Automated Sheet Metal Processing: How To Pick The Right Technology

This article highlights automation options in sheet metal processing and compares different production setups to different technologies. Furthermore, it points out important things to look for when automating sheet metal processes.

Sheet metal processing refers to various operations performed on metal sheets. Some of the more commonly known are:

• Pressing or Bending

• Stamping or Punching

• Cutting

These processes are often marked by repetitive work in high volumes. This calls for the use of robots and automated processes. Different options are possible depending on which types of processes and products the company is working with. It is crucial to consider the product in alliance with integrators and experts. Based on the material and process, they could help you decide what kind of technology to go for.

Possibilities based on volume and variation

Automation solutions in the sheet metal industry depend on the product mix. In general, volume and variation have a high influence on what makes a good solution for the company.

For large volumes with little variation, the setup is often automated production lines or cells. This is done with special purposed machinery with integrated loading and unloading to ensure no human interaction. Operators are not able to work in the same space as automated machinery and are removed from the processing tasks. They are reassigned to monitoring and certifying the quality.

Mass production gives benefits such as high throughput rate and low takt times. Among the disadvantages are the high initial investment, low flexibility and high setup- and changeover times.

With medium volume and variation, changeover times, tool changes and positioning need to be considered. With a varying mix of products, it is possible to have multi-purposed machinery that can handle different products types. To further increase productivity, one could look into automated loading and unloading of products, done for example by an articulated robot.

Low volume with high variation production has other benefits than mass production. Flexibility, faster time-to-market and customization. The volumes might not be big enough for automated productions lines to be favourable. Therefore, it might be a better solution to keep for instance loading and unloading manual.

Sheet metal processes can be fully automated

As an example of a fully automated cell, you could have a cutting table and a bending press unit. These could be arranged around an articulated robot in the middle that moves metal sheets from process to process. It is important to have tooling which can handle the metal sheets, for example suctions cups or magnets, and that these do not damage the metal or leave marks.

Make sure parts can be moved both into the cell and out to a stock by rollers, a rail or another articulated robot. Such a solution could, if properly built, run 24 hours without human interaction.

A setup like this would require competent programming and consulting from experts to align the machines. It is important that the robot is suited to the task, both in terms of reach and payload depending on the dimensions and the weight of the metal sheets. This will cost time and money, but once it is set up there will be benefits in terms of increased quality, accuracy, precision and throughput.

These benefits only come into force if the produced parts are of high volume and low variety. If not, too much capital is used to handle the many changeovers required, and the advantages of the automated cell would therefore be lost.

With the proper product mix, there will be benefits. Workers normally doing the transferring, bending and transportation of the sheets could be released from the cell. This enables them to work in other areas where creativity and critical thinking is needed.

When and why to go for automated sheet metal processing

Going into robotic processing requires a high initial investment compared to manual work. Despite this, it might be beneficial for SMEs (Small-Medium sized Enterprises) who have grown and need additional capacity to keep up with the increasing demands.

It could be a SME who considers expanding by starting to do metal sheet processing in-house instead of buying the components from suppliers. By producing in-house, you get more control over your quality. This is desirable if, for example, your products need a high-quality finish without too many scratches or rough edges. Naturally, switching to in-house processing requires some capital for investment. One must make out the business case beforehand.

Therefore, you should make sure the right machines are purchased for the right purpose. Make sure the robot has the required specifications to handle the big sheets of metal. For instance, some crucial parameters of articulated robots are the payload and reach of the robots. This is important in feeding and unloading processes where products must not be too heavy for the lifting robots.

When looking into sheet metal processing, always consider the trade-off between volume and variation. Does your product mix allow for the benefits of mass production despite the high initial investment? Or do you need more flexibility to handle different products on your production lines?

How To Find The Right Robot Solution

HowToRobot is a global platform connecting end-users with robot and automation suppliers worldwide. We have the world’s largest directory of robotics companies. Using our guide, you can find the type of robot you need, ideally suited for your application.

You can get tailored solution proposals from various suppliers. Simply describe your project and start receiving answers.

