Sheet Metal Stamping is a process in which the sheets of metals are converted into the desired shapes by pressing metal sheets with the help of dyes and using high pressures in the stamping press.
In this process, the stamping press uses the dyes or tools to mold the metals into the required net shape, including bends, curves, cutouts & embossing. Stamping press includes a number of ways of making sheet metals, including punching using the machine press or stamping press, bending, flanging, embossing, blanking, & coining are possible.
Through this process, the process becomes faster in producing the desired shapes of metal sheets or coils, the lead time becomes higher, the overall cost of the process becomes low, and mass production becomes possible.
By Sheet Metal Stamping, you can ensure the dimensional accuracy of the final product with the consistent quality & repeatability of manufactured parts. Production of very complex parts, including car door panels or gears, to the smallest equipment used in computers, phones, or other industries, including Automotive, Electrical, Lighting, Medical, Home Appliances, Defence, and many others.
Types of Metal Stamping Processes
There are numerous types of metal stamping processes, and they are categorized based on specific processes and techniques involved in their functions. Here are 4 significant types of metal stamping processes are explained:
Progressive Stamping
Progressive Stamping Setup
This is a type of stamping that involves mass production in one go. In this, the workpiece is attached to the metal strip throughout the process. It involves shaping the workpiece into complex geometrical angles and shapes.
It is mainly used for industries that require complexly shaped materials and parts in large quantities and bigger sizes. It involves continuously feeding metal sheets, and each section performs its specific functions like bending, cutting, forming, & many more functions while ensuring the accuracy of dimensions.
Transfer Stamping
Transferring Stamping Setup
Like the progressive stamping in this process, the metal sheet is not continuously fed into the system and is put in one go. In this technology, the working piece is not attached to the metal sheet but removed from the metal strip and moves along the conveyor.
This process can be used for industries requiring larger and more complex parts with more precise positioning and detailing.
Fourslide Stamping
Fourslide Stamping Setup
In this stamping, four different tools are used to shape the metal sheet. By name, it is obvious there is an involvement of four machines or, you can say, four slides. This process can be used to design more complex designs that need detailing and are small parts.
Using this technology makes designing the small parts in more detail and with more complexity easy. This technology has provided more chances for design changes and allows the production of mass products in less time with less cost and more accuracy and precision.
Deep Draw Stamping
Deep Draw Stamping Setup
In this technology, the metal sheet is drawn on the empty die with the desired shape, which might be cylindrical or box-shaped. So, by punching heavier pressure, the sheet of metal is converted into the desired shape.
This process involves the extra bending of the metal sheets that converts them into a more crystalline form. By this, the shapes can be produced, which requires deep cavities. Automotive, aircraft, electronics, and many more industries often utilize this technology.
Prototype Sheet Metal Stamping
Prototype sheet metal stamping is not the type of metal stamping but a process to produce a small quantity before producing a large quantity for some material or, you can say, parts of any industry.
It’s for testing purposes and plays the role of a bridge to decide whether the designs made by any industry engineers or experts are for 100% usage. So, for testing the prototype sheet, metal stamping is applied first on a smaller scale to save time, cost, and efficiency and to test the actual facts.
If the prototype works well, then larger production is carried out according to industry needs; otherwise, it does not. This process is often carried out by industries like automotive to test custom models before launching them into the industry, by the medical industry to test the prototypes of new surgical instruments before launching them directly into the market & there are many more examples.
Understanding Metal Stamping Dies
There are 4 basic types of metal stamping dies. We explained in detail the primary function of each and what each term means.
Single Station Stamping Dies
Single Stage Stamping Dies
In this process of stamping the die, movement of the hydraulic press/mechanical system is noticed, moving from its initial position and punching the metal sheet into the net shape of the die. After the metal sheet converts into the die’s shape, the hydraulic returns to its initial position.
This process suits industries like automotive, electronics, Construction & much more. This is often used for parts that require unique detailing at low cost with maintained accuracy and precision of dimensions.
