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%0D%0A%20%20%20%20%20%20%20%20%20%20%20%20%20%20%20%20%20%20%20%20%20%20%20%20With coining, a metal sheet is compressed between two rigid tools that have a clearance that is less than the thickness of the sheet of metal. Coining reduces spring back and helps increase dimensional accuracy. When coining bent areas of a part, the effect of bending is minimized, and even compression is the result.
During the process, the tip of the punch tool penetrates the metal sheet and repeatedly bends the metal to relieve stress on a workpiece, removing spring back effects. Coining minimizes the need for additional finishing and requires immense pressure to achieve the desired plastic deformation.
The purpose of metal stamping bending is to change the geometry of the workpiece. Force applied by a stamping machine causes stress on the sheet metal, which is beyond its yield strength. The result is the physical deformation of the metal without breaking the metal. On the surface, sheet metal bending seems to be a simple straightforward process. Although this may be the initial impression, there are a variety of sheet metal bending methods that are both similar and different.
The list of metal stamping bending methods includes V-bending, air bending, bottoming, wipe bending, roll bending, and rotary bending. Each of the different methods renders a different deformed shape.
Flanging is a metal stamping bending process where the workpiece is bent to a 90° angle or more. The process involves spinning or deep drawing a workpiece using a flanging machine. The purpose of flanging is to connect extensions or for holding lids on parts. The effect of flanges is an increase in the durability and strength of a part.
With flanging, the workpiece is positioned between a bottom die and pressure pad. The metal stamping punch tool forcefully pushes down on a portion of the workpiece that extends out from between the die and pressure pad. The force of the downward motion of the punch is adjusted to the proper angle of the die and punch to avoid the occurrence of springback. A sheet metal flange can be a projection or rim that adds strength, attaches to parts, or creates a flat surface. The three basic types of flanges are angle, pipe, and flat, which are used and designed for a specific purpose. In certain instances, flanging is used in place of trimming by bending at an angle greater than 180° to form a U-shape.
Metal stamping technologies refers to several types of forming processes which shape and form coiled or sheet metal. The choice of stamping method depends on several factors from the design of the part to the number of required stamping operations. The choice of process is initially determined and specified by engineers or designers.
Progressive stamping removes the need for multiple machines performing several functions. Workpieces are shaped by a set of operations. A strip of metal unrolls into a single die press with several workstations that perform individual functions. Each station adds to what has been previously completed resulting in the ejection of a finished part.
The process of progressive metal stamping produces complex and intricate parts. The workpiece is automatically transferred from one workstation to the next and requires the use of high tonnage stamping presses that apply extreme pressure to create the desired shape. The various workstations perform coining, bending, punching, forming, and drawing. At each workstation, the workpiece is changed and formed in preparation for the next workstation, shaping the workpiece as it moves through the various stamping processes. Once the completed part design is achieved, it is cut from the metal strip as the final product.
With progressive stamping, the production of complex and intricate parts is simplified, decreasing production times while increasing efficiency. Each movement of the workpiece is precision aligned to avoid waste and to ensure quality. Cuts, bends, or punching happen gradually to achieve the desired end shape and design. The process is quick and easy and produces minimal waste.
The key factors regarding the choice of progressive die metal stamping are the size of a component, its complexity, and the number of components to be produced. In the majority of cases, progressive die stamping is used for high volume part production due to progressive die stamping’s ability to produce high volumes at a low cost per part.
Aside from its ability to produce high volumes of parts, progressive die stamping has several advantages over other stamping methods.
The unique nature of progressive die stamping requires certain steps to prepare for the process. The first steps in the process are the most critical since they determine the quality of the final product.
Although progressive die stamping can shape a wide variety of metals, it normally is used for shaping steel, aluminum, and copper. These three metals are used due to their versatility and their ability to withstand the force and pressure of the process. The choice of metal is highly dependent on specifications of the final product and its required characteristics.
Steel – Steel can be easily formed using progressive die stamping to create a wide range of geometries with intricate and complex features.
Aluminum – Aluminum, with its many grades, is an ideal metal for progressive die stamping. It is easy to shape, can be used for complex design features, has exceptional corrosion resistance, has low density for lighter parts, and can be used for electrical conductivity and connector parts.
