Metal stamping technology is the basis for the production of many thin sheet products. So what is metal stamping and do you know the types and applications of metal stmaping?
Through this blog, you will get to know what is metal stamping, the scenarios of metal stamping, how it works and its benefits. I am sure you will get everything you want from it!
What is Metal Stamping?
What is Metal Stamping? Metal stamping is a fast, efficient metal forming technology. This technique allows sheet metal to be machined into a specific shape or structure.
Metal stamping mainly involves the interaction of a metal mold and a press, which causes plastic deformation of the metal material under pressure to form the desired part or component. Metal stamping is widely used in many fields such as automotive, electronics, electrical, aerospace and construction. This method of production is ideally suited for high volume production of high precision, complex metal parts.
Metal stamping is a complex process. The production of a qualified metal stamping parts product generally requires the following steps:
- Blanking
- Bending
- Drawing
- Punching
- Flanging
Before formal metal stamping, the engineer must define the stamping die through CAD/CAM. These designs must be precise enough to achieve the best stamping results. A 3D model can contain hundreds of stamped parts, making the design process very complex and time consuming.
However, once the stamping mold design is complete, the production of stamped parts is very fast.
Types of Metal Stamping
A qualified metal stamping goes through many steps from design to production. Below are the types of metal stamping that may possibly be involved in the metal stamping process.
1. Progressive Stamping
Progressive stamping is a stamping process that uses a continuous die to progressively process sheet metal in multiple stations, ultimately forming the desired part. In this process, the workpiece passes sequentially through multiple stations, each of which accomplishes a different stamping step.
Progressive stamping is a highly efficient, automated method of metal processing that is ideal for the production of high volume, complex shaped parts. Due to its high efficiency and accuracy, progressive stamping is an essential molding process in modern manufacturing.
Features of progressive stamping：
- High efficiency: The entire stamping process is completed automatically and continuously, enabling high-speed and efficient mass production.
- Multi-process integration: Multiple processes are completed in a single stamping cycle through continuous molds, reducing the number of individual processing steps.
- High consistency: The mold is precisely positioned to produce parts with high dimensional consistency and quality stability.
- Cost savings: Reduced processing and assembly costs due to the completion of multiple processes in a single mold.
Applications of Progressive Stamping
Progressive stamping is widely used for small metal parts with complex structures that need to be mass produced, and is particularly suited to producing parts that require multiple machining steps. Common areas of application include:
- Automotive components: e.g. connectors, spring plates, brackets, retaining clips, etc.
- Electronic and electrical components: e.g. terminals, pins, connectors, heat sinks, etc.
- Household appliances: including internal structural parts of electrical appliances, brackets, fixing parts, etc.
- Consumer electronics: cell phone housings, connectors, shrapnel, etc.
2. Four-slide Stamping
Four-slide stamping or multi-slide stamping utilizes multiple independent slides to apply stamping force to metal from different directions to form the metal material into complex geometric structures. This type of metal stamping is primarily used to produce complex, small, and precise metal stamping parts, even for the most intricate components.
Of course, four-slide metal stamping has many advantages over traditional metal stamping methods. These advantages include:
- Suitable for complex parts
- Higher flexibility for small batch and diversification production
- High efficiency
- High machining accuracy
Applications of Four-slide Stamping
Four-slide stamping is particularly suitable for the manufacture of small, complex metal parts and is widely used in the following areas:
- Electronic and electrical components: such as spring clips, terminals, connectors and battery shrapnel.
- Automotive parts: such as small springs, clips, clips and other automotive connectors.
- Medical devices: small parts requiring high precision, such as metal clips and fixtures.
- Consumer goods: metal fittings and hardware inside household appliances, etc.
3 Transfer Stamping
Transfer stamping is a multi-station stamping process. In this type of stamping, metal workpieces are transferred between multiple stations by means of an automatic conventional system, with each station completing a specific stamping step. Transfer stamping is particularly suitable for processing large metal parts.
The transfer stamping process relies heavily on automatic transfer systems. And the entire process is fully automated, which can significantly increase productivity and machining accuracy.
