Metal Fabrication

Understanding your needs

The chapter and learning of metal removal, metal cutting, and machine tools is one of the fascinating experiences. Machining of different types, composition and grade of material is invented and adopted to get the required geometrical sizes and shapes, to get higher surface finish and to achieve the finish product within required tolerances.

Manufacturing technology is going through major technological revolutions because of the continuous development. After the introduction of computers and microprocessors, development of Numeric Control has completely changed the machine tool scenario by bringing in the flexibility which was not possible earlier through the conventional mechanisms.

Evercon adopted the different manufacturing processes and brought them all into one roof to deliver the turnkey service and solution to its client.

Evercon uses different cutting processes and tools, like laser cutting, plasma cutting, and bandsaw cutting according to the material, grade and tolerance requirement and perform the job to the optimized solution to generate minimum scrap and rejections.

Among all manufacturing processes available, metal removal is one of the most expensive one because of the raw material, quite a substantial amount of material is removed in the form of chips in order to achieve the required shape.

Evercon uses the CNC operated Milling machine to complete the material removal process and bring the required shape with mentioned tolerances and with proper surface finish for further processing.

Bending is also a very universal process which is required in almost every turnkey metal fabrication process and for the same, Evercon uses the Sheet Bend and Tube Bend machine to achieve the process and complete the angular bending for the production.

Sheet Metal Fabrication

Sheet Metal Fabrication is a widely used operation especially for automotives and machine manufacturing. It comprises:

Cutting Operation

Bending Operation

Drawing Operation

Forming Operation

Sheet metal fabrication includes metal sheet and tube cutting process by conventional and unconventional machines, sheet and tube bending process by bending machines, metal drawing and metal forming processes.

Evercon majorly adopted the cutting and bending process because these processes are required for almost every product manufacturing. Evercon can also produce products that require drawing or forming processes.

Evercon uses unconventional laser cutting machine for sheet (0.5mm – up to ≥6mm thickness) and plate (<6mm – up to 20mm thickness) to achieve the finish and lesser lead time of completing the operation within customer time frames.

Evercon uses bend machines for 90° and 45° angle requirements to metal sheets and tubes.

CNC Laser Cutting Machine

Laser cutting is one of the faster and higher quality finishes compared to other cutting methodologies like Plasma, Waterjet, Punch, Ultrasonic, Oxyflame. It is completely automated with CNC operated and generally does not need to clamp the work piece.

Tool wear is zero as the operation is a non-contact process and noise level is very low. It includes very minimum tool changing segment and almost every type of material can be cut irrespective of hardness, ductile or brittle.

A very narrow Heat Affected Zone (HAZ) can be formed and very thin re-solidified layer of µm, particularly on dross free cuts and there is negligible distortion.

Evercon uses the CNC laser cutting machine and the additional point of our machine is –

Comparison of Different Cutting Processes

QUALITY

Rate

Edge Quality

Distortion

Noise

Metal + Nonmetal

Complex shapes

Part Nesting

Multiple Layers

High Volume

Flexibility

Tool Wear

Automation

HAZ

Laser

✓

–

✓

Punch

✓

–

✘

–

✘

✓

✘

✓

Plasma

✓

✘

–

✓

✘

Fluid Jet

✘

✓

✘

✓

–

✓

–

✓

Wire EDM

✘

✓

–

✘

–

✘

✓

Sawing

–

✘

–

✘

–

Ultrasonic

✘

✓

–

✓

–

Oxy Flame

✘

–

✓

✘

Plasma Cutting Machine

Plasma is a conductive gas that induces electricity as the ionization of gas causes the formation of free electrons and positive ions among the gas atoms. When this occurs, the gas becomes electrically conductive with current carrying capability and becomes plasma.

The plasma cutting principle is the arc generated between the electrode and the work piece is constricted through a bore nozzle and the phenomenon increases the temperature and velocity of plasma spread out from the nozzle.

The plasma arc temperature is more than 20,000°C and the velocity can approach the speed of sound. During cutting, the plasma gas flow is very high and forms a deeply penetrating high temperature plasma jet there by cutting through the material.

The force of the arc blows away any molten material in the form of dross.

The plasma process operates by using the high temperature arc to melt the metal. The plasma process can therefore be used to cut metals including cutting metals which form refractory oxides such as stainless steel, aluminum, cast iron and non-ferrous alloys. The cut quality is dependent on many parameters, but the system is easy to use and often is the only practical or cost-effective solution.

Evercon uses P.A.M to cut the plates wherever the cost-effective solution required in the projects and feasibility include the quality and within tolerances.

Bandsaw Cutting

A sawing machine is a machine tool designed to cut off bar stock, tubing, pipe, or any metal stock within its capacity, or to cut sheet stock to desired contours. The sawing machine functions by bringing a saw blade containing cutting teeth in contact with the workpiece to be cut and drawing the cutting teeth through the workpiece. The sawing machine is much faster and easier than hand sawing and is used principally to produce an accurate square or mitered cut on rectangular or cylindrical material.

Evercon buys the standard stock raw material from supplier, i.e., 2.4m X 1.2m sheet and plates, 4m/6m/12m long tubes and according to production requirement, cut sizes have been made with the help of Bandsaw machines wherever possible.

Metal Sheet Bending

Bending process in sheet metal has been extensively used in manufacturing especially in Automotives and machinery manufacturing as it is one of the operations to change the shape of the sheet as per the requirement and geometry.

This is the most common metal sheet forming process produces a V shaped shape along the axis of a material by applying force to a metal sheet causing it to bend into the desired shape. This is done with ductile materials. Such materials are used in brake presses, pan brakes and specialized machine processes. Wipe bending needs the sheet to be held against the die by using a pressure pad, causing the sheet to bend against the radius of the edge.

Two main quality considerations when doing the sheet metal bending process –

Formability

Dimension

Consistency is also necessary as it is minimizing the variations in dimensions which is an essential requirement within the manufacturing space particularly with the focus on bending operation are analyzed.