FASCINATION OF

SHEET METAL

A material of limitless possibilities

ABOUT THIS PUBLICATION

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in part or total, except where prohibited by law.

Editor Dr. Nicola Leibinger-Kammller, TRUMPF GmbH + Co. KG, Ditzingen, Germany
Author Gabriela Buchfink
Translation Matthew R. Coleman
Project coordinators Frank Neidhart, Gabriela Buchfink
Project associates Dr. Nicola Leibinger-Kammller, Dr. Klaus Parey, Ingo Schnaitmann
Layout and design Felix Schramm, Karen Neumeister (SANSHINE GmbH, Stuttgart)
Text consultant Gurmeet Rcker
Translation coordination euroscript Deutschland GmbH, Berlin
Production coordination Jeanette Blaum (SANSHINE GmbH, Stuttgart)
Printing Rsler Druck GmbH, Schorndorf
Finishing Oskar Imberger & Shne GmbH, Stuttgart
Binding Josef Spinner Grobuchbinderei GmbH, Ottersweier
Image editing Reprotechnik Herzog GmbH, Stuttgart

Publisher Vogel Buchverlag, Wrzburg

ISBN-13 978-3-8343-3071-0
ISBN-10 3-8343-3071-X

1st edition 2006

SHEET METAL
DISCOVER THE
POSSIBILITIES
S H E E T M E TA L D E S I G N I S M O R E T H A N
J U S T E N G I N E E R I N G I TS A N A R T. I T
M E A N S W O R K I N G C R E AT I V E LY W I T H I N
S T R I C T T I M E A N D C O S T R E S T R A I N T S,
WHILE FORGING AHEAD IN NEW DIRECT I O N S. P R O V E N S T R AT E G I E S A N D
S TAT E - O F-T H E - A R T C O M P U T E R T E C H NOLOGY ARE INDISPENSABLE TOOLS
FOR FINDING OPTIMUM SOLUTIONS FOR
FA B R I C AT I N G I N C R E A S I N G LY C O M P L E X
S H E E T M E TA L PA R T S.

26

SHEET METAL DISCOVER THE POSSIBILITIES

28 |

THE DAYS OF THE DRAWING BOARD ARE OVER

30 |

THE SHEET METAL PROCESS CHAIN

Putting it all together
Creating the finished product step by step
Data flow

34 |

BEFORE DESIGNING BEGINS

When to choose sheet metal
Strategies for finding new solutions

36 |

MAKING IT WORK
Creating functional designs
Creating economical designs
You designed it. Now can you produce it?

46 |

CREATIVE IN CYBERSPACE

27

The days of the drawing board are over

Designing parts on a drawing board

3D design on a computer

Simple sheet metal part

Complex sheet metal part

The end of the white coat For a long time, the word design engineer
conjured up images of a fussy, narrow-minded perfectionist dressed in
a white coat. Because of their outfit, design engineers were sometimes
called white coats. Despite their image, design engineers were the
same back then as they are today: inventive, creative minds striving to
meet a wide range of demands.

SERVING EM UP HOT WITH SHEET METAL

What can I get you? Ill have the spaghetti Bolognese. An
extra large portion of spaghetti lands with a gentle plop
on a preheated plate. The Bolognese sauce is poured over
the noodles, and the plate is placed on the table in front of
Reinhold Portscheller. The spaghetti isnt the only thing hes
happy about. Reinhold Portscheller is a design engineer at
Rieber GmbH + Co. KG in Reutlingen, Germany, and knows
just how much work went into designing the plate dispenser
cart from which his preheated plate just came. The sheet
1

metal part used for pushing up the plates used to look very
different from the way it does now.
The part holding up the plates used to be composed of

There was a time when the most important tools of a design

the way to machine programming are performed by the

seven elements with 39 bends and numerous welding spots,

engineer were parchment paper, ink pens, razor blades for

computer. Even production can be simulated with the help

recalls Portscheller. Manufacturing the part was extremely

erasing mistakes, a drawing board, and stacks of tables listing

of special design and programming software. If the software

complicated. All single parts were manufactured separately,

standardized parts. As a manufacturing material, sheet metal

detects any problems, the engineer can make the appropri-

put into temporary storage, and then joined. The spot weld-

turned out to be the crucial question. The sheet metal part

was not as flexible or versatile as it is today. For this reason,

ate changes to the part. Electronic data flow bridges the gap

ing jig alone was, in Portschellers words a real behemoth.

