Sheet Metal Stamping is a low-cost high-speed manufacturing process that produces a high volume of identical metal components, which has contributed importantly to many industrial applications such as vehicles, equipment, electronics, appliances, tools, and so much more. For example, sheet Metal Stamping provides a large number of wholesale machine parts for Mechanical Industry.
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At AM Industries Vietnam, our experts can produce highly detailed custom sheet metal stampings and components that meet all customer design specifications. We serve customers across all industries and deliver short- to medium-run metal stampings and sheet metal prototyping for parts and components of all sizes and shapes.
To learn more about our precision metal stampings and custom steel fabrication capabilities, speak with an expert or give us an at , and we&#;ll gladly answer your specific questions.
What is Sheet Metal Stamping?
Sheet Metal stamping is a cold-forming process that uses dies and stamping pressing machines to shape sheet metal into various forms. Pieces of flat sheet metal typically referred to as blanks, are fed into a sheet metal stamping press that uses a tool and dies surface to transform the metal into a new shape. The material is placed to be stamped between die sections, where the use of pressure will form and shear the material into the desired final shape for the product or component.
Stamping operations are suitable for both short or long production runs, and be conducted with other metal forming operations, and may consist of one or more of a series of more specific processes or techniques that we will mention below.
With stamping presses built to handle capacities up to 440 tons and precision stamping dies and tooling that we make in-house, we can create parts as thin as 0.005&#; while maintaining tolerances that often exceed industry standards.
Basic techniques of Sheet Metal Stamping
Metal stamping machines may do more than just stamping; they can cast, punch, cut, and shape metal sheets. Machines can be programmed or computer numerically controlled (CNC) to offer high precision and repeatability for each stamped piece. Electrical discharge machining (EDM) and computer-aided design (CAD) programs ensure accuracy
Blanking is a steel manufacturing process in which a flat, geometric shape (or &#;blank&#;) is created by feeding a coil of sheet metal into a press and die. The blank is punched out from a large metal sheet in this process. Here&#;s a graphic representation of the process:
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.
CNC punching is an important option for generating sheet metal blanks. Punching is an inherently faster operation that lends itself to metal fabrications that have many similar features or where there is a higher volume of parts per run.
Metal embossing is used to impart a design upon metal sheets. The metal is pushed with an embossing tool or stylus to create a raised effect on the opposite side. By placing the metal sheet on a rubber or foam pad, the positive impression has a smooth surface that will shine or can take pigment.
Bending refers to the general technique of forming metal into desired shapes such as L, U, or V-shaped profiles. The bending process for metal results in a plastic deformation that stresses above the yield point but below the tensile strength. Bending typically occurs around a single axis.
When you are designing the bends into your stamping metal part, it is important to allow for enough material &#; make sure to design your part and its blank so that there is enough material to perform the bend. Some important factors to remember:
Coining is a bending technique wherein the workpiece is stamped while placed between a die and the punch or press. This action causes the punch tip to penetrate the metal and results in accurate, repeatable bends. The deep penetration also relieves internal stresses in the metal workpiece, resulting in no spring-back effects.
Flanging is the process of introducing a flare or flange onto a metal workpiece through the use of dies, presses, or specialized flanging machinery.
Custom Sheet Metal Stampings Material Options
We work with a wide range of custom materials for your projects. If you don&#;t see your preferred material option listed below, contact us to discuss your project&#;s specific requirements.
Custom Sheet Metal Stamping
Our Custom Sheet Metal Stamping service provides metal forming processes that apply custom tooling and techniques to produce parts specified by the customer. We could offer a wide range of industrial and application parts and components that employ custom stamping processes to meet high-volume production needs and ensure all parts meet exact specifications.
Custom Sheet Metal Stamping Projects
Our engineers can work on a wide range of sheet metal part projects for clients across various industries. To better illustrate the versatility of custom stamped metal parts, we&#;ve outlined a few recent projects completed by AM&#;s engineers below.
An American client in the automobile industry approached AM to make their custom metal stamps with special requirements for their vehicle-specific kits.
