Designing sheet metal parts with fasteners requires careful planning to streamline assembly and reduce costs. Discover how to effectively incorporate fasteners in sheet metal while avoiding common design pitfalls.
The Role of Material-Fastener Compatibility
Fasteners are secured to sheet metal by the material flowing around the fastener during installation. Therefore, material hardness plays a critical role:
- Steel sheets: Compatible with hardened steel fasteners.
- Stainless steel: Requires hardened stainless hardware.
- Aluminum: Can use steel, stainless, or aluminum fasteners. Avoid galvanic corrosion by opting for stainless or aluminum fasteners, as steel and aluminum contact causes rapid corrosion in humid environments.
Tips for Aluminum Sheets
Although aluminum accepts various hardware types, consider:
- Corrosion risks: Avoid steel fasteners due to galvanic corrosion.
- Coating compatibility: Stainless steel is a safer option as it resists corrosion and works with chromating.
Plan ahead to save time and iterations by specifying stainless or aluminum hardware for aluminum parts.
Hardware Installation Challenges
Proper fastener placement is essential to avoid issues during manufacturing. Consider these factors:
Proximity to Edges and Features
Material must flow into the fastener to secure it. Maintain minimum distances:
- Avoid placing hardware too close to edges, holes, or cutouts.
- Near bends, ensure space for forming tools (typically ≥ 0.5 in. or 12.7 mm).
Avoid Tack Welding
Clinch fasteners are not designed to withstand the heat of welding. Use weld nuts and studs if welding is necessary, as clinch fasteners will fail under extreme heat.
Managing Stainless Steel Fastener Limitations
Hardened stainless hardware availability can be a challenge. Some types may not exist in hardened stainless, while others require large custom orders. For panel fasteners, consider flare-in types as a viable alternative.
Best Practices for Clinch Fastener Design
- Design for manufacturing (DFM) principles to streamline production.
- Send a email to confirm inventory and compatibility for your chosen fasteners.
- Provide adequate spacing and design simplicity to avoid costly iterations.
By following these guidelines, you’ll minimize costs, reduce revisions, and achieve efficient, high-quality manufacturing outcomes.