what is 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.
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Advantages of Stamping
Precision and consistency
Stamping can produce parts with tight tolerances and consistent quality, which is important in many industries.
Versatility
Stamping can be used for a range of part complexities, from simple to intricate, across many industries. For example, metal stamping can be used for medical parts and components, which can be simple or complex designs that require precision and accuracy.
Rapid production
Stamping can quickly produce large quantities of parts, which can lead to higher productivity and lower costs per unit.
Cost savings
Stamping can create less scrap than other methods, such as machining, which can result in cost savings. Stamping simulations can also reduce the forming severity of a part, which can further reduce scrap and material requirements.
Efficiency
Stamping can be an efficient way to produce metal components or products from sheet metal stock. Dies are also quicker and easier to create than in other methods, such as die casting or metal injection molding, which can reduce costs and speed up production.
Importance of Stamping in Manufacturing Processes
Stamping is a versatile process that is not slowing down, especially within the automotive industry. From the evolution of carving coins to being a driving force in the automotive industry, stamping is a process that can’t be ignored.
Given the demand for metalwork across an endless number of industries, the process of stamping manufacturing continues to help make components and products with specific needs.
Stamping is also known to be a very efficient method of metal manufacturing, delivering results in a fraction of the time compared to many other processes. Moreover, stamping is often a cost-effective solution, making it a reliable option for metal manufacturers of all sizes. Lastly, using the stamping process allows manufacturers to handle large production orders more easily.
Types of Metal Stamping
There are three major types of metal stamping techniques: progressive, four-slide, and deep draw.
Progressive Die Stamping
Progressive die stamping features a number of stations, each with a unique function.
First, strip metal is feds through a progressive stamping press. The strip unrolls steadily from a coil and into the die press, where each station in the tool then performs a different cut, punch, or bend. The actions of each successive station add to the work of the previous stations, resulting in a completed part.
A manufacturer might have to repeatedly change the tool on a single press or occupy a number of presses, each performing one action required for a completed part. Even using multiple presses, secondary machining services were often required to truly complete part. For that reason, progressive die stamping is the ideal solution for metal parts with complex geometry to meet:
Faster turnaround.
Lower labor cost.
Shorter run length.
Higher repeatability.
Fourslide Stamping
Fourslide, or multi-slide, involves horizontal alignment and four different slides; in other words, four tools are used simultaneously to shape the workpiece. This process allows for intricate cuts and complex bends to develop even the most complex parts.
Four slide metal stamping can offer several advantages over traditional press stamping that make it an ideal choice for many applications. Some of these advantages include:
Versatility for more complex parts.
More flexibility for design changes.
As its name implies, a four-slide has four slides meaning that up to four different tools, one per slide, can be used to achieve multiple bends simultaneously. As material feeds into a four-slide, it is bent in quick succession by each shaft that is equipped with a tool.
Deep Draw Stamping
Deep drawing involves pulling a sheet metal blank into the die via a punch, forming it into a shape. The method is referred to as "deep drawing" when the depth of the drawn part exceeds its diameter.
This type of forming is ideal for creating components that need several series of diameters and is a cost-effective alternative to turning processes, which typically require using up more raw materials. Common applications and products made from deep drawing include:
Automotive components
Aircraft parts
Electronic relays
Utensils and cookware
Common Metal Stamping Processes
Disregarding steps such as design and prototyping, which are necessarily performed prior to stamping, there are nine primary processes involved in the actual stamping of metal parts.
Blanking
When required, blanking is the first step of the stamping process. Blanking is the process of cutting larger sheet or coils of metal into smaller, more manageable pieces. Blanking is usually performed when a stamped metal piece will be drawn or formed.
Drawing
Drawing is the actual stamping in the metal stamping process. A punch forces a section of metal through a die, providing the primary shape of the part. When the depth of the part is less than the primary opening, it is considered shallow drawing; parts with a depth greater than the opening are deep drawn.
Air Bending
Air bending is when the flat surface of a part is bent by a punch into a die, often V-shaped. The space between the punch and die is larger than the metal thickness, resulting in a bend that relaxes slightly when the part is released. Air bending uses less power and pressure than other bending methods.
Piercing
If a part requires slots, holes, or other cutouts, piercing can be employed. Piercing, which can be performed simultaneously with blanking, punches the requisite shapes out of the metal sheet.
Forming
Forming is a bending process similar to bending, bottoming, and coining. It creates parts with multiple bends, such as U-bends, in one step.
Lancing
A unique process, lancing is a type of metal cutting used to make vents or tabs. A section of a part is cut along three edges and simultaneously bent. This creates the opening or hook-like feature required but eliminates a scrap collection or secondary machining step.