is now triangular in shape. We reduced seven single parts

parts were often constructed of individual prefabricated stan-

between design, programming, and production. As in the

No question about it: the sheet metal part was in dire need

to two. Also, we now only need seven bends and a few weld

dardized components.

past, design engineers work at the start of a process chain in

of some serious production streamlining. Portscheller and his

spots, says Portscheller with a smile. But thats not all the

which they play a key role. An important part of their job is to

colleagues were delegated the task of improving operation

new solution has to offer.

ensure that processes run smoothly and efficiently.

while lowering production costs. With this in mind, the de-

The last 25 years has seen a complete change in the way

design engineers work. Todays manufacturing techniques
allow sheet metal to be cut, formed, bent, or joined in almost

sign engineer turned to an out -of -company workshop.

The plate dispenser is used to hold and dispense heated plates. The plates
rest on an optimized sheet metal element.

The plates are pushed upwards much more evenly, the

part is more attractive than it used to be and our production

any way imaginable. In the past, it was common practice

This was a good decision, says Portscheller looking back.

to construct a module of many simple parts. Today, design

You had colleagues from other companies and industries all

schellers colleagues now require much less time for laser

engineers strive to use as few single parts as possible. The

sitting at the same table. We were eager to exchange infor-

cutting, bending, and spot welding than they did before. Plus,

parts themselves, however, can be extremely complex.

costs have been slashed considerably, he explains. Port-

mation, and we approached things in an open -minded way.

they no longer have to put the single parts into temporary

Instead of simply modifying aspects of the part, the workshop

storage. This saves both time and space. A success story?

peared from engineering firms long ago. Today, design engi-

participants started over from scratch. They asked them-

It sure is, confirms the design engineer and finally turns his

neers can create 3D sheet metal parts directly at the computer

selves, is this hexagonal form really necessary? Indeed, this

attention to his lunch.

Once an indispensable tool, the drawing board disap-

screen. All subsequent steps from unfolding the part all

28 |

Sheet metal discover the possibilities

29

The sheet metal process chain

PUTTING IT ALL TOGETHER

that take steps to ensure that their corporate organization

Design | Strictly speaking, the design stage does not start

with the idea for a part or module, but with the description of

From the idea to the finished part to put it in a nutshell,

and technical infrastructure are well equipped to meet this

thats what the sheet metal process chain is all about. The

challenge will be prepared, even when a rush job comes

the functions that the part or module is intended to perform.

companys goal is to manufacture high-grade parts in a way

along. If a customer calls on Monday and wants 500 steel

These functions are specified in a document known as a

that is both fast and cost effective. For this to happen, in-

angles by Thursday evening, this will only mean completing

requirements specification.

dividual stages of the process have to be coordinated as

an additional cycle and not a desperate race against time.

On the basis of the specification, the design engineer

CREATING THE FINISHED PRODUCT STEP BY STEP

on paper. Often, several people will be working together on

the engineer decides to create a part that will have round

There are several process steps that have to be completed

one job, resulting in a wide variety of designs. Design en-

punch holes, he or she will try to use only diameters that can

from placement of the order to delivery of the product. The

gineers frequently use paper models to see which design

be produced with existing tools. In production, meanwhile,

main process steps are:

will provide the optimum solution. After a design is chosen,

precisely as possible.

comes up with several initial designs and then sketches them

Coordination begins at the design stage. For example, if

speeding up the punch press does not make any sense if

a mountain of blanks is already waiting to pass through the
press brake and the programmer is still busy programming
the machine. Instead, the idea is to set up processes so that
they dovetail, or interlock into a unified whole. Companies

Design

30 |

Programming

Sheet metal discover the possibilities

Design

Programming

it is drawn using computer-aided design software. As the

design engineer models the part, the computer creates a

Production (flat processing, bending, joining)

Final processing

three-dimensional shape on the screen, while taking into

account material, tool, and machine data. Using the data,
the system checks whether the part can be manufactured.

Flat processing

Bending

Joining

Design sketch
Ideas are first drawn on paper.

Final processing

31

Common problems are:

creates on the screen is three dimensional. The sheet that

Missing tools | The part may have been designed with

oval holes but only round punching tools are available at
the time of machining.