Applications of Transfer Stamping
Transfer stamping is widely used in the production of large, complex metal parts, and is particularly suited to parts that require multiple forming processes. Common areas of application include:
- Automotive manufacturing: e.g. car chassis, body frames, brackets and other large metal parts.
- Home appliance industry: e.g. internal and external structural parts for washing machines, refrigerators and air conditioners.
- Aerospace: e.g. aircraft structural components, brackets, internal structures, etc.
- Architectural hardware: such as metal components, brackets and decorative metal parts for construction.
4. Compound Stamping
Unlike other stamping methods, compound stamping involves the simultaneous completion of multiple steps in the same mold. This type of stamping is a very efficient metal forming process. In compound stamping, the workpiece is formed in a single pass through the die, making it ideal for metal parts that are relatively simple in shape and require a high degree of precision.
The productivity of composite stamping is very high. This method of completing multiple processes in a single operation simplifies the production process and is ideal for high volume production. And this type of stamping reduces material waste, and the structure of the mold is relatively simple, reducing costs.
Applications of Compound Stamping
compound stamping is suitable for the production of parts with simple shapes, requiring multiple processes for molding and high precision requirements, and is widely used in the following fields:
- Electronic components: such as terminals, connectors, pins and other small precision parts.
- Automotive components: such as gaskets, seals, small brackets and other small parts that require high precision.
- Home appliance industry: such as small hardware, terminals, brackets and so on.
- Architectural hardware: such as metal fasteners, decorative parts, etc.
5. Deep Drawing Stamping
Deep drawing stamping stretches sheet metal into a three-dimensional shape with a certain depth by means of a stamping die. During the stamping process, the sheet metal is placed on a die, which uses a punch to press the sheet metal into a concave die, causing it to plastically deform and gradually stretch into the specified shape. In order to avoid cracking or destabilizing the material, deep drawing stamping usually requires multiple passes to achieve the desired depth.
Applications of Deep Drawing Stamping
Deep drawing stamping is widely used in the manufacture of parts that require greater depth and complex shapes, common applications include:
- Automobile manufacturing: such as fuel tanks, filter housings, silencers, drive shaft covers, etc.
- Home appliances: such as kitchen utensils (pots, pans, bowls, pots), washing machine barrels, refrigerator liners.
- Electronic products: such as battery shells, electronic equipment shells, cell phone metal shells.
- Aerospace: such as aircraft parts, spacecraft internal structure parts, etc.
We offer our customers professional and cost-effective stamping solutions.
Applications of Metal Stamping
Metal stamping has characteristics not found in other production methods. Therefore it has strong application scenarios in many industries.
Automobile Industry
Manufacturing a competent automobile requires the composition of several components. Conventional methods can make it difficult to manufacture complex components on a large scale and quickly, which is why metal stamping is being used on a large scale in automotive manufacturing.
In the automotive industry, large body parts such as doors, hoods, roofs, etc. of automobiles are usually done using the metal stamping process. In addition to the large components, the chassis mounts, measurements, dashboard mounts, interior trim parts, and transmission components of automobiles are all made using metal stamping.
Home Appliance Industry
You can actually observe if you have a lot of metal appliances in your home. Appliances like washing machines, refrigerators, air conditioners and microwave ovens have metal casings and made structures that are produced through metal stamping technology. Apart from these appliances, the metal connectors, contactors and wire connections in the appliances are also manufactured through metal stamping.
It may be possible to produce them by other manufacturing methods, but metal stamping saves even more money.
Lamps and Electronics
Metal housings for lamps and light fixtures, as well as metal housings for cell phones and tablet computers, are mass-produced by metal stamping. If there is no way to standardize these products, the cost of their housings will be very high. This is why metal stamping technology is so prevalent in the mass production industry.
Hardware Accessories
We use a lot of hardware in our daily life to serve our life. This includes door locks, hinges, door frames and window frames. The style and function of these products are uniform. And metal stamping provides a quick and cost-effective solution to this repetitive production.
