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What Is Metal Stamping? | ESI Engineering

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Morgan

Jul. 15, 2024
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What Is Metal Stamping? | ESI Engineering

Varieties of Metal Stamping Techniques

Metal stamping encompasses several primary methods, chiefly: progressive stamping, fourslide stamping, and deep drawing.

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Progressive Die Stamping Explained

The process of progressive die stamping incorporates multiple workstations, each designed to execute a specific function.

The initial stage involves feeding a metal strip through a progressive stamping press. The strip gradually unrolls from a coil and enters the die press, where each subsequent station performs a distinct action such as cutting, punching, or bending. The cumulative effects of these actions result in a finished piece.

A manufacturer may need to frequently modify tools on one press or utilize several presses, each dedicated to one particular part of creating the finished product. Despite employing multiple presses, secondary machining was often essential to finalize a component. Consequently, progressive die stamping is particularly suitable for metal parts featuring intricate designs can deliver:

  • Accelerated processing time
  • Reduced labor costs
  • Shorter production runs
  • Enhanced consistency

Overview of Fourslide Stamping

The fourslide stamping method, also known as multi-slide stamping, employs a horizontal setup with four distinct slides; essentially, it utilizes four tools concurrently to mold the workpiece. This capability enables the execution of elaborate cuts and sophisticated bends, ideal for even the most complicated components.

One significant benefit of fourslide metal stamping over traditional press stamping is its flexibility and adaptability for intricate applications. Key advantages include:

  • Capability to manufacture more complex components
  • Increased adaptability for design modifications

As the name indicates, a fourslide apparatus features four slides, allowing up to four tools to perform various bends in quick succession as the material advances through the machine.

Deep Draw Stamping Defined

The deep drawing technique entails pulling a sheet metal blank into the die using a punch, effectively shaping it into a defined form. It is labeled 'deep drawing' when the depth of the resulting part surpasses its diameter. This method is particularly well-suited for producing components needing several varying diameters, providing a cost-effective solution compared to traditional turning processes, which often require a greater quantity of raw materials. Typical applications resulting from deep drawing include:

  • Components for automobiles
  • Aerospace parts
  • Electronic relay housings
  • Cooking utensils

Short Run Stamping: An Economical Approach

Short run metal stamping entails minimal initial tooling costs and serves as an effective option for prototype development or limited production orders. Once the initial blank is formed, manufacturers utilize an array of custom tooling components and die inserts to achieve the desired bends, punches, or drilled features in the part. Although this custom approach can elevate the per-piece cost, the elimination of tooling expenses often makes short runs more financially viable for various projects, particularly those requiring quick turnaround times.

Comprehensive Overview of Custom Metal Stamping

Custom metal stamping is meticulously designed specifically for a unique component and its operational requirements. Unlike conventional mass-produced stampings, custom options are selected when high precision and intricate dimensions are critical for unique parts. This process necessitates the preliminary development of a specialized stamping tool that cuts and molds each part as it runs through the stamping press. Custom metal stampings may range from substantial parts utilized in automotive applications to micro components designed for medical devices and electronic equipment.

Methods Used for Crafting Custom Metal Stampings

The stamping process comprises various sheet metal forming stages, which can operate as either a singular station where each press stroke produces the desired part form or through multiple sequential stages. The following techniques are employed to achieve the correct shape in the press.

Bending Processes

In bending, a formed feature is established through the angular alteration of a sheet metal workpiece. In certain workflows, one edge of the workpiece remains stationary while the opposite side is clamped and bent against a form to generate a precise bend or shape. Alternatively, the workpiece may be pressed into or against a forming die.

Blanking Technique

The blanking process effectively removes a metal piece from a larger strip or sheet by striking the material, where the removed section is designated as the new blank or workpiece.

Coining Methodology

Coining is a method that applies intense pressure to press the workpiece into a die, which molds the metal into a specific configuration and solidifies permanent features within the material. Coining also refines metal edges through high-force impaction, eliminating burrs and increasing material strength. This process can reduce the requirement for post-processing tasks such as deburring and grinding, thus saving both time and costs.

Crash or Crush Forming

This method reshapes metal using only a punch and a cavity, lacking control over the material flow and unable to avert issues like wrinkling or buckling. It is predominantly applied in crafting straightforward components, such as brackets, from thicker materials that resist wrinkling more effectively than thinner ones.

Cutting Techniques

Cutting ranks among the most prevalent stamping operations, generating parts through extreme pressure within the stamping press. Cutting encompasses various methods including trimming, notching, piercing, blanking, lancing, and shearing.

Drawing Methodology

Large metal parts, such as automotive components, are shaped using a complex drawing die. The technique involves managing the material flow into a die cavity via a pressure-loaded draw pad, which mitigates wrinkles as the material moves over a forming punch.

