Complex sheet metal bending is a process in which sheet metal is modified when force is applied. The metal is stressed beyond its yield strength to bend at an angle and form the anticipated complex shape – usually a ‘V’ or ‘U’ shape.
Here, we take a look at exactly how this is done and consider the different types of machinery used to achieve it.
How is complex sheet metal bending done?
A press brake is a tool used in order to bend sheet metal and uses a punch and die to do it. Although press braking may seem straightforward, it can be quite difficult to remain accurate throughout the process. There are several types of press brake – including mechanical, pneumatic and hydraulic – and each one delivers a different level of force. Press brake operators handle the machines and require a detailed knowledge to bend metals.
Mechanical
This press brake’s design is steeped in the 1930s. It’s powered by a flywheel with an electric motor. The two major benefits of a mechanical press brake are speed and accuracy, but other press brakes are considered safer and easier to use (CNC press brakes, for example).
Pneumatic
Here, a compressor is used to supply air power for bending the metal sheets. This type of press brake is often used when less pressure is needed. A pneumatic press brake is also best used for bending small parts of metal.
Hydraulic
This press brake often has the latest technology incorporated within it. Best used for precise bending of metal sheet, the hydraulic press brake is usually a common choice. It operates via two or more synchronised hydraulic cylinders on the C-frames.
Computer Numerically Controlled (CNC)
This machine produces a very accurate result. CNCs are capable of bend sheet metal work from just a few millimetres across to sections that are metres long on some of the larger machines.
What are the main types of complex sheet metal bending?
This is a widely used bending method. During this process, the workpiece comes into contact with the outside edges of the die, as well as the punch tip. The punch is then forced past the top of the die into the V-shaped opening without touching the ‘V’. Air bending requires the least amount of contact. The equipment only touches the material at three points: the punch, tip and the die shoulders. Because the tonnage doesn’t produce the bend, you don’t need as much as you would do when using the coining method.What’s more, because the punch tip doesn’t need to be pushed past the surface of the metal, much less weight is required to bend in comparison to bottom bending and coining.
Bottom bending
A key difference between air bending and bottom bending is the radius. Bottom bending has many advantages, including greater accuracy and less spring back when using the tooling. This makes it a safer option when considering metal bending techniques. It differs from coining, as the punch and the tie don’t make full contact with the material, and there isn’t enough tonnage to make an imprint into the metal.
Coining
Coining is a bending process in which the punch and the workpiece bottom on the die. This produces a controlled angle, which leads to little spring back. There is more tonnage required on this type of bending than in air bending and bottom bending. There are advantages to coining – its accuracy to produce outstanding results for one. Repeating the results is also an easy task when it comes to using this technique. Spring back is less common when using coining, meaning that the metal is less likely to return to its original state.
Complex sheet metal bending involves many processes and requires skill and a detailed knowledge to operate. Find out more about Salamander’s bending and folding service or get in touch to discuss the intricacies of your project.
Despite turbulence across the sector in the first half of 2020 as businesses attempted to navigate the initial impact of COVID-19, manufacturing is arguably stronger than ever – and the UK public agrees. In the last few months, manufacturing has had to step up to play an integral role in providing for the NHS to help its keyworkers meet the pressures of the pandemic – and it hasn’t gone unnoticed.
Research commissioned by Cadence Innovation Marketing in early May 2020 found that three in four UK adults believe more strongly in the importance of UK manufacturing as a result of its response to the global crisis. In the latest of the consultancy’s Attitudes to UK Industry polls, it found that more than seven in 10 adults believe that UK manufacturing has risen to the challenge of COVID-19.
This is great news for the sector, as it prepares to head into a ‘new normal’, but what does it mean for its long-term future? We expect manufacturing will emerge from 2020 stronger than ever, and here we explain why.
