Rapid Sheet Metal Design Guide
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Rapid Sheet Metal Overview ............................................................................................................ 3 Capabilities ......................................................................................................... 4 Certifications & Registrations .............................................................................. 4 Stock Materials ................................................................................................... 5 Design Guidelines Uniform Wall Thickness....................................................................................... 6 Bends ................................................................................................................. 7 Hems .................................................................................................................. 8 Offsets ................................................................................................................ 9 Holes & Slots ...................................................................................................... 10 Counter Sinks ..................................................................................................... 11 Notches & Tabs .................................................................................................. 12 Bend Relief ......................................................................................................... 13 Welding ............................................................................................................... 14 PEM Hardware .................................................................................................... 15 Design Tools Standard Tooling ................................................................................................ 17 Finishing Plating ................................................................................................................ 18 Powder Coating & Silk Screening ......................................................................... 19 Resources .......................................................................................................................... 20 Rapid Sheet Metal Rapid Sheet Metal began in 2001 with the mission: “Prototypes First” and it is still the foundation of our business. The shop is structured similar to an additive manufacturing facility. This approach uses 3D CAD data to streamline the quoting and manufacturing processes which eliminates long que times. Currently, Rapid Sheet Metal has two facilities totaling 75,000 square feet of space servicing prototype and low volume production quantities. Sheet Metal Fabrication is the creation of parts through forming, bending, punching and cutting sheets of metal. This guide will cover sheet metal best practices and tips to ensure your sheet metal parts are optimally designed for durability, manufacturability, and end-use applications. Rapid Sheet Metal Part Size: Max 8’ length In-House Capabilities: Laser Cutting Punching Shearing Forming & Bending TIG, MIG & Spot Welding PEM Hardware Hardware Insertion Rolling Riveting Basic Tool Making Tumbling Secondary Machining Assembly Plating Powder Coating Certifications & Registrations: ITAR Registered ISO 9001:2008 Aerospace Welding RoHS Compliant Joint Certificate Program Central Contractor Registered SOLIDWORKS Certified Solution Partner Silk Screening Part Marking Rapid Sheet Metal CRS Galvanneal Galvanized 26 304 316 5052 0.024 0.020 6061-T6 C101 C110 CDA260 0.020 0.020 0.020 0.025 0.025 0.025 0.032 0.032 0.040 0.040 0.040 0.018 24 0.024 0.024 0.024 0.024 22 0.030 0.029 0.029 20 0.036 0.036 0.036 19 0.042 18 0.048 0.048 0.048 0.047 0.047 0.040 0.040 0.050 0.050 0.050 16 0.060 0.060 0.060 0.059 0.059 0.050 0.050 0.062 0.062 0.062 14 0.075 0.075 0.075 0.074 0.074 0.062 0.062 0.080 0.080 0.080 13 0.090 0.089 0.089 0.089 0.089 0.090 0.090 0.090 12 0.104 0.104 0.104 0.104 0.104 0.080 0.080 11 0.119 0.119 0.119 0.119 0.119 0.090 0.090 0.125 0.125 0.125 10 0.134 0.134 0.134 0.134 0.100 0.100 8 0.164 0.125 0.125 7 0.179 0.160 0.160 0.250 0.250 0.036 0.025 0.030 0.030 0.179 6 0.250 0.036 0.025 0.250 Design Guidelines Because Sheet Metal parts are manufactured from a single sheet of metal the part must maintain a uniform wall thickness. Rapid Sheet Metal is capable of manufacturing sheet metal parts with a minimum of 0.010” to 0.25” in thickness. Design Guidelines Bends in sheet metal are manufactured using sheet