What Is The Stamping Process?

What is the stamping process?

The stamping process is a manufacturing process in which a flat sheet of metal is molded into its final shape. In this method, blanks or coils of flat sheet metal are placed in a stamping press. The metal is then shaped into its final shape by means of tools and mold surfaces.

Stamping includes many different methods of forming sheet metal, such as punching, dropping, embossing, bending, flanging, and embossing using a machine press or stamping machine.

There may be more than one step in the process, or each contact of the stamping press makes the desired shape in the sheet metal part. The process is usually performed on sheet metal, but can also be performed on plastics and other materials.

Cascading dies are usually fed from a steel coil pan where the coil is unrolled and then fed into a straightening machine to make it level. The coils are then fed through a feeder into the press and mold at set lengths. The number of stations in the die can vary depending on the complexity of the part.

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Origins of Metal Stamping

The earliest coins were probably made in the 7th century BC. The Lydians were making coins in what is now Turkey. Coin hammering remained the most important method of making coins until 1550.

Marx Schwab of Germany came up with a new way to make coins out of metal. As many as 12 men could turn a large wheel to press the metal into coins. Other changes in the cutting process occurred in the 1880s.

In the 1880s, stamping was used extensively in the manufacture of bicycles. Stamping replaced die casting and machining and greatly reduced costs. Although the quality was good enough, they were not as strong as die-forged parts.

In 1890, stamped bicycle parts were introduced to the United States from Germany. American companies then began having American machine tool builders make stamping presses specifically for them. After much work and research, Western Wheel was able to stamp most bicycle parts.

Now, many automobile manufacturers use stamping to make parts. Engineers told Henry Ford not to use stamped parts, but when his company could not meet the demand for die-cast parts, Ford had no choice but to use stamped parts.

All types of presses were important in the past in metal stamping, forging, and deep drawing. Moving more metal in a single stamping stroke perfected the process. Presses and connected automated equipment sped up output, reduced labor costs, and made the workplace safer for workers.

Today, metal stamping controls such as I-PRESS and Connected Enterprise can record history and send reports, and I-PRESS and automation controls can also be monitored from a distance or from a mobile device. This is a new way to collect data on products being produced for historical purposes.

What is the stamping process?

Types of Metal Stamping

There are three main types of metal stamping: progressive die stamping, four-slide stamping, and deep-drawing stamping.

1. Progressive Die Stamping

Progressive die stamping usually has multiple stations, each with a different function.

The first step in progressive die stamping is to feed a metal strip into a progressive forging press. The metal strip slowly unwinds from the coil and enters the press. The different stations of the tool then cut, punch, or bend the metal strip in different ways. Each station builds on the work of the previous station to make the part one piece.

Manufacturers may need to change tools on a single press several times, or they may need to use multiple presses. Each press has different steps required to complete a part.

Even when multiple presses are used, additional machining services are often required to complete the part. For this reason, progressive die stamping is the best method for manufacturing metal parts with complex shapes.

To summarize, progressive die stamping offers the following advantages:

  • Faster turnaround
  • Lower job costs
  • Shorter run times
  • Higher repeatability

2. Four-slide Stampin

Quad-slide stamping, also known as multi-slide stamping, uses four different slides arranged horizontally. This means that four tools are used at the same time to produce the workpiece. This means that up to four different tools can be used to make multiple rotations at the same time.

The material is quickly bent by each stick with a tool as it moves through the four slides. Using this method, even the most complex parts can be produced with very precise cuts and corners.

If you compare Quad Slide Metal Stamping to standard stamping, you will find that it is superior in many ways. Here are some of those advantages:

  • Flexibility in the number of parts that can be machined
  • Greater freedom to change the design

3. Deep Draw Stamping

To perform deep drawing stamping, a blank sheet of metal is drawn into a die and shaped using a punch. When the depth of the stretched part is greater than its width, the process is called “deep drawing.”