The Importance of UK Manufacturing
As lockdown measures in the UK continue to ease and there’s an attempt to move towards business as usual, it comes with a stark reminder that many elements of our society might never return to what we once knew as normal. Manufacturing isn’t exempt. In the last few months, the sector has battled against and worked with every challenge thrown at it. The global supply chain has seen disruption of an unprecedented scale, assembly lines were halted or cut, many industries closed and workforces were temporarily laid off. Yet what this has shown, if we didn’t already know it, is that we’re working in a sector crucial to the survival of the UK economy. It’s now about how we use our learnings and apply them to the long-term future of manufacturing.
The pandemic impacted modern manufacturing in a way never felt before. While some have faced an uphill struggle to meet unprecedented demand, for others demand dramatically dropped and it brought pressures in other ways. In fact, manufacturing is instrumental for our prosperity and the fact it stepped up when the prime minister requested the urgent production of vital medical equipment is only testament to this. UK manufacturers have risen to challenges never seen before now.
Automation to Reduce Infection Risk
However much the sector relies on its machinery and technology, there’s a huge need to protect the people who operate them and make the decisions. Manufacturers will have to bear in mind how rules around social distancing and safety measures, alongside the nervousness and apprehension now felt by employees, will affect duties and output. As is the case across any sector, employers will have to ensure staff health and productivity, which will inevitably lead to increased use of automation.
Vital in manufacturing, automation has long-helped businesses meet huge demand – but it could now be key to the sector’s comeback. Automation and robotic technologies can limit human handling of goods – alleviating workforce fears – and may even be critical to productivity and growth as it creates opportunities for the digitally capable and could enable remote engineering support.
We recently announced we’ve joined forces with Biofresh to supply products to eradicate harmful bacteria – and we couldn’t be more excited about the partnership.
Biofresh, a market leader in room sanitation and odour removal, has had to increase its product offering. The company has led the way in chemical-free treatments for the fresh produce industry since it was established in 2003 – modifying the atmosphere in food storage facilities, preventing mould and bacteria via a safe substance called Ozone.
But the COVID-19 outbreak has seen the firm receive a real increase in requests – from all sectors – for the immediate supply of its sanitation products to help stop the virus’ spread. Biofresh reached out to us in need of immediate supply of metal boxes suitable for a range of facilities. The units would store and release high levels of Ozone safely.
We’ve helped the firm meet demand – Biofresh previously received up to 300 enquiries a year for the boxes. However, it’s now taking orders for around 250 a month and supplying to the UK, Italy and France.
Jeremy Barraclough, director of operations at Biofresh, explained: “Our focus had always been on fresh produce storage – it’s what our business was built on. But we were getting so many requests for our sanitisation products that demand for our supplies were going through the roof,” said Jeremy Barraclough, director of operations at Biofresh.
“Being based in Huddersfield, we needed a local supplier that could meet this vast interest. We required help to turn these boxes around swiftly and to a professional, high-quality standard – and that’s when we were introduced to Salamander.”
And our services for Biofresh haven’t stopped there. After the initial provision of the boxes, we also began to produce cabinets that sanitise clothes – they were distributed to 38 UK go-karting facilities to allow for frequent cleaning of helmets and overalls.
What’s next for the partnership?
It’s great news for Salamander and Biofresh’s collaboration. We’re about to supply cabinets to schools and libraries for book returns. Currently, books must be quarantined for 72 hours before they can be read again. But Biofresh’s product allows them to be safely back on the shelf within 15-30 minutes of their being returned.
Our managing director Michael Haskell said: “This is such an exciting project to be a part of and just goes to show how swift evolution – and the ability to diversify product offerings even during the toughest climates – can really help to meet current customer demand.
It’s been a whirlwind since we first started only a few months ago, but Biofresh’s forward-thinking ambitions match ours, so there is so much more to come. We’re keen to help even more premises to stop the spread of harmful bacteria.”
Summarise your role at Salamander in just one paragraph
I’m part of the sales team – I look after various customer accounts, assist with design queries, provide quotes for projects and keep our customers informed about the status of their order and the expected delivery date.
What’s your absolute favourite part of the job?
