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4 Design Tips For Sheet Metals to Increase Strength

Considering their high versatility, sheet metal components are commonly used in all the industries. However, because the sheet metal parts are relatively thin, there are often challenges related to rigidity and strength under certain conditions. This article will introduce the 4 main design tips to enhance the strength (rigidity) of sheet metal components. We will be doing this by taking as example the machine below, where one conveyors transports workpieces to a rotating stage and the other brings the workpieces discharged from the rotating stage to the next process

1. Adding Welding Ribs to Strengthen Sheet Metals

The most common solution that comes to mind is to add ribs to increase strength. These ribs are welded to the bracket in a shape similar to the one shown in the diagram. It’s safe to say that adding ribs is the most frequently seen method for enhancing the resistance of sheet metal.

When implementing this design, it’s essential to consider the bent sections indicated by the red circles in the picture above. By notching the corners of the added ribs and leaving space around the bracket’s bend radius, the part will further improve its strength.

2. Attaching Ribs with Screws to Strengthen Sheet Metals

If insufficient strength is identified in the bent sections after attaching the bracket, there is also a method of attaching ribs with screws.

When implementing such a design, it is crucial, as indicated by the red circle, to ensure that the heads of the screws do not interfere with each other. Also, there might be limitations in drilling taps to fix ribs to the base where the bracket is attached, so careful consideration is needed in the design of the screw part.

3. Adding Tapers to the Bends to Strengthen Sheet Metals

If welding ribs is not feasible, another method is to add tapers to the bends of the bracket. This is a simple method to increase rigidity without adding components or increasing the amount of material used. However, this method achieves less strength compared to adding ribs. This is a useful approach when only a slight increase in rigidity is needed without adding additional materials.

4. Inserting Reinforcement Inside the Bracket to Strengthen Sheet Metals

In the example above, the through holes for screws are elongated, allowing for absorption of variations in the width dimensions of the conveyor. In cases like attaching ribs with screws in the previous example, concerns arose about the interference between the screws securing the ribs and the base. However, in this design, such concerns are alleviated.

Conclusion

In conclusion, these four design tips offer valuable insights into enhancing the strength of sheet metal components. By incorporating ribs, either through welding or screws, and adding tapers to bends, engineers can significantly boost the rigidity and durability of their designs. Additionally, reinforcing brackets with supplementary components serves as an effective method to bolster structural integrity. Employing these strategies not only ensures the reliability of sheet metal components but also optimizes their performance across various applications. As manufacturers continue to innovate and refine their designs, these tips serve as indispensable tools in achieving superior strength and resilience in sheet metal fabrication.