metal brakes. RAPID will hold a +/- 1 degree tolerance on all bend angles. RAPID’s preferred bend radius is 0.030”. Other standard bend radii available, some of which will add additional cost to your part, include: 0.060” 0.090” 0.120” 0.188” 0.250” 0.375” 0.500” 0.750” 1.000” NOTE: RAPID recommends keeping the same bend radii across all bends when possible. This helps minimize the amount of brake setups and keeps cost down. Design Guidelines Hems are folds at the end of a part to create a rounded edge. RAPID can form both open and closed hems as required. The tolerance of a hem is dependent upon the hem’s radius, material thickness and features near the hem. It is recommended the minimum inside diameter equals the material thickness and the hem return length is 4 times the thickness. Design Guidelines An offset is used to create a “Z” shaped profile in a sheet metal part. RAPID’s offset height tolerance is +/- 0.012” top of sheet / top of form. RAPID’s preferred offset is 0.030”. Other standard offsets, which can add costs to your part, include: 0.060” 0.093” 0.125” 0.187” 0.213” 0.250” 0.281” 0.312” Design Guidelines Holes and slots should be a minimum of material thickness in diameter. If a material is 0.036” or thinner the hole should be 0.062” from the material edge. If the material is thicker than 0.036” then the hole should be at least 0.125” from the material edge to avoid distortion. If hardware inserts are required the spacing should be according to manufacturer’s specifications. Hole Tolerances: Hole Diameter +/- 0.005” Unless otherwise specified Hardware Hole Diameter +0.003”/-0.000” Per manufacturers specifications Counterbore & Spotfacing 0.063 to 0.250 +0.010”/-0.005” Counterbore & Spotfacing 0.251 to 0.500 +0.015”/-0.005” Counterbore & Spotfacing >0.500 +0.020”/-0.005” Machined Diameter +/-0.001” NOTE: If using eRAPID, all holes and cutouts need to be a minimum of 4x the material thickness away from the material edge to avoid additional costs in estimating. Design Guidelines Rapid Sheet Metal offers both machined and formed countersinks. Machined counter sinks are created with a drill press while formed counter sinks are created with punch press tooling. Counter Sink Tolerances: Machined Counter Sink Major Diameter +/-0.010” Machined Counter Sink Minor Diameter +/-0.010” Formed Counter Sink Major Diameter +/-0.015” Formed Counter Sink Minor Diameter +/-0.015” 2/3 thickness Design Guidelines Notches must be at least the material’s thickness or 0.04”, whichever is greater, and can be no longer than 5 times its width. Tabs must be at least 2 times the material’s thickness or 0.126”, whichever is greater, and can be no longer than 5 times its width. Design Guidelines Bend reliefs are implemented where a bend extends on an edge. The relief notch is added to prevent tearing. Bend reliefs will be no deeper than the material thickness plus the bend radius and no wider than 0.030”. Design Guidelines When designing a part requiring welding, it is best to not specify the exact method or type of welding unless required for function. This provides the manufacturer increased flexibility when fabricating the sheet metal part which often results in the most economical and fastest lead-time choice for the customer. The three most common types of welding include Resistance Spot Welding (RSW), Gas Metal Arc Welding (MIG), and Gas Tungsten Arc Welding (TIG). Design Guidelines When designing sheet metal parts with PEM Hardware it is important to make sure the hardware is not too close to a bend, edge or other fastener. When designing near a bend or edge, use the Centerline-toEdge (C/L to Edge) value to find the minimum distance to the outside edge. When calculating the spacing between multiple pieces of hardware, use the C/L to Edge formula plus ½ the diameter of the second mounting hole. Hardware Plating Specifics “Before” means hardware is required to be inserted before plating. “After” means hardware is required to be installed after plating. Material Hardware Iridite, Chromate, Alodine Aluminum AC, CLS, CLSS, FHS, SOS, BSOS Before Aluminum CLA & FHA Before Stainless Steel SP, FH4, SO4, BSO4 AS, BSO, FH, S, SO, SS AS, BSO, FH, S, SO, SS AS, BSO, FH, S, SO, SS CRS Galvanneal Galvanized Zinc Nickel Plate Black Oxide After Before Before Anodize Tin Plate After After Before After Before Before Before Passivate Before Before PAINT / POWDER ONLY PAINT / POWDER ONLY Hardware Lengths Hardware Type 0.25” 0.312” 0.375” 0.5” 0.625” 0.75” 0.875” 1” 1.25” 1.5” FH, FHS, FH4, FHL, FHLS, TFH, TFHS, HFH, HFHS 4 5 6 8 10 12 14 16 20 24 All metric lengths are in millimeters (ex. Dash 10 is 10MM long) Design Guidelines Material Thickness vs. Shank Numbers Hardware Type S, SS, CLS, SP, CLA Thread Code Min Sheet Thickness Shank 0.03” 0 0.04” 1 0.056” 2 0.091” 3 0.056” 1 0.091” 2 M6, M8 0.0125” 3 256, 440, 632, 832, 032 0.060” – 0.090” 1 M2.5, M3, M4, M5 0.090” – UP 2 AC, CLS, CLSS, F, FHS, SOS, BSOS, CLA 632, 832, 024, 032 S, SS, CLS, SP, CLA F SO, SOS, SO4, BSO, BSOS, BSO4 SO, SOS, SO4, BSO, BSOS, BSO4 0420, 0428, 0518 440, 6440, 632 0.040” IF LESS THAN 0.40” USE TSO TO TSIS (0.025” MINIMUM) M3, M4 8362, 832, 032 0.050” 256, 440, 632, 832, 024, 032, M2.5, M3, M4, M5 0.040” FH, FHS, FH4, FHA 0.062” .0420. 