Overlap | Material overlapping results in the flat layout

Collisions during bending | The workpiece collides

For flat processing: combination punching and laser cutting

machine with storage system

production means creating the final shape in as few steps

will be used to make the part, however, is flat. For this reason,

as possible. There are two ways of doing this. One way is

the design stage is concluded by literally unfolding the vir-

through targeted part design. For example, contours and

tual three -dimensional part. The unfolding process produces

formed sections can be designed so that they can all be

a flat sheet metal part showing how the initial sheet needs

produced using the punch press.

Another way is to use machines that combine various man-

lines are also shown. This data is then transferred to the pro-

ufacturing techniques. On combination punching and laser

gramming software.

cutting machines, for instance, it is possible to do forming

Programming | On the basis of the unfolded part, the

that can only be cut with the laser.

Bending flanges are too short | The bending line is

programmer creates NC programs for all machines used to

too close to the edge of the workpiece, causing the

process the part. NC programs tell the machines what oper-

flange to slip into the die.

ations to perform in order to produce the part. Nowadays NC

production, the sheet metal itself is still unfinished. Scratches,

Holes are too close to the bending line | Holes may

programs are no longer programmed manually. Instead, they

welding seams, and dirt are still visible on the part. The final

be so close to the bending line that they undergo defor-

are created semi -automatically, using programming software

processing stage is when the steps still required to finish the

mation during bending.

that contains precise information about the machine and tools.

part are carried out.

Final processing | When sheet metal parts come out of

The programmer selects the machining strategy, specifies

The software detects these and other problems and then

the tools, and optimizes the parameters. Then, with a simple

warns the design engineer. The final product that the engineer

click of the mouse, the programmer tells the programming

software to generate the NC program.
The programming software determines the optimum processing sequence and generates error-free NC programs. In
the past, the only way to detect errors was to perform a test
run on a sample piece. Today, programmers can be certain that
the NC code does not contain any typos or invalid command
sequences that might disrupt the program.

of data connecting everyone involved in the entire process,

Typical steps that are performed:

Cleaning up welding edges

Hardening / tempering

Coating

Marking

Painting / varnishing

As in production, the time required for final processing should

Sheet metal discover the possibilities

nothing would work. Orders are entered and created using

resource management or production planning systems. Design
engineers rely on computer-aided design software to model
the part. The data flows to the programming software, which
is used for creating the production programs. Once the job
is complete, the purchasing department may have to order
more material. The accounting department, meanwhile, prepares and sends the invoice.

be kept to a minimum. Through appropriate part design, the

The entire process can only run smoothly when everyone

is able to access and utilize the required data at the proper

welding edges can be reduced.

time. For the design engineer, for example, this means being

ways flat processing. Blanks are punched out of the sheet,

DATA FLOW

design stage. It is also possible to standardize the design

or a laser is used to cut them out. The blanks are then bent

The IT infrastructure has become a key factor determining

process to a certain degree. When this is done, the design

on a press brake. For assembled units, the final step is to

the productivity of both man and machine. Today, this is also

engineer only needs to modify existing designs to produce

join the individual sheet metal parts. Fast and cost -effective

true in sheet metal processing. Without the electronic flow

similar sheet metal parts.

through several stations. The first step in production is al-

amount of work needed for processes such as cleaning up

Production | During production, each part must pass

32 |

Thin but strong Tall power poles are able to withstand hurricanestrength winds of over 120 kilometers per hour, even though the steel
sheet used to construct the poles is only a few millimeters thick. The
reason the poles are so strong is because of their design. They have a
large number of supporting elements that make them strong.

work, while, at the same time, producing complex contours

with the machine or tool during bending.

Flat blank and bent part

to be cut or punched. Holes, formed sections, and bending

of the part.

able to access machine, technology, and tool data during the

33

Before designing begins

WHEN TO CHOOSE SHEET METAL

Device housings are typical sheet metal parts.

Lasers can even be used to cut contours on deep -drawn sheets.

Multilayer technique: multiple blanks form a complex component

Multilayer technique Solid sheet metal forms can be created by

stacking multiple layers on top of each other and joining their surfaces.
This technique is used for parts with complex internal structures. Each
layer is first processed individually. The finished parts are then placed on
top of each other and soldered together in a vacuum oven.

