Precision Metal Stamping, also known as Progressive Metal Stamping, is a common method of quickly and inexpensively manufacturing very accurate parts. Many metal fabrication facilities utilize this manufacturing process.
With a full understanding of its benefits and capabilities, metal fabrication companies choose to use this process for many tasks. Next, let’s learn more about precision metal stamping and the benefits of this metalworking process.
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What is Precision Metal Stamping?
In this process, a machine with a die is used to cut sheet metal into precise shapes. The metal fabrication plant even completes the product in just one stamping. This is known as a single process. For more complex workpieces, you may need to use multiple strokes, which is known as a series process. Precision metal stamping is adaptable and fluid, making it especially suitable for making large quantities of items.
The precision metal stamping process is different from other similar processes because it allows for very precise machining of the desired part. This is true even for complex parts. Precision metal stamping presses allow producers to perform micro-stamping. Which involves making very small and complex parts.
Even the smallest mistake can render these complex parts useless. Because precision metal stamping is so accurate and fast, many fields from the automotive industry to aerospace can use this process to make parts.
Precision Metal Stamping Process
When using precision stamping, the project usually begins with computer modeling that simulates the stamping process to look for errors or defects. Once all of these tests are complete, the computer sends the plan directly to the machine. This is a fast and error-free process.
For the precision metal stamping process, there are three main types of tooling:
- Soft Tooling. This is a simple method that uses only one machine to make a small amount of something.
- Stage Tooling. more machines are added to the process, which means workers must move workpieces by hand from one machine to another.
- Hard Tooling. this is a fully automated process that is best suited for making large quantities of items.
Metal fabrication plants can use many different techniques depending on the job and how the tools are made.
Benefits of Precision Metal Stamping
- Automation: After the molds are set up in a metalworking plant, the machine can make a large number of the same designs without the help of a human.
- Handling Problems: Precision metal stamping is often the best choice for difficult jobs that require microstamping or fine machining. Other types of machining may not be able to meet the tolerances of a project, but precision metal stamping can. Precision metal stamping can also solve difficult problems and produce high-quality finished parts.
- Speed: Because the process is automated, accurate parts can be manufactured quickly, saving both time and money in the long run.
- Cost-effective: Precision stamping is an affordable option, especially for larger projects. This is because this metalworking process works quickly and does not require much work. The quality of the process means that parts don’t have to be reworked as often, resulting in additional cost savings.
- Quality and Accuracy: Precision metal stamping always produces high-quality, accurate parts with a very low chance of error. Metal fabricators can use this method to make very complex parts for areas where mistakes cannot be made.
Types of Steel Used for Fine Blanking
A wide range of different metals can be used for fine blanking. However, certain processes and metals are better suited to the fine blanking process.
When steel is heated and then rapidly cooled, it is rolled and pressed. This roughens the surface of the steel. The cold working method is used to process sheet metal at room temperature. This method is suitable for tasks that require tighter tolerances and greater precision.
During cold rolling, the solid structure of the metal is permanently changed when it is subjected to mechanical stress. As a result, the metal becomes stronger and is generally less prone to rust. Cold-rolled stainless steel coils can be precision-manufactured. This makes it possible to produce metal with very precise dimensions. For precision metal stamping, the metal is shaped by a stamping die. This process usually takes place at room temperature and is therefore cold working.
Cold-rolled steel meets the growing demand for precision metal stamping. Compared to hot-rolled steel, it offers the following advantages:
- Smooth, finished surface
- Precise edges and flatness
- More uniform dimensions (width, thickness)
- Higher strength and greater hardness
- Stable and predictable material properties
When choosing a metal, consider the advantages and disadvantages of each metal as well as your actual needs. Aluminum is less hard, lighter in weight, and better conductive. However, stainless steel can withstand higher temperatures and remain stable in environments where rust is more likely to occur.
Titanium, on the other hand, is stronger and lasts longer, and it is even lighter than aluminum. Therefore, titanium is perfect for aerospace, military, and security applications that require a high strength-to-weight ratio. In addition, titanium does not rust and can be used for implants in the human body, making it safe and reliable.
