A metal stamping process's production procedure

In the cold-forming manufacturing process known as metal stamping, large-scale processes are used to transform flat metal sheets into unique forms with details like bends, holes, grooves, and slots. An important phase in the design process is choosing the procedure that is suitable for a certain part. The most popular manufacturing techniques for metal stamping are listed below.

Blanking

In order to create a flat, geometric shape (or "blank"), a coil of sheet metal is placed into a press and die during the blanking stage of the manufacture of steel. During this procedure, a metal sheet is punctured to create the blank. In contrast to piercing, blanking uses the excised portion as a brand-new metal piece. The technique and instruments are identical. Here is an illustration of the blanking procedure

Piercing

In part, slots, holes, or other cuts can be made by piercing. Making a hole in sheet metal or a plate using a punch and die is the shearing procedure known as "piercing." The needed forms are punched out of the metal sheet during piercing, which can happen concurrently with blanking. The useless portion of the metal is cut away during the piercing process and turned into scrap.

Punching

To make a hole with a specific shape and location, a press is used to force a punch through a metal form. The surplus material is typically separated from the freshly formed shape using the punching tool. Shear may or may not be involved in punching.

CNC punching is essential for producing sheet metal blanks. Punching is a speedier operation that lends itself to metal fabrications with numerous comparable features or a higher volume of parts per run.

Embossing

Metal embossing is a process for imparting a design on metal sheets. The opposing side can produce a raised effect by pushing the metal with an embossing tool or stylus. The positive impression has a smooth surface that can shine or take pigment by laying the metal sheet on a rubber or foam pad.

Engraving and embossing are very comparable processes. To produce a logo or a symbol on a metal object, engraving, on the other hand, involves cutting a little amount of the metal. In order to create an indentation in the shape of the desired message or picture, embossing uses a preset punch.

Bending

A key technique for forming metal into desirable forms, such as L-, U-, or V-shaped profiles, is bending. The plastic deformation caused by metal bending has stresses beyond the yield point but below the tensile strength. Many times, bending occurs around a single axis.

Making ensuring your item and its stock have adequate material to execute the bend is essential when designing bends for stamped metal parts. Keep in mind the following:

Making ensuring your item and its stock have adequate material to execute the bend is essential when designing bends for stamped metal parts. Keep in mind the following:

If a curve is too close to the hole, it may get distorted.

Your blank design must feature corners with radii that are at least half the material's thickness.

Slots, tabs, and notches should all have widths that are at least 1.5 times the material's thickness.

To reduce the occurrence and severity of burrs, try to steer clear of sharp edges and complex cuts.

Coining

During the coining process, the workpiece is stamped while being sandwiched between a die and a punch or press. In order to achieve exact and repeatable bends, this movement pushes the punch tip into the metal. Additionally, since internal tensions in the metal workpiece are reduced by the deep penetration, there are no spring-back effects.

A component may experience considerable stress and strain during coining. The workpiece has smoother surfaces and edges and is more closely matched to the design tolerances as a result of the plasticized material flowing as a result. To thin down the metal and form the component, coining is routinely utilized. Coins (metal money) can be made through the coining process.

Flanging

Using dies, presses, or specialized flanging equipment, flanging is the process of adding a flare or flange to a metal object. The two basic types of flanges are tension (stretch) flanges and compression (shrink) flanges. Tension flanges can fracture easily. Wrinkled compression flanges are common.

Flanging is accomplished along a curved line, much like bending. Due of this small complexity, specific flanging equipment needs to be purchased.