Sheet metal parts can be used as a substitute for:

So when does it make sense to use sheet metal parts? This is

a question that companies are often faced with. The answer?
More often than you think. Classic sheet metal parts typically

Cast parts made of molten metal, like radiators.

Milled parts made from solid metal blocks. Parts like

these include holders with numerous holes and threads.

include covers, trim, brackets, profiles, and machine components that have to be very lightweight so that they can be

moved at high speeds. In cases like these, using sheet metal

Drop forgings made of red -hot metal that is pressed

into a mold. Parts such as these include collars used

seems like the obvious choice. And, increasingly, sheet metal

in automobile transmissions to engage individual gears.

parts are also being used in areas that were previously the

Instead of forging these parts, manufacturers can weld

domain of other manufacturing methods.

together two sheet metal shells to form a hollow body.

There are two reasons for doing this. First, the manufacturing
techniques used to process sheet metal have become so precise that staying within the required tolerances is no longer

an obstacle. Second, steel has become more expensive. A

large amount of material is required to produce solid parts
from metal blocks. This, in turn, makes the parts more ex-

It is always important to consider whether a sheet metal part

job, but there are three strategies that can help. The first

pensive. To reduce costs, companies have begun to explore

should be used instead of a solid part in the following cases:

strategy is always start at the beginning. This is true even

alternatives like sheet metal.

The advantage of sheet metal is its weight, price, and the
flexibility with which it can be processed. Sheet metal parts
1

are also more quickly available. For instance, considerably

Whenever a part is developed from scratch

Whenever modifying an existing part that has previously

strategy is start with the parts function, not its present ap-

been manufactured from solid material

pearance or production method. This ensures that the final

less time is required to manufacture a sheet metal part than

34 |

Sheet metal discover the possibilities

up your mind to new and unconventional ideas. The second

design includes only those elements that are actually needed.

a cast part, for which a model and mold must be prepared

Even if a part is already made of sheet metal, it is possible to

Finally, the third strategy is two heads are better than one.

before the first part can even be produced.

reduce costs through optimization. Combining several parts

Inspiration frequently comes from other people in the team.

At the same time, the production quantity can be an im-

into a single part is usually more economical on the whole.

portant factor. For small to medium lot sizes, sheet metal is

Remember: small savings can mean big gains, especially

development of many different solutions to a single prob-

less expensive. For quantities over 100,000, however, cast

when it comes to standard parts produced in big quantities.

lem. Maybe theres a bend that can go somewhere else, or

factured more quickly. In the end, it is necessary to weigh

STRATEGIES FOR FINDING NEW SOLUTIONS

90 -degree angle that would be better as a 120-degree angle.

Sometimes a few minor changes are all that are needed. The

parts are usually more economical and can also be manu-

if the goal is to optimize an existing part. This method opens

Because of its great flexibility, sheet metal allows the

a hole that could be shaped differently. Perhaps theres a

all the factors involved on a part-by -part basis to determine

A new solution has to be innovative and more cost effective,

whether sheet metal is the more economical alternative pro-

while providing a higher level of quality. These are the require-

optimum solution usually combines an ingenious idea with

viding a solution that is of an equal or higher quality.

ments that design engineers strive to meet. It can be a difficult

thorough testing and a concrete set of rules.

35

Making it work

Design engineers are often not aware of the full range of possibilities
that sheet metal has to offer. Thats why I present a variety of examples,
tips, and tricks in various workshops. A lot of the people who take part
in the workshops are amazed to discover just how easy it is to cut and
bend a 10 -millimeter thick sheet. Others, meanwhile, are impressed by
the complexity of some of the sheet metal parts. These workshops give
people inspiration and insight that they can apply in their daily work.
Jrg Heusel, Design

engineers must have extensive knowledge of sheet metal

Distributing loads | If a strong load is applied to an

facturing times its a goal that every sheet metal processing

properties and take these properties into account when crea-

unfavorable spot or if it is concentrated on too small an area,

company strives to meet. These are also the requirements

ting the part.

the sheet metal part may become deformed. That is why

Producing functional parts while minimizing costs and manu-

that design engineers must take into consideration when

Sheet metal offers certain advantages. It weighs less

parts are designed to distribute stresses to different areas

creating a part. Using different strategies and rules of thumb

than solid metal blocks and is easy to shape. At the same

of the component. This reduces the amount of force applied

can be of great help here.

time, this means that sheet metal is not as sturdy or rigid. If

at each point. If the load is still too great, features such as

stressed improperly or subjected to excessive loads, it can

braces can be used to reinforce certain areas.

