Processing: Forming and Machining

Bending, shaping and folding metal from sheet into objects or parts, also known as machining and forming, is an important stage in the value-added fabrication process.

HISTORY

Around 2000, Olympic Steel began forming and machining metal for an existing customer, JLG Industries, in our Chambersburg, PA division. This addition began a natural evolution of adding processing options to increase value and the ability to offer additional fabrication opportunities.

Currently, many of our divisions have the ability to form and machine. There is strong collaboration between facilities to best provide the capability and expertise needed to support the customer. Our forming machines and machining centers consist of:

• 23 Press Brakes
• 19 Machining Centers
• 3 Stamping Presses
• 2 Roll Formers
• 2 Folding Machines
• 1 Lathe
• …and counting!

MACHINING

One of the most widely used techniques in the production of metal parts, machining, selectively removes material from a piece of metal to form it into a desired shape with specific dimensions and surface finishes. The machines have a spindle with a tool holder that can include cutters, drills and taps. Olympic steel uses CNC Milling (horizontal and vertical) and CNC Lathes (turning) to machine holes, create threads, add bevels for welding, and construct parts with characteristics unique to our end users’ specifications.

FORMING

In metal fabrication, forming is simply the process of bending the metal to create desired shapes. There are many processes, each with specialized equipment, to perform specific tasks. Olympic Steel currently uses Press Brakes, Stamping Presses, Folding Machines and Roll Forming, with plans to introduce Panel Benders in the near future.

• Press Brake – Bends sheets of steel in a straight line to create the desired shape. A punch on the top of the press and a die on the bottom helps form the material and create a bend at a certain angle. Found in simple brackets, panels in food service equipment, tractor frame and structural parts, trailer frames and 5th Wheels for trailers.
• Stamping Press – Uses the same concept as a Press Brake, with an upper and lower die set, but forms multiple bends at once or creates a more sophisticated shape. It can form the part in one stroke, have multiple sections that form a portion of a part at a time (progressive die), or shape the material into very complex objects (draw die). Familiar items: body panels for cars, beer kegs and lawn mower decks.
• Roll Forming – Forms metal sheets or strips into desired cross-sectional profiles with a continuous bending process. It is typically used with long lengths of metal and involves feeding it through a series of rollers that gradually shape it. Everyday items include steel framing, door frames, gutters, roof panels and shelves.
• Punch Press or Turret Press – Cuts, shapes or forms flat metal parts with many holes, notches or embossments using one or more die and punch sets. Common uses: vents, grills, HVAC components and enclosure panels.
• Folding Machine – Bends sheet metal along straight lines, lifting and folding the material around a fixed edge, creating precise angles such as flanges, hems or box shapes. Used for ductwork, gutter systems, frames, tools and excavator buckets.
• Panel Bender – Automatically bends flanges and panels from a flat sheet to create programmed forms such as 4-sided boxes, cabinets, doors and enclosures. It is a highly automated alternative to traditional press brakes with reduced manual intervention. Parts of: white goods (washer, dryer, refrigerator) panels, control cabinets, server racks, electrical panels.

OUTLOOK

Olympic steel is well-positioned for reshoring of processing and fabrication services and is prepared to accept returning business and support those customers. Fabrication is a key component of Olympic Steel’s strategy to double profitability in the next five years, while safely providing solutions for growth.

Expand your knowledge about our processes, business segments, divisions, subsidiaries and family of brands at Olympic Steel Academy!