Sheet metal reinforcement is a key technology to improve the strength, stiffness and durability of sheet metal parts through structural optimization, material reinforcement or process improvement. WORLDSOARING recommends 16 practical methods, which are classified into four major directions: design optimization, material selection, process improvement and auxiliary technology:

I. How is sheet metal reinforcement designed and optimized?

Bending reinforcement edge

Adding a 90°~120° bend to the edge to form a vertical rib structure can increase the bending stiffness by more than 30%.

Concave and convex rib design

Suppressing longitudinal/transverse reinforcement ribs (depth recommended 0.5~2 times the material thickness) can increase stiffness by 50% without significantly increasing weight.

Flanging hole process

Flanging the mounting hole (flange height ≥ 2 times the material thickness) can enhance local strength and avoid sharp edges.

Topological optimization structure

Remove materials in low stress areas through CAE analysis (weight reduction can reach 20%) and concentrate reinforcement on key parts.

2. How to strengthen the material for sheet metal reinforcement?

High-strength material substitution

Use DP780/DP980 dual-phase steel or 5052 aluminum alloy to increase strength by 2~3 times (cost and formability need to be evaluated).

Composite laminated structure

The sheet metal interlayer is filled with polyurethane foam or honeycomb aluminum core, and the bending stiffness can be increased by 5~10 times.

Local reinforcement plate

Weld/rivet reinforcement plate in stress concentration area (thickness recommended is 1.5~3 times the base material), such as door hinge.

3. How to improve sheet metal reinforcement process?

Hot stamping

22MnB5 boron steel is heated at 900℃ and then quenched in the mold, with a tensile strength of more than 1500MPa.

Tailored Blank

Laser welding of plates of different thicknesses/materials to form, reducing weight while optimizing strength distribution.

Shot peening

Steel shots impact the surface to form a 0.1~0.3mm compressive stress layer, extending fatigue life by 3~5 times.

Rolling hardening

Rolling the bending edges optimizes the material fiber flow direction and increases the edge strength by 40%.

4. Sheet metal reinforcement auxiliary strengthening technology

Structural adhesive bonding

Use epoxy or acrylic adhesives (shear strength>20MPa) to replace some spot welding to reduce stress concentration.

Local carbon fiber attachment

Paste CFRP reinforcement sheets (thickness 0.2~0.5mm) in key areas to increase stiffness by 70%.

Micro-arc oxidation (aluminum alloy)

A 50~100μm ceramic layer is generated on the surface, with a hardness of HV800~1500 and a wear resistance of 10 times.

Vibration aging treatment

Mechanical vibration is used to eliminate welding residual stress and improve dimensional stability by 60%.

Bionic structure design

Imitating the trabecular structure of biological bones, 3D printing lightweight reinforcement ribs (weight reduction of 15%~30%).

Selection suggestions

Economical solution: bending reinforcement edge + rib design + shot peening

High performance requirements: hot stamping + laser welding + carbon fiber attachment

Corrosion protection scenario: 5052 aluminum alloy + micro-arc oxidation treatment