0.93” .0518. FEO (Locking), FEOX FE (Locking), FEX 440, 632, 832, 0.032. M3, M4, M5 440, 632, 832, 0.032. M3, M4, M5 0.039” - 0.045” AFTER PLATING 0.059” - 0.070” Special Cases Hardware Type PL, PLC TD, RAS, RSS All Panel Fasteners: PF11, PF12, PFC2 LK, LKS, LKA Special Info Install In Stainless Nylon Threads NO Steel Only NO Installed Post Finishing (This includes powder coat) NO Treated w/ Black Dry Lubricant NO Design Tools By using standard tooling features you can be assured we have the in-house punch tooling to create the geometry you are modeling. This eliminates the phone calls and e-mails back and forth to match your needs with our in-house tooling, and avoids the time and expense of ordering custom tooling. SOLIDWORKS and PTC Creo™ users can download a model of their specific tooled feature and immediately integrate it into their design. Embossments Card Guides Louvers Lances Forming Tools NOTE: In addition to native file formats, STEP files are also available in either SOLIDWORKS or PTC Creo. Finishing Plating Type Description MIL-A-8625 Type II Sulphuric Acid Electrolyte Standard MIL-A-8625 Type III Hard Coat Specialty MIL-DTL-5541 Type I Contains Hex Chrome Non RoHS Yellow Unless Specified MIL-DTL-5541 Type II Contains Non-Hex Chrome RoHS Clear Only ASTM-B-633 Type I Non Chromate Conversion Colored Chromate Conversion Black or Yellow, Yellow is RoHS Compliant Colorless Chromate Conversion Please Specify RoHS Compliancy ASTM-B-633 Type II ASTM-B-633 Type III MIL-T-10727 Type I Electrodeposited MIL-T-10727 Type II Hot-dipped MIL-C-13924 Class Class I – Non Dyed Natural or Clear Class II – Dyed Specify Color: Black, Blue, Red, etc. Class I – Non Dyed Natural or Clear Class II – Dyed Specify Color: Black, Blue, Red, etc. Class IA – Maximum Protection, Thick Coating Class II – Corrosion Protection, Thin Coating Class IA – Maximum Protection, Thick Coating Class II – Corrosion Protection, Thin Coating SC1- Durability Mild SC2 – Durability Moderate SC3 – Durability Severe SC4 – Durability Very Severe SC1- Durability Mild SC2 – Durability Moderate SC3 – Durability Severe SC4 – Durability Very Severe SC1- Durability Mild SC2 – Durability Moderate SC3 – Durability Severe SC4 – Durability Very Severe Class I – Iron & Steel Class II – 400 Series Stainless Steel Class III – Fused Salt Process Class Iv – Stainless Steel MIL-f-495 Finishing RAPID offers in-house powder coating and silk screening to ensure fast deliveries. RAPID facilities are ITAR registered and we powder coat or silk screen your parts in compliance with government regulations. In addition, we can order any other powder you need but it will extend lead-times. Silk screen colors can be matched to any Pantone number you provide and all inks are in stock. Resources eRAPID: eRAPID is a FREE instant sheet metal part quoting, ordering and design for manufacturing feedback plugin for SOLIDWORKS. To download the plugin go to www.erapid.com myRAPID: myRAPID is the RAPID customer portal. It allows you to quote multiple files at once (instantly quoting sheet metal parts), see past quotes, update contact and shipping information, and order multiple parts. Visit: rapidmanufacturing.com/myrapid RapidQuote: Upload 3D CAD files and our team of engineers will process your request and send a quote out within 24 hours. Visit: quote.rapidmanufacturing.com/ Powder Coat Library: To see a list of powders we keep in stock. Visit: rapidmanufacturing.com/powdercoat CAD Tooling Library: To download the CAD Tooling Library. Visit: rapidmanufacturing.com/3d Sheet Metal Design for Manufacturing – LinkedIn Group: This group is designed for engineers who design sheet metal parts. It provides them with an on-line forum to collaborate and discuss techniques to better design sheet metal parts for manufacturability. Join: https://www.linkedin.com/groups/8531417
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