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This Article takes an In-depth look at Metal Stamping
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The metal stamping process began during the industrial revolution as a cold forming means for producing frames and handlebars for bicycles. From its beginnings in Germany, it has grown into an essential part of modern industry for the production of parts and components for a wide variety of industries. The early auto industry transferred its parts production from forging to metal stamping because of the lower cost of the stamping process.
Metal stamping is a relatively simple process where rolled or sheet metal, referred to as a blank, is placed in a press that has a die in the desired shape of the part. With force and compression, the die is pressed into the metal. After a predetermined amount of time, a partially completed part is removed. Though this may seem very easy to understand, in reality, there are several different steps that need to be taken that include trimming, finishing, and other procedures designed to produce the finished part.
Though metal stamping started 100 years ago, over the years, it has been updated, improved, and made a part of the technological age. This can be seen with the introduction of computer numerical control (CNC) into the stamping process where designs are created and tested on a computer then fed into a CNC metal stamping machine.
Metal stamping offers several advantages. As a cold shaping process, it eliminates the need for heating, which reduces costs. This technique allows for the creation of complex and intricate designs that would be challenging or impossible to achieve with other methods. Additionally, metal stamping's precision and accuracy make it the preferred choice for manufacturing parts.
Metal stamping takes a flat piece of metal and transforms it into a specific and desired shape. It is a complex process that involves several complicated and intricate procedures. From the auto and aerospace industries to the medical and electronics industries, metal stamping is an integral part of producing affordable and well-crafted parts and components. Metal stamping involves the use of a wide array of processes and techniques such as punching, blanking, embossing, coining, bending, and flanging.
Metal punching is a fabricating process that removes a scrap slug from the workpiece when the punch enters the punching die. Punched material is normally in sheets but rolled metals can be used as well. The process leaves a hole in the die that exactly matches the dimensions of the design. Holes of varying shapes and sizes are accurately produced using this process.
Sheet metal blanking is a shearing and cutting process where a piece of metal, known as the "blank," is cut from a larger sheet. The blank is shaped to match the final part's desired form and is typically used in a 2D forming process.
Embossing produces a raised or recessed design by forcing a blank against a die in the shape of the desired pattern. When the metal is pushed into the embossing machine, a tool or stylus creates a raised effect on the opposite side of the blank. By placing the blank on a sheet of rubber or foam, the embossed image has a smooth surface finish.
Coining is required when the edges of a stamped part need to be flattened. The process creates a smoother edge, produces finer details, and adds strength to the workpiece. Coining helps avoid any forms of secondary finishing such as deburring or grinding. A great deal of pressure is required for coining to produce the necessary plastic deformation.
Bending refers to a method of deforming metal into L, U, or V-shaped profiles. A press brake bends the metal using a punch and die. The different forms of press braking are mechanical, pneumatic, hydraulic, and CNC. The bending process results in a deformation that stresses above the yield point but below the tensile strength and occurs around a single axis.
Flanging is a metalworking process where a metal piece is shaped to create a flare or flange using a die, press, or specialized flanging machine. This technique forms a 90-degree bend in the metal. If the breakline of the bend is longer than the trim line, it is referred to as a stretch flange. Conversely, if the breakline is shorter than the trim line, it is known as a shrink flange.
Metal stamping machines can cast, punch, deform, and bend metals using computer programming or computer numerically controlled (CNC) machines for precision and accurate parts. The modern process of stamping can quickly create exact metal shapes with meticulous accuracy and measurements. These highly technical tools provide custom solutions for 300 different kinds of raw materials. The low cost of stamping has made it a major factor in the production of the items we depend on to make life easier.
Metal stamping machines are crucial in the United States and Canada for efficient, cost-effective mass production of metal components. These machines play a key role in various industries, including automotive, aerospace, electronics, and medical, driving technological advancements and economic growth. Below, we explore a range of these machines and highlight the features that have made them popular.
