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Sheet metal assembly involves joining individual sheet metal parts to create a complete product or structure. There are several commonly used processes for sheet metal assembly, each with its own advantages and limitations. Here are some of the most common sheet metal assembly processes:

1. Fasteners and Hardware: Fasteners such as screws, bolts, nuts, rivets, and threaded inserts are commonly used to join sheet metal parts. They provide a secure and often removable connection. Fasteners can be particularly useful when disassembly is required for maintenance or repairs.
2. Welding: Welding involves fusing two or more sheet metal parts together using heat. Common welding methods for sheet metal include MIG (Metal Inert Gas) welding, TIG (Tungsten Inert Gas) welding, and spot welding. Welding provides a strong and permanent joint, but it may introduce heat-related distortion and require skilled welders.
3. Clinching: Clinching is a mechanical joining process that involves deforming the metal sheets to create a interlock between them. This is achieved by pressing the sheets together using a punch and a die. Clinching provides a strong joint without the need for additional materials like fasteners.
4. Adhesives: Specialized adhesives designed for metal bonding can be used to join sheet metal parts. Adhesive bonding can provide uniform distribution of stress and create a smooth surface finish. However, adhesive bonds might be susceptible to environmental factors and temperature variations.
5. Riveting: Riveting involves using rivets (metal pins with a head on one end) to join sheet metal parts. Rivets are inserted through pre-drilled holes and then deformed or "riveted" to secure the parts together. Riveting is particularly useful for joints requiring high strength and durability.
6. Snap-Fit or Tabs: Tabs or flanges can be designed into the sheet metal parts to interlock and create a snap-fit assembly. This method is often used for cases where no additional fasteners or external hardware are desired.
7. Bending and Folding: Sheet metal parts can be bent or folded to interlock and create an assembly. This process can be used to create complex shapes and structures by forming the metal itself without additional fasteners or joining methods.
8. Interlocking Joints: Sheet metal parts can be designed with interlocking features such as tabs, slots, and hooks that fit together to create an assembly. These joints can be secured by folding, bending, or other methods.
9. Forming and Deep Drawing: Forming and deep drawing processes can shape sheet metal parts in a way that they can fit together to create an assembly. The parts are typically designed with matching features that allow them to align and interlock.

The choice of assembly process depends on factors such as the design requirements, desired strength, production volume, material properties, and the available manufacturing equipment. Often, a combination of different assembly methods is used to create complex sheet metal assemblies.

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