CREATING FUNCTIONAL DESIGNS

bend or buckle. Special design techniques, however, can

Every sheet metal part is designed to perform a specific task.

be used to lend greater strength and rigidity to the parts. In

For example, the part may be used to support another part or

addition to resilience, appearance can also play an important

ponents with small cross sections can bulge or buckle easily

cover machine components, or it may have to move at very

role. The surfaces of external parts like covers and paneling

when subjected to pressure. This is because the force and

high speeds. Creating functional designs means designing

have to be flawless. Here, too, design engineers have a few

counteracting force collide within the metal. The same com-

the part so that it is able to fulfill its task. To do this, design

tricks they can use.

Using tension instead of compression | Long com-

ponents, however, remain stable when subjected to tensile

force. This is due to better distribution of forces. For this
reason, components are designed so that parts with small
cross sections are stretched instead of being compressed.

As great force concentrated on a single spot causes the sheet to deform,

it needs to be distributed. Energy absorbing areas are reinforced.

Different thicknesses | The thicker the sheet, the greater

the load it can withstand without becoming deformed. Put
simply, if you need more stability, use a thicker sheet. Greater
sheet thickness, however, also means more weight. Large
parts often need to be lightweight and are only stressed in
a few spots. That is why thicker material is used only and
exactly at the stressed points.
In large -scale production, tailored blanks can be used.
Tailored blanks are made up of different pieces of sheet metal
that are welded together into a single sheet. This means
thick and expensive materials are used only in areas where
they are needed most.
For small and medium -sized quantities, making tailored
blanks is not a cost-effective solution. Here, another approach
is used. In areas where the part needs to be thicker, another
Making it all work: design engineers have to meet a wide range of demands.

36 |

Sheet metal discover the possibilities

sheet is simply welded on to it.

If pressure is applied to a long component, it may buckle. The component

fares much better, however, when subjected to tension.

37

Corrugations make cans stronger.

Folds are used to reinforce ducts.

You know youve achieved perfection, not when you have nothing more
to add, but when you have nothing more to take away.
Antoine de Saint-Exupry

Formed sections for added stability | Forming is the

store. Parts with large surfaces such as ventilation or heat-

Closing of cross sections | Closed sheet metal struc-

most common method of making sheet metal more stable. On

ing ducts can be made more stable by adding intersecting

tures are much sturdier than open ones. This is especially

tin cans, for example, corrugated areas or beading around the

creases. When this is done, the walls of the ducts resist bulg-

true of parts that are subjected to torsion, or twisting. For

can make it sturdier. These corrugations can have different

ing and, at the same time, are less susceptible to vibrations.

this reason, box-shaped forms should be closed wherever

possible, for example, by welding together the edges.

configurations or spacing and are used on other products as

A greater degree of stability can also be attained by forming

well not just tin cans. You can spot corrugations on cars or

the edge of the sheet metal part. Oftentimes, simply bending

on the brackets holding up a row of shelves at the hardware

or folding over the edge is all that is needed.

Tension

Forces act in opposite directions, stretching the part.

Composite structures | Ribs, rods, braces and reinforcement plates can also be used to add stability to parts made
of thin sheet metal. Corner or center plates are frequently
used on open box structures made of profiles (tubes having a

Pressure Forces converge on a single area, compressing the part.

variety of cross sections) like those used to construct stands

at exhibitions or trade shows. Evenly spaced ribs are used to
reinforce large -volume parts.

Joining from the inside | On sheet metal parts requiring

a flawless appearance, processing marks must not be visible.
On parts like these, visible edges that are welded from the
outside can prove to be problematic. To avoid having to polish

Torsion

Forces pass in different directions, causing the part to twist.

them by hand, special joining methods are used to create a

clean seam. Such methods include TIG welding for stainless
steel or laser welding. Another alternative is to weld the edges
from the inside. Here, the edges of the sheet are bent over
1

so that the welding seam is on the inside.

Bending Forces act in the same direction, causing the part to bend.

Edge variations
Edges can be made more robust by bending or folding them over or joining the edges at the corner.

38 |

Sheet metal discover the possibilities

Corner or center plates can be used to reinforce open box structures.