The Komatsu E2W series presses stand out for their precision, dependability, and energy efficiency. Featuring advanced servo-driven technology, these presses offer precise control over the ram&#;s movement, ensuring consistent and accurate stamping. Their design focuses on minimizing energy usage and reducing operational costs, making them a favored choice for diverse metal stamping needs.
AIDA's NC1 series presses are celebrated for their durable construction, exceptional speed, and versatility. Designed with cutting-edge controls and automation capabilities, these presses ensure swift and efficient production. Renowned for their precision, the NC1 series adeptly manages a diverse array of stamping applications, making it a preferred choice for metal stamping enterprises.
The Bliss C1 Straight Side Press is celebrated for its exceptional durability and rigidity, ensuring stable and precise stamping operations. Its straight side design offers easy access to the working area, making die changes and maintenance straightforward. Known for its capability to handle heavy-duty stamping applications effortlessly, this press is a reliable choice for demanding tasks.
The DSF Series Servo Presses from SEYI are renowned for their precision and high-speed performance. By harnessing servo motor technology, these presses ensure precise control of the ram&#;s movement, leading to lower energy consumption and enhanced productivity. Ideal for tasks involving complex forming and intricate shapes, the DSF Series is a top choice for demanding applications.
Metal stamping refers to several types of forming processes each of which performs a special type of operation. The type of stamping method depends on several factors from the design of the part to the number of required stamping operations. The choice of procedure is normally defined and specified by the engineer or designer.
Normally, stamping refers to a single operation where a portion of a part is formed in one machine before being moved on to another machine or set of machines. The process requires multiple dies on several pieces of equipment. Finishing and shaping are separate operations performed after the part has been through the various machines. Progressive stamping removes the need for multiple machines performing several functions and handling of the workpiece in a single set of operations. A strip of rolled metal unrolls into a single die press with a number of stations that perform individual functions. Each station adds to what has been done previously resulting in a completed, finished part.
Progressive stamping simplifies the production of complex and intricate parts decreasing production time while increasing efficiency. Movements must be precisely aligned since the part is still connected to the metal roll. The first station separates the fabricated part from the rest of the metal. Progressive die stamping is ideal for long runs since the dies last longer and do not sustain any damage as a result of the process. As with several stamping processes, progressive stamping is repeatable. Each station performs a different cut, bend, or punch to gradually achieve the desired end shape and design. Progressive die casting is faster and has limited waste scrap.
Transfer die stamping uses a mechanical transport system to move the part from station to station. It is used for tube applications, frames, shells, and structural components. A die can be a simple single die or part of several dies lined up in a row. To perform transfer die stamping, the part is removed from the metal strip as it transfers between stamping stations. Transfer die stamping was developed to produce large parts and workpieces with the additional benefit of lower tooling costs.
Four slide, multislide, or four way stamping shapes the workpiece horizontally sliding it between four different tools. As the workpiece feeds, it is bent by each tool using a smooth set of processes. Each slide is driven by a shaft controlled by the rotations of a cam. The shafts are connected by a bevel gear with one electrical motor to power the shafts. The workpiece may be shaped with all tools working at once or in succession. The key to four slide stamping is the shafts, which allows the work piece to be shaped on all four sides.
Fine blanking is a special type of stamping that produces flatness and a sheared edge that is impossible with traditional stamping. Any secondary machining of parts is not required since profiles, web sections, and holes are completed in one process. To achieve the perfection of fine blanking, the blank is compressed between the upper and lower punches allowing the process to hold a very tight tolerance. The process is known for its high accuracy and smooth edges. It is done with hydraulic or mechanical presses or a combination of the two.
The blanking process involves three key movements: clamping, blanking, and ejection. Fine blanking presses operate under high pressures, necessitating tools that can endure these conditions. This entire process is executed in a single cold stamping step.