I really enjoy meeting new customers, establishing their requirements and tailoring an order to suit them. I also like the challenge of solving any problems that may arise during a project.
Share an interesting fact that we might not know about you
Everyone with the same surname as me in the whole of England, is related to me!
Which one word would your Salamander colleagues use to describe you?
Knowledgeable.
And the word you think best describes Salamander?
Progressive.
Why do you personally think Salamander stands out from its competitors?
Salamander is one of the few skilled one-stop shops around, where you can go from the initial design to powder coating the finished product – all completed under the same roof! We also offer our customers a diverse range of high-quality products.
The phone rings and it’s your dream client… who would it be?
A company that wants to utilise our robust fabrication knowledge to help develop a project, which then results in regular orders.
What’s the most personally satisfying moment in your Salamander career so far?
I managed to secure one of Salamander’s largest orders to date, within less than 12 months of joining the business.
What did you want to be when you were growing up?
Apologies for the cliché, my dream was to be a professional footballer as I was a promising young prospect!
What is the biggest challenge facing the sheet metal manufacturing industry over the next 12 months?
The global recovery from the Coronavirus pandemic and the staggered regrowth of the industry from country to country.
Its introduction to the team may have been paused following the COVID-19 outbreak but we’re excited to announce that we’ve welcomed an automated laser and integrated handling system. This latest investment (from Switzerland and Italy) will enable us to cut and process sheet metal twice as quickly as our existing machinery.
Efficient sheet metal handling
The addition of the 6Kw Bystronic laser and automated warehouse means we can switch between profiling one material to the next in under four minutes.
The whole system – for which we’ve used some of our £240,000 funding pot granted by the Leeds City Region Partnership (LEP) – sits at over 25m x 15m x 4.5m in height and can cut a variety of aluminium, steels and yellow metals. It will increase work and process reliability. And the great news is that we’re expecting it to increase our production capacity by up to 70%.
Up to three of our manufacturers will be trained on how to fully operate the integrated system and mentor others.Salamander Fabrications managing director Michael Haskell said of the investment: “It’s a big day for everyone at Salamander Fabrications as we welcome such a stunning piece of kit that will further enhance the speed in which we can react to customer requirements.”
He added: “This kind of automation not only optimises our material flow, it improves our machine use, provides us with a greater level of reliability and upskills our workforce to operate first-class machinery.”
This is the latest in a long line of investments to advance the business and upskill our workforce. We’ve already integrated collaborative robotic welding into our operations to cater for a number of substantial contracts – including one to supply components for a large rail refurbishment assignment.
Want to discuss a sheet metal project that could benefit from our new piece of kit? Get in touch today and we’ll talk through your requirements.
Advances in technology are ever-evolving the landscape of manufacturing – and particularly sheet metal fabrication. In such a fast-paced industry with increasing pressure to supply to meet demand and often within tight turnaround times, many firms are embracing automation and it’s empowering them.
Here, we consider how automation facilitates successful sheet metal fabrication, during and especially after the COVID-19 pandemic.
Driving the Industry Forward
Automation helps businesses meet huge demand. They have the capability to produce vast quantities of products all to a high-quality spec and meet within those shortened lead times. Simply, automation results in higher productivity, as it means equipment can run for longer periods of time with very little input from the workforce. Staff are freed from manually intensive jobs a smart tool can take the lead on – and can spend vital time on projects requiring the human touch instead.
Businesses – and importantly, their customers – can also benefit from lower costs where automation is implemented. Automation systems ensure the utmost efficiency – there’s little waste, minimum power and precise, controlled movements, all adding up to cheaper costs and increased profit.
Encouraging a 24/7 Service
We’re all human and we all make mistakes. Automation removes the risk for human error, increasing accuracy and repeatability as the machines are programmed to perform a task over and over again.
Meanwhile, automated systems allow management in sheet metal fabrication companies to monitor all processes at any time. This would-be tedious manual labour is left to the machines and can be managed from anywhere (senior teams don’t even have to be on the workshop floor). All this effectively leaves businesses with a round-the-clock service to offer customers, enabling them to clinch that lead spot in a saturated market.
