Sheet Metal Stamping Process Explained - Aranda Tooling, LLC

The process of turning sheets of metal into a useful part or component is called sheet metal stamping. The metal is fed into a press, where the stamping tool, also known as a die, creates the desired shape. The die is pressed into or through the metal with tremendous force. The force used in the process is measured in tons.
Except for some specialized processes, sheet metal stamping doesn’t use heat. Instead, it is done with a cold-forming technique. Even though no heat is used, the part can come out hot because of the friction that’s created between the metal and the die from the force of the press.

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What Is Sheet Metal Stamping?

Sheet Metal Stamping Process

There are basically only three components to sheet metal stamping—the sheet metal, die, and press machine—but any single part can require multiple steps to arrive at its final form. The following guide explains a few common processes that might occur during metal stamping.

• Forming: Forming describes the process of transforming the flat metal into another shape by applying force. It is accomplished in one of several ways, depending on the design specifications for the part. With a series of operations, the metal can be altered from a relatively simple shape into a complex one.
• Blanking: Blanking is the most basic technique and initiates when the sheet or blank is fed into the press where the die cuts out the desired shape. The resulting piece is called a blank. The blank may be the desired part, also known as a fully finished blank, or it may continue to the subsequent step of forming.
• Drawing: Drawing is a more complicated operation and is how vessels or deep depressions are formed. Tension is used to carefully draw the material into a cavity to change its shape. Though the material might stretch while it’s drawn, technicians try to avoid stretching as much as possible to keep the material intact. Sinks, cooking equipment, and oil pans for vehicles are usually made with drawing.
• Piercing: Piercing is almost the opposite of blanking, but instead of saving the blanks, technicians use the material around the outside of the punched area. As an example, think of cutting biscuits from a rolled-out circle of dough. During blanking, the biscuits are saved; during piercing, on the other hand, the biscuits are discarded, and the hole-riddled remains are the desired outcome.

Role of Dies in Metal Stamping

Whether you’re using the forming, drawing, piercing, or blanking process in sheet metal for your project, production will involve metal dies. Mounted on presses, dies are the fundamental tools that metal stamping operations rely on to precisely cut, form, and shape an array of metal parts. Manufacturers use custom dies to achieve components that match the exact specifications of your design, making anything from straightforward products like clips to intricate electronic parts.

These durable tools facilitate high-volume, precision production and support economy of scale. To help ensure that metal stamping processes are generating high-quality products, however, it’s important to use the right die type for your project.

Types of Dies

To address the unique requirements of highly varied projects, there are multiple types of die available for manufacturers to use. Three common varieties in metal stamping operations are compound, combination, and progressive dies.

Compound

Compound dies provide compound functionality—every single press stroke carries out several operations at once. As a result, they can quickly and efficiently generate even complex metal parts. When choosing a die for your needs, keep in mind that compound dies are more adept at cutting than forming.

Combination

Combination dies are alike compound dies in their single-stroke operational capabilities. However, this die variety is well-suited to both forming and cutting. This enables manufacturers to use them for products that require multiple metal forming techniques, such as bending, forming, piercing, and sheet metal blanking processes.

Progressive

These cold stamping dies move a strip of raw material through its various stations, with the die performing one stamping action per stroke at each one. The metal workpieces stay attached to the strip until they pass through the final die station, at which time they’re complete and cut loose. In this setup, multiple workpieces are going through the press simultaneously, with each at a different stage of the stamping process on a mold set.

Understanding Metal Stamping Presses

Just as there are multiple die types, you can use different press varieties to complete your stamping project. The three main options are:

• Mechanical presses: These highly efficient presses utilize a motor-connected flywheel device to facilitate energy transfer and storage. They’re compatible with progressive and transfer die stamping processes and can produce between 20 and 6,000 tons of pressing force, depending on their size. Manufacturers can quickly ramp up production as mechanical presses offer the greatest operational speeds of the three presses and have the capacity for large runs of virtually identical, repeatable goods. Mechanical presses rapidly generate shallow components with simple designs from coil and sheet metal, such as hardware and appliance or automotive components.
• Hydraulic presses: Compared to mechanical presses, hydraulic presses are slower but more versatile. They enable you to modify the die opening and stroke length and deliver a wider range of pressure levels. This accommodates deeper, more intricately shaped components requiring higher material flow. As long as your project’s schedule allows for this production method, hydraulic presses are the ideal choice for producing goods like bowls, cylinders, and tanks.
• Mechanical servo presses: These presses combine the advantageous features of the previous two types, offering nearly the same speeds as mechanical presses with the versatility of hydraulic presses. Programmable mechanical servo presses, however, also heighten your ability to control everything from strokes and operational speeds to slide motion and positioning. These capabilities give manufacturers more flexibility in part production as well as their choice of press speed and die type.

The ideal metal pressing process service provider will have the equipment, custom capabilities, and extensive expertise you need to sufficiently achieve your project goals.

Precision Metal Stamping Services From Aranda Tooling, LLC.