The normal categories for stamping presses are mechanical, hydraulic, and mechanical servo. Feeding is done automatically either in sheets, coils, or perfectly sized blanks. The type of feeder depends on the thickness of the sheets. The reel type is used for thinner sheets while thicker metal sheets are fed individually. With roll metal feeders, as the metal unrolls, it is straightened to remove any residual effects.
Mechanical milling is a method for preparing and reshaping metals without the use of heat or chemicals. Its function is to remove metal from a workpiece by using a cutter where the metal has a flat, rough, or irregular surface, and the workpiece is fed into the cutter. Mechanical milling requires a high powered motor to rotate the cutter to break down the structure of the workpiece. The size of the cutter and speed vary depending on the type of machine. Most mechanical milling equipment weighs several tons and is designed for heavy duty operation. They have been a major part of manufacturing and product production since the industrial revolution.
Hydraulic milling machines use the force of hydraulic power to compress the workpiece onto the die. This form of milling is widely used because of its accuracy and cost effectiveness. Pressure applied to the die is more uniform than produced by mechanical milling machines. In many cases, the hydraulic milling machine&#;s process is referred to as stamping since the workpiece is stamped into the mold or die. The workpiece is fed into the machine and aligned with the die where pressure is applied. The amount of pressure and speed can be adjusted to fit the type of metal. As with all milling equipment, hydraulic machines come in several sizes to fit the type of manufacturing.
Until recently, the only way to increase tonnage on a press was to build a bigger press with a larger motor or flywheel, an expensive process. Press designing engineers decided to build a better press by removing the motor, flywheel, and clutch and replacing them with a servo motor focused on needed energy.
Servo presses offer greater flexibility by allowing precise adjustments to stroke and slide positions. Unlike traditional presses that use a flywheel, servo presses utilize a servo motor to deliver torque through a controlled and programmable system. This innovation enables exact control over speed, making it possible to adjust velocity, dwell time, and stroke length to meet the requirements of various applications.
Using high capacity motors, mechanical servo presses can create complicated stampings at a faster rate than hydraulic presses and are powered by a link-assisted drive system or a direct drive one. Of the three types of presses listed, the mechanical servo press is the newest and most expensive. Regardless of the drawback of cost, several manufacturers have installed mechanical servo presses and have found them to be more efficient and cost effective.
Stamping dies are precision tools specially designed to cut and form metal sheets into a specific shape or profile. Dies are made from hardened steel called tool steel, a variety of high-hardness and abrasion resistant steel. Included in a die can be cutting and forming sections made from other metals that are hard and wear resistant. Dies for metal stamping can be either single-station or multiple-station.
Dies used for single station operations can be compound or combination . Both perform multiple operations in a single function. The main difference between them is their design and the type of stamping they do where a compound die mainly cuts and a combination die does both cutting and non-cutting processes.
Compound dies are designed to execute multiple cutting operations in a single press, such as those required to manufacture a simple steel washer. They can produce a part every three seconds, which minimizes labor costs and shortens lead times. By cutting complex parts in a single stroke, these dies ensure precise accuracy for each piece. The high precision of compound dies also reduces material waste, contributing to additional cost savings.
Combination dies feature both cutting and non-cutting tools, allowing them to reshape materials in a single operation. This integrated approach enables simultaneous processes such as cutting, drawing, and bending. One of the key advantages of combination dies is their efficiency and cost-effectiveness for large projects. They streamline die setup, reduce waste significantly, and can perform tasks like creating holes and flanging with a single cut.
Multi-station dies employ progressive milling to automate the movement of the workpiece through various stages. Raw metal is introduced into the machine, where it undergoes processes such as cutting, bending, coining, or punching, based on the system&#;s programming and the part&#;s specifications. Each station within the die can perform one or multiple functions, streamlining the manufacturing process.
Steel rule dies, also referred to as knife dies or cookie cutter dies, were first used to cut softer surfaces such as plastics, wood, cork, felt, fabrics, and paperboard. Though they are not as sturdy as steel dies, they have found use in the cutting and shaping of thin non-ferrous metals such as aluminum, copper, and brass.
