All sorts of metals can be formed into sheets. Steel, aluminium, brass, nickel, titanium and copper are types of sheet metal that manufacturers produce for industry on a daily basis. In addition, precious metals like gold, platinum and silver are made into sheets for the jewellery making industry. The sheet form of metal is delivered in thin sections that are ready to be turned into a wide range of products and components. In order to be further processed, sheet metal is often formed. There are a number of industrial forming processes to choose between. What are the common ones?
Bending
This is perhaps the most commonly utilised forming process of all. A great deal of physics goes into establishing how much force is needed to bend a section of sheet metal to just the right degree of angle without weakening the material.
Curling
When metal is curled, its edge is bent back on itself. The forming process of curling is often used to remove the leading edge of a section of sheet metal so that it does not present a sharp, blade-like surface. Curling is usually done with a die which forces the metal through 180 degrees.
Expanding
Expanding is a forming process where cutting or stamping slits are made in sheet metal sections. This is often done in an alternating pattern or in zigzags. After the slits have been formed, the metal can then be stretched out, with the size of the slits consequently expanding. A sheet of metal can, therefore, be turned into a type of mesh with a concertina-like appearance. The holes allow light and air to flow through.
Hydroforming
This manufacturing process forms sheet metal by forcing it over a stationary die. The force required to form the metal is generated by hydrostatic pressure rather than by hydraulics. Hydroforming usually means being able to form an entire sheet of metal in a single step.
Ironing
Used to make things like beer cans from a single sheet of aluminium, ironing is a forming process that makes the metal thinner in a very specific area, usually by stretching it over a mould. This approach produces a uniform thickness throughout the metal being worked on.
Spinning
A forming process that makes casings for the aeronautical industry as well as things like satellite dishes and metal funnels, spinning makes all manner of tubular components from sheet metal. Rollers process the metal, which is spun on a mandrel as it is formed.