Key Factors to Consider When Selecting Precision Metal Stamping Materials
When selecting precision metal stamping materials, you need to consider their malleability and formability, tensile strength, ease of processing, and rate of hardening under pressure.
| Material | Properties | Typical Applications |
| Steel | Durable, strong, can be hardened | Automotive body parts, structural components |
| Stainless Steel | Corrosion-resistant, durable, strong | Food processing equipment, medical devices |
| Aluminum | Lightweight, corrosion-resistant, good conductor | Electronic housing, consumer products |
| Copper | Excellent electrical conductivity, malleable | Electrical components, roofing materials |
| Brass | Good corrosion resistance, excellent machinability | Decorative hardware, gears, locks |
| Nickel Alloys | High-temperature resistance, highly corrosion-resistant | Aerospace components, power generation equipment |
| Titanium | High strength-to-weight ratio, corrosion-resistant | Aerospace frames, surgical implants |
Ductility and Formability
The formability of a material is between its yield strength and tensile strength. If the yield strength is not exceeded, no deformation occurs. If the tensile strength is exceeded, however, the material breaks. When it comes to stronger materials, the range between yield strength and tensile strength is very small.
The grain size of a material is often used to indicate its formability. In other words, a homogeneous grain size means that the material is easier to form. By monitoring the temperature of the annealing furnace and the speed at which the strip moves along the production line, the rolling mill can control the grain size within a very narrow range.
Tensile Strength
Tensile strength is the force that a material can withstand before breaking. The strength of different metals varies, depending on the composition of the elements in the metal alloy. When selecting a metal, its tensile strength should be checked to ensure that it can withstand the force applied to it.
Workability
The ease with which a material can be cut or shaped is known as its workability. Improving the material properties usually reduces its workability. You should therefore consider whether the metal you have chosen is easy to work with, after all your other requirements have been met. If you choose a material that is easy to work with and works well, you can save costs. However, it is more important to choose a material that is suitable for the requirements of the part than to choose a material that is easy to work with.
Work Hardening Rate
The toughness of a metal can change during machining or pressing. During this process, the metal can become harder or more brittle. Work hardening refers to the rate at which this change occurs in the metal. The metal may need to be annealed to restore its properties and prevent cracking, breaking, and other defects. This depends on the amount of machining and deformation the metal needs to withstand during a particular operation.
Applications for Precision Metal Stamping
Automotive Industry
The automotive industry requires millions of complex parts every year. These parts are used in a wide range of applications, from electrical systems to vehicle frames. On the other hand, the most common uses for precision metal stampings are terminals and electrical connectors. These parts are often designed with two-part sockets and inserts that need to be very durable. Other common uses in the automotive industry include wire forms, brackets, and hangers.
Aerospace
Parts manufactured for the aerospace industry must meet very strict standards. This is because the safety of the public and workers depends on each part being durable, error-free, and meeting very precise measurement standards.
Precision metal stamping is commonly used in the aerospace industry to make parts such as clips, shields, brackets, and more.
Medical Device Field
Medical devices are very important in detecting, treating, and stopping diseases. The parts used in such cases need to be made from materials that are easy to clean and free of defects or contaminants.
Precision metal stampings are well suited for medical applications such as the manufacture of temperature readings, surgical tools, prosthetics, and more.
Electronics
High-precision parts help deliver energy safely to customers. As a result, receptacles, circuit breakers, and fuse boxes are all commonly used in the electronics industry.
Appliances
Complex appliance systems require high-quality stamped metal parts if they are to work properly and last a long time. Stoves, ovens, and dryers fall into this category, as well as HVAC equipment and irrigation systems.
Renewable Energy
The green energy business is expanding rapidly, and to meet the demand, it requires specialty parts. Precision-stamped metal parts are used to make solar panel wires, aluminum frames, and housings for inverters and controllers.
Specialty Parts
Companies that make complex or specialty items use the precision metal working process because it allows for custom molds. (For example, customizing very small printer wheels)
Precision Metal Stamping Considerations
However, while this method has many benefits in many areas, it is not always the best choice for every project. There are several important things to consider when deciding whether or not to use this process:
- Design Accuracy: To avoid errors that can be costly, prototype drawings for this process must be very accurate. Defects can weaken the performance of the part both when it is manufactured and when it is used.
- Material Characterization: Metals react differently than plastics when heated and pressed. In order to determine if this process is a good choice, it is important to know exactly what kind of material is required.
- Ordering Quantity: Precision metal pressing is often the best and most cost-effective method for manufacturing large quantities of items. However,in small-scale production, the cost of progressive dies is often too high for companies to afford.
Contact Us
Therefore, precision metal stamping is useful in many different types of metal fabrication plants. Yonglihao Machinery is committed to providing our customers with the best precision metal stamping services available.
On the other hand, our skilled staff is dedicated to ensuring customer satisfaction. In addition, we will ensure that the metal stamping parts produced will work under all circumstances.If you would like to work with us on your next job, get a quote today.