Copper Alloys – Like aluminum, copper is available in an assortment of grades, which can be adapted to a variety of applications. The main common characteristic that makes copper ideal for progressive die stamping is its exceptional electric conductivity.
While steel, copper, and aluminum are most commonly used for progressive die stamping, other exotic metals with high strength and unique properties are also used. In most cases, they are alloys that are based on steel, stainless steel, titanium, and magnesium. These metals are chosen for their special features to meet the specific requirements of an application.
Transfer die stamping is a form of progressive die stamping that completes the process by transferring the workpiece from station to station instead of moving the workpiece along progressively in one machine. A mechanical transport system that is incorporated into the system moves the workpiece to each station.
Transfer die stamping is used for frames, shells, and structural components. The main feature of the process is the freeing of a part from the metal strip that is common to progressive die stamping. Simple single dies or several dies lined up in a row are used to complete deforming. During transfer die stamping, the removal of the part from the metal strip, that is similar to progressive die stamping, facilitates the easy transfer of the part between workstations. The process of transfer die stamping was developed to produce large parts and workpieces with the additional benefit of lower tooling costs.
Traditional stamping involves a vertical press that applies downward force using a tool and die to shape and form a workpiece. It is a compression or pressing process used to form and shape coiled or flat pieces of metal. The upper portion of a stamping machine or ram has a die or tool that moves downward to the bolster that holds the die. When the upper and lower portions meet, at high pressure and speed, the metal that lays upon the die is punched, bent, cut, and shaped.
Fourslide or four slide stamping is similar to progressive die stamping in that several stamping processes are completed in a single stamping cycle. It involves four fixed stamping tools that form metal sheets at a 90o angle. Each slide has a tool for bending, twisting, cutting, and forming. As with progressive die stamping, four slide stamping generates less waste and is highly efficient.
With progressive die stamping, a workpiece moves horizontally from workstation to workstation. Unlike progressive die stamping, the workpiece for fourslide stamping is positioned in the center of the mechanism. Each stroke of the four tools is precision timed to perform its function shaping the workpiece at 90o angles. Prior to entering the core of a fourslide die stamping machine, the material to be shaped is processed by a straightener to prepare a workpiece for the process.
The slides of a multi-slide or fourslide stamping machine are driven by four shafts connected by a series of bevel gears. One of the shafts is powered by an electric motor that drives the shafts of the other four slides. As with progressive die stamping, each shaft is affixed with a tool that strikes the workpiece. The design of the four shafts makes it possible to work a workpiece on four sides for exceptional precision and repeatability.
Traditional stamping presses are ideal for shaping parts by bending and pressing. Although their single direction accuracy is beneficial and efficient, it limits their ability to produce complex and intricate designs. Fourslide stamping manipulates a workpiece on four axes, which enables the process to form intricate and complex shapes. Multiple operations are performed in a single cycle. The results are less energy use, limited waste, and high levels of precision.
Fourslide stamping integrates stamping and forming to produce intricate components. The benefits of fourslide stamping include versatility, design flexibility, rapid processing, and lower production costs.
The speed, accuracy, tolerances, and versatility of fourslide stamping has made it the go to method of production for several industries. The quick turnaround times for the production of small parts gives manufacturers several options during the production of products.
Automotive Industry – From the engine to parts for the brakes, fourslide stamped components are found in every system of a vehicle. The ability of fourslide stamping to produce identical parts with exceptional quality is a necessity for automobile manufacturing. Battery cable connectors, HVAC parts, key fob terminals, brackets, clips, and fasteners are quickly produced using fourslide stamping.
Medical Services – The quality and precision of fourslide stamping makes it an ideal process for the manufacture of medical instruments. The rapid pace of fourslide stamping enables it to keep up with the many advancements in medicine. Since many medical instruments are small and complex, fourslide stamping can produce such devices to meet medical grade standards.
Electrical – The key to the success of electrical components is the absence of flaws or failures that can result in catastrophic results. With super tight tolerances, fourslide stamping produces defect free electronic parts to ensure reliable electrical distribution.