Steel rule dies are made of high grade, high density, and hardwood plywood with steel strips added. Slits are cut into the flat plywood. Steel rule, which is similar to a razor blade, is inserted into the slits. Rubber is glued to the flat side of the plywood to help eject it after the cutting process and prevent it from sticking to the metal press. Steel rule dies come in several thicknesses depending on the application.
The steel strip material used for the cutting surface is designed to match the desired shape. The characteristics of the workpiece, such as thickness and hardness, help determine the steel rule thickness to be used in the cutting blade. Steel rule dies can be used to cut exotic materials, thick foam, carpet, and rubber. It is an inexpensive and effective method of cutting thin sheet metals.
Stamping involves a detailed understanding of metals and their manipulation. The choice of metal for a project is crucial and depends on the desired result. While metal is typically used for stamping, non-metal materials like paper, leather, and rubber can also be shaped through this process. DIY enthusiasts and hobbyists often use hand-operated stampers for home projects and for shaping non-ferrous metals.
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Though there are thousands of metals that can be stamped, there are two general categories - ferrous and nonferrous where ferrous metals have iron and nonferrous do not. Nonferrous metals that are commonly stamped are aluminum, brass, bronze, gold, silver, tin, and copper. One of the factors that determines the formability of a metal is its carbon content, though carbon is only one of many factors.
Alloys, a compound of two or more metals, are commonly used in metal stamping. Each alloyed metal has special characteristics that has to be considered when being used for metal stamping. For example, non-standard alloys, such as beryllium nickel and beryllium copper, are excellent for metalworking, forming, and shaping musical instruments and bullets.
The art of shaping and forming precious metals has deep roots, stretching back to ancient civilizations such as the Romans, Greeks, and Egyptians. What was once the domain of skilled artisans has evolved with the advent of modern stamping machines. Today, silver, gold, and platinum can be crafted into elaborate designs using advanced dies and cutting tools. While the craftsmanship of yesteryear has been largely replaced by technological innovation, the essence of metalworking continues to thrive through these sophisticated machines.
Ferrous metals are excellent for manufacturing components thanks to their durability, high tensile strength, and hardness. Low carbon steels, in particular, offer exceptional formability, making them suitable for creating hardened machine parts and various other versatile applications.
As with any industrial process, careful planning and preparation are necessary when using metal stamping. The selection of the correct metal and the quality of the final product depends on the type and quality of the materials for the process.
When a workpiece has completed the stamping process, it may require other processes to remove any imperfections, deformities, or excesses as well as the addition of other parts and applications. This is performed during post stamping production operations, which include deburring, tapping, reaming, and counterboring.
After stamping, workpieces may have rough, sharp, or jagged edges known as burrs. The process of eliminating these imperfections is called deburring. Various methods can be employed for deburring, including manual techniques, electrochemical processes, and thermal treatments. Burrs can form not only on edges but also in seams, meaning multiple sections of a workpiece may need deburring.
Deburring improves the quality, aesthetic value, functionality, and appearance of a workpiece. Also, there is the matter of safety where a small notch or deformity can catch on a piece of equipment or cause personal injury. More difficult burrs may need to be flanged over to produce a smoothed edge and direct the burred edge to the inside fold where it will not cause injuries or be noticed.
When a design is created using CAD, onscreen results and calculations give the impression that what has been produced is perfect and flawless. What may be ignored are some of the limitations to processing and types of material, which can lead to the production of parts that do not perform as they were designed. Thickness, formatting area, grain direction, and hardness all have an influence on the design of a part and the stamping process.
Design flaws can compromise the quality of the final product. One such flaw is overly narrow projections, which can distort the workpiece.
Designs are tailored to match the manufacturer&#;s existing equipment, tools, dies, and materials. Utilizing custom dies or special equipment raises both manufacturing and fabricating expenses, ultimately increasing the cost of the final product.