They needed custom stainless steel brackets with no sharp edges at the final products and were having trouble finding a supplier who would provide a high-quality design at an affordable price within a reasonable timeline.
To meet the client&#;s unique request for precise thickness and the complex design requirements, we used a material blanking and bending technique that allowed us to create a smooth surface and exact shape as designed, limiting costs and reducing lead times.
In another instance, we were asked to remake an existing electrical cable tray; our client was looking for a higher-quality product at a lower price with shorter lead times.
The design was not highly complex, but this application includes a number of small parts, therefore it inherently presented strict size limitations. The manufacturing process was complicated and expensive, as some of the client&#;s jobs required a fully completed powder coating and others did not.
Working with a sample tray, our team at AM was able to reverse engineer the part and its tool. From here, we designed a new stamping die set that allows us to manufacture the parts easier and lower cost.
See more our case studies here: https://aminds.com/case-studies/
Types of Stamping Operations
Progressive die stamping uses a type of tooling called a progressive die, which contains multiple stamping stations to carry out simultaneous operations on a sheet metal strip. By combining all the necessary tools into one die set, progressive die stamping is a great solution for high-volume production runs.
Transfer die stamping is similar to progressive die stamping, but the part is separated from the metal trip early on in the process and is transferred from one stamping station to the next by another mechanical transport system, such as a conveyor belt. This process is usually used on larger parts that may need to be transferred to different presses.
Four-slide stamping is also called multi-slide or four-way stamping. This technique is best-suited for crafting complex components that have numerous bends or twists. It uses four sliding tools, instead of one vertical slide, to shape the workpiece through multiple deformations. Two slides, or rams, strike the workpiece horizontally to shape it, and no dies are used. Multi-slide stamping can also have more than four moving slides.
Four-slide stamping is a very versatile type of stamping, as different tools can be attached to each slide. It also has a relatively low cost, and production is fast.
Fine blanking, also known as fine-edge blanking, is valuable for providing high accuracy and smooth edges. Usually done on a hydraulic or mechanical press, or by a combination of the two, fine blanking operations consist of three distinct movements:
Fine blanking presses operate at higher pressures than those used in conventional stamping operations, hence tools and machinery need to be designed with these higher operating pressures in mind.
The edges produced from fine blanking avoid fractures as produced with conventional tooling and surface flatness can exceed that of other stamping methods. Since it is a cold extrusion technique, fine blanking is a single-step process, reducing the overall costs of fabrication.
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:
Short-run metal stamping requires minimal upfront tooling expenses and can be an ideal solution for prototypes or small projects. After the blank is created, manufacturers use a combination of custom tooling components and die inserts to bend, punch or drill the part. The custom forming operations and smaller run size can result in a higher per-piece charge, but the absence of tooling costs can make short-run more cost-efficient for many projects, especially those requiring fast turnaround.
Stamping Advantages and Disadvantages
Sheet metal stamping has several advantages including lower die costs, lower secondary costs, and a high level of automation compared to other processes. Metal stamping dies are less costly to make and maintain than dies used in other typical operations. Cleaning and plating are also less expensive than identical treatments for other metal manufacturing techniques. Stamping machines are generally simple to automate and may use sophisticated computer-control systems to give more precision, faster output, and shorter turnaround times. The high level of automation also reduces labor costs.
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.
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Precision Quality Stampings & Fabrication
We produce only the highest quality custom metal stampings. Our workforce is dedicated and committed to quality through Quality Circle involvement. Our products are high-quality and are certified to ISO : certified, AU, US, EU, or CA standards.
Sheet Metal Stamping Applications
Stamping parts are 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, military and defense, 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 also 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.
Design Concepts
Overly narrow projections should generally be avoided in stamped products, as these may be more easily distorted and impact the perception of quality in the finished product.
Where possible, designs should be based on the use of existing dies for standard shapes and bends. The need to create a custom die for stamping will increase initial tooling costs.
Avoidance of sharp internal and external corners in stamped product designs can help reduce the potential for the development of larger burrs in these areas and sharp edges that require secondary treatment to remove. Also, a great potential for stress concentrations exists in sharp corners, which may cause cracking or subsequent failure of the part through extended use.
