-- Sheet Metal Stamping is typically a cold-forming technique. It shapes flat metal sheets into functional products and components. The metal sheets are fed into a press where a stamping tool (typically, a die) forms the desired shape. This die presses into or through the metal using extreme force, normally measured in tons.
Although the process does not involve heat, the metal can become hot due to the friction between the die and the sheet during pressing. Therefore, you need the proper metal stamping tooling, material combination, and equipment to fabricate quality stamped parts. Each material has a different response to pressure. Besides, the stamping technique, like progressive, transfer, or deep draw, should align with the produced parts' volume and complexity.
This guide will cover all the must-know details about custom sheet metal stamping.
Key Processes in Sheet Metal Stamping
There are three essential elements in sheet metal stamping. These are
- Die
- Press machine
- Metal sheet
However, the majority of parts demand several operations. All these steps shape the metal according to the final form. The following are the core processes that any stamping setup can possess.
Forming
Forming reshapes flat sheet metal using force. It corely depends on the part design and its complexity. With the right tools, you can create basic blanks into detailed shapes. No material is removed during this step.
Blanking
In blanking, manufacturers put the sheet into the press. The die is used to cut out the shape. This cut-out is the blank. It can be the last stage or a shift to the next step.
Sheet Metal Drawing
Drawing forms deep or hollow sections from flat metal. This includes complex shapes like enclosures, housings, or cans. Deep drawing may involve multiple stages. Tension in the press draws the metal into a hole in a die. While some stretching occurs, skilled setups limit it. This assists in maintaining the strength of the material.
Piercing
Piercing removes sections of material to form holes. You retain the sheet, not the cut-out. It is the opposite of blanking. Clean piercing demands a good alignment of the punch and the die.
Critical Role of Metal Stamping Dies in High-Volume Stamping
In sheet metal fabrication, custom metal stamping dies are crucial to shape and cut metal pieces, whether forming, drawing, piercing, or blanking. They are mounted on the press and press and guide the metal into the desired shape. You may not achieve the correct or consistent results without the proper diet.
Assuring Part Geometry
The dies regulate the bending, cutting, or stretching of the metal. They specify all aspects of your component form. This implies that you will receive parts that exactly fit your design specifications. As a standard, the better the die, the tighter the tolerances, and the higher the quality.
Supporting High-Volume Production
This allows you to fabricate large quantities in a short time. They are economical in the long production runs. The appropriate die can help you minimise errors and scrap.
Enabling Process-Specific Operations
Many dies are made to suit particular stamping procedures. For example, a blanking die will cut shapes out, whereas a drawing die will pull metal into deeper shapes. Using the right die type ensures each process runs smoothly. This will save you any downtime and make your parts consistent.
Benefits of Metal Stamping
Stamping cuts precise shapes from metal sheets, but material efficiency depends on part geometry and nesting. However, complex layouts may still generate notable scrap. Here are the common benefits:
- Consistent and reliable parts
- Reduced material waste
- Faster production speed
- Lower labour costs
- Durable long-lasting dies
Choosing Material for Sheet Metal Stamping Parts
Almost all metals can be stamped, though it is a matter of choosing the correct one. Here are the primary materials and the reason for selecting each.
Stainless Steel Stamping
Stainless steel is hard and corrosion-resistant. Therefore, it remains a top pick for the marine, medical, and food industries. The 300 series grades are tough and easy to handle. Options for varied strength and hardness requirements are available in other grades such as 410 and 420 (martensitic) or 15-5 PH (precipitation hardening).
Carbon Steel Stamping
Carbon steel is inexpensive and highly durable, especially in high-strength or heat-treated forms. Low-carbon (mild) steel can be welded and shaped easily, whereas high-strength alloys usually require punching. It is ideally used in structural components such as panels and housings. Carbon steel can not fight corrosion like stainless steel, but can withstand heat better.
Aluminum Stamping
Aluminium is lightweight and is ideally used in the aerospace, automotive, and construction industries. The various aluminum alloys suit multiple applications. For instance;
- 1100 series grades are used in chemical gear.
- 2024 or 7075 in aircraft components, and prototype sheet metal stamping
- 6061 in structural applications.
Besides, it stamps out easily under different processes such as blanking or bending.
Titanium Stamping
Titanium is a tough, light, and corrosion-resistant metal. It is perfect in high-demand areas such as medical devices and aerospace. Grades 1 and 2 titanium are commonly used for stamping. They feature excellent formability, while Grade 9 (Ti-3Al-2.5V) offers a balance of strength and workability for certain applications..
Brass and Copper Stamping
- Brass is rust-resistant, malleable, and a good conductor of electricity. It is mainly used for marine and telecommunications components.
- Copper is ornamental, antimicrobial, and highly ductile. Both copper & brass are widely used where conductivity and surface finish are paramount.
Finishing Processes for Stamped Sheet Metal Parts
Although stamped parts appear relatively precise, surface finishing enhances their quality and usability. It also eliminates minor defects that occur during stamping.
Polishing
Polishing gives parts a mirror-like finish. It improves the aesthetics and part texture. Polishing is suitable for decorative and visible parts.
Powder Coating
Powder coating uses a dry powder. It applies through an electrostatic gun. The coated section is then hardened by heating to make the part tough and protective. This finish increases corrosion resistance and the intensity of the products.
Deburring
Metal Deburring removes burr and sharp edges from stamped parts. It is usually done mechanically and chemically. The process enhances the safety of parts and their performance.
Plating
Plating adds a thin layer of metal on the stamped part. It increases resistance to corrosion and surface durability. Some of the common plating metals are
- Nickel,
- Chrome, and
- Zinc.
Anodizing
Anodizing is mainly applicable to aluminum. It is an electrochemical process that forms a strong oxide film. It increases corrosion resistance and may be coloured.
Summarizing Key Details
This article focuses on sheet metal stamping, including choosing materials, designing tooling, and using the proper stamping methods.
- Always design your part following stamping guidelines.
- Choose the right metal, like stainless steel, aluminum, or brass, based on your needs.
- Create the proper stamping dies and tooling
- Select a stamping press (mechanical, hydraulic, or servo) that fits the material type, process complexity, and production volume.
- Apply stamping steps like blanking, forming, drawing, and piercing to shape the metal.
- Apply post-finishing treatments like polishing, powder coating, or plating to improve part aesthetics and function.
- Inspect common defects and fix them with the practical solutions provided.
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