Stamping dies are tools for shaping and forming metal sheets into a specific shape or profile. They are made from hardened tool steel that has high-hardness and abrasion resistance.
Dies have cutting and forming tools designed for the cold forming process. The sizes of dies vary from very small microelectronics dies up to dies that are several square feet and very thick for making automobile bodies. The many uses of metal stamping require the use of a wide range of dies due to the uniqueness of the different stamping processes.
Within each type of die are subcategories of dies designed for a specific and unique process. The term cutting die refers to dies that trim, notch, blank, pierce, lance, and shear. Dies for deep drawn stamping are a form of die that deforms a workpiece to achieve unique shapes. Progressive die stamping is a form of die that performs multiple functions.
Single station dies can be compound or combination to perform multiple operations in a single function. The main difference between compound and combination dies is their design and the type of stamping they perform. Compound dies cut while combination dies do 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, with minimal labor costs and short lead times. Cutting complex parts in a single stroke ensures precision accuracy. Compound dies reduce waste, contributing to additional cost savings.
Combination dies feature cutting and non-cutting tools, allowing them to reshape materials in a single operation, an integrated approach that enables simultaneous processes such as cutting, drawing, and bending. A key advantage 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 are part of progressive die stamping that moves a 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 a part’s specifications. Each station within the die can perform one or multiple functions, streamlining the manufacturing process.
Steel rule dies do not fall into the common category of stamping dies due to their structure. Referred to as knife dies or cookie cutter dies, steel rule dies were first used to cut soft materials, such as plastics, wood, cork, felt, fabrics, and paperboard. They are still used today for DIY projects.
Although not as sturdy as steel dies, steel rule dies are used to cut and shape thin non-ferrous metals, such as aluminum, copper, and brass. The blade of a steel rule die, under pressure, pierces the metal material and separates a part from its waste material. It is a two dimensional process, which has earned steel rule dies the name of cookie cutter die. The process of a steel rule die is a low cost effective method for producing uniform components, such as control panels, gaskets, membrane switches, and medical disposables.
Steel rule dies are made of high grade, high density, and hardwood plywood with steel strips. Slits are cut into the plywood to insert razor sharp blades in the preformed slits. Rubber is glued to the flat side of the plywood to help eject the cut piece after the cutting process, preventing the blade from sticking to the pressed metal. 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 metals.
Stamping requires an understanding of metals and their properties. The choice of metal for a project depends on the requirements of the application for which a component or piece will be used. While metal is typically used for stamping, non-metal materials like paper, leather, and rubber are also selected for a variety of purposes.
Carbon steel is strong, affordable, and easy to form and is available in different grades based on the metals carbon content.
HSLA steel is a step up from carbon steel with higher strength and less weight. It’s used for automotive parts, heavy equipment, and structural applications where strength and lightweight properties are crucial. The benefits of HSLA include higher tensile strength, improved corrosion resistance, and weldability. The grades of HSLA include HSLA 50 and HSLA 70, which are used in accordance with strength requirements.
Coated steel is coated with various materials to provide corrosion resistance. The types of coatings are:
Stainless steel is one of the most popular manufacturing metals. Its many grades and chemical compositions makes it ideal for stamping any number of products.
As with stainless steel, aluminum has characteristics that have made it a very popular metal for manufacturing. It is perfect for applications where weight reduction is crucial without sacrificing strength.
Copper and its alloys are used for their electrical and thermal conductivity, making them ideal for electronics, electrical connectors, and HVAC components.
The most difficult and crucial aspect of the stamping process is the selection of the right metal for an application. During the initial design phase, various kinds of metals are computer tested to determine their applicability. In the majority of cases, metal stamping companies know the perfect metal for a project and guide their clients. It is the wisdom, expertise, and knowledge of stamping specialists that provides the greatest assistance in metal selection.
The final step in the metal stamping process is finishing, which is completed to improve the appearance, durability, functionality, and other factors to meet design parameters. Finishing is a post processing step that is performed by metal professionals that are capable of configuring and adjusting a completed part. Finishing processes take several forms depending on the requirements of an application.