Overall dimensions for the finished product are going to be limited by the available dimensions of the sheet metal sheets or blanks, and these limits need to be factored in for the material consumed in folds on edges or flanges and any additional material removal or use. Very large products may need to be created in multiple steps and mechanically joined together as a second step in the production process.
For punching operations, consider both the direction of punching as well as the size of the punched feature. Generally, it is best to do punching in one direction, so that any sharp edges produced by the punch will all be on the same side of the workpiece. These edges can then be hidden for appearance purposes and kept away from general access by workers or product end-users where they might represent a hazard. Punched features should reflect the thickness of the raw material. A general rule is that punched features should be at least twice the material thickness in size.
For bends, the minimum bend radius in sheet metal is roughly the same as the material thickness. Smaller bends are more difficult to achieve and may result in points of stress concentration in the finished part that may subsequently cause issues with product quality.
When drilling or punching holes, performing these operations in the same step will help to assure their positioning, tolerance, and repeatability. As general guidelines, hole diameters should be no smaller than the material thickness, and the minimum spacing of holes should be at least twice the material thickness apart from each other.
Bending operations should be performed with awareness of the risk of distorting the material, as the material on the interior and exterior surfaces of the bend point are compressed and stretched respectively. The minimum bend radius should be approximately equal to the thickness of the workpiece, again to avoid stress concentration build-up. Flange lengths should be more like three times the workpiece thickness as a good practice.
Contact us for Precision Sheet Metal Stampings and More
Are you searching for a reliable precision sheet metal stampings manufacturer at a reasonable cost? Look no further than AM Industries Vietnam. Request a quote on your custom sheet metal stamping project or contact us to find out what we can do for you.
Source: www.thomasnet.com
What is stamping, and what does a stamping press do?
Metal stamping is a cold-forming metal fabrication method that uses pre-shaped dies and pressure to shape sheet metal blanks into products and components. Using automated or manual feeders, manufacturers insert metal sheets into the stamping press between the tool and die surface. The press lowers onto the sheet metal, using compressive force to press the material into the die to create the desired shape.
Also known as metal pressing, metal stamping is a highly versatile process that can produce accurate, uniform products quickly and efficiently. The process is used in both large and small scale production runs and is often combined with other metalworking processes such as machining, assembly, and finishing. There are many specialized stamping techniques that can be used to produce specific results, including:
Involves using a die and press to create holes through the workpiece.
Punches the workpiece out of the sheet metal blank.
Creates raised or indented words, figures, and designs into the sheet metal.
Similar to embossing, but the workpiece is stamped on both sides to create raised or indented words, patterns, and figures.
Using a press brake, force is applied to the metal workpiece, which bends at an angle from the original axis to create a V or U shape.
Edges of the workpiece around punched holes are bent at a 90° angle from the sheet, creating a rim around each hole.
Precision metal stamping, also known as progressive metal stamping, is a particular stamping process that uses a series of consecutive dies to produce detailed and complex metal components quickly and affordably. With precision stamping, the workpiece is fed through the press one station at a time. At each stage, the sheet metal is progressively shaped by minor changes to each die in sequence, ultimately producing detailed components with a high degree of accuracy and repeatability. The reliability, speed, and cost-effectiveness of precision metal stamping make it ideal for large-scale production of detailed metal components, where machining time and costs would be prohibitive.
What materials are stamped most commonly?
Stamping can be used to shape a wide variety of metals, both ferrous and non-ferrous. The type of metal you choose for your metal stamped components depends greatly on the application for which it is intended, as well as the size, shape, and design of your product.
Ferrous Metals
Ferrous metals, which contain iron, are typically magnetic and tend to be strong and durable. Steel is a well-known ferrous metal that is used in an extensive range of applications. Ferrous metals are valued for their high strength, but their iron content makes them more susceptible to rust and corrosion than non-ferrous materials. Carbon steel is the most commonly used ferrous metal for metal stamping applications due to its extremely high tensile strength.
