Introduction of metal stamping
What is metal stamping?
Stamping (also known as pressing) is the process of placing flat sheet metal in either blank or coil form into a stamping press where a tool and die surface forms the metal into a net shape. Stamping includes a variety of sheet-metal forming manufacturing processes, such as punching using a machine press or stamping press, blanking, embossing, bending, flanging, and coining. This could be a single stage operation where every stroke of the press produces the desired form on the sheet metal part, or could occur through a series of stages. The process is usually carried out on sheet metal, but can also be used on other materials, such as polystyrene. Progressive dies are commonly fed from a coil of steel, coil reel for unwinding of coil to a straightener to level the coil and then into a feeder which advances the material into the press and die at a predetermined feed length. Depending on part complexity, the number of stations in the die can be determined.
Stamping is usually done on cold metal sheet. See Forging for hot metal forming operations.
- Bending – the material is deformed or bent along a straight line.
- Flanging – the material is bent along a curved line.
- Embossing – the material is stretched into a shallow depression. Used primarily for adding decorative patterns. See also Repoussé and chasing.
- Blanking – a piece is cut out of a sheet of the material, usually to make a blank for further processing.
- Coining – a pattern is compressed or squeezed into the material. Traditionally used to make coins.
- Drawing – the surface area of a blank is stretched into an alternate shape via controlled material flow. See also deep drawing.
- Stretching – the surface area of a blank is increased by tension, with no inward movement of the blank edge. Often used to make smooth auto body parts.
- Ironing – the material is squeezed and reduced in thickness along a vertical wall. Used for beverage cans and ammunition cartridge cases.
- Reducing/Necking – used to gradually reduce the diameter of the open end of a vessel or tube.
- Curling – deforming material into a tubular profile. Door hinges are a common example.
- Hemming – folding an edge over onto itself to add thickness. The edges of automobile doors are usually hemmed.
Piercing and cutting can also be performed in stamping presses. Progressive stamping is a combination of the above methods done with a set of dies in a row through which a strip of the material passes one step at a time.
The advantages and disadvantages of metal stamping
Some of the benefits of stamping include lower die costs, lower secondary costs, and a high level of automation compared to other processes. Metal stamping dies tend to be relatively less expensive to produce and maintain than those used in other common processes. The secondary costs, such as cleaning and plating, are also cheaper than similar treatments for other metal fabrication processes. Stamping machines are relatively easy to automate and can employ high-end computer-control programs that provide greater precision, faster production, and quicker turnaround times. The high level of automation also lowers the cost of labor.
One of the disadvantages of stamping is the higher cost of presses. The dies must also be acquired or created and producing custom metal stamping dies is a longer pre-production process. Dies can also be difficult to change if the design must be altered during production.
The application of metal stamping
Stamping is used in a variety of applications, especially those involving three-dimensional designs, lettering, or other surface engraving features. Such stamping products are commonly produced for home appliance manufacturers, automotive companies, the lighting industry, telecommunications services, aerospace industries, medical equipment manufacturers, and electronics companies. Odds are you have a product in your home that has parts created through metal stamping because it is a process used in everything from your household appliances to your cars.
The specific products and components can range from simple stamping items, such as metal clips, springs, weights, washers, and brackets, to more complex designs, such as those found in engine bases or friction plates. This process is used for producing both parts for large machinery and incredibly detailed small parts. Micro-precision stamping can create parts with diameters of up to 0.002 inches.
Electronic stampings are electronic components manufactured through the metal stamping process. They are used in a variety of industries, from home electronics and appliances to telecommunications and aerospace. Electronic stampings are available in several metals, including copper, copper alloys, aluminum, and steel, as well as more expensive metals, such as platinum and gold. Electronic components produced by the metal stamping method include terminals, contacts, lead frames, springs, and pins. They can be created from ferrous or nonferrous materials. Metal stampings find wide use in computers, electronic equipment, and medical devices. Because of the specialized shapes that can be made by the various stamping processes, many electronics are made by this cold forming process.
What can we do metal stamping for you?
Die casting is a very effective manufacturing process to produce parts that have accurate dimensions and sharp definition in large quantities, made possible using reusable metal dies.
- Product size: as customer’s required
- Material available: alloy steel, aluminum, brass, carbon steel, copper, stainless steel etc.
- Tolerance: normally UNI-ISO 2768, as customer’s required
- Surface treatment: Cr-plating, Ni-plating, Tin-plating, Zn-plating, copper-plating, powder coating, etc.
- Packing: as per customers’ requirement
- Measurement: 2.5D Projecting apparatus, Altimeter, Calipers, Coating thickness tester
- Application: as customer’s required
To know more about die casting parts, please feel free to contact us. We can base your drawings to give more advise about which manufacturing process is better, and how to do it.