Techniques for How to Work Sheet Metal

Various forming techniques are used to create objects from sheet metal.

Techniques for working sheet metal range from simple and manual to complex and mechanized. Creative and practical applications for metal forming are varied and numerous. They involve creating metal objects and customizing existing metal items such as auto bodies, motorcycles and ductwork. With hundreds of metals and metal alloys to use, as well as a wide range of metalworking processes, those who work with sheet metal have a huge selection with which to work.

Techniques

Numerous techniques for working with sheet metal require tools and equipment. Hammer forming is the process of forming metal over or into "plugs," wooden forms in the shape of the item to be created from metal. Metal is shaped over or into a form with an air hammer or a planishing hammer, a tool that has a hammer and anvil and is very noisy. Cutting metal into shapes or specific sizes is done with a foot shear machine or metal shears. Bending is the process of forming metal by bending it into curved or angled shapes, with single bends or compound bends. Metal shrinking is accomplished by either dimpling the metal or heating a section with a torch to contract it. Stamping is the process of pushing text, logos, forms and graphics into metal to create specific visuals and convey specific information, such as trademarked patterns or designs. Punching is the process of pushing parts or whole objects out of metal, usually with mechanized machinery. Welding and riveting are processes for joining metal pieces together.

Metalworking Tools

Working with sheet metal involves a variety of tools, including the air hammer, planishing hammer, metal shears, calipers, cutting torches, files, pliers, hacksaws, dollies and mallets. Metalworking tools have various functions but all hold, shape or manipulate the metal during the process of creating a new object from it.

Metalworking Equipment

Many techniques for working with sheet metal include using machinery and equipment. A CNC (computer numerical control) router prepares three-dimensional plans for metal workers to follow to create forms to shape metal over or into. Foot shears allow operators to cut metal sheets into different sizes and shapes for forming. Press brakes are adjustable bench devices used to bend large sheets of metal to form square and rectangular shapes. Milling machines allow complex forming operations with mechanized cutters and drills. Lathes are machines with turning and grinding parts for forming shapes. Grinding machines smooth rough and sharp edges and remove bits of metal for finishing. Welders, including gas-flame welders, electric-arc welders, laser welders and electron-beam welders, cut through metal more quickly and easily than manual cutters such as shears and snips.

Training and Education

Training on sheet-metal techniques includes learning on-the-job, formal union apprenticeships, vocational training programs and two- and four-year-degree programs in construction or related industries. The field of heating, ventilation and air conditioning requires some knowledge of sheet-metal forming, from beginner to advanced and expert level, for heating and air ductwork.

References

• "Machinery's Handbook Toolbox Edition"; Erik Oberg et al.; 2008
• "Sheet Metal Fabrication: Techniques and Tips for Beginners and Pros"; Eddie Paul; 2008
• "Turning Tools and Operations"; George Schneider; 2010
• United States Department of Labor Bureau of Labor Statistics; Occupational Outlook Handbook, 2010-11 Edition, Sheet Metal Workers
• Popular Mechanics; How to Work With Sheet Metal; Stuart Deutsch; July 2010