To get a detailed account of automation within sheet metal fabrication, head over to Made in Yorkshire, where Salamander’s director David McStrafick offers his opinion.
Copper has been proven an extremely effective metal in helping prevent the spread of bacteria, viruses and fungi. Installing antimicrobial metals – copper and its alloys – for surfaces that receive high volumes of traffic or are frequently touched is a simple but effective measure that, while slightly higher in cost, could dramatically reduce infection rates.
As the world continues to feel the impact of COVID-19, we consider copper’s place in the healthcare setting, highlight its importance in the fight against infections and discuss whether public facilities may look very different in the not-too-distant future in our bid to combat the spread of germs.
Copper Kills Germs
An antimicrobial is an agent that actively destroys microorganisms and prevents their growth. Antimicrobials act against all types of microorganisms, including bacteria, viruses and fungi, such as mould and mildew. Copper has been found to have such properties and can destroy germs and eliminate bacteria and viruses. It kills microorganisms on contact and interferes with its processes so it’s extremely effective in combating infection spread.
Antimicrobial copper is the term given to copper and its alloys (like bronze and brass). Copper’s antibacterial, antiviral and antifungal properties have been drawn on since ancient times, when filings from bronze swords placed in wounds were thought to reduce chance of infection and speed up the healing process. But we are still learning about the undisputed benefits of copper.
Many establishments around the world have already taken advantage of copper’s great abilities and replaced frequently touched surfaces as an infection-control measure. But what does this mean at a time when the world is fighting against the catastrophic effects of the coronavirus pandemic?
In the US, new research published in the New England Journal of Medicine stated that SARS-CoV-2, the virus responsible for coronavirus, was infectious in aerosols for up to three hours, up to 24 hours in cardboard and up to two to three days on plastic and stainless steel. However, it found the virus could only survive on copper’s surface for up to four hours. The research begs the question of whether in years to come in the almighty push to prepare ourselves for and fight against another pandemic, we’ll see more copper touch surfaces installed, particularly in a healthcare setting.
Antimicrobial Copper vs Traditional Materials
The healthcare environment has long relied on antimicrobial silver to combat the spread of infection – and alongside this, good hand hygiene, cleaning and disinfection play a huge role in the prevention of healthcare-associated infections (HCAIs). But stainless steel does have some minor pitfalls. It can fall victim to microscopic scratches and wear and tear, leaving surfaces vulnerable to reservoirs of infection, where viruses reside and evade cleaning procedures. Copper, on the other hand, is inherently antimicrobial – it works around the clock to quickly kill pathogens that settle on its surface.
Clinical trials have taken place across the globe (including at Birmingham’s Selly Oak Hospital) and have found that antimicrobial copper surfaces hold 80% fewer pathogens than non-copper alternatives.
Weighing Up the Costs of Change
The world is likely to find itself fighting against COVID-19 for months, if not years, and if we’re to seriously reduce any likelihood of future pandemics, perhaps we should be looking to more copper-based surfaces in healthcare settings at the very least. Door handles, sinks and taps, bed rails, for example, made from antimicrobial copper will be effective in drastically reducing infection rates in hospitals and protecting public health. While copper is a more costly material, its germ-fighting qualities could prove invaluable and lessons learned in the current climate may mean for key decision makers, cost simply no longer comes into the equation.
With research ongoing and as we begin to better understand the antimicrobial properties of copper, the fight continues against microorganisms that threaten public health.
If you’d like to discuss the use of copper in the fight against COVID-19 or other aspects of sheet metal manufacturing, get in touch and we’d be happy to help.
We know our manufacturing is just as important as our people. That’s why we want you to get to know them a little better. So, next up is Reece Snow…
Summarise your role at Salamander in just one paragraph
It’s very varied considering the wide range of industries that we supply to. My role mainly consists of pricing up whatever our customer requires, utilising Salamander’s in-house machinery and skillsets. I determine the best and most cost-effective way in order to achieve what our client requires.
