What is metal stamping in manufacturing?

Table of Contents

1. Introduction to Metal Stamping
2. The Metal Stamping Process
3. Types of Metal Stamping Techniques
4. Applications of Metal Stamping in Manufacturing
5. Advantages and Disadvantages of Metal Stamping
6. SUNMETAL Company Solutions
7. References

Introduction to Metal Stamping

Metal stamping is a crucial manufacturing process used to convert flat metal sheets into specific shapes through tooling. This process is commonly used in industries such as automotive, aerospace, electronics, and appliances, providing both strength and precision in manufacturing components.

The Metal Stamping Process

The metal stamping process consists of several key stages, typically involving blanking, punching, bending, and forming operations. Each stage manipulates the metal to achieve the required shape and dimensions.

Blanking

Blanking is the initial step where a metal sheet is cut to the outline of the part. This process ensures minimal waste, with typical material utilization rates ranging from 80% to 95%.

Punching

Punching involves removing material from the blank to create holes or indents. Tolerances as tight as ±0.05 mm are achievable with precision tooling.

Bending

Bending deforms the metal along a straight axis, which can be done at angles varying from 1° to 180°, depending on the design specifications.

Forming

Forming involves shaping the metal into a complex three-dimensional geometry with minimal springback, typically maintaining angles within ±1°.

Types of Metal Stamping Techniques

Several techniques are utilized in metal stamping, including progressive stamping, transfer stamping, and fine blanking.

Progressive Stamping

Progressive stamping utilizes a series of stations, with the metal strip fed through multiple dies, performing different operations. This method is ideal for high-volume production, achieving up to 1,200 strokes per minute.

Transfer Stamping

Transfer stamping involves moving the workpiece between stations. It is suitable for larger parts, ensuring each operation can be optimized without the constraints of strip feeding.

Fine Blanking

Fine blanking offers superior precision with smooth edges and minimal burr. This process can achieve part thicknesses up to 19 mm.

Applications of Metal Stamping in Manufacturing

Metal stamping is applied in creating various components such as brackets, clips, springs, terminals, and connectors. It is widely used in producing automotive parts like seat belt housings and electronics components like battery contacts.

Advantages and Disadvantages of Metal Stamping

Advantages

• High precision and repeatability with a dimensional tolerance of ±0.05 mm.
• Cost-effective for mass production due to high-speed operations.
• Capability to produce intricate designs with complex geometries.

Disadvantages

• High initial setup cost for tooling design and fabrication.
• Limited to sheet metal thicknesses, typically between 0.0015 mm and 12.7 mm.
• Not ideal for low-volume production due to cost inefficiency.

SUNMETAL Company Solutions

SUNMETAL specializes in delivering highly customized metal stamping solutions. Their state-of-the-art facilities are equipped to handle both high-volume and small-batch orders, offering precision stamping services with tolerances as low as ±0.02 mm.

The company utilizes progressive and transfer stamping technologies to ensure efficient processing. With a focus on quality and customer satisfaction, SUNMETAL offers solutions tailored to sectors including automotive, electronics, and consumer goods.

• Progressive Die Stamping Capabilities: Up to 1,500 strokes per minute.
• In-house Tool Design: Reducing lead times by 20%.
• Material Range: Processing metals from 0.2 mm to 15 mm in thickness.

References

• Smith, J. (2020). Metal Stamping Process and its Technological Implications. Industrial Press.
• Johnson, L. (2019). Advanced Manufacturing Techniques: A Comprehensive Guide. McGraw-Hill.
• SUNMETAL Company. (2023). Retrieved from www.sunmetal.com