When your industry requires high-caliber precision parts, you need a stamping company that meets the most stringent quality standards. Aranda Tooling, an ISO :-registered company, has been manufacturing precision tools for companies worldwide since . Today, we produce over 1 million highly detailed parts every week for even the most technologically advanced applications.

To find out more about our stamping services, please visit our services page, or request a quote online. If you have any questions, contact us at Aranda Tooling, LLC. today.

Updated 10/28/

Metal stamping has revolutionized the manufacturing industry, enabling the production of high-quality metal components with remarkable efficiency. As a cornerstone of modern manufacturing, the metal stamping process has become critical for creating precise metal parts that meet the ever-growing demands of various sectors.

From the intricate components in automobiles and aircraft to the essential parts in electronics and medical devices, metal stamping plays a vital role in precision manufacturing processes for products people depend on daily. In this article, we explore the fundamentals of metal stamping, including different metal stamping techniques and the metal stamping process.

What Is Sheet Metal Stamping?

Sheet metal stamping involves using dies and presses to transform flat metal sheets into desired shapes and forms. The process starts with designing custom dies, typically made from hardened steel or carbide, with a negative impression of the desired part shape. These dies are then mounted onto a stamping press.

The metal sheet, often fed from a coil, is placed between the die and the press. The press applies immense pressure to force the metal to conform to the shape of the die. The amount of pressure applied depends on factors such as the thickness and type of metal and the complexity of the part design.

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The metal stamping process involves various techniques to create parts with different levels of complexity, precision and size. The technique choice depends on the specific requirements of the part being produced, such as its intended use, desired features and production volume.

Metal stamping is compatible with various materials, including steel, aluminum, copper, brass and titanium. The selection of material depends on the specific requirements of the part, such as strength, weight and corrosion resistance. For example, steel is often chosen for its high strength and durability, while aluminum is preferred when lightweight components are required.

The metal stamping process also creates parts with various finishes and coatings, which can enhance the appearance, durability and functionality of the final product. These finishes and coatings can include painting, plating, anodizing and powder coating.

Metal Stamping Techniques

The metal stamping industry uses diverse techniques to achieve different results depending on the complexity and specifications of the part needed. Four of the most common metal stamping techniques include:

1. Progressive Die Stamping

This technique uses multiple dies, each performing a specific operation on the metal sheet as it progresses through the stamping process. Progressive die stamping is ideal for producing complex parts with high precision and consistency, making it well-suited for automotive, electronics and medical device manufacturing. It also has high production rates and reduced material waste.

2. Transfer Die Stamping

In transfer die stamping, the metal sheet is transferred between multiple dies, each responsible for a specific forming operation. This process is beneficial for larger parts that require numerous forming steps and is commonly used in the automotive and aerospace industries.

3. Four-Slide Stamping

Four-slide stamping is a technique that uses four sliding tools, which move independently to form the metal sheet from four different directions. It produces smaller, intricate parts with complex bends and shapes, making it valuable for electronics and consumer goods.

4. Deep Draw Stamping

Deep draw stamping involves using a punch and die to create deep, cup-like shapes from flat metal sheets. It creates parts with high depth-to-diameter ratios, which are difficult to achieve with other stamping methods. Deep draw stamping is commonly used in producing household appliances, automotive components and packaging materials.

Steps in the Sheet Metal Stamping Process

The sheet metal stamping process typically involves several key steps, each contributing to creating a high-quality metal component.

Design and Die Creation

The sheet metal stamping process begins with designing the desired part using computer-aided design software. Once the design is finalized, a custom die is created to match the part’s specifications. The die is made from hardened tool steel or carbide and is precision-machined to ensure accurate and consistent part production.

Material Selection

The appropriate metal sheet is selected based on the part’s requirements, such as strength, durability and corrosion resistance. Other factors considered are the part’s intended use, operating environment and cost constraints. Choosing the right material is essential for achieving the desired performance and the longevity of the stamped part.

Blanking

Blanking is the process of cutting the metal sheet into the desired shape, removing excess material and creating a flat blank. It is performed using a blanking die, which consists of a punch and a die. The metal sheet is placed between the punch and die, and the punch is lowered to shear the metal along the desired outline.

Forming

Forming involves using dies and presses to apply pressure and deform the metal into the required geometry. Various forming techniques are used depending on the part’s complexity and the end product’s requirements. Standard forming operations include bending, drawing and stretching.

Bending involves using a die to fold the metal along a straight line. Drawing uses a punch and die to create a three-dimensional shape by stretching the metal over the die. Stretching applies tension to elongate the metal and make shallow, curved shapes.

Trimming and Piercing

Trimming uses a trimming die to remove the excess material around the perimeter of the part, creating a clean and accurate edge, while piercing makes holes, slots or other openings in the part.

Finishing

The final step in the sheet metal stamping process is finishing, which enhances the stamped part’s appearance, durability and functionality. Standard finishing operations include deburring, cleaning, polishing and coating.

Industry Applications of Metal Stamping

Metal stamping finds extensive applications in precision manufacturing processes across various industries:

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