This molding method is ideal for manufacturing parts that require different diameters. It is also a cheaper alternative to turning, which typically requires more raw material.

Deep drawing is commonly used to manufacture the following parts:

  • Automotive parts
  • Aircraft parts
  • Relays for electronics
  • Tools and pots and pans
  • Short-run stamping

Short-run metal stamping is a great option for prototypes or small projects. This is because it doesn’t require significant upfront tooling costs. Manufacturers use a mix of specialized tooling parts and die inserts to bend, punch, or drill the part after the blank is made.

Because it’s custom molded and produced on a smaller scale, the price per part may be higher. However, for many projects, especially those that need to be done quickly, short-run stamping can be less expensive. This is because there are no tooling costs, making it more suitable for projects that require a quick turnaround.

Stamping operations

A flat sheet of metal in coil or billet form is placed into a stamping press, which is known as stamping, also known as pressing. In a stamping press, tools and die surfaces make the metal into the correct shape. The metal is shaped in different ways such as stamping, blanking, bending, embossing, embossing, and flanging.

  • Bending. The metal changes shape or bends along a straight line.
  • Flanging. The metal is bent along a curve.
  • Embossing. It is the stretching of a material into a small depression. Mostly used to add decorative shapes.
  • Punching. In making a blank, a piece is cut from a thin sheet of material. This is usually done to make a blank for further processing.
  • Stamping. Squeezing or compressing a pattern into a material. It used to be commonly used in the manufacture of coins.
  • Stretching. Changing the shape of the surface area of a blank by controlling the flow of material.
  • Ironing. Tensioning a blank so that the surface area of the blank becomes larger, but the edges of the blank do not move inward. Commonly used to make smooth body parts.
  • Ironing. Material is flattened along straight walls while reducing thickness. Used to make beverage cans and bullet casings.
  • Reduction/Necking. Used to slowly reduce the opening of a tube or container.
  • Curl. Refers to molding something into a tube shape. For example, making hinges for doors.
  • Wrapping. Refers to folding the edges to make them thicker. The sides of automobile doors are usually folded.

In stamping press operations, piercing and cutting operations can also be performed. In progressive stamping, a strip of material passes through a row of dies one step at a time. In other words, a combination of the above stamping techniques is progressive die stamping.

Advantages of Metal Stamping

If you need to manufacture metal parts, components, or products, there are many benefits to working with a company that has metal stamping tools.

1. Accuracy

Stamping companies have the right tools and methods to cut your product with great precision. Cutting shapes with such a high level of accuracy costs a lot of money, so it’s easy to cut corners during production to save money. With a stamping company, you can get a better product for less money.

2. Consistency

Some companies say that cutting one piece at a time is the only way to ensure proper accuracy. But most of the best metal companies agree that this is not the case.

To make mass production consistent, you need to carefully monitor the entire process. It starts with an accurate computer-aided design (CAD), followed by the right tool, a professionally run metal stamping press. Finally, check the quality control of each piece or part to make sure the products are all the same.

3. Manufacturing large quantities

This is very clear. Do you need a lot of good products? Hire a company that has the right machines and tools to get your job done both quickly and well.

4. Workspace

If you hire another company for stamping, you won’t have to set aside time and space in your own company to make products.

Additionally, you free up time to work on other parts of your business without having to worry about production details.

Application Areas for Metal Stamping

Metal stamping can be used for many different types of materials, as each material acts differently on the metal. It can be used for many different purposes in many different businesses. In order for metal stamping to work well, it may be necessary to shape and process basic common metals as well as rare alloys for their specific benefits.

Some industries, such as aerospace, electrical, and military, require beryllium copper to conduct electricity or heat. Other industries, such as automotive, require steel and its many alloys for high strength.

Metal stamping companies typically operate in the following areas:

  • Automotive parts
  • Industrial machinery
  • Consumer electronics
  • Aerospace
  • Electrical field
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