Descriptions of metal stamping technologies with a list of leading metal stamping companies
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Metal stamping is a process where coiled or sheet metal is forcibly compressed by a stamping machine that reshapes the selected metal into a technologically designed component or part. The compressive force applied by a stamping press transforms plain sheets of metal into a variety of shapes and configurations. The success of metal stamping is dependent on the amount of time that a metal is subjected to the compressive force applied by the press and die. Once ejected from the stamping press, the shaped form is submitted for trimming, finishing, and other processes designed to complete the form to match design parameters.
Despite metal stamping's century’s old roots, over the years, cutting edge technology has been added to the process. The introduction of computer numerical control (CNC) has rapidly advanced the stamping as an essential manufacturing process. Computer conceptualized designs, such as computer aided design (CAD), are digitally tested before being transformed into CNC metal stamping G-codes and M-codes.
Metal stamping provides multiple benefits. It is a cold forming technique that eliminates the need for heating, which lowers costs. Complex and intricate shapes from detailed designs that are difficult to produce using other techniques can be inexpensively formed using metal stamping. The precision and accuracy of metal stamping make it the most reliable method for manufacturing intricate parts.
The metal stamping process involves transforming a flat metal sheet into a specified shape. From automotive and aerospace sectors to medical and electronics industries, metal stamping plays a pivotal role in producing cost-efficient, high-quality parts and components. Metal stamping includes a variety of techniques, such as punching, blanking, embossing, coining, bending, and flanging.
Punching is a metal stamping process that involves a punch and dies to place holes and other features in sheet metal. The punch tool is pressed against the sheet metal while the die supports the metal sheet. The created feature is the result of the force of the punch tool being pressed against the metal sheet under great force. The shearing of the metal sheet by the punch tool produces burrs along the edge of the top side of the hole, which are removed by deburring. For punching thick steel plates, maximum tonnage stamping machines are used.
Blanking is an essential part of metal stamping due to it being the process that cuts metal stock into a designated shape before being submitted for follow up processing. It is a fundamental shearing process that undergoes stamping to produce a predictable cross-sectional profile. Blanking is where a normally scrap piece becomes the saved necessary part. Punch tools for blanking have a die clearance of less than 5% and are straight tapered. The reduced clearance of blanking requires that tools be frequently inspected and sharpened.
In normal metal stamping, vertical pressure is applied to metal to deform a workpiece that is placed on a die. For the process to be successful, there is a sufficient amount of clearance between the die and punch. The purpose of the process is to convert flat metal into different shapes using pressure and a die.
With fine blanking, pressure is applied to a workpiece from its top and bottom with minimal clearance. It allows for micron (µm) precision stamping, which is difficult for traditional stamping. Sheared surfaces are smooth and clean, removing the need for secondary processing. The workpiece is secured by three pads from multiple directions. One punch moves down to create a part’s features. A counter punch is placed below the workpiece, while a guide plate securely holds the material.
The perfection of fine blanking is due to the blank being compressed between the upper and lower punches, which results in very tight tolerance. Fine blanking 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 clamping, blanking, and ejection. Fine blanking presses operate under high pressures, necessitating tools that can endure these conditions. All that is need for fine blanking is a single stroke to form a completed part.
As with all aspects of stamping, embossing involves pressing the surface of a workpiece to place a design or image on the workpiece. The result of embossing is a raised or sunken surface with a specific texture that is visually pleasing. It is a transformative process that places decorative marks, images, information, and other forms that enhance and improve the visual aspects of pieces of metal.
Embossing allows for the creation of a wide range of designs from simple repetitive patterns to complex and intricate works of art. The critical aspect of embossing is choosing the correct metal to meet the design requirements and stipulations of an application. Embossing can be completed using small manual stamping machines or large stamping presses.
The opposite of embossing is debossing where a design is pressed into metal. The resulting creation is an indented or sunken impression. Debossing adds tactile and visual depth to metal creating a depressed inward image, which is the opposite of embossing that produces a raised image.
With 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.
Deep drawing or deep drawn stamping stretches a metal blank around a plug and forces it into a die. It is a stamping process that is designed to produce a specific type of component or workpiece, such as cylinders and long protective enclosures. The results of deep drawing are cuplike shapes that can serve as protection for other components. Deep drawing is similar to stamping in that it involves a punch that is lowered vertically onto a workpiece using a punch. The difference between the stamping processes is that deep drawing moves deeply into a workpiece producing configurations that are longer than the hole created by the punching tool.
Deep drawn stamping forms hollow axisymmetric components. Its name comes from its end products having a depth that is two or more times greater than its width or diameter. Although most of the produced shapes are cylindrical, deep drawn stamping can also be used to produce box shapes. Boxes formed using deep drawn stamping have high dimensional accuracy with exceptionally smooth even surfaces. It is used to produce geometries with great detail, such as oil filters, pots, pans, cups, and bowls. Blanks are normally semi-developed to simplify production but developed blanks are also used.
During the drawing process, the loaded blank is stretched as it is pulled down into the cavity of the die, a process that can thin or thicken the metal depending on a parts geometry. The flow of the metal into the die cavity is controlled by a draw pad or binder that restricts metal movement to prevent wrinkling. The draw ratio theory defines the relationship between the diameter of the draw punch and the size of the blank. Blanks that are too large with respect to the punch cause too much material to be trapped between the die face and the binder. Excessive material of this type can cause stretching, thinning, or splitting. This aspect of drawn stamping requires precision control and monitoring.
The perfect positioning of the punch ensures that the metal will compress and flow inward without stretching, thinning, or splitting. In some cases, multiple drawing operations may be necessary to achieve very tall geometries, a process referred to as draw reduction. Each drawing operation is carefully monitored in regard to the starting blank and drawing punch and the relationship between the various drawing operations.
