Why do sheet metal parts need chamfering and rounded corner effects ?

• Why do sheet metal parts need chamfering and rounded corner effects ?
  • Why are rounded corners and chamfers designed for sheet metal parts?
  • Rounding the corners improves coating adhesion.
  • The necessity of rounding galvanized parts
  • Rounded edges on sheet metal can prevent equipment from malfunctioning and stopping.
  • Rounding corners helps prevent workplace injuries.
  • Rounding corners is for employee safety.
  • Safe subsequent processing without oxide layer
  • Deburred sheet metal parts protect tools from wear.
  • mating and connecting parts
  • Aesthetic value
  • Create fillets and chamfers for your sheet metal projects using Elimold.
  • Summarize

Incorporating fillets and chamfers into your sheet metal parts offers multiple benefits beyond just enhancing aesthetics. These features truly give sheet metal parts a highly attractive and flawless appearance. Both chamfers and fillets eliminate sharp, raw or semi-raw cut metal corners, replacing them with rounded corners (radius) or bevels (chokes).

For modern sheet metal manufacturing companies, chamfering and rounding of sheet metal edges and corners are essential processes for reliable production and high-quality sheet metal parts processing. They not only reliably remove burrs remaining on the parts but also ensure the smooth operation of subsequent processing steps in the sheet metal fabrication chain. This article will explain the reasons why chamfering and rounding design and processing are so important in sheet metal parts processing.

Why are rounded corners and chamfers designed for sheet metal parts?

First, we must clarify that the purpose of rounding corners is not only for aesthetics, but more importantly, to ensure equipment safety and processing efficiency. Furthermore, assuming the normal operation of downstream equipment such as gate presses and bending machines, the necessity of rounding corners depends on the condition of the parts themselves. Burr-free parts can proceed directly to subsequent processes without additional treatment, as this facilitates normal equipment operation. Regarding edge safety, experience shows that a 0.1 mm rounding is sufficient to provide safety protection while preventing damage to contact materials such as latex gloves. However, the coating process has a more complex impact on rounding corners. Coating type, quality, equipment parameters, and placement environment all affect corrosion protection. Through testing, a minimum rounding of 0.5 mm is generally recommended to ensure a reliable coating.

Rounding the corners improves coating adhesion.

During spray painting, whether using liquid or powder paint, paint slippage can occur at the edges of sheet metal parts. As the paint cures, it may slide off sharp edges or burrs, failing to form a sealing layer. The sheet metal edges are then exposed to air and external factors due to the lack of protection. Therefore, sheet metal parts requiring painting should avoid having sharp edges, especially those made of materials with a risk of corrosion.

Furthermore, the quality and adhesion of various coatings depend on whether the edges of the sheet metal parts have been rounded on both the inner and outer sides beforehand. Therefore, rounding the edges of sheet metal parts is an integral part of the deburring process. Whether it’s powder coating, galvanizing, wet coating, or KTL primer, the coating cannot adhere firmly to sharp edges, resulting in peeling. Therefore, rounding the edges of sheet metal parts is essential. It not only ensures a uniform coating on the edges but also provides rust prevention.

The necessity of rounding galvanized parts

Although edge skidding does not occur during the zinc plating process, and the coating automatically reaches at least the same thickness as the surface coating even at sharp corners and edges, galvanized parts still require edge rounding. Generally, the galvanized layer near edges is more sensitive to mechanical loads or impacts than smooth surfaces. Experience shows that even if a single galvanized component passes inspection after galvanizing or arrives at the construction site undamaged, edge defects will appear shortly after assembly or deployment. In contrast, sheet metal parts of the same material, even with only slight rounding, exhibit a significantly more uniform coating structure at the edges. Therefore, standards such as DIN EN 1090 require that the edges of steel structural sheet metal parts be rounded to a radius of at least 2 mm to ensure corrosion resistance.

Rounded edges on sheet metal can prevent equipment from malfunctioning and stopping.

