Stamping
What is Stamping Parts
Metal Stamping parts are pieces of metal that are shaped by applying an intense force through a die. Metal blanks are inserted into dies and then pressed to create specific shapes. Commonly stamped items include car body panels, engine components, and household appliances.Stamping is a manufacturing process that can be used with many different materials, including metals such as steel, aluminum, brass, and copper; composite plastics; or other special types of materials. It depends largely on what you want the finished product to look like: whether it's hardy yet malleable enough or whether it has all the qualities you need when pressing it into certain shapes.
Advantages of Stamping Parts
High efficiency and convenience
Precision metal stamping is a highly efficient process that can produce parts quickly and easily. This is because the die does the work of shaping the metal, which eliminates the need for time-consuming and labor-intensive machining operations. Precision metal stamping machines can run at speeds of up to hundreds or even thousands of parts per minute, which can significantly reduce production time and costs.
Stable stamping quality
During stamping, the quality remains stable due to the molds ensuring the specifications and appearance accuracy of the stamped components. The surface quality of stamped components is generally not compromised, resulting in consistently smooth quality and well-coordinated tolerances. This process exhibits a characteristic of producing “identical parts from the same mold.”
Versatility in customization
Precision metal stamping can produce various specifications and complex customized parts, such as clock timers, large automobile side beams, coverings, and more. Combined with the cold deformation hardening effect of the raw material during stamping, the stamped components exhibit high compressive strength and bending stiffness.
Cost-effective and environmentally friendly
Stamping generally does not generate cutting edge materials, leading to lower material consumption. Additionally, it does not require other heating equipment, making it a cost-effective and environmentally friendly production method. The cost of stamped components is relatively low.
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Why Choose US
Our Factory
Our workshop occupies over 10,000sqm in a modern manufacturing facility, equipped with advanced machinery that offers the comprehensive manufacturing servince for sheet metal parts, machined parts, stamped parts and cast parts. and we are offering assembly service to our customers as per request in our own workshop.
Our Projects
We are committed to help clients realize the concepts and designs with support of our engineering and manufacturing advantages that includes projects made of processes as:
--Sheet metal fabrication
--CNC machining
--Casting
--Stamping & Forming Assembly
Our Certificate
Starway MFG is an ISO9001:2016 certified manufacturer, and also a 5-Star Premium supplier on Alibaba.com, serving global customers from many different industries, like Machinery, Building, Vehichle, Telecommunications ect.
Manufacturing Processes
For sheet metal parts, there are manufacturing steps inhouse like laser cutting, CNC bending, welding, grinding, PEM insertion ect
For the Machined parts, there are manufacturing steps inhouse like CNC milling, CNC turing, Grinding, Drilling and EDM wire cutting.
Our stamping machines range from 200-400 tons that allows our to do stage stamping and progressive stamping, tooling designed and built in house.
For high quantity aluminum parts, we are providing die casting service.
Key Factors to Consider When Choosing a Material for Precision Metal Stamping
Some of the key factors to consider when choosing a material for precision metal stamping are the metal's ductility & formability, tensile strength, machinability, and work hardening rate.
Ductility & Formability
Forming occurs somewhere between the yield strength and tensile strength of the material. If yield isn't exceeded, forming doesn't occur but exceeding the tensile strength results in a material fracture. In higher-strength materials, the window between yield and tensile is very small.The grain size of a material is commonly used to indicate its formability, and consistent grain size is highly desirable for forming operations.
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Tensile Strength
Tensile strength measures the amount of force a material can withstand without breaking. Some metals are stronger than others, and the strength varies depending on the component materials in a metal alloy. You should consider the tensile strength of the metal you choose to ensure that it can withstand the amount of force applied during use.
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Machinability
Machinability measures how easily the material can be cut or shaped. Because properties that improve a material's performance often reduce its machinability, you should consider the machinability of the metal you choose after satisfying other requirements for your part. A machinable material can be cut quickly with a good finish, which reduces costs. However, it's more important to choose a material that meets the requirements of your part rather than choosing a machinable material.
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Work Hardening Rate
As metal is worked or stamped, the temper changes, and the metal either becomes harder and more brittle. The rate that this occurs is work hardening. Depending on how much work is done to the metal and how much it needs to be deformed in a particular operation, the material may require annealing to reset its properties to prevent cracking, breaks, and other material imperfections.
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What Equipment Is Needed For Metal Stamping
The equipment needed for metal stamping depends on the specific requirements of the stamping process, as well as the type and size of the parts being produced. In general, the main pieces of equipment needed for metal stamping include:
Stamping press
This is the main piece of equipment used in the stamping process. A stamping press applies force to the stamping die, which cuts and forms the metal into the desired shape. Stamping presses are available in a range of sizes and configurations, depending on the specific requirements of the stamping process.
Stamping die
This is a specialized tool that is used to cut and form the metal parts. The die is typically made of hardened steel and is precision-machined to match the desired shape of the finished part.
Workpiece
This is the piece of metal that will be formed into the desired shape. The workpiece is placed on the press bed and positioned so that it lines up with the stamping die.
Press bed
This is the stable base on which the stamping press, stamping die, and workpiece are positioned during the stamping process.
Bolster plate
This is a plate that provides support for the stamping die and workpiece during the stamping process.
Hydraulic or mechanical system
This is the system that powers the stamping press, providing the force needed to cut and form the metal parts.
Other pieces of equipment that may be needed for metal stamping include automatic feed systems, safety guards, and handling equipment to move the finished parts.