What’s your absolute favourite part of the job?
The varied drawings that I receive for pricing – especially when they are parts that you instantly recognise from your day-to-day life outside of work. It’s so rewarding to see something that has gone through your works and to know that you’ve aided in the manufacturing of that specific part.
Share an interesting fact about you that we might not know.
I’m a qualified scuba diver.
Which one word would your Salamander colleagues use to describe you?
Meticulous.
And the word you think best describes Salamander?
Dedicated.
Why do you personally think Salamander stands out from its competitors?
Our ability to react at a fast pace throughout the entire company. From receiving fast, accurate quotations to getting products out of the door. We work closely with our customers to keep to their timeframes.
The phone rings and it’s your dream client… who would it be?
Rolls Royce
What’s the most personally satisfying moment in your Salamander career so far?
Probably being trusted with one of our biggest spending accounts and knowing that I was being handed that responsibility.
What did you want to be when you were growing up?
A firefighter of course!
What is the biggest challenge facing the sheet metal manufacturing industry over the next 12 months?
I’d say it’s about staying ahead of the competitors in terms of machinery. We need to make sure our work is being produced with the latest technology.
We know our manufacturing is just as important as our people. That’s why we want you to get to know them a little better. We asked Trevor to answer a few questions below…
Summarise your role at Salamander in just one paragraph
My job – with the support of my team – is to make sure that our customers get their orders on time, in full, and to the standard they expect.
What’s your absolute favourite part of the job?
I really enjoy cracking a problem.
Share an interesting fact about you that we might not know
At just 15 years old I walked into an engineering company – and they gave me a job, and an apprenticeship!
Which one word would your Salamander colleagues use to describe you?
Committed.
And the words you think best describes Salamander?
Forward-thinking.
Why do you personally think Salamander stands out from its competitors?
We are not happy to stand still, and we are always exploring new technologies to streamline the business and improve efficiencies.
The phone rings and it’s your dream client… who would it be?
Difficult one to answer as I see every customer as being important.
What’s the most personally satisfying moment in your Salamander career so far?
It has to be my climb through the positions within the company, and knowing that I’m making a difference.
What did you want to be when you were growing up?
I always fancied being a landscape gardener – and I still enjoy spending time in the garden now.
What is the biggest challenge facing the sheet metal manufacturing industry over the next 12 months?
It’s the implementation of new technology and what opportunities that will present. I expect many companies in the industry to be facing the same challenges too.
Summarise your role at Salamander in just one paragraph
I guide my team to help drive the company forward. This is done by setting targets and plans, in order to maximise new business development , and nurture – and support – existing customers. We are constantly looking at new ways of staying ahead of our competitors.
What’s your absolute favourite part of the job?
I most enjoy the variation that comes with working with such a broad client base across many sectors – it’s never a dull day!
Share an interesting fact about you that we might not know
I was one of a handful of people to fly on Concorde the day it came out of service.
Which one word would your Salamander colleagues use to describe you?
Confident.
And the word you think best describes Salamander?
Family.
Why do you personally think Salamander stands out from its competitors?
The level of service can be very personal – we always aim to ensure that our communication is clear, and often.
The phone rings and it’s your dream client… who would it be?
Amazon – they have their fingers in so many pies!
What’s the most personally satisfying moment in your Salamander career so far?
Seeing the business grow on many levels, and not just concerning our turnover. I’ve seen several exciting changes in the eight years I have been here, and it’s been great to see us both flourish – financially and professionally.
What did you want to be when you were growing up?
I’ll let you know when it happens – I always fancied being a train driver!
What is the biggest challenge facing the sheet metal manufacturing industry over the next 12 months?
Staying ahead of the game. We’re in quite a saturated industry and are based in a highly competitive location. The challenge is to make sure we look after people and keep looking at new ways in which to improve – whether that’s via investing in technology or putting systems in place to give us that all-important advantage.
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