Sheet Metal Push Button Enclosure with Knockouts
This is a sheet metal push button enclosure designed with two circular knockouts for mounting switches. The knockouts can easily be removed if needed. The enclosure is made of electro galvanized steel (also known as zinc coated steel), providing durability and corrosion resistance.
Knockout Design in Push Button Enclosure
As shown in the photo, the knockout in the enclosure is connected at four points, while the rest of the circular section is separated, with visible gaps. The connection points are not symmetrically positioned, which is intentional. This design allows for the knockout to be easily removed in stages, starting from one point and then detaching the rest. The manufacturing process ensures that the knockout can be conveniently removed when needed, while also preventing it from detaching unintentionally during handling.
Part specification
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Dimensions: 230 x 125 x 48 mm
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Material: Electro galvanized steel, 1.5mm thickness
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Surface Treatment: None
Critical feature
Precision Tolerance: ±0.5mm
This push button enclosure is formed using a high-precision press brake. The process utilizes carefully selected bending dies and backstrokes, ensuring that the critical dimensions are achieved with high accuracy. The tolerance for key dimensions is ±0.5mm, while the overall enclosure length and width maintain a tolerance of ±0.8mm. The precise dimensions are achieved through multiple bending operations, resulting in a streamlined manufacturing process, as shown in the bending video below.
Material: Electro Galvanized Steel
The enclosure is made from electro galvanized steel, which is also known as zinc coated steel or Zintec steel. The material is first stamped to form the blanks, which gives the enclosure its overall shape and features, including the two knockouts for mounting switches.
Surface Polish for Scratch Concealment
During the stamping process, the surface of the electro galvanized steel may experience minor scratching.
To address this, we polish one side of the material, creating a subtle, textured finish that helps conceal any light scratches. The other side of the enclosure, which is hidden during assembly, does not require polishing and can tolerate minor imperfections.
Bending Process Overview
3 Sets of Bending Dies
The part undergoes eight bending steps, which require three different sets of bending tools. These tools vary in width, and the V-slot size of the die also differs. The tools are arranged in such a way that all the bends can be completed in one go, streamlining the entire bending process.
Dual Back Gauges for Precision
Additionally, the back gauge is divided into two sections. For the first six bends, the back gauge is designed to accommodate the thickness of a single sheet, and it spans the entire width. However, for the last two bends, narrower back gauges are used. This is because the final bends involve a 90° edge, which can have some dimensional variation. Using a narrower back gauge ensures better control and avoids errors that might occur with a full-width back gauge.
Bending Process in Action: Watch the Manufacturing Steps
Contact Us for Custom Fabrication
We have extensive experience in sheet metal fabrication. If you have similar product manufacturing needs, please don’t hesitate to contact us.
