Month: November 2020

How much Auto Stamping Parts Cost? (Equipment selection for tooling Manufacturing)

Auto Stamping Parts are common in engineering, shipbuilding, aircraft construction. Only earlier we used to carry it manually. In addition, the method gained wide popularity. Because it was possible to make everything - from a small, insignificant part, to an airplane wing.

Today's technologies and equipment allow automatic metal stamping. This process has a number of advantages, which we will discuss below.

What is Auto Stamping Parts?

There are two methods of metal processing:

1. cold and
2. hot

Generally, cold forging is common in producing:

• machine bodies
• aircraft parts
• and other single or multi-batch parts.

The advantages of cold stamping include the cost-effectiveness of consumables. Moreover, it increases the ability to manufacture parts that will absolutely match each other, and high production efficiency.

Auto Stamping Parts is a technological process that we use to produce metal sheets up to 4 mm in volume. Moreover, during operation, the material is subjected to high heating.  And then special machines carry the process.

How does Auto Stamping work?

Automatic metal stamping according to customer's drawings allows you to create products of original configuration and shape in a single version and multi-batch. Thanks to automatic stamping, the parts are exactly the same. Similarly, the error can be a maximum of 0.05 mm.

Technological processes of metal stamping:

1. The two pieces of sheet metal work in a straight or curved line.
2. Notching. Subsequently, notches and cuts work on the metal without disturbing the overall integrity of the sheet.
3. Simultaneously, the process is designed to work with the edges of the sheet. In addition, we peel off and waste the unnecessary parts.
4. Punching. Auto Stamping Partsprocess with one or more holes. Hence, a pattern or pattern appears.
5. Cutting down. A closed loop is made inside the metal blank and a whole fragment is removed along it. In this case, the entire part remains closed.
6. It is a decorative element that allows you to correct irregularities in the metal sheet and smooth the ends.
7. Cones appear on the metal surface, in other words, breaks, but without cutting off the metal layer.

How much Auto Stamping Parts Cost?

The most frequently asked and popular question: "How much does a stamped part cost?"

To calculate the cost of manufacturing, you need to add the following components:

• material cost + shipping cost / useful output (pcs),
• cost of design documentation + cost of a stamp + cost of commissioning / estimated life of a stamp,
• Cost of medium and minor repair of a stamp + cost of spare parts. Moreover, it also includes / number of parts produced from service to service,
• Moreover, Shift cost / production rate.
• Information for customers

1. Generally, mass production of metal products requires technology, raw materials, equipment and tooling.
2. a) Technology - we will develop,
3. b) raw materials - we will purchase,
4. c) equipment - in stock,
5. d) equipment - we will design and order.
6. We work using your tooling and can make our own.

Technology development of auto stamping

This is the very first stage of Auto Stamping Parts. Furthermore, here the cost of the part depends. At this stage, you need to clearly understand your monthly need. Based on many years of experience, we will develop the most optimal manufacturing technology for the parts you need according to the criteria "need - terms - price - quality".

At the moment, for cold stamping of parts, you can select the required steel grade: cold-rolled, hot-rolled, cold-worked, stainless, etc. Moreover, there is cretion of waste during the production of steel products. Unlike foundries, this waste cannot be recycled locally and must be disposed of. Therefore, we include the costs of disposal in the price of the products.

• Metal waste from production can range from 3 to 80%.
• Material selection - steel grade Material selection - steel grade

Equipment selection for Auto Stamping Parts

For the production of products based on the technology, equipment is selected taking into account:

• the steel grade
• the size of the workpiece
• the permissible force of the forging and
• Pressing equipment and the size of the finished product.

Production of documentation

For the manufacture of dies, design documentation is required - drawings. Similarly, the term for the development of design documentation is 3-4 weeks. The cost of a set of drawings for a stamp depends on the project.

Moreover, the development of design documentation is an important process. Therefore, we recommend checking cost of the forming equipment.

Tooling (stamp) manufacturing

For the manufacture of tooling (stamp), it is enough for us to receive a drawing or a sample of the part from you. Furthermore, you can allocate the cost of Auto Stamping Parts. For the manufacture of large batches of products on an ongoing basis, it is necessary to have at least two sets of dies. Subsequently, it is in order to ensure the required volumes of products. Moreover, it is to exclude downtime in the event of their breakdown.

How to even approximately understand the cost of Auto Stamping Parts? 

Generally, the more complex the part, the larger the holes in it, the larger its size - the higher the cost of the stamp.

In addition, the term for making a stamp is from 1 month, the term for debugging a stamp is up to 2 weeks

Service stamps

Stamps are equipment that undergoes a high operational load and require regular maintenance:

• Inspection
• replacement of parts

Generally, small and medium repair of dies is done according to operating time and if necessary. The Auto Stamping Parts production facility carries on-site operations. Similarly, it includes:

• disassembly
• fault finding
• replacement of wear parts
• sharpening of cutting surfaces
• demagnetization and assembly

Advantages of Descartes punching scanner-positioner

Improving punching efficiency:

• reduction in the cost of procurement
• Moreover, it increases in productivity (maximum positioning speed 50,000 mm / min).

Saving material:

• 5 times more parts from one metal volume,
• Hence, reduction of waste by 2.5 times,
• The possibility of stamping from illiquid blanks.

Savings on wages up to 9 times:

• One person can serve 3 presses.

