Full Guide to Metal Stamping: Process, Techniques ...

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In the metal stamping process, various shapes are crafted from flat sheet metal through cold-forming techniques. This manufacturing method employs a combination of dies and stamping presses to effectively convert flat metal into applicable designs used across multiple sectors.

Industries such as automotive, aerospace, and medical machinery increasingly depend on metal stamping to create essential equipment. As the demand for mass-produced, complex parts surges globally, metal stamping proves to be a cost-effective solution.

The metal stamping process is intricate and can be executed through various metal-forming techniques. These methods include bending, punching, blanking, hydroforming, and piercing, all aimed at achieving the desired shape.

This article details the metal stamping process and explores various techniques to enhance your understanding of how this manufacturing method operates.

Understanding Metal Stamping

The metal stamping process, often called metal pressing, involves taking flat sheet metal and introducing it into a stamping press. The press applies pressure and uses a die to convert the metal into a pre-defined shape.

Common stamping techniques include punching, coining, embossing, bending, blanking, and flanging.

To ensure the resulting metal part meets specifications, stamping professionals utilize CAD/CAM engineering technology for precise design. Accuracy is paramount for each part to function as intended.

Metal stamping is a preferred method for producing high volumes of identical parts efficiently, making it suitable for various industries.

Applications of metal stamping include:

• Hardware such as nuts, bolts, screws, hinges, and washers used in various equipment.
• Specialty stamped components like household tools, locks, and power tools.
• Electrical parts including cups, covers, fasteners, and electronic assemblies.
• Durable components for construction that ensure longevity and reliability.
• Fastening solutions such as hooks or intricate contact elements.
• Parts for appliances including grills, microwaves, and more.

Metal stamping machines not only stamp but can also cut, punch, cast, and shape metal sheets into required dimensions. These machines are designed for precision and can be programmed for accuracy.

Metal Stamping Techniques

Numerous metal stamping techniques are employed for specific applications. Here are some examples:

Progressive Die Stamping

Progressive die stamping breaks down the manufacturing process into several stations, each executing a different function. The metal strip moves from one station to another until the part is fully formed.

The metal strip is fed from a coil into the die press, traversing horizontally through each station. Each desired bend, punch, or cut is performed before advancing to the next station. This method guarantees the part remains attached to the strip, emphasizing precision to ensure usability.

This technique is cost-effective for producing mass quantities of parts with minimal scrap wastage, making it highly desirable. However, maintaining high precision is critical for quality output.

Transfer Die Stamping

Transfer die stamping functions similarly to progressive die but utilizes a mechanical system to transport parts between stations. This method is suited for parts that need to be separated from the metal strip.

Often applied as single dies or sequential dies, transfer die stamping is praised for its lower tooling costs and versatility, enabling production of cut-outs, ribs, and pierced holes without the need for subsequent operations.

This method finds applications across several markets, including automotive and electronics, particularly for larger parts requiring multiple presses.

Fine Blanking

Fine blanking, or fine-edge blanking, is adept at achieving flat surfaces and fully sheared edges. This cold extrusion process proves cost-effective as a single-step operation.

Hydraulic or mechanical presses, or both combined, carry out fine blanking processes, which encompass three movements:

1. Clamping the workpiece into position.
2. Executing the blanking action.
3. Removing the finished part.

Fine blanking is perfect for components like gears that necessitate flatness for proper engagement.

Four-Slide Stamping

Four-slide stamping, or multi-slide stamping, employs four tools concurrently to shape components. As the metal piece feeds through, it is rapidly bent by multiple shafts.

This method is effective for creating intricate cuts or bends, even those exceeding 90 degrees. Four-slide stamping allows multiple bends, punches, or cuts in a single step with minimal tooling costs and waste.

Stamping Press Types

There are three fundamental types of stamping presses, categorized by their power sources: mechanical, hydraulic, and mechanical servo.

Typically, a stamping press is linked to an automatic feeder facilitating the movement of the sheet metal through the press. Below is a closer look at each press type.

Mechanical Presses

Mechanical stamping presses utilize a motor connected to a flywheel, which stores energy for operation. They can accommodate various punch sizes and function at speeds ranging from 20 to 1,500 strokes per minute, depending on the press designed.

With shorter stroke lengths optimizing speed, mechanical presses effectively create simple, shallow parts for high-volume production runs.

Hydraulic Presses

Hydraulic presses, utilizing hydraulic fluid as their energy source, offer enhanced control over pressure application. These presses can operate at set pressures while still delivering consistent power throughout each stroke.

Designed for small, intricate parts, hydraulic presses range from 20 tons to 10,000 tons, catering to various production needs effectively.

Mechanical Servo Presses

Mechanical servo presses diverge from using flywheels, favoring high-capacity motors for rapid design execution. Highly programmable, servo presses enable precise control over stroke, slide position, and operating speeds, making them the priciest option among the three.

Stamping Dies

In metal stamping, dies are integral, falling into two categories: single-station dies and multi-station dies.

Single-station dies encompass compound and combination dies, which have various operational capabilities. Compound dies perform multiple actions in a single press, while combination dies incorporate both cutting and non-cutting actions simultaneously.

Multi-station dies include progressive and transfer dies and perform diverse operations such as cutting and punching.

Pros and Cons of Metal Stamping

Let's evaluate the advantages and disadvantages of metal stamping.

Advantages include:

• Lower cost compared to other stamping methods.
• Enhanced automation levels.
• Lower expense in production and maintenance.
• Cost-effective secondary processes like plating or cleaning.
• Utilization of advanced computer programs for precision.
• Faster production times.
• Lower labor costs due to automation.

However, drawbacks include:

• High transportation costs for heavy presses.
• Difficulty in sourcing dies quickly.
• Lengthened pre-production for custom dies.
• Challenges in changing dies mid-production.

Utility of Metal Stamping

Now that we've reviewed the fundamentals of metal stamping, let's examine its applications. Metal stamping is instrumental in producing three-dimensional designs essential in various facets of life. Appliances and fixtures frequently originate from this manufacturing process.

Its applications span multiple sectors, including automotive, lighting, electronics, telecommunications, and much more, producing everything from basic components to highly intricate machinery.

For further details, you can visit metal stamping machinery.

Final Thoughts

The process of metal stamping is interconnected with everyday applications, providing significant value. If you're eager to delve deeper into metal stamping or explore our additional metal capabilities, Schaumburg Specialties is at your service.

With decades of experience in the Chicagoland area, we look forward to assisting you. Please fill out our contact form, and our team will connect with you shortly!