Applications of Stamping Parts in Various Industries
The Materials Commonly Used for Metal Stamping & Fabrication
Aluminum: Aluminum is a soft, non-metallic metal with a high strength-to-weight ratio, great formability, and good thermal and electrical conductivity. These features make it an excellent choice for creating metal stampings for aerospace, automotive, and construction applications requiring lightweight, high-strength components.
Beryllium copper: Beryllium copper is a strong, corrosion-resistant copper alloy with a beryllium content ranging from 0.5 to 3%. With its high ductility, this alloy can be easily stamped into complex shapes with tight tolerances.
Brass: Brass is a copper and zinc alloy known for its hardness, workability, and bright gold-like coloration. Its unique appearance and resistance to tarnishing and corrosion make it ideal for fabricating commercial and residential door hardware as well as automotive components.
Carbon steel: Carbon steel is an iron and carbon alloy containing 2.1% carbon by weight. Low cost, high strength, and great solderability make carbon steel a popular choice for creating durable stamped brackets, vehicle panels, wear plates, and more.
Copper: Copper is a soft, malleable metal with a distinct pinkish-orange appearance. A unique combination of electrical conductivity, durability, ductility, and corrosion resistance makes copper ideal for everything from stamped architectural features and decorative hardware to air conditioning components and medical parts.
Additional alloys and superalloys: Metals like aluminum and copper can be alloyed with other metals or elements to create stamped components with improved strength and other enhanced properties. Superalloys include high-performance and specialty alloys such as Waspaloy and Monel. While somewhat harder to work with, stamped components made from superalloys can maintain their shape in a range of extreme environments.
Stainless steel: Stainless steels are ferrous alloys containing various proportions of chromium, molybdenum, and nickel. With their excellent corrosion resistance, hardness, tensile strength, and temperature tolerance, stainless steel materials are well-suited for fabricating knives, cutting tools, to easy-to-clean medical appliances.
Which Metals are Best for Stamping?
When designing precision metal components, it is important to choose materials for metal stamping that are amenable to the stamping process while providing the functional and aesthetic characteristics required to support the application. Part of what makes metal stamping so versatile and widely used is its compatibility with thousands of different metals, all of which can be categorized as either ferrous or nonferrous:
Ferrous: Ferrous metals have a significant proportion of iron in their elemental composition. One of the most commonly stamped ferrous metals is steel, an alloy primarily derived from iron ore. Ferrous metals containing higher amounts of carbon tend to be strong and brittle, while those with lower carbon content are softer and more ductile.
Nonferrous: In contrast to ferrous metals, nonferrous metals lack appreciable amounts of iron in their composition. This makes them less susceptible to oxidation- or rust-induced deterioration. Examples of nonferrous materials used in metal stamping include copper, aluminum, brass, and bronze.
Both ferrous and nonferrous metals can be used to create alloys, which are metals that have been combined with at least one other metal or element. The resulting combination produces a material with a new set of physical, chemical, and mechanical properties that are generally superior to those exhibited by the parent material.
Stamping Operation
Stamping also called pressing involves placing flat sheet metal, in either coil or blank form, into a stamping press. In the press, a tool and die surface form the metal into the desired shape. Punching, blanking, bending, coining, embossing, and flanging are all stamping techniques used to shape the metal.
Bending - The material is deformed or bent along a straight line.
Flanging - The material is bent along a curved line.
Embossing - The material is stretched into a shallow depression. Used primarily for adding decorative patterns. See also Repoussé and chasing.
Blanking - A piece is cut out of a sheet of the material, usually to make a blank for further processing.
Coining - A pattern is compressed or squeezed into the material. Traditionally used to make coins.
Drawing - The surface area of a blank is stretched into an alternate shape via controlled material flow. See also deep drawing.
Stretching - The surface area of a blank is increased by tension, with no inward movement of the blank edge. Often used to make smooth auto body parts.
Ironing - The material is squeezed and reduced in thickness along a vertical wall. Used for beverage cans and ammunition cartridge cases.
Reducing/Necking - Used to gradually reduce the diameter of the open end of a vessel or tube.
Curling - Deforming material into a tubular profile. Door hinges are a common example.
Hemming - Folding an edge over onto itself to add thickness. The edges of automobile doors are usually hemmed.
How to Cut Sheet Metal Stamping Parts
Trimming
Trimming is a process in which the outer perimeter of a formed or flat part is cut away to give the piece part its finished or partially finished profile. The excess material, commonly called addendum or offal, often is recovered, collected, and resold as scrap. However, sometimes the scrap from one part can be used to make a different, smaller part in another die. Using excess material in this fashion is smart engineering, because the cost of coiled material often is 10 to 15 times greater than the amount paid for scrap.
Notching
Usually associated with progressive dies, notching can be defined as a metal cutting operation in which the outside edges of the strip are cut in an effort to create the flat starting shape of the piece part, or the blank.
Blanking
Blanking is a method in which the sheet metal is cut and the slug is saved for further pressworking. The size and the shape of the blank are proportional to the size and shape of the part.
Blanking through refers to a method in which a formed part is cut free from a strip of material and pushed through the die.
Three basic types of blanks are used in sheet metal stamping: fully developed, partially or semideveloped, and undeveloped.
Piercing
Often called perforating, piercing is a metal cutting operation that produces a round, square, or special-shaped hole in flat sheet metal or a formed part. The cutting punch that produces the hole is called the pierce or perforating punch, and the hole into which it enters is called the matrix or the button.
Lancing
Lancing is a metal cutting operation in which the metal is sliced or slit to free up metal without separating it from the original sheet. Unlike other metal cutting processes, lancing does not create a slug. This process can save material and eliminate the need for expensive scrap removal systems.
FAQ
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