Sheet Metal Parts Overview
What can Safewell offer?
- Reliable QC
- Materials
- Bending Capability
- FAQ & Solution
Our QA/QC department conducts stringent quality control on all incoming materials, spare parts, and throughout the entire production process, ensuring the highest quality for every product.
- Customer Approved Orders: The process starts when customer-approved orders are received.
- PMC (Production and Material Control): The production and material control department plans and manages the orders, ensuring smooth workflow.
- NCT Cutting: Orders proceed to NCT (Numerical Control Turret) cutting for the precise shaping of materials.
- Hydraulic Bending: After cutting, the materials move to hydraulic bending for forming into desired shapes.
- Welding: The shaped parts are then welded together to form assemblies.
- Polishing: After welding, the parts undergo polishing to smooth surfaces and edges.
- Powder Coating: The polished parts are powder-coated to add a protective and decorative finish.
- Assembly: The coated parts are assembled into final products.
- Packing: The assembled products are packed for delivery.
- Delivery: The finished products are then delivered to customers.
Outsourcing: Certain steps, such as NCT cutting, may involve outsourcing, where external quality control (IQC) is applied before materials reenter the internal process.
Quality Control:
- IPQC (Input Process Quality Control): Inspects products at various stages to ensure quality.
- FQC (Final Quality Control): Ensures the quality of the finished product before packaging.
- OQC (Outgoing Quality Control): Inspects the final products before delivery.
Warehousing: After packing, the products are stored in the warehouse before delivery.
Each stage in the process is controlled with strict quality measures to ensure that products meet the required standards.
Steel Bending Expertise
- Cold-Rolled Steel: Ideal for precision work, offering smoother surfaces and tighter tolerances. Prone to rust, it is usually treated with anti-rust oil before processing. After processing, powder coating is applied to enhance rust resistance.
- Hot-Rolled Steel: More malleable and cost-effective, suitable for larger or simpler components.Often have surface defects that can be repaired by pre-treatment.
- Stainless Steel: Corrosion-resistant and strong, often used in food processing, medical devices, and harsh environments.We have extensive experience in controlling deformation problems.
Other Materials
- Aluminum: Lightweight and corrosion-resistant, with alloys like 5052 offering excellent malleability.Cracking can be minimized through optimized processes, and aluminum sheet scratching can be reduced with protective measures.
- Brass & Copper: Known for their malleability and aesthetic appeal, often used in decorative and electrical components.
- Bronze: More brittle but used in specialty applications with careful heat treatment.
Metal bending can be performed on both thin sheets (up to 4 mm) and thicker plates (above 10 mm). The feasibility of bending a particular workpiece depends on the manufacturer’s equipment, There are two important factors: thickness and bending length, which determine how much tonnage is required for the equipment. As material thickness and bending length increase, more force is required. For example, a 200-ton press is sufficient for many tasks, such as bending a 2-meter line in 10 mm thick material or 1.5-meter line in 8mm thick material. However, some projects demand greater force. Fractory, for instance Safewell, offers metal bending services with pressing capabilities of up to 2000 tons, enabling the bending of larger or thicker components with precision.
The maxium Metal Bending Capacity: Up to 2000 tons
The maxium Metal Bending Length: Up to 9800 mm (386 inch)
The maxium Metal Bending Thickness:Up to 20 mm(0.8 inch)
The following chart can serve as a guide when choosing bending force.
Sheet metal processes are typically used to produce metal casings for various products. In the automotive industry, this includes car doors and frames, while in aerospace, it encompasses components like wings and fuselage skins. In widespread applications, we commonly encounter problems in the following process:
Common Issues in Sheet Metal：
1.Cutting
- Material Thickness Issues: Conflicts between specified thickness and annotations.
- Material Selection Issues: Incorrect or unclear material choice.
- Mismatched Hole or Opening Sizes: No specific requirements provided, and sizes do not match the company’s existing dies; some dimensions are labeled incorrectly or unprofessionally.
- Special Process Issues: For instance, no direction indicated for drawn holes.
- Unmarked Dimensions on Drawings: Missing key dimension annotations.
2.Bending
- Complex Dimensions Causing Die Marks: Complexity of dimensions may result in top die problems.
- Inconsistent Bending Dimensions: Same bending operation but different dimension requirements without clear specifications.
- Drawn Holes Hitting the Die: Holes created by the drawing process conflict with the die.
- Impact on Subsequent Processes: For example, post-bend operations like riveting screws may become impossible.
3.Welding
- Spot Welding Issues: Problems with the location, size, number, and dimensional requirements of the weld spots.
- Unclear or Missing Welding Requirements: Welding specifications are not clearly defined or entirely absent.
- Lack of Welding Requirements in Frame Assembly Drawings: Assembly drawings for frames lack welding specifications.
- Inconsistent Welding Standards: Non-standard or unclear welding annotations.
- Incorrect Surface Treatment Annotations: Errors in specifying surface treatments.
4.Assembly
- Interference Issues: Lack of consideration for interference in the design, making assembly difficult.
- Unreasonable Positioning: Misplaced positions during design, requiring manual drilling for installation.
- Insufficient Strength in Corner Pieces: Weak corner pieces that result in deformation.
- Tight Clearance in Door Panel Installation: Small installation gaps leading to tight or improper door panel fitting.
Safety You Can Rely On