39

If it isnt there, it doesnt cost anything. This applies, above all, to sheet
thicknesses and the number of single parts that make up a component.
Lutz Hartmann, Design

CREATING ECONOMICAL DESIGNS

includes the sheet skeleton remaining between the parts

Minimize the number of single parts | As a general

The maximum allowable cost of a sheet metal part is deter-

and the cutouts that are produced when holes are cut in the

rule, it is better if components comprise a small number of

mined before work begins on designing the part. Naturally,

workpiece. Design engineers can fit more parts on the sheet

complex parts than a large number of simple parts. This is

the more economical the part is, the better. There are two

by designing the parts so that they nest inside each other.

because joining processes are usually very time consuming.

ways of achieving this. You can either save on material or cut

Depending on the design, it may be possible to fit smaller

Todays manufacturing techniques and programming software

costs in production. Economical, however, is not the same

parts inside some of the larger cutouts. Enlarging a notch

make it easy to produce even complex single parts.

as cheap. The goal is to combine the various production

on the outside contour may also allow parts to be nested

factors the type of material, material consumption, time,

closer together. Parts with straight contours can be placed

Why weld when you can bend? | Welding not only takes

machines, and tools in the best way possible.

right next to each other and separated with a single cut. This

up valuable time, but also generates heat that could poten-

helps to reduce scrap.

tially warp the workpiece. For this reason, it is always a good

Production factors influence each other. One change can

oftentimes have a positive effect on a number of different

The benefits of these methods are particularly apparent

idea to check whether an attached part can be substituted

areas. For example, a reduction in the number of single parts

when manufacturing parts in large quantities or producing

by simply bending another section. This eliminates the need

used to create a module not only saves material, but also

sets of parts for use as components in sheet metal modules.

for welding along with all the associated prep work such as

reduces production time. The following methods have proven

The visible edges of this cover are welded together using a laser.
The welding seams are clean and smooth, eliminating the need for
extra cleanup work.

setting up, aligning, and clamping the parts.

to be successful in creating economical designs:

One part, many functions | In many cases, the sheet

metal part can be designed to fulfill two or more functions.

Minimize cleanup | Cleanup work can be reduced by

Minimize sheet thickness | Save material by select-

Often, these parts only need some additional holes or larger

eliminating welding seams entirely, by welding sections from

ing the smallest sheet thickness possible. This means lower

recesses in order to perform a different task. Advantages:

the inside, or by designing edges so that they are straight

material costs, reduced part weight, and faster production.

larger quantities can be produced and only one storage loca-

and smooth after welding. New manufacturing techniques

tion is needed.

such as laser welding also help to reduce cleanup work.

Using design to reduce scrap: designing parts so that they nest closer
to one another is a way to maximize sheet utilization.

Alternatives to welding: flanges can be bent and side elements can be secured in place using pegs that fit into holes.

Use the same sheet thickness | Wherever possible, the

single parts making up a component should all have the same
sheet thickness, so that they can be produced from a single
sheet in one work cycle. When this is done, an entire sheet
can be used for flat processing instead of portions of several
different sheets. This is especially important for small sheet
metal fabricators who handle each job individually. It not only
makes purchasing and storage easier, but also cuts down on
transport between the storage bay and the machine. Also, it
takes less time to set up the machine.

Maximize nesting potential | Everything left over after

the parts are punched or cut out of the sheet is scrap. This

40 |

Sheet metal discover the possibilities

41

Housing with different ventilation openings

Microjoints: thin support pieces keep punched parts from falling

out of the sheet skeleton.

YOU DESIGNED IT. NOW CAN YOU PRODUCE IT?

same time, there are certain joining techniques that reduce

When designing a part, design engineers not only have to

the amount of prep work involved in processes such as weld-

keep in mind the function and cost of the part, but also how

ing. Instead of using a device to position multiple parts and

it is going to be manufactured. Here, there are a number of

secure them in place, you start by fitting the matching parts

different strategies that engineers can rely on.

together. Now all that is needed is a simple welding jig to hold

the parts securely in place.

Allow extra space for bending zones | When a sheet

Microjoints | The idea of using microjoints was a solution

is bent, the metal on the inside of the bend is compressed.

Certain areas can be notched in order to obtain better corners.