When a workpiece is completed, it may require other processes to remove imperfections, deformities, or excesses or may necessitate the addition of other parts and applications. Finishing is performed during post stamping production and includes deburring, tapping, reaming, and counterboring.
Metal stamping exposes metals to lubricants, metal shavings, dust, debris, and assorted materials that need to be cleaned from a part. Metal stamping companies use different cleaning processes including aqueous degreasing and vapor degreasing. Other cleaning methods include passivation with citric acid and nitric acid and rinsing followed by a rust inhibitor.
Deburring removes sharp edges to make them smooth and even. All forms of stamped metals can require deburring to improve the surface of a part to enable it to adhere to its dimensions or to be joined to an assembly. Various methods are used for deburring, including manual techniques, electrochemical processes, and thermal treatments. Burrs form on edges and seams, requiring multiple sections of a workpiece to be deburred.
Deburring improves the quality, aesthetic value, functionality, and appearance of a workpiece. Any small notches or deformities left on a workpiece can catch on equipment or cause personal injury. Difficult burrs may be flanged to produce a smoothed edge.
Tumble finishing is a mass metal finishing method that involves placing parts in a device that tumbles stamped parts to remove burrs and produce a rough polished finish. In most cases, tumble finishing takes several hours as parts are rolled over and over through a gritty material. There are a variety of tumbling methods, which are mainly designed for small and medium sized stamped parts. During tumbling, a part is cleaned, deburred, de-flashed, descaled, polished, and smoothed.
Tapping is a process for creating threads in a workpiece using a tapping tool that has specialized teeth to cut threads into metal holes. It is widely used on stamped workpieces that have had holes punched into them. The results of tapping make it possible to connect bolts or screws to a workpiece.
Reaming is a cutting process that removes a small amount of metal from a stamped hole to bring the hole up to design specifications and improve the finish of a hole. The purpose of reaming is to ensure that a hole meets dimensional requirements by providing dimensional accuracy, tolerances, and improved hole surface finish. Much like other finishing processes, reaming is a precision process that is carefully executed such that the correct amount of stock is removed.
Countersinking creates a conical cavity that matches the angle and shape of a flathead screw. The process of countersinking makes it possible for a screw to fit flush with the surface of a material. The process is used in coordination with tapping.
Counterboring creates a cylindrical hole for a flathead screw to fit into a drilled cavity. The diameter of the cylindrical hole is slightly larger than the head of the screw, which allows room for a washer and driving tool. As with countersinking, counterboring works in unison with tapping that provides the threads for a screw.
Deburring, tapping, and reaming are a few of the processes designed to alter the physical aspects of stamped parts. They are designed to perfect and improve the mechanical features of components. Other finishing options include various types of surface finishes that improve the physical appearance and surface of components.
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 transforms simple flat pieces of metal into functional and practical shapes with ease.
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There are several benefits to metal stamping, which include lower costs for dies, quick turnaround times, and high tolerances. Modern era stamping machines are automated and work with little need for the 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 products are nearly finished after being pressed. Automated processes are uncomplicated, fast, and adaptable functions that reduce labor costs and increase stamping efficiency. Computer programs provide precision, control, and dimensional accuracy for quicker turnaround times.
With metal stamping, upfront costs of equipment, tools, and dies are high and require a significant investment. For custom parts or designs, special steel dies are required resulting in longer pre-production and extended turnaround times. Changing dies during production due to design flaws can be difficult and time consuming, further increasing manufacturing costs.
Metal stamping is rapidly emerging as one of the fastest growing production techniques. 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 have fewer 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.
The accuracy of metal stamping is critical for intricate components in automotive set-ups to large metal industrial housings. Clips, cups, covers, fasteners, and sensitive electronic assemblies are made from stamped metal parts. Common hardware items such as catches, latches, locks, and door closers are quickly and easily produced using metal stamping. As would be expected, metal stamping, in combination with hardware items, is used to produce hooks, bolts, and other forms of fasteners.
Metal stamping is at the foundation of every industrial operation and produces components, assemblies, parts, and products that are found in every aspect of life. Although the nature of metal stamping is rather simplistic, its complexity and intricacies can be found in the wide assortment of applications that depend on its accuracy and exceptional dimensional tolerances.
