
Alternatives to sheet metal bending
If you are unsure if sheet metal bending is the right service for your requirements, Auditoria offers other metal fabrication techniques. These include laser cutting and metal welding.
Speak to one of our metal manufacturing experts today to find the best option for you and your specifications.
Sheet Metal Bending FAQs
What is the maximum thickness for sheet metal bending?
Typically, 6mm-12mm is the maximum sheet metal thickness for metal bending. Specialised equipment may be able to bend thicker sheets of metal with significant force.
Is sheet metal bending a dangerous process?
Sheet metal bending can be very dangerous if not carried out by a professional in a safe environment. Injury from highly pressurised, moving parts, sharp edges, and heavy materials can happen if proper safety precautions are not followed and safety equipment is not worn. It is therefore recommended that sheet metal bending is carried out by a professional who is aware of these risks.
Where can I get metal bending for prototypes?
Some metal manufactures only service large clients with multi-batch requirements. Auditoria offers prototype manufacturing for one-off designs, servicing clients of all sizes. Auditoria also offers online prototype submissions, where an expert will review your design sheet and provide you with a custom quote.
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