This causes the material at both ends of the bend to be

pushed outward, which, in turn, may lead to inaccuracies.

initially developed for laser cutting. Microjoints are narrow

tabs located between the workpiece and the sheet. They

To prevent this from happening, small recesses are designed

There are a number of ways to create extra space for bend-

hold the workpiece in the sheet and keep it from becoming

into the ends of the bending zones so as to provide extra

ing zones. A punch press can be used to punch round holes

displaced. After the sheet has been processed, the parts are

at both ends of the bending line. Or a laser can be used

snapped out of the sheet by hand.

space for deformation.

Extra space is frequently provided for bending zones,

to cut fillets, which are more complex. This makes corners

regardless of whether two edges meet at a corner or whether

There are other ways that microjoints can be used. For

more attractive after the parts are bent.

example, they can serve as production aids in the manufacture

Use existing tools | Especially when it comes to small

They are bent together and then separated by hand. Another

a flange is bent upwards. This produces much better cor-

of small angles. The blanks remain connected by microjoints.

ners, while permitting greater freedom in the selection and

arrangement of bending tools.

and medium-sized quantities, acquiring new tools is not a

example is creating bends in parts where accuracy is not

worthwhile investment for a company. In most cases, it is

crucial. Microjoints are placed along the bending line, making

Everything on the punch press | When solid parts are

not even necessary. For many shapes and functions, there is

it possible to bend the parts by hand.

substituted by sheet metal parts, these parts often still require

more than one alternative. It is the design engineers job to

machining of some kind. Holes still have to be drilled, and

find the alternatives that make do with existing tools.

threads have to be cut. The most cost -effective solutions,

A good example is the ventilation holes on a PC housing. A

however, do not require any cutting at all. This can be done,

punch press that permits tool rotation can be used to arrange

for example, by using the punch press to form threads instead

simple oblong holes in a radial pattern. An alternative would

of cutting them.

be to arrange small squares in rows or use a louver tool to

Life after production | The true life of a sheet metal

produce ventilation slots.

part actually begins after production. For this reason, it is

Use positioning and joining aids | Where was the part

important for design engineers to take into account aspects

supposed to go again? Was it on the left or the right? Ques-

such as transportation, storage, assembly and disassembly.

tions like these can be avoided by designing the parts so

For example, parts that are transported and stored in large

that there is only one way to put them together. This is done
1

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Sheet metal discover the possibilities

by using matching holes and pegs to assemble parts. At the

numbers should be designed so that they can be stacked on

Joining made easy: there is only one way of joining the parts together.

top of each other to save space.

43

Virtual manufacturing: the movement of the laser cutting head

is simulated on a computer.

FIVE WAYS TO PRODUCE AN ANGLE

Design is an art. Designers not only have to know plenty of
good tricks, but also when to use them. Sheet metal is so versatile and the parts are often so complex that engineers may
not immediately recognize all the possibilities. Jrg Heusel,
design engineer and instructor at TRUMPF Werkzeugmaschi-

nen GmbH + Co. KG in Ditzingen, knows just how challenging

this can be. He conducts workshops in which participants

Production simulations | Many types of design and

search for new solutions for their existing parts. The people

programming software enable users to simulate production.

in my workshops frequently ask me to demonstrate the many

This allows design engineers to test sheet metal parts as

possibilities available using only a simple example, says Jrg

often as necessary to identify problems. Today, computer

Heusel. His response is to show them five ways to produce

simulation has become an indispensable pre-production tool,

an angle. Angles are always positioned in areas where two

particularly for the manufacture of complex parts.

surfaces meet. They hold the surfaces in place and help sup-

Angle with welded cross

brace for reinforcement

The cross brace has tabs

that help to join parts.

One -piece design: sides

instead of cross brace.

Three bends are used to

produce a center brace.

One bend only: cross beading instead of cross brace

The use of simulations ensures that workers in production

port them when they are stressed. If the angle is subjected to

no longer have to stand next to the machine for hours trying

extreme loads, it may need to be reinforced. There are many

Method 3 | One part only Two parts generally mean more

position. Here, too, a tab is used to fit the brace to the angle.

to figure out the optimum production sequence for a sample

different ways of doing this.

work than one part, because they are often produced sepa-

This results in a single part that requires only three bends.

rately and then put into temporary storage. So lets try using

Now, all thats left to do is to weld the brace at one single

point.

piece. Company directors will also be pleased to see that

the machine is being used to produce something instead of

Method 1 | Using cross braces The first way to make

one part instead of two. Two supports on the sides of the

completing endless test runs.

angles sturdier is to weld a cross brace down the middle of

angle now replace the cross brace. As before, these sides

Method 5 | Dont forget what the parts made for Lets

the angle. What this means for production: two parts have

are also designed with joining aids that facilitate welding.