Custom metal stamping is, by definition, designed exclusively for a specific part and its functions. Unlike mass-produced stampings, custom metal stamping is chosen when precision and complex dimensions are required to produce a unique part. This process requires the upfront development of a custom metal stamping tool that cuts and forms the part as the metal goes through the stamping press. Custom metal stampings can range from large components for automobiles and custom assemblies to micro-miniature parts for medical devices or electronics.
Stamping includes a variety of sheet metal forming processes consisting of either a single station operation where every stroke of the press produces the desired form of the metal part or could occur through a series of stages. The following techniques are used to achieve the desired shape in the press.
Bending creates a formed feature by angular displacement of a sheet metal workpiece. In some processes, one edge of the workpiece is clamped in a stationary position while the other edge is clamped by a metal tool and bent over a form to create a precise bend or shape. Alternatively, the metal piece may be pushed into or against a form.
The blanking process removes a metal piece from the primary metal strip or sheet when it is punched through the strip/sheet. The material that is removed becomes the new metal workpiece or blank.
Coining is a forming process that uses an extreme amount of pressure to push the workpiece into a die. The die then forms the metal into a precise shape and creates permanent forms in the workpiece. Coining also smooths the edges of metal parts by striking them with a high degree of force. This removes existing burrs and hardens the metal. Coining may reduce the need for deburring, grinding, and other secondary processes at the end of the project, which saves both time and money.
This process deforms the metal using only a punch and cavity. These dies do not control metal flow and cannot prevent the metal from wrinkling or buckling. They are used to form simple parts, such as brackets and braces, made from thick, stiff metals that are more wrinkle-resistant than thinner metals.
One of the most common stamping operations, cutting trims the metal into a part by the use of extremely high force in the stamping press. Cutting operations include trimming, notching, piercing, blanking, lancing, and shearing.
A complex drawing die is used to create large metal parts, such as automotive components. The process involves controlling the flow of metal into a cavity via a pressure-loaded draw pad to prevent wrinkling as the material flows over a forming punch.
Embossing is a cold-forming process used for creating specific formations or designs on metal pieces. Male and female embossing components press a workpiece between them with sufficient force to form the three-dimensional feature.
Extrusion forms the metal inside the diameter of a pierced hole, which may be used for applications such as holding fasteners during part assemblies.
The flanging operation bends metal along a curved axis, which may be used to form a projection or the rim of a part as it relates to part assembly and stiffness requirements.
Metal stamping involves a variety of forming operations. The stamping press forms the metal material by applying tension, compression, or both. The specific type of forming operation selected depends on the material’s properties and the part’s critical dimensions, balancing formability and strength.
Similar to the coining process, ironing employs compression to form the part by squeezing the metal along a vertical wall to achieve exact thickness and length dimensions.
In order to free up metal without separating it from the metal strip, lancing slices or slits the metal, which may be used in progressive dies as a part carrier.
This metal cutting operation, also called perforating, produces a hole in a formed part or sheet metal, which may be round, square or a custom shape. The slug is then discarded.
Pinch trimming is a special method in which the vertical walls of a drawn or stretched vessel are cut by pinching the metal.
This forming process uses a punch press to force a tool, called a punch, through the workpiece/material to create a hole and produces a scrap slug that is deposited into the die below the sheet metal.
Used primarily after major forming operations are complete, restriking employs an additional station in the die to finish precision details such as small embossing and sharp radii.
An operation used to eliminate or minimize die-break, while maximizing the amount of sheared edge. The general concept with shaving is to pre-punch the hole slightly smaller, then post-punch the hole to size, using a very tight die clearance. This can also be done on a straight or outside edge.
Cutting force is applied perpendicular to the material, causing the material to yield and break.
The trimming process achieves the specified profile of a stamped part by forming its perimeter or cutting away excess metal, with precision trimming designed to minimize scrap.
The method chosen for metal stamping production takes into account the complexity of the part and how metal stamping can best form that part. For precision parts with tight tolerances, the method may include the use of in-die sensors to continually monitor part quality, along with other inspection methods. The method also takes into account secondary operations, such as plating, heat treating, welding, and cleaning or sterilization.
