Metal stamping involves a variety of different processes, each different, depending on the shape of the component or product. These processes are used to achieve the complex and meticulous design of parts and products in industries including aerospace, consumer products, automotive, aviation, electronics, food and beverage, among others. It is usually not possible to fabricate a component using a metal stamping method because each process involves making a specific design.
A lot of stamping technology involves extrusion, stretching, reinforcement and other processes. Each Deep Draw Stamping involves a mixture of processes to achieve the desired parts. All of these methods are performed at room temperature and usually involve minimal or zero heat. Metal stamping is a typical cold forming manufacturing process that involves the use of several tools and equipment, such as stamping machines (punch presses), dies, etc., to form complex shapes and appearances.
With this in mind, we will discuss some of the most popular hardware stamping processes used by manufacturers.
Punching is a common metal stamping process. A sheet of metal is held in place, or more precisely, a countertop. Using different tools and machines, a hole is made in the sheet metal to form a series of different hollow areas in the sheet metal. Punching is a bit different because after punching a hole in the sheet metal, the part with the hole is removed and no longer used.
To ensure that the sheet metal does not deform, punching must be a continuous process. The area around the punch must be precisely designed. The machines used in this hardware stamping process are manufactured with high carbon steel and must be thoroughly maintained so that there are no passivation or places of passivation, which have the potential to deform the shape of the sheet metal.
There is not much difference between blanking and punching - a big difference, however, is that the punched sheet is not thrown away. The punched sheet is the final component. Many metal stamping companies usually punch the project before doing anything else. After blanking, manufacturers proceed to other hardware stamping stages, such as extrusion and bending.
Blanking essentially involves making sheets -- usually small or medium metal sheets cut from larger pieces. This is a particularly advantageous process when it comes to high volume manufacturing, as it is easy and leads to making high quality and precision based cuts.
In some cases, however, metal plates may contain undesired edges or burrs. This is a common question; however, sharp edges and burrs are eventually removed through several processes such as thermal deburring, manual deburring, and/or vibration methods.
When it comes to metal stamping, some manufacturers also use a process called stretching. The method basically involves fastening the ends of the metal plate firmly (opposite ends). The next step is to place the sheet metal on top of a mold that has a cross section shape. Through a powerful stamping process, the die creates a punch that pushes the sheet onto the machine. This helps to develop the cross-sectional shape of the machine, sufficiently deforming the sheet metal to meet the requirements.
The stretching method can also be divided into two other processes called deep stretching and shallow stretching. These are similar processes to achieve the desired depth on a sheet metal. For example, during a shallow stretch, the radius of the main metal plate will always correspond to the depth of the stretch, which means that it will be equal.
Deep stretching, on the other hand, is basically cup-cutting into a sheet of metal to form different products. During deep drawing, the total radius of the sheet is much smaller compared to the depth to be performed.
The extrusion method in metal stamping is a typical process used by manufacturers to make extruded shapes of products and components. The extrusion method relates to a "closed die" manufacturing technology. In this case, the sheet metal is used as a whole, or is extruded into parts. The process involves two separate molds that are positioned closer together at the ends of a metal plate, forming a coin shape.
One of the greatest benefits of the extrusion method is that it is very effective in manufacturing a wide variety of metal parts and products with different amounts of tolerance. It is also a relatively straightforward technique that can quickly and reliably produce deformations (often permanent) on products. This essentially makes the component or product highly resistant to deep physical wear and strong impact.
Cut the tongue method
The tongue cutting technique is completely different from blanking and punching methods. How can I put it? Well, tongue cutting involves a unique metal stamping process that doesn't need to remove any metal from the sheet. The punch and die process is programmed to make a deep slit in the metal surface. The goal is to avoid creating any scrap metal -- for example, plugs that need to be disposed of or removed during the post-processing phase.
One of the main reasons manufacturers use the tongue cutting method is that the process facilitates the creation of a variety of unique and custom designs and shapes using different types of metals. For example, it is commonly used to create parts and parts that are needed for applications such as openings, vents, labels, etc.
Sheet metal reinforcement is another unique technique used to design a raised surface in a specific area of sheet metal. The bars can be created using two different methods -- through a die set or a machine. The stiffening method is primarily used to create parts and components for a variety of different applications, depending on the complexity of the desired design and its form. For example, some of the best examples of the use of reinforced parts include metal coverings, hoods, engine housings, door frames, checkerboard steel plates, and so on.
The stiffening technique can be used on different metal surfaces; however, the most popular type of metal for this process is aluminum. This is mainly because the metal is so easy to work with. In addition, the material is durable and lightweight, two great features that help make the stiffening process more efficient and effective.
Important factors to understand in the metal stamping process
Metal stamping technology is very useful when it comes to metal manufacturing. In this case, each process is referred to in terms of technical complexity. For example, fast and direct processes such as blanking, or punching, are often referred to as the initial level of any project. These processes are then accompanied by other processes to form the finished product.
On the other hand, complex stamping procedures such as deep drawing, tongue cutting, extrusion and/or bar pressing are mainly used to create complex designs that do not require machining during their entire production cycle.
All in all, metal stamping is an extremely important, future-oriented process that is vital to many industries. The process is used to make everyday consumer products, as well as larger parts and parts used to make vehicles and other things.