How Does Metal Stamping Work?
Metal stamping is a manufacturing process in which a stamping press and a die simultaneously apply pressure to a sheet of metal to form it into a specific shape and size. It relies on three main components:
1. Stamping Die
A qualified metal part cannot be produced without a precise stamping die. Dies are a crucial part of the metal stamping process and are usually divided into upper and lower dies. The main function of a stamping die is to extrude the metal material into the desired shape under the action of a stamping press.
The precision and design of the die directly affects the quality of the finished product.
2. Stamping Equipment
Depending on the drive power, stamping equipment can be categorized into the following three types:
- Mechanical stamping presses
- Hydraulic presses
- Servo presses
3. Programming and Selection of Stamping Type
Metal stamping machines are run automatically. The automation of the machines is all achieved by running complex software on a computer. Engineers tend to choose the most suitable stamping method according to the customer’s needs. As a result, metal stamping can fulfill the needs of almost any application.
We offer our customers professional and cost-effective stamping solutions.
Major Advantages of Using Metal Stamping
Metal stamping continues to be the main production method in manufacturing. Metal stamping now has an irreplaceable position in the production of large-scale sheet metal products.
1. High production efficiency
- Automation and mass production: metal stamping is able to realize mass production through automated equipment, and the production speed is fast, which is suitable for high production demand.
- Continuous production capacity: Combined with feeding and stamping automation, continuous production of multiple processes can be realized, resulting in a significant increase in productivity.
2. Low Production Costs
- Labor cost savings: automated stamping equipment reduces dependence on manual operations.
- High material utilization: The stamping process enables precise control of material usage, reducing scrap and lowering raw material costs.
3. High Precision and Consistency
- Consistent product quality: the use of mold production ensures that each stamped part is dimensionally accurate and consistently shaped.
- Complex shapes can be realized: The ability to accurately produce complex part shapes reduces the need for subsequent machining and calibration.
4. Versatility
- Wide range of material adaptability: metal stamping can be applied to a wide range of metals and alloys, including steel, stainless steel, aluminum, copper, magnesium and more.
- Multiple product forms: flat and three-dimensional shapes can be manufactured, such as punching, deep drawing, bending and molding processes, which are suitable for different product needs.
5. Reduced Secondary Processing
- Finished product close to final shape: Stamped parts are often close to the finished shape, reducing or avoiding cutting, drilling and other machining processes, saving time and costs.
- Integration of multiple processes: Multiple operations, such as cutting, forming and punching, can be performed in a single stamping, reducing the need for additional processes.
6. Suitable for Mass Production
- Durable molds: Stamping molds have a long service life and can support long periods of high intensity production.
- Repeatable: Suitable for the production of a large number of standardized parts, it is an indispensable process for the automotive, home appliance and other industries.
7. Environmental Protection and Sustainability
- Material saving: High material utilization reduces metal waste and contributes to environmental protection.
- Recyclable: The metal materials used are usually recyclable and environmentally friendly.
Who can Benefit from Use of Metal Stamping?
Any industry that uses metal is well suited to use metal stamping. As long as your product requires a lot of metal parts, then stamping is the most affordable option for you.
For simple and repetitive production of metal parts, metal stamping can save you a lot of money on your project. Additionally, precision automotive and aircraft parts can benefit a lot from metal stamping technology. This is because although the upfront tooling costs are high, the overall project costs are much lower!
We offer our customers professional and cost-effective stamping solutions.
FAQs
What is the Tolerance Range for Metal Stampings?
Tolerances depend on the size of the stamping and the type of material. In general, however, we control the tolerance of small metal parts between ±0.01mm and ±0.1mm. Large parts can have tolerances of ±0.5mm or more.
How long is the Usual Lead Time for Metal Stampings?
Lead time is related to many factors: 1. product complexity 2. mold design time 3. production quantity. However, generally speaking, mold design and production may take 2-8 weeks, and production time will usually be within 1 month.
Custom Metal Stamping Parts with DYB Stamping
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