Progressive metal stamping is a stamping process that advances a metal strip from station to station performing different operations on the same part in the die until the part is complete. Conical-shaped pilots are inserted into pre-pierced holes in the strip to ensure the precision of the alignment as the part advances to guarantee the accuracy of the finished product. Since the part is attached to a metal strip throughout its formation, the entire process and parts will be out of tolerance if the strip is off by even a tiny fraction of an inch.
Progressive die stamping offers some advantages such as being a highly repeatable process and since the material is continuously fed into the stamping press, long production runs can be completed, producing more finished parts in less time resulting in lower cost per part.
Progressive Stamping Delivers High Speed Production and Lower Costs.
Transfer die stamping uses one press to operate multiple tools. The part is removed from its metal strip so that it can be freely transferred. A part, which can be turned or rotated, is shaped by each station until it is complete. Automation of the transfer process streamlines the operation into a single press.
Transfer dies can handle many part features in one press pass, such as holes, cut-outs or threading, which can eliminate costly secondary operations.
Transfer die stamping is typically used for large parts like frames, tube applications, draws, shells, and structural components.
Is Progressive Die Stamping or Transfer Die Stamping Best for Your Next Precision Metal Stamping Project?
Beneficial for applications requiring recessed cavities, where the depth of the drawn part exceeds its diameter, deep drawing uses blanking, swaging or sizing to deform the base material and apply recessed features.
Fine blanking is optimal for parts that require very smooth, precise edges or exceptional flatness. Fine blanking is particularly suitable for moving parts such as gears. Fine blanking is a combination of metal stamping and cold-metal extrusion techniques, requiring special presses.
Progressive Stamping vs. Fine Blanking: Three questions OEMs Should Ask
Multi-slide / Four-slide stamping is best suited for fabricating complex components that have numerous bends or twists and for forming wire. The difference between multi-slide and four-slide is that four-slide metal stamping machines have four moving slides while multi-slide machines have more than four slides. The slides or rams in the machines strike the material to produce the finished parts.
Multi-slide / Four-slide equipment can manufacture complicated parts with multiple, complex, or over 90° bends and twists including clips, brackets, flat springs, terminals, retainers, and wire formed parts. Both flat and round materials can be formed.
A key factor in the success of a precision stamped part is specifying the best metal for the process and the application, ranging from lightweight aluminum to heavy-duty steel to high-cost precious metals. OEM engineers can benefit by consulting metal stamping specialists early in the part design phase to evaluate how metal stamping can work and the exact material specifications needed for the application at hand.
Material selection involves evaluating:
Some of the most commonly used materials for precision metal stamped parts include:
Carbon steel is one of the most popular materials used in metal stamping, which can take on many different forms, properties and finishes, offering optimal strength, performance and cost-effectiveness. Each year, steel production exceeds 1.3 billion tons worldwide. Basic steel is magnetic material. With the addition of chrome and nickel to make stainless steel, it loses its magnetic properties. Many different types of steel may be used including hot and cold rolled steel; stainless steel; high-tensile steel; low, medium and high carbon steel; and spring steel.
Aluminum offers many advantages for metal stamping applications. Aluminum has the highest strength-to-weight ratio of any metal. Aluminum conducts electricity better than copper and is non-magnetic. For companies seeking sustainability, aluminum is 100% recyclable without losing any of its natural characteristics. However, aluminum can be abrasive in tooling and is more expensive that steel.
Copper that is suitable for metal stamping comes in many forms, including such alloys as aluminum clad copper, brass, phosphor bronze, beryllium copper and aluminum alloys. Copper is often selected for stamped components and conductors for electronic devices, as well as electrical wiring, heating and plumbing, and other applications that require its extremely high electrical and thermal conductivity. Copper also resists corrosion while maintaining an attractive appearance. The softness of copper makes it one of the best metals for stamped parts.
With its reasonable price and flexibility, brass can work for almost any function in metal stamping. As an alloy of copper, brass can easily be soldered to copper. Brass is highly resistant to corrosion and will not rust. It is also effective in carrying electrical current while dealing with high stress very well. As a result of its unique properties, brass is one of the most-used metal materials in the world.
