select
navigate
switch tabs
Esc close

Adding countersinks to formed stainless sheet metal

0
D
2

Hello, I’m working on a sheet metal enclosure (as in the image) that requires flush mounting for M6 countersunk screws. I need to add a countersink on a few holes, but the part is already flat-cut and formed. Has anyone successfully added a countersink post-process in this kind of setup without warping the part? Looking for the most practical approach, either manual or otherwise.

    • D

      Hello, I’m working on a sheet metal enclosure (as in the image) that requires flush mounting for M6 countersunk screws. I need to add a countersink on a few holes, but the part is already flat-cut and formed. Has anyone successfully added a countersink post-process in this kind of setup without warping the part? Looking for the most practical approach, either manual or otherwise.

      0
    • D

      Yes, I’ve dealt with this exact scenario. Adding a countersink after forming is doable, but you’ll want to proceed carefully to avoid deforming the part, especially since you’re working with stainless, which is tougher than aluminum or mild steel. The safest manual method is using a hand deburring/countersink tool with a depth stop. It gives you full control, and since you’re only working with a 2 mm thick sheet, it won’t take much effort. Just make sure to clamp the part securely on a flat surface to prevent flexing while you work. Go slowly and check the fit with a sample M6 countersunk screw as you go.

      If you have access to a drill press with variable speed and a good quality countersink bit, that’s another reliable option. Keep the RPMs low and use a sharp bit to reduce work hardening or generate heat that warps the part. Support the sheet fully underneath. Don’t let it hang or flex.

      0
      Reply
    • M

      Avoid aggressive CNC countersinking unless the part is fixtured really well; otherwise, you risk creating a twist or stress in the sheet. If this is a recurring need, you might want to look into press-style countersinking dies, which can dimple the countersink rather than cut it.

      0
      Reply
Adding countersinks to formed stainless sheet metal
Your information:




Suggested Topics

Topic
Replies
Views
Activity
Fastener size choice for a through-hole in 4 mm anodized aluminum plate
Hi! Designing a lightweight enclosure for a small UAV component, using 4 mm thick anodized aluminum sheets. For the assembly, I need to fasten this plate to a 3D-printed ABS bracket underneath, which acts as... read more
K
e
E
3
117
Jun 30
Cracking at snap-fit hook base in SLS PA12
Hello everyone, I'm using SLS 3D printing (PA12, 0.12 mm layer height) to create a snap-fit enclosure for a handheld sensor device. The enclosure has three internal hooks that flex about 1.5 mm during... read more
F
A
2
123
Jun 24
Choosing sheet metal thickness for a lightweight bracket
Hey, working on a small mounting bracket for a consumer electronics housing, cut and bent from stainless steel sheet (304 or 316). The part needs to stay under 200g, but it also has to... read more
D
M
2
155
Jun 24
Visibility of parting line on GF30 PA6 injection molded handle
Hello everyone, how visible can the parting line be on final molded parts? My team is currently designing a handle cover for an industrial machine, injection molded in PA6 with 30% glass fiber. Aesthetics... read more
T
M
C
2
170
Jun 20
Minimum embossed text size for TPU molding
Hey there, I'm designing a flexible watch strap that will be injection molded in TPU (Shore 85A). I want to include some small embossed text (branding and serial number) directly on the strap, but... read more
A
T
n
3
304
Jun 24