Embossing Techniques

Embossing represents a cold-forming operation to craft specific designs or formations on metal surfaces. A mix of male and female embossing components exerts pressure on the workpiece, forming three-dimensional features.

Extruding Techniques

Extrusion shapes the metal within a pierced hole and is often utilized for functions such as securing fasteners during assembly.

Flanging Operations

The flanging technique bends metal along a circular axis, generally employed to create a projection or rim related to a part's assembly and rigidity needs.

Forming Processes in Metal Stamping

Metal stamping comprises an array of forming operations where a stamping press utilizes tension, compression, or a combination of both. The precise forming method selected hinges on the material properties and the critical dimensions of the components to strike a balance between formability and durability.

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Ironing Process

Similar to coining, ironing employs compression to achieve uniform thickness and length dimensions by squeezing the metal along a vertical wall.

Lancing Operations

Lancing frees up metal sections without separating them from the original strip, creating slits or slices which may facilitate parts in progressive dies.

Piercing Techniques

This cutting operation, also termed perforating, produces holes in formed components, which might be circular, square, or custom-shaped, with the removed slug being discarded.

Pinch Trimming Innovations

Pinch trimming is a unique technique featuring the cutting of vertical walls on drawn or stretched vessels by pinching the metal material.

Punching Mechanisms

This forming technique employs a punch press to force a specialized tool through the material to create holes, yielding a scrap slug that falls into the die located below the sheet.

Restriking and Sizing Processes

Predominantly utilized to refine precision details after major forming is complete, restriking employs an additional die station to finalize small embossings and sharp radii.

Shaving Techniques

This operation seeks to minimize die-break while maximizing sheared edges. The approach usually involves pre-punching a hole slightly smaller before post-punching it to size with precise die clearance. This technique can be applied to the outer or straight edges as well.

Shearing Methods

Here, a cutting force is applied perpendicular to the material, prompting it to yield and fracture.

Trimming Processes

The trimming procedure defines the specified profile of a stamped part by shaping its borders or removing excess metal, undertaking precision trimming designed to minimize scrap generation.

Approaches to Custom Metal Stamping Production

The chosen method for metal stamping production considers the intricacy of the part and the most efficient means to shape it. In scenarios requiring precision parts with tight tolerances, techniques may involve in-die sensor utilization for quality assessment alongside various inspection methodologies. This also includes secondary procedures such as plating, heat treatment, welding, and cleaning or sterilization.

Progressive Die Stamping Insights

The progressive stamping technique advances a metal strip through various stations, with each performing a different function until the piece is complete. Conical-shaped pilots inserted into pre-punched holes in the strip ensure precise alignment as the part moves forward, maintaining accuracy throughout its formation. Given that the component remains connected to a strip during the entire process, a slight misalignment may compromise the entire assembly.

Progressive die stamping provides notable benefits including high repeatability, and continuous material feeding facilitates long production runs that yield a greater number of complete parts swiftly—resulting in lower costs per item.

Progressive Stamping Offers High-Speed Production and Cost Efficiency.

Transfer Die Stamping Overview

The transfer die stamping method operates a single press to manage multiple tools. Transferring parts from their metal strips allows them to be shaped freely at every station until completed. Automating this transfer process centralizes operations within a single press.

Transfer dies efficiently manage numerous part features in one press pass—such as holes, cut-outs, or threading—eliminating expensive secondary procedures.

This technique is typically deployed for large components like frames, tubes, shells, and structural elements.

Choosing Between Progressive Die Stamping or Transfer Die Stamping for Your Next Precision Metal Stamping Endeavor?

Deep Drawing Methodology

Highly beneficial for applications demanding recessed cavities, deep drawing excels where the depth exceeds the part's diameter, employing blanking, swaging, or sizing techniques to manipulate the base material while incorporating recessed features.

Fine Blanking Explained

Fine blanking is optimized for components requiring exceptionally smooth and flat edges. Especially fitting for moving parts, such as gears, this method merges metal stamping with cold-metal extrusion, utilizing specially designed presses.

Progressive Stamping vs. Fine Blanking: Essential Queries for OEMs to Consider

Multi-slide / Four-slide Stamping Insights

Multi-slide or four-slide stamping is ideally suited for crafting intricate components that necessitate multiple bends or twists as well as wire formation. The primary distinction is that four-slide machines host four operational slides, while multi-slide machines incorporate more than four. The machine strikes the material to create the final parts.

Multi-slide / Four-slide machines can fabricate complicated components with varied and intricate bends, including clips, brackets, flat springs, terminals, retainers, and wire-formed items, utilizing both flat and round materials.

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