Progressive Stamping Dies
Progressive Stamping Dies
In this type of stamping, the continuous feed is given to the system. For example, the metal sheet is fed continuously in four-slide stamping, and the time interval of metal sheet movement in the system is already calculated.
The movement of the mechanical system responsible for applying the force and bending the metal sheet according to the shape of the dies becomes possible. This process gives you mass production with low-cost assurance and dimension accuracy. However, handling accuracy during the process is difficult.
Compound Stamping Dies
Compound Stamping Dies
This is a technology that is capable of performing multiple functions in steps or in one go. For example, if it punches the material for someone’s purpose, there is an option available that we can take two tasks from this technology in one step. For example, if it punches the hole, it can also bend the edges of the material at the same time.
It is beneficial to produce mass production, but if conciseness and more detail are needed for the material, it must go through more processes. But it ensures the quality with cost and by saving the time & material also.
Transfer Stamping Dies
Transfer Stamping Dies
In this technology, the blank sheet of metal is entered into the system, and a grip, often called a “finger,” is responsible for transferring the sheets from one section to another. In transfer stamping dies multiple operations are performed on one machine.
When one operation is completed, the sheet automatically transfers with the help of grip to the next die portion, and the process continues. Transfer stamping dies can handle the complexity of the procedures easily and can be used to produce large mass production at a lower cost and in less time with minimum waste of materials.
Custom Metal Stamping Dies
Custom Metal Stamping Dies
Custom metal stamping dies are specialized types custom-made according to the client’s needs. It also requires a deep relationship and clear communication between the manufacturer of metal sheet stamping products and the maker of custom metal stamping dies.
The products that are produced after the processing from custom metal stamping dies are also known as custom sheet metals and the process is called a custom sheet metal stamping.
They are made out by first creating a design using Computer Aided Design (CAD) software, focusing on the client’s custom demand and pain points. After that, they are made using complex geometric angles and bending, piercing, and embossing. They will be used to make custom prototypes or other materials.
They are ideal for mass production but are also used to make small materials, parts, or prototypes by ensuring enhanced production efficiency with precision, accuracy, and cost-effectiveness for custom designs for a particular client.
Metal Stamping Tooling
While discussing the metal stamping tooling, some crucial and fundamental aspects are necessary. Here, we discuss every tool that is used for this purpose and how it functions also discussed in detail:
Design and Tools Preparation:
The first step is to design the geometry of the desired part in the final output. The engineers look at the final product’s geometric angles and all requirements, design the final model, and then create the design.
The design is then put in the CAD software to ensure no errors in the calculations or findings. Then, engineers take the calculations of the dies and the machines and figure out how to initiate the process and ensure the desired results within all possible circumstances.
Preparation of the Material:
After completing the first process, experts select the desired material by keeping some points about its strength, flexibility, corrosion resistance capability, conductivity, cost, and capability for stamping.
Feeding of Material in Stamping Press:
Then, the third process is to prepare the material to be fed into the stamping process, but before that, to make sure the material is capable of being fed into the process or not, which includes making sure of its thickness and all other stuff necessary for the stamping process.
Stamping Operations:
After finishing these 3 steps, the operation begins and dies close together, and high pressure is applied to the material to de-shape it according to the need. The process is carried out by the several processes responsible for stamping the material.
The experts notice and examine the bending, blanking, coining, and punching processes to ensure the smoothness of the work and deliver the marked quality of the final product with accurate dimensions and precision.
Finishing Process with Final Touches:
In the end, after the product is made out, experts apply the final touches to the product, like removing sharp edges, giving a final coat to the product surface, cleaning, surface treatment, and much more.
Conclusion:
Metal stamping is a highly cost-effective technology that ensures accuracy and precision from large-scale mass production to small-scale prototype custom parts making. It ensures the material’s durability within a low budget by decreasing idle time. Perfect for automotive, electrical/electronics, lighting, defense, medical, furniture, home appliances and much more.