Some sheet metal processing companies often neglect the rounding of internal parts, leading to frequent equipment malfunctions. This is because pneumatic or hydraulic hoses and cables move back and forth during equipment operation. If these hoses or cables travel along sharp metal edges during continuous operation, they will inevitably be damaged. Rounding the edges of sheet metal parts is the most direct and effective way to eliminate this potential problem.

Rounding corners helps prevent workplace injuries.

Sharp edges on sheet metal parts are more dangerous than blades and can easily cause personal injury. Every company wants to avoid these injuries, so rounding the edges is an absolutely necessary processing step. Similarly, in work involving handling parts that requires wearing protective gloves, the gloves must not be torn by sharp sheet metal edges. In this case, rounding the edges of the sheet metal parts is also essential.

Rounding corners is for employee safety.

Besides customers, the processing company’s own employees also benefit from the rounding process. Like customers, they may be cut by sharp sheet metal edges. While protective gloves offer some protection, they wear out over time. Therefore, rounding the edges of sheet metal better ensures the safety of the company’s own workers.

Safe subsequent processing without oxide layer

After laser cutting using oxygen as an assist gas, an oxide layer will appear on the edges of sheet metal parts, negatively impacting subsequent processing. Paint will also peel off along with the oxide layer, leading to rust later. Furthermore, the oxide layer between sheet metal parts can even prevent uniform welding results. Strictly speaking, oxide layer removal is a separate process, but it can be achieved to some extent using specialized deburring tools or blasting techniques.

Deburred sheet metal parts protect tools from wear.

Many sheet metal fabrication companies have recognized that deburring improves the quality of sheet metal parts, facilitates subsequent processing, and thus saves time and reduces costs. Smooth, deburred workpieces are easier to assemble, paint, or weld. They also protect machining tools from wear. Burrs on sheet metal parts are particularly prone to damaging bending dies and leveling rollers or causing them to wear quickly. Deburred sheet metal parts protect machining tools during subsequent processing, saving production costs.

mating and connecting parts

Sheet metal parts are often the final piece of a product development puzzle, used to encapsulate or connect other machined or molded parts or off-the-shelf products. The most common sheet metal parts that include chamfers or rounded corners are brackets, housings, and panels, most of which are typically attached to other parts of an assembly.

Aesthetic value

It’s not uncommon for sheet metal parts to include radii or chamfers to facilitate easy mounting within another component. 90-degree angles aren’t always easy to clean when trying to secure or nest one part inside or within another. Chamfers and fillets not only improve a part’s functionality, but adding these features also enhances the aesthetic value of the design. While safety is the most common reason for including chamfers and fillets on sheet metal parts, these design elements also provide a beautiful, professional finished look. These two design features are often simple, can be combined, and shouldn’t cost you an astronomical sum compared to other more sophisticated elements. Therefore, you can get the most benefit for the least amount of money.

Create fillets and chamfers for your sheet metal projects using Elimold.

Why bother with design when you can outsource it to a professional firm? Elimold is here to help. Our engineering team, with years of experience in design engineering and parts manufacturing, will help you choose the right approach for your precision sheet metal parts, so you can be confident that your design will be perfectly translated into a physical product according to your requirements and specifications. Submit your documents and start your sheet metal parts project with us. Working with Elimold, we’ll reward you with the best results at competitive prices. We also offer a range of secondary processing options, packaging, assembly, and shipping to meet your diverse needs.

Summarize

Rounding and chamfering is a crucial part of the sheet metal parts processing chain. Workpieces that have undergone chamfering and rounding have a refined surface finish, ensuring a smooth production chain. Therefore, chamfering and rounding will give you a decisive competitive advantage. As an important technology in the sheet metal processing field, chamfering and rounding not only improve the appearance and texture of products but also increase their safety and lifespan. With continuous innovation and development in processing technology, rounding and chamfering are expected to see wider applications in various fields, bringing more possibilities to product design and manufacturing. In the pursuit of manufacturing excellence, rounding will continue to play its unique role, contributing to the development of various industries. If you need to mass-produce precision sheet metal parts, please contact Elimold for services.