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Please note that impartial HowToRobot experts can help you navigate through the process. Click here to set up a consultation with an expert advisor.

Metal processing equipment encompasses a wide range of machinery used in the manufacturing and fabrication of metal products. This article will delve into various types of metal processing equipment, including blanking lines, rolling mills, tube mills, levelers, pickle lines, slitting lines, cut-to-length lines, presses, edging lines, pipe straighteners, and more.

• Blanking Lines: Blanking lines are used to cut flat metal sheets into specific shapes or blanks. These lines typically consist of a decoiler for unwinding the metal coil, a straightener to flatten the material, a feeder to position the metal accurately, and a blanking press to cut the desired shapes. Blanking lines are commonly used in industries such as automotive, appliance manufacturing, and metal stamping.
• Rolling Mills: Rolling mills are essential equipment in metal processing for shaping and reducing the thickness of metal sheets or strips. These mills consist of a series of rollers that exert pressure on the metal, causing it to pass through and undergo plastic deformation. Rolling mills are used in the production of various metal products, including sheets, plates, bars, and rails.
• Tube Mills: Tube mills, also known as pipe mills, are used to produce seamless or welded metal tubes or pipes. These mills use a series of rollers to gradually shape the metal strip into a tubular form. The edges are then welded together to create a continuous tube. Tube mills are widely employed in industries such as construction, automotive, and oil and gas for the production of pipes and tubes of various sizes and shapes.
• Levelers: Levelers are machines used to flatten and level metal sheets or coils. They consist of a set of rollers or leveling heads that apply pressure to the metal to remove any curvature or irregularities. Levelers are commonly used in metal fabrication processes where flat and even surfaces are required, such as in the manufacturing of automotive body panels, appliances, and metal furniture.
• Pickle Lines: Pickle lines are used for surface treatment and cleaning of metal coils before further processing. The metal coils are passed through a series of tanks containing acidic solutions, such as sulfuric acid, to remove scales, rust, and other impurities. Pickle lines play a crucial role in preparing the metal surface for subsequent processes like rolling, coating, and painting.
• Slitting Lines: Slitting lines are used to slit wide metal coils into narrower strips of specific widths. These lines consist of a decoiler, a slitter head with circular knives or blades, and a recoiler to wind the slit strips into individual coils. Slitting lines are commonly used in industries like steel service centers, metal stamping, and packaging for the production of narrow strips used in various applications.
• Cut-to-Length Lines: Cut-to-length lines are used to cut metal coils into precise lengths or sheets. These lines typically consist of a decoiler, a straightener or leveler to flatten the metal, a measuring system to determine the desired length, and a flying shear to cut the material. Cut-to-length lines are widely used in industries like construction, roofing, and fabrication for producing metal sheets of specific dimensions.
• Presses: Presses are versatile machines used in metal processing for a wide range of operations, including punching, stamping, forming, and bending. These machines use mechanical or hydraulic force to shape the metal into desired configurations. Presses come in various types, such as mechanical presses, hydraulic presses, and servo-driven presses, and are widely used in industries like automotive, appliance manufacturing, and metal fabrication.
• Edging Lines: Edging lines are used to trim the edges of metal coils or strips to achieve precise widths and remove any irregularities. These lines typically consist of a decoiler, a leveler or straightener, and an edging unit with circular knives. Edging lines are commonly used in industries like steel service centers, where tight tolerances and accurate strip widths are required.
• Pipe Straighteners: Pipe straighteners are used to straighten metal pipes or tubes that have become bent or deformed during the manufacturing or handling process. These machines apply controlled pressure and bending forces to restore the pipes to their original straight shape. Pipe straighteners are commonly used in industries like oil and gas, construction, and automotive for ensuring the quality and integrity of metal pipes.

These are just a few examples of the diverse range of metal processing equipment available in the industry. Each type of equipment serves specific purposes and plays a vital role in shaping, cutting, forming, and finishing metal materials. By employing the appropriate equipment for specific metal processing requirements, manufacturers can achieve high-quality products with precise dimensions and desired characteristics.