Metal Stamping:

A Comprehensive Guide to Sheet Metal Stamping

Sheet metal stamping is a versatile and cost-effective method of transforming sheet metal into a desired shape. This process involves the use of stamping dies and presses to create custom-stamped metal parts and components. The metal stamping process starts with a flat sheet metal, which is fed into the stamping machine. The machine then uses the die to shape the metal into the desired shape. There are many types of metal stamping including progressive die stamping, line dies, hot stamping, and many more.

"Mass production requires a division of labor, the use of specialized machinery, and the most efficient methods of manufacturing." - Henry Ford

Basic Concepts of Metal Stamping

Metal stamping also termed pressing is a cheap high-speed production technique that produces large quantities of the same metal components. Metal stamping operations have been designed and implemented for short and long production runs, and they may consist of one or more different specific processes or techniques. These processes include:. The punching and blanking method involves cutting the paper with the die. Upon insertion into the die, scraps of material can be removed and effectively left in the workpiece.

Materials Used in Metal Stamping Dies

A variety of materials are used in the sheet metal stamping process, with varying material thickness, including copper alloys, precious metals, and stainless steel. The material choice depends on the intended use of the stamped part and the desired properties, such as corrosion resistance, mechanical properties, and material cost. Beryllium copper and beryllium nickel are commonly used in the medical industry for their high level of corrosion resistance.

Metal Stamping Stations and Fabrication Processes

Stamping stations are essential to the sheet metal stamping process, with one or multiple stations available depending on the complexity of the part being produced. The fabrication process or custom machining process usually involves multiple operations, including cutting surfaces into complex shapes, performed by computer numerically controlled (CNC) machines. The cutting operation is used for creating components for each station. Usually, the part involves the use of knife dies (trim steels) to cut the blank and any developed trims while bending refers to the process of transforming the metal strip material into the desired shape. The goal is to transform sheet metal from steel strip material to complex parts in a stamping press.

Heat Treatment and Mechanical Properties

Heat treatment is a crucial step in hot stamping, as it improves the mechanical properties of the stamped part. This process is used to alter the microstructure of the material, leading to improved hardness and strength. The mechanical properties of the stamped part also depend on the material thickness, with thicker materials typically having better properties than thinner materials. Hot stamping is a sub-sector of sheet metal stamping, as it is a specialty but has been growing rapidly in the past years. The hot stamping process is used to increase strength while decreasing the weight of vehicles.

Stamping Dies and Techniques

Stamping dies are critical to the sheet metal stamping process and are available in various types, including single-station dies, multi-station dies, progressive dies, transfer die stamping, and compound dies. Compound dies are a combination of different types of dies, designed to perform multiple operations in one pass. Fine blanking presses operate using a similar principle, using precision metal to produce high-quality stamped parts.

The metal stamping process also involves the use of various stamping techniques, including fine blanking and deep drawing. The die surface is critical in producing smooth edges and sharp corners, and the use of tool steel for the cutting blade ensures the desired surface finish.

The Automotive Industry and Precision Metal Stamping Services

The automotive industry is a significant consumer of die stamping services, with stamped parts used in a variety of applications, including mechanical transport systems and link assisted drive systems. Precision metal stamping services are also available for customers looking for custom stamped metal parts, with companies offering a wide range of metal stamping operations, including cutting, bending, and deep drawing.

Tool and Die and Progressive Die Stamping Companies

These are companies specializing in the production of metal parts and components using a variety of processes, including metal stamping dies. Progressive die stamping is a popular method of metal stamping, producing complex parts using a combination of cutting and bending operations using tool steel mounted inside a die shoe and mounted in stamping presses. The use of multi-slide stamping can also produce parts with high precision, while the mechanical transport system ensures efficient and accurate production.

Conclusion

Metal stamping is a versatile and cost-effective method of producing high-quality metal parts and components. The process involves the use of stamping dies, stamping press of varying tonnages, and techniques to shape sheet metal blank into the desired form. The material choice, heat treatment, and die surface play a crucial role in determining the mechanical properties and surface finish of the stamped parts.

FAQ

What are the disadvantages of metal stamping?

These types can be simple die, compound die, combinations of die, progressive die, and transfers die. A steel stamping machine has many disadvantages: costly tools cost high investment costs and difficulty to alter parts design.

Is stamped steel strong?

Metal stamping replaced machining and forged parts, making parts much cheaper. These parts are less robust in shape than metal die forged, but they can withstand almost any task.

What is the difference between stamped steel and cast steel?

Steel stamp and steel casting processes differ drastically from each other in metal fabrication. Stamping involves putting steel into a machine which then presses it out to shape it into a certain shape. For steel castings steel has a heating process in an oven then is poured in the mould. This cooling is then removed.

Is stamping cheaper than casting?

Stamping Dies are more cost effective and last a longer time than cast dies. The cost per unit of metal stamping is considerably less because it uses stronger materials. Much lower labor costs as well in punch presses, hydraulic presses with one stamping station may be much more costly to run, but still far cheaper than casting each component.

What is sheet metal forming and stamping process?

The process for turning sheet metals into valuable parts or components is called sheet metal stamping. The metal is fed into a stamping press in which dies can be inserted into desired shapes. The die has tremendous force in the metal.

What is the difference between stamping methods and forming?

Stamping is easily automated with a number of value-add operations, such as indie welding. Rollforming allows for consolidating second operations like hole punching and trimming into the same efficient form.

What kind of metal is best for stamping?

Copper alloys are generally silver, copper, brass and nickel that may be formed in different sizes and shapes to suit particular applications. It is a versatile material and a popular tool to make metal stamping.

What are Custom Stamped Metal Parts?

They are basically parts made from metal sheets into complex shapes. They are made from a die, mounted in stamping presses with hardened steel components, precision metal, and usually sharp edges to cut. Many variables in sheet metal stamping greatly change the design of the bending process. For example, if you need a metal stamping from stainless steel it will change the fundamentals of how you design that tool., and if it is a highly complex process or a simple trim or how compound dies perform.