Special consideration is necessary regarding sharp edges, corners, and bends in a design to help in the reduction of burrs and other deformities since they will require special finishing and other secondary treatments. Sharp bends or corners may cause cracking due to increased stress on the workpiece. Increased stress can lead to failure of the part.
During the design phase, precise adjustments are necessary to accommodate the folds on edges, flanges, and material removal, ensuring the product fits within the width and length constraints of the workpiece.
Large stampings require a stamping press with a large bed and higher tonnage. When larger machines are not available or practical, production can be completed by using multiple steps that are later joined together.
Punching is a cutting process used to modify and deform a metal blank where shearing force is applied. It is similar to blanking with the exception of the piece being removed, slug, is scrap. Punched holes are in simple geometric shapes either individually or combined. Holes formed from punching normally require secondary finishing since burrs are left around the edges of the hole. The punch is driven into the workpiece at high speed. CNC punch presses can be hydraulic, pneumatic, or electrical able to deliver over 500 punches per minute. Most punches have a turret that can hold close to 100 different styles of punches.
Bending is applying force to the workpiece causing it to bend at an angle to create a desired shape. The operation is performed along one axis, but a set of operations are possible for complex pieces. Parts can be as small as a bracket or several feet. Bending creates both tension and compression in the workpiece. The outside part will have tension while the inside, as it shortens, experiences compression. In some cases, it may be necessary to overbend to account for any springback.
When milling holes by punching or drilling, ensure that the holes are spaced at least twice the sheet thickness apart. This distance is crucial for maintaining the metal's strength and preventing deformation. For holes positioned near the edge of a workpiece, they should be placed at a distance equal to the thickness of the workpiece from the edge. Additionally, the space between holes and bends should accommodate the bend radius and be sufficiently far from the bend to avoid compromising the structural integrity.
Metal stamping is a versatile method for reshaping and deforming metal sheets, allowing for the creation of highly intricate and complex designs that other processes cannot achieve. This technique can transform a simple flat piece of metal into a functional and practical shape with ease.
There are several benefits to metal stamping, which include lower costs for dies and any secondary factors. Modern era stamping machines are automated and work with little need for any handling of the workpiece. The dies and tools required for stamping are inexpensive and can be used multiple times. Cleaning, plating, and other secondary processes are less expensive since many products are nearly finished after being pressed. Automation processes for stamping machines are uncomplicated and adaptable. Various computer programs offer precision, control, and precise dimensions for the completion of a product providing quicker turnaround times. An added benefit of automation is a significant decrease in labor costs.
One of the drawbacks to metal stamping is the cost. Upfront cost of equipment, tools, and dies are high and require a significant investment. For custom parts or designs, a special steel die has to be created leading to longer pre-production and extended turn around times. Changing dies during production due to design flaws can be difficult and time consuming.
Metal stamping is rapidly emerging as one of the fastest-growing production techniques globally. Over the next decade, the stamping market is projected to reach $300 billion worldwide. While this figure might seem ambitious, it becomes more understandable when you consider the wide range of industries that rely on stamping for their manufacturing processes.
The process of metal stamping is used by industry to produce parts and products with high precision, accuracy, and speed. Products produced using stamping methods have lower errors per production cycle than any other process, which eliminates flawed or faulty products.
Several industries rely on stamping to produce products. The automotive industry uses it for structural components such as body frames, electrical systems, and steering systems. The aerospace industry requires parts that need to meet strict manufacturer specifications to ensure safety and maintain certifications. The medical industry has requirements similar to aerospace and depends on metal stamping for its accuracy and reliability.
Computer and electronics manufacturers use metal stamping to create their internal components. Technical parts have special shapes and dimensions requiring precision manufacturing and production methods. The stamping process plays a critical role in the fabrication of these modern conveniences.
The metal stamping industry has played a part in the production of most of the items found in homes, schools, business, and offices. It has become an essential part of 21st Century advancements. It is highly likely industry will continue to depend on it for many years to come.