Bending
Bending is a fairly self-explanatory process. The part-in-progress is placed on a specially designed die and a ram pushes against the metal, providing the required bend. Bending is performed after drawing, as attempting to punch an already bent piece of metal causes the entire part to deform.
Bottoming and Coining
Bottoming and coining are bending processes are similar to air bending, but use anywhere from two to 30 times the pressure and the material is forced fully into a tight-fitting die, resulting in a more permanent bend.
Pinch Trimming
Pinch trimming is a method of cutting a piece from the metal sheet, separating it from the scrap metal. It is an unconventional process: the metal is pinched against a flat vertical surface. It is often, but not exclusively, used to cut deep drawn round cups from the sheet.
Deep Drawing and Stamping are similar manufacturing processes that are often confused with each other. Each process produces strong and durable parts with high accuracy and tolerances.
Deep Drawing and Stamping each require a design process, with considerations of how the materials will affect the manufacturing process, production costs, and the ease of manufacture. Material thickness, the type of bending or formability involved are also characteristics that will be different for each process, depending on the shapes being formed, and the shape of the end product. While there are many similarities between these two processes, there are not as many differences.
What is Metal Stamping?
Stamping is a manufacturing process when coils or flat sheets of material are formed into specific shapes. The Stamping process is used to make small changes to parts, such as bends, tabs, or embossments. These features tend to be much shallower in depth than a deep drawn part. Stamped parts start flat and go through a sequence of stamps from a press, where new features such as small tabs, are folded in, or holes are punched out. These features are very sharp, detailed, and precise. Stamping is a broad term that includes many specific forming techniques such as embossing, blanking, punching, bending, flanging, and the list goes on. Each of these methods involve short, quick, and abrupt hits or press movements.
How is Stamping different from Deep Drawing?
Deep Drawing is used to make larger features such as as cups, pans, or domes. We draw parts from our two hydraulic AP&T presses. Drawing a cup requires exerting a significant amount of pressure on a flat sheet, and gradually drawing it over a die to sculpt it into the cup shape. Forming these shapes requires much more pressure over a longer period of time than a quick stamp. If the pressure is not controlled properly or is performed too fast, the metal will fracture or break, and will not be usable.
The shape of the part is the main difference between a stamped or deep drawn product. Drawn parts will have more pronounced curves in the shapes, and will be larger than a stamped part. Below is an example of one of our deep drawn cups. Take note of the defined edges and curves, while its strength and durability is present.
Applications of Stamping Parts in Various Industries
The automotive industry is one of the largest users of stamping parts. Stamping is used to manufacture body and structural components, engine and transmission parts, and electrical components. Body and structural components include items like fenders, hoods, and doors, while engine and transmission parts include items like valve covers and transmission housings. Electrical components include items like battery trays and fuse boxes.
The aerospace industry also relies heavily on stamping parts. Stamping is used to manufacture structural and engine components, electrical and avionics components, and fuel system components. Structural components include items like wing spars and fuselage frames, while engine components include items like compressor blades and turbine housings. Electrical and avionics components include items like control panels and communication equipment. Fuel system components include items like fuel tanks and fuel lines.
The electronics industry is another major user of stamping parts. Stamping is used to manufacture circuit board components, enclosures and covers, and connectors and terminals. Circuit board components include items like heat sinks and shielding, while enclosures and covers include items like computer cases and phone covers. Connectors and terminals include items like USB connectors and power connectors.
The medical industry also uses stamping parts to manufacture surgical instruments and equipment, implantable devices, and diagnostic equipment. Surgical instruments and equipment include items like forceps and scalpels, while implantable devices include items like pacemaker components and joint replacements. Diagnostic equipment includes items like ultrasound probes and CT scanner components.
Stamping parts are a critical component of many industries due to their precision, consistency, versatility, and cost-effectiveness. The automotive, aerospace, electronics, and medical industries are just a few examples of industries that rely heavily on stamping parts. The stamping process enables manufacturers to produce parts quickly and efficiently, with a high degree of accuracy and repeatability. It also allows for flexibility in design and customization, making it possible to create unique parts that meet the specific needs of customers.
Our Factory
King Siu Metal Products (Shen Zhen) Limited is located in Sun San Ping Xi South Road, Lunggang District, Shenzhen City, China. The main product range is Audio cabinet, Speaker grille, Heat sink and Metals accessories. In February, 1998, the factory acquired the ISO9002 quality system certification. It covers an area of more than 6,000 square meters, with around 102 employees, management and technical personnel exceed 20 people.
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