The successful completion of deep drawn stamping is dependent on certain fundamental key processes that are carefully monitored.
Drawing � The lubricated blank is securely clamped and held on the die between the die and punch. This aspect of the process is crucial to its success. Having the blank tightly secured prevents wrinkling and buckling during the drawing process. As with other parts of the deep drawn stamping process, proper clamping and blank holding ensures consistent material flow into the die. The pressure of the clamping process is adjusted to match the specifications of the part being drawn.
During the drawing process, compressive force is applied to both ends of the blank by the blank holder. Axial force is applied by the punch tool as it forces the blank to deform and flow into the die cavity to achieve the designed part shape. During the deep drawn stamping process, the material undergoes radial and axial deformation. The depth of the drawing is determined by the ratio of the blank’s diameter to its height.
As the punch makes contact with the blank, it embosses the material and a shock line from stretching appears, an area where thinning occurs. The bottom of the blank maintains its thickness as the punch moves downward. The punch pulls the blank into the die, and the circumference gathers, thickening the walls to 10% over the original wall thickness. Sufficient clearance is provided to avoid binding between the punch and die.
As with all forms of stamping, deep drawn stamping is widely used by a long list of manufacturers. Companies are drawn to deep drawn stamping due to its versatility and many benefits. Manufacturers that depend on deep drawn stamping include:
The origins of deep drawn stamping are a bit sketchy. It is presumed that it was introduced during the first industrial revolution and came into full force near the end of the 19th and the beginning of the 20th centuries. In the over 125 years of its use, deep drawn stamping has become an essential part of the production of metal products.
Deep drawing uses a punch and dies to stretch metals into a desired shape. Items produced by deep drawing are stronger with a higher strength to weight ratio. The reason for the impressive strength and durability of deep drawn stamped parts is due to their seamlessness. Although the initial cost of deep drawing is expensive, much of the expense is offset by lower tooling costs, minimal waste, and the speed of production.
Stamping presses are categorized as mechanical, hydraulic, and mechanical servo. Their feeding mechanisms include automatic sheet and coil feeding or automatic or manually fed blanks. The type of feeder depends on the thickness of the sheets. Reel feeders are used for thin sheets while thicker metal sheets are fed manually. Roll feeders have straighteners that prepare rolled metals before they are fed to remove residual effects.
Mechanical stamping reshapes metals using mechanical force provided by an electronic drive, which can be a flywheel, single geared, double geared, double action, slide motion, or eccentric gearing type. The control system of the press activates a stamping cycle. The ram, under extreme pressure, descends on the workpiece forcing the upper die to make contact with the workpiece. The resulting force cuts and shapes the metal.
Single geared mechanical presses are the most popular. They provide tonnages ranging from 200 tons up to 1600 tons with a two point connection to the slide. Single geared presses are used for progressive stamping using dies that are shallow drawn or forms with piercing and blanking. They run continuously producing, typically, 40 SPM to 80 SPM using a 12 in stroke.
Double geared mechanical presses are used for SPMs of less than 28 SPM and are the best alternative for heavy duty applications for stamping high strength metals. Stamping that requires a long stroke over 24 in is an eccentric mechanical press that is a double geared press with better accuracy.
Hydraulic stamping machines are powered by a hydraulic pump that has two cylinders, two pipes, and two pistons. One of the cylinders functions as the ram of the press, while the other acts as the plunger. Both cylinders are connected to a chamber that is filled with a hydraulic fluid that is designed to produce high pressure. The fluid in the chamber is pumped into one of the cylinders where a piston applies compressive force to the fluid sending it through a pipe to the larger cylinder.
In the larger cylinder, the fluid experiences increased compression that activates a larger piston that forces the fluid back to the smaller cylinder. As the fluid cycles back and forth between the cylinders, pressure continues to build. At some point in the cycling, the created force becomes powerful enough to force the ram down against the die.
To regulate and control the pressure, a mechanism is built into a hydraulic system to prevent overload. When the set pressure is reached, a valve is activated for pressure reversal to ensure safe controlled hydraulic operation. Hydraulic presses have relatively simple components that force the ram against a stationary anvil or die. The working mechanism is the two cylinders that work in tandem to generate the necessary force to shape the workpiece.
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 precision 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.
Metal stamping is the backbone of modern manufacturing with each of the various types providing advantages to support specific applications. For the best results, the type of metal stamping should be matched to the desired shape and form of the final product. High volume production, types of designs, cutting versatility, and dimensional accuracy are key factors in selecting a stamping method. Metal stamping companies work with their clients to select the correct stamping method for a component.
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.
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.
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Bolts are mechanical devices used in assembling and fastening objects, typically used with a matching nut. They are designed to be installed in aligned unthreaded holes of multiple parts...
Contract manufacturing is a business model in which a company hires a contract manufacturer to produce its products or components of its products. It is a strategic action widely adopted by companies to save extensive resources and...
Precision sheet metal fabrication is a common manufacturing process where the structure of a metal workpiece is cut, bent, and assembled by machining. There are any number of operations that are performed in the creation of a finished sheet metal product...
Sheet metal fabrication is metal that has been formed into thin and flat sheets which is then cut and bent into various shapes. Different metals, brass, steel, copper, tin, titanium, aluminium, etc., can be made into sheet metal...
Stainless steel can be fabricated using any of the traditional forming and shaping methods. Austenitic stainless steel can be rolled, spun, deep drawn, cold forged, hot forged, or stippled using force and stress...
Secondary manufacturing processes, or fabrication, work on products from primary processes to create a metal part or structure that is suitable for end-use. In these processes, semi-finished metal products are reshaped and joined...