Stamping is a major part of manufacturing and part production. It is very likely that it will continue to play an important role in the production of future parts for innovations and inventions that are presently on the drawing board or in the imaginations of engineers. For more information on milling and stamping companies consult IQS Directory for a complete listing of local and national fabricators, processors, and producers who can meet your production requirements.
Metal stamping is a cold-forming manufacturing process that uses specialized tools (i.e., dies) and equipment (i.e., presses) to form and cut sheet metal into various shapes and sizes. At the start of a stamping operation, the die(s) is/are installed within the press(es), which provide(s) the force needed to turn the material into the desired component. While stamping dies may vary from project to project depending on the part and production needs, they can be categorized into two main groups: single-station dies and multi-station dies. Below, we go into greater detail on the unique characteristics of each type of metal stamping die.
Multi-station stamping dies are used in stamping operations in which a part is produced by moving the material through different stations. These dies come in series; each die in the series makes slight changes to the workpiece that gradually forms and cuts it into the desired shape and size.
The two main types of multi-station stamping dies are progressive stamping dies and transfer stamping dies.
In progressive stamping operations, each station in the die performs a specific task within the press. Once the task is completed, the workpiece is automatically moved to the next station. This process gradually forms and cuts the material until it has been turned into the desired component. At the final station, the component is cut free from the larger piece of material.
The transfer die stamping process is highly similar to the progressive die stamping process; components are produced by passing the workpiece through a series of consecutive stations within a single die. The main difference between the two processes is that the component is cut from the sheet metal at the beginning rather than the end. Parts are then transferred through the stations manually, robotically or with some mechanical means.
Both progressive stamping dies and transfer stamping dies are widely used for stamping projects. However, given the difference in their processes, they are utilized for different types of projects. Progressive stamping dies are better suited for components that are small and simple, while transfer stamping dies are better suited for components that are large and complex (e.g., frames, shells, tubes, and other structural components and systems). The former dies are also commonly used for parts that require multiple forming and/or cutting operations to be performed simultaneously, while the latter dies are often used for parts that need to be transferred among multiple presses.
Single-station stamping dies&#;also referred to as single-stage or single-operation stamping dies&#;are used in stamping operations in which a single element is created or a single operation is performed by each stamping press. If multiple elements and/or operations are needed to produce a finished component, the workpiece must be moved from press to press until it is completed, which can be time-consuming. That&#;s why these dies are generally used for simple parts and products and low-volume production runs.
Some of the most commonly used single-station stamping dies are simple stamping dies, compound stamping dies, and combination stamping dies.
Simple stamping dies are designed to perform one operation per stroke of the press. They are ideal for basic jobs, like blanking or piercing, but are not suited for larger applications.
Compound stamping dies are designed to perform multiple operations per stroke of the press. They are better suited for complex or demanding jobs than simple stamping dies since they can complete the job faster. However, while they can handle cutting operations (e.g., blanking and piercing), they are not ideal for forming operations (e.g., bending).
Combination stamping dies are similar to compound dies. They can perform multiple operations per stroke of the press. However, they are suitable for both cutting and forming operations, meaning they can be used for blanking, piercing, bending, and forming.
Single-station dies can be used for a variety of stamping operations, including:
This stamping process involves cutting a piece from the sheet material. The cut piece is the desired component, while the remaining material is scrap.
This stamping process is similar to blanking. The main difference between the processes is that that cut piece is scrap, while the material from which the piece was cut is the desired component.
This stamping process places compressive and tensile forces on the sheet metal to draw it over and/or into the die, resulting in the production of a hollow component.
Want additional information on the different types of metal stamping dies? Ask the experts at Premier Products of Racine. Equipped with extensive custom metal stamping experience, we can answer any questions and address any concerns you may have about these components. Additionally, if you need a partner for your next metal stamping project, we&#;ve got you covered. Contact us or request a quote today to discuss your project with one of our representatives.
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