Knowledge transfer | Design engineers who have exten-

to be punched or cut with a laser; the angle is bent; and the

The angle is punched or laser cut and then bent three times.

look back for a moment at the function of the angle. It has

sive experience in the field are able to rely on their expertise

cross brace is positioned and welded to the angle, producing

The sides are then welded. Although we have not significantly

to be sturdy and be able to support a load. Wait, does the

to tackle each new task. Working together with colleagues

two seams. Not bad, but how can we find a better solution?

reduced the amount of work required to produce the angle,

angle even need a cross brace? Or would a simple, well-

in production, they have gained knowledge of the attainable

tolerances and learned which hole spacings, edge formats,

we now have a part that is very robust.

Method 2 | Using joining aids This method is aimed at

placed corrugation do the trick? If cross beading is enough,

you could consider first punching or cutting the rectangular

side lengths, and bending radii work and which ones dont.

reducing the amount of positioning and welding work. The

Method 4 | The answer is just around the corner So what

parts from the sheet. Afterwards, the edge and corrugation

To ensure that this knowledge can be used by others, it has

cross brace has two tabs, and the angle has two rectangular

do you do if the brace absolutely has to be positioned down

can be produced in a single bending process. This approach

to be documented. Ideally, this is done using the design

slots. The tabs are inserted into the slots, and the joint is

the middle of the angle? The solution is easier than you might

not only minimizes production time, but also makes it possible

software, which helps to integrate individual experience and

welded from the outside at two points.

think. This time, two bends are made to bring the brace into

to stack and store parts to save space.

safeguard company standards.

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Sheet metal discover the possibilities

45

Creative in cyberspace

1, 2

The changing nature of the job | The job of a design

Virtual space | A number of companies are already using

engineer is constantly changing. Each new material, tool, and

virtual space to present and elaborate their product models.

manufacturing technique adds to the ever-growing array of

Multiple projectors are used to display the image of a part

design possibilities for sheet metal parts. At the same time,

on several screens at the same time. People in the room

new design software and virtual modeling methods are

wear special glasses that combine the different images into

changing the way design engineers work. Even so, it usually

a three-dimensional model, just like in a 3D movie. People

takes years before new technology becomes known among

in the automotive industry have found a way to project an

professionals in the field and is then applied.

entire vehicle interior around a simulated drivers seat. The

Many companies feel that the engineering design programs

Still in the design stage and yet incredibly real: developers discuss
their designs in virtual space.

Virtual space or cave Complex computer and projection technology

make it possible: multiple projectors are used to display the image of
a part on several different screens. The people in the cave wear special
glasses that combine the images on the various screens into a single
three -dimensional image. Cameras, meanwhile, are used to monitor the
position of the observer. If the observer moves, the image changes accordingly. This allows the observer to examine the part from different angles:
from above, from below even from the inside!

virtual interior makes it possible to see how well the different

offered by various schools do not give enough attention to

elements of the design fit together or whether the steering

sheet metal design. To fill the gap, an effort has been made

wheel is properly positioned. The simulation makes it easy to

to provide workshops and special training courses.

move any elements that dont fit.

Mechanical engineers can also use virtual space to present
components or entire machines. This allows them to discuss
the models with other departments.
As the technology becomes easier to use and the costs
become lower, use of virtual space will continue to grow.
Even so, computer-aided design software will remain crucial
for the design of the part. This is because most of the work
involved in designing a part is actually drawing it.

Automated design? | Computer technology has come a

long way, and is still advancing every day. Nevertheless, computer software is no substitute for human creativity. Design
software will remain a tool that design engineers use to make
modeling easier, while enhancing the precision and efficiency
of their work.
At the same time, the data interfaces between the resource
management system, computer-aided design software and
programming software continue to undergo optimization. The
goal and essence of the design process, however, remains
the same: creative, intelligent people working to find innova1

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Sheet metal discover the possibilities

tive solutions.

47