Non-Ferrous Metals
Non-ferrous metals and alloys do not include iron and are therefore not magnetic. Non-ferrous metals are very popular for a variety of stamped products due to their high ductility and wide range of useful properties. The most commonly used non-ferrous metals for stamping applications include aluminum, tin, copper, brass, bronze, gold, and silver. Aluminum is particularly popular for stamped components and products due to its low cost, lightweight strength, and corrosion resistance.
When selecting the right material for your metal stamping application, it is also important to consider the material composition of the die you will be using. While most dies are composed of tool steel or hardened steel, different workpiece materials or processes may require an alternative die material, such as aluminum or mild steel.
What is a die or press tool, and how is it used?
Metal stamping dies, also known as press tools, are the tools used to shape the metal blanks during the stamping process. Die tools with sharp edges used to cut, punch, shear, or blank the sheet metal are called cutting dies. Those that are used to form, bend, or otherwise shape the workpiece without removing material are called forming dies.
Parts of a Die and Their Functions
While dies can come in many shapes, sizes, and configurations, the following die parts are typically included in the mechanism:
The die block is a pre-shaped mold that is cut, drilled, and indented to establish the shape of the product. The press or punch compresses the workpiece into the die block, cutting, punching, or forcing the metal to conform to the desired shape.
The die holder holds the die block in place on a bolster plate, which is in turn supported by the upper or lower die shoe.
The punch plate is the mechanism that holds the punch to the ram or press and moves with the press against the die.
The punch is the portion of the die that presses onto the workpiece to punch or compress it into the desired shape.
This is a thin plate that keeps the workpiece from sticking to the punch after each press stroke.
Guide pins ensure that the upper and lower parts of the die are cleanly aligned.
A collection of back-up and pressure plates installed around the die help to ensure that the punch pressure is evenly distributed across the workpiece.
What are the main types of stamping presses?
Metal stamping presses are engineered with a variety of actuation methods and press designs to facilitate a wide range of manufacturing needs. The main types of stamping presses include single- and double-acting presses, mechanically driven presses, and hydraulically driven presses.
Single-Acting vs. Double-Acting Presses
A single-acting press features a single ram, while the ram of a double-acting press is divided. Single-acting presses perform one task for each cycle. Double-acting presses perform two tasks at once using two rams, one to hold the blank and one to punch or stamp. For both single- and double-acting presses, the ram is attached to the top of the press and generates motion to compress the metal sheet against the die. Before it is fed into the press, the sheet metal for the workpiece is straightened to create a streamlined flow.
Mechanically Driven Presses
Mechanically driven presses are operated using a motor and flywheel mechanism. The flywheel transfers kinetic energy into the press, moving the ram toward the plate in a smooth, regular motion. Mechanical presses are quick and efficient and can be relied upon to produce consistent results in repeated cycles. The speed and accuracy of mechanical presses make them particularly useful for assembly lines and industrial manufacturing.
Hydraulically Driven Presses
Hydraulically driven presses use fluid or gas pressure to transmit force into the press. They press the ram down onto the workpiece using a constant pressure, unlike mechanical presses which show force progression. Hydraulic presses operate more slowly than mechanical presses but provide a high degree of versatility and control when it comes to tonnage, workpiece size, and component complexity. For this reason, hydraulically driven presses are ideal for creating detailed, complex, and unusually shaped components.
Precision Metal Stamping from the Experts at Keats Manufacturing
Precision metal stamping offers unique advantages for a wide range of industries. It is quick, affordable, and efficient, creating everything from simple components to complex products with an exceptional degree of consistency between parts. At Keats Manufacturing, we are committed to providing superior metal stamped components for every application.
Using state-of-the-art stamping technology, Keats Manufacturing is pleased to provide industry-leading metal stamping services that meet and exceed your expectations. With more than half a century of experience, we remain at the forefront of the metal manufacturing industry by providing exceptional service and superior solutions for every project. To learn more about our metal stamping and other metal fabrication capabilities, contact us today or request a quote for your next project.
The company is the world’s best stamping machine for sheet metal supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.