Metal stamping is a very flexible and fast process for manufacturing parts. It allows flat metal sheets or coils to be shaped into parts with complex and precise shapes. By applying force, pressure, and special tools, parts with different shapes such as bends, curves, cuts, and embossing can be created.
This manufacturing process can effectively reduce production costs. In addition, the parts manufactured using this process are always the same in terms of quality, size, and shape. Now, let’s learn more about the interesting world of metal stamping, as well as its various stages and details.
Table of Contents
The Principle and Process of Metal Stamping
How it Works
Metal stamping requires the use of a press. The press applies the necessary force and pressure to form or shape a sheet or coil of metal into the desired shape. The dies are special tools built into this powerful machine. They enable a wide range of different stamping processes to be carried out on metal. The way the press moves and the way the dies interact with the metal in the line are carefully controlled. The stamping process can change the shape and structure of the material in amazing ways.
Designing and Manufacturing Tools
The stamping process begins with careful engineering and planning. This is why the shape of the desired part needs to be carefully planned. Stamping professionals need to consider many factors, such as the properties of the material, the shape of the tool, and the requirements of the tool. Once the design is complete, it can be drawn using CAD (computer-aided design) or CAM (computer-aided manufacturing) software to ensure it is correct.
Once the tool has been designed, different types of machining tools and techniques are used to manufacture the special equipment. These include, for example, blanking dies, forming dies, and punching dies. The tools and dies must be constructed in such a way that the material flows smoothly and leaves enough space for the sheet metal. This provides the part with the appropriate support during the stamping process.
Preparing the Material
Experts select sheets or coils of metal according to the requirements of the part. They take into account the strength, ductility, cost, conductivity, and corrosion resistance of the material. The material you choose should be suitable for the stamping process and the function of the part you want to manufacture.
Feeding
Before stamping, the selected material needs to be cut, slit and flattened. The aim is to give it the right size and shape. Once the sheet or coil is ready, it is fed into the stamping machine. An automatic feeding system ensures that the metal is in the right position for stamping.
Punching Operation
When the punching machine starts working, the dies close together. This exerts a lot of force and pressure on the metal. This pressure changes the shape of the material so that it fits the dies. Different metal forming techniques may be used during the punching process. These include blanking (i.e. cutting out the desired shape), bending (i.e. creating angles or curves), embossing (i.e. adding small details), and perforating (i.e. creating holes or cuts).
Depending on the design of the part, these specialists may carry out these steps in any order or simultaneously. During the stamping process, operators carry out quality control measures. These include inspections and real-time tracking. They ensure that the parts meet the specified tolerances and quality standards.
Finishing and Post-processing
After stamping is complete, these professionals may do more work on stamped parts. For example, deburring (removing sharp edges), cleaning, surface treatment, and sealing. This can make stamped parts look better, more durable, and more effective.
The stamping process uses this methodical approach to shape flat sheets or coils of metal into precise parts for many industries and applications. The marriage of precision engineering, materials science, and advanced manufacturing methods continues to transform the production of complex metal parts.
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.
Types of Metal Stamping
There are three main types of metal stamping: progressive die stamping, four-slide stamping, and deep-drawing stamping.
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
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
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. There are many ways to shape metal:
- 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. Different punching processes have unique advantages, disadvantages, and working principles.
- 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. As a result, 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.
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.
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.
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.
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.
Automotive Industry
Metal stamping is an important part of the automotive industry. It produces body panels, brackets, chassis components, engine mounts, brackets, and suspension components. The process ensures that the parts produced are strong, durable, and lightweight. It also meets stringent safety and performance standards.
Aerospace
The metal stamping process also shines in the aerospace industry. Key components such as engine parts, aircraft structural parts, brackets, and fittings can be manufactured using this process. It enables the production of lightweight, robust, and durable parts with complex geometries. This improves the performance and fuel economy of aircraft.
Electronics
The electronics industry makes extensive use of electronic devices such as connectors, terminals, heat sinks, shields, and brackets. Metal stamping technology enables the manufacture of precisely complex parts for computer components. These parts conduct electricity well and have a long service life.
Household Appliances
Metal stamping processes are also used extensively in the manufacture of household appliances such as refrigerators, washing machines, ovens, and HVAC systems. They enable the manufacture of components such as attractive and well-constructed panels, housings, brackets, and handles.
Healthcare Industry
In medicine, surgical instruments, orthopedic implants, stents, and connectors are manufactured using the metal stamping process. This ensures the precision, sterility, and biocompatibility of the components. That is to say, these properties are essential for medical applications.
Construction
And let’s not forget construction. Brackets, connectors, fasteners, hinges, and cladding are just a few of the structural and decorative products commonly used. Overall, the process produces parts that are durable and rust-free.
Summary
Metal stamping is a complex process that only companies with extensive experience in the field can handle. When your business needs the best metal stamping products and services, Yonglihao Machinery is the company to turn to. Yonglihao Machinery is a well-known top metal processor that specializes in providing you with the best options to suit your exact needs.
Yonglihao Machinery offers a variety of services, including metal stamping. We employ advanced technology and incorporate new ideas that have been developed over many years. In addition, Yonglihao Machinery partners with many companies to provide top-notch products and services around the world.