Titanium is known for its corrosion resistance and high-impact toughness. Titanium is very expensive to manufacture but has the highest strength to density ration of any metallic element. It is often used in aerospace structures and implantable medical devices.
Precious metals may be used as a plating or coating on stamped parts to increase conductivity or to add strength and corrosion resistance to the finished products. In metal stamping, designing a process that conserves the precious metal is critical, due to its high cost and limited availability in some cases. Manufacturers in the automotive, electronics, telecommunications and medical device industries are among the leading users of precious metals such as gold and palladium in critical parts.
Nickel alloys resist high pressure and maintain their properties under extremely high temperatures. They also offer high strength and toughness and excellent resistance to atmospheric corrosion. High nickel alloys are perhaps the most frequently used material for metal stamping production among the hundreds of specialty alloys used in the industry.
Each industry favors particular metals for their precision metal stampings, due to their unique applications and the environmental and operating conditions that the parts must withstand. For example, stamped parts for the automotive industry must be able to hold up under extreme heat and cold, as well as contact with a variety of liquids, while medical devices require high sanitation and safety standards, and electronic parts require electrical conductivity.
Production of precision metal stampings involves a complex process that begins with design collaboration between the stamper’s and the manufacturer’s engineers. Software simulations are often followed by developing a prototype tool to produce sample parts. Full production planning takes into account every step of the process from custom tool design and stamping through finishing and assembly/packaging to ensure that all critical specifications are met, with quality control from start to finish.
Metal stamping engineers can offer solutions for cost-effective part design and production upfront during the estimating process, as they review the part design, prints and material specifications. Using advanced technology, such as 3D CAD, metal stampers can test design options and recommend improvements to reduce failure risk and increase functionality, while meeting all critical specifications and quality standards.
With the development of new custom stampings, it can pay to test and analyze small quantities of stampings before investing in full production. By building a prototyping tool to run sample parts and using simulation software to evaluate how the part and material will function in the tool, the metal stamper can identify and correct potential weaknesses prior to production, which saves on development costs and time to market. The stamper may recommend specialized tool functions, such as progressive dies or in-die assembly, to improve manufacturability.
Collaboration between the manufacturer's technical staff and the metal stamper's engineers in the initial planning stage is key to ensuring efficient production and long-term functionality of the part. In-depth planning sessions allow for review of:
For manufacturers in the planning process for new products, the technical team of the precision metal stamper can add valuable guidance upfront to help speed time to market.
A designated project manager is responsible for ensuring the project is completed on time and on budget and for communicating status updates to the cross functional team.
Tool designers review technical specifications and provide critical feedback for tool design. Once designs are approved, highly complex, high-precision tools are built, often including in-die sensors to ensure tool safety and consistent quality. Tooling experts conduct preventative maintenance to ensure tools last the duration of the program with little or no downtime.
Sophisticated technology is used for high-speed, precision metal stamping, with a variety of presses that are augmented with advanced features such as electronic servo feeds, robotics, and real-time quality control. Multiple operations like in-die tapping, in-die fastener insertion and in-die assembly can be performed in the stamping press, which can eliminate the need for those secondary operations.
Secondary operations are often required to fully finish the metal stamped part for seamless integration into a product or system. Parts may need to be trimmed or welded. Finishing techniques such as coating, plating, polishing or deburring may be chosen to inhibit corrosion, improve appearance, or smooth sharp edges. Metal stampers provide many services in-house, such as cleaning and custom assembly, and also coordinate with approved suppliers for specialized metal finishing services, such as welding or electropolishing.
Metal stamping engineers evaluate assembly and packaging needs in the production planning phase to ensure finished parts are ready for further production or shipment when delivered to the manufacturer. Parts may be shipped fully assembled or as sub-assemblies and packaged based on manufacturer specifications (i.e. reel-to-reel, loose piece, on a bandolier).
Precision metal stampers apply mistake-proof processes that incorporate quality controls into every phase of a metal stamping project. Company-wide information sharing systems ensure quality commitments are understood and implemented by every project team member. Sophisticated quality control technology is leveraged throughout the process to ensure zero defects, such as in-die sensors, real-time statistical process control, and optical vision systems.
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