Reducing the price of stamps by 30%:

• Moreover, you can use 2-column and non-column dies,
• Stamps without guides, stepping knives and catchers.

Occupational Safety and Health:

• The presence of a person directly near the press is not required.

Brief Description of Auto Stamping Parts Scanner-Positioner Assemblies

1. High strength frame

Auto Stamping Parts includes the high-strength, full-size frame. Similarly, it comes with high-tech welding. Moreover, it can withstand loads of up to 63 tons, ensuring stable and reliable operation.

Stamp frame Descartes   Stamp frame Descartes

2. Technology of compensation of unevenness of the workpiece

Generally, the roller can freely follow the curvature of the sheet surface. To compensate for unevenness of the sheet during travel, the drive rollers have a vertical stroke.

Friction welding: principle, advantages and applications

Friction Stir Welding (FSW) is a type of pressure welding. Here, the melt of the surfaces comes by converting the mechanical energy of the friction force of the parts into thermal energy.

Friction Stir Welding (FSW) - what is it?

Friction stir welding is a type of connection using pressure. It means that the parts to be welded will heat up as a result of friction against each other. One part remains stationary, while the other rotates, which allows the parts to connect with each other.

This method is quite new. And, perhaps, not all specialists or amateur welders had time to get acquainted with such welding technology. Therefore, we will read the principles of its operation, advantages, disadvantages, parameters, features and varieties of this method in more detail.

In this article we will look at:

1. How Friction Stir Welding (FSW)works?
2. What types of technology exist?
3. What are the advantages and disadvantages of friction welding?

 

Application and types of Friction Stir Welding (FSW)

Generally, friction welding is commonly applicable in the following operations:

• compounds of metals and alloys with a melting point of up to 1800 degrees
• welding flat parts of the same thickness at a turned angle
• longitudinal pipe welding
• making bolts
• Replacing soldering of small parts with machined surfaces.

Friction welding is suitable for joining contaminated parts, since it does not require their preliminary cleaning. Moreover, we remove the oxide film and grease at the beginning of mutual friction of the surfaces.
There are the following main types of friction welding:

1. oscillatory (linear)
2. with stirring, with continuous drive
3. radial
4. orbital, inertial

Advantages and disadvantages of the method

The advantages of Friction Stir Welding (FSW) are:

• lower energy consumption compared to other types of welding
• Moreover, a small number of defects
• uniform structure of the weld
• the ability to accurately control the process
• Small amount of harmful emissions
• Hence, high metal utilization rate
• The ability to automate the process.

1. Low requirements for surface cleanliness. There is no need to clean the surface of the parts to be welded. The side surfaces may also be uncleaned. Similarly, this significantly saves time spent on auxiliary operations.
2. Possibility of welding various metals. The welding process allows welding both alloys and metals of the same name and dissimilar alloys. Furthermore, other welding methods are useless here. For example, it is possible to weld steel to aluminum, copper; aluminum with copper, titanium and so on.
3. Hygienic process. The welding process compares favorably with the absence of ultraviolet radiation.

Disadvantages of the Friction Stir Welding (FSW):

• Friction Stir Welding (FSW) giveslimited applicability
• bulky equipment
• Limited connection surface.

Friction welding, principle and features:

Friction welding is a type of pressure welding in which heating goes out by friction caused by the rotation of the welded product.

Due to the emerging frictional forces at the points of contact, a very rapid heating and transition of the material into a plastic state occurs.

Thus, friction welding goes by a process in which mechanical energy supplied to one of the parts to be welded is converted into heat.

Friction welding is a process that converts the mechanical energy of the movement of one of the parts into heat energy. Rotation is the most common method for this. Similarly, either one of the parts or an insert between them can rotate. At the same time, the parts presses against each other by constant or increasing pressure. In this case, heating occurs directly at the junction of the parts.

How does Friction Stir Welding (FSW) work?
Friction Stir Welding (FSW) process is not so simple. After the completion of the welding process, upsetting occurs and the rotation stops quickly.

In the welding zone at the joints of the parts, the following processes take place: with an increase in the rotation frequency of the workpieces and the effect of compressive pressure, the contact surfaces rub against each other.

Similarly, fatty and contact films present on parts in their original state are destroyed. After which the boundary friction comes by dry friction. Hence, individual micro protrusions begin to contact each other and deform.

Juvenile areas form, where the bonds of surface atoms do not saturate. Moreover, metal bonds immediately appear between them. In addition, they immediately destroy due to the relative movement of the surfaces.

Principles of using friction stir welding for joints

This process means that one does during its rotation. Moreover, it will create thermal energy, as a result of which the materials combines with each other.

But not only one of the parts can rotate, but also a special tool for friction stir welding in the form of an insert. In addition, it also contributes to a high-quality connection of parts.

Friction welding: technology features

 

Friction welding is a subtype of pressure welding. The technology involves heating the parts to be welded using friction. For this, one of them moves (rotates), while welding with the other.

Application area of Friction Stir Welding (FSW)

Friction Stir Welding (FSW) is most widely applicable in mechanical engineering, primarily in tool production. It is also common in the assembly of internals of nuclear reactors. Friction bonding of aluminum and magnesium alloy workpieces is popular in:

• electrical engineering
• electronics and
• aerospace

The technology is also common in transport engineering. The radial method is famous in the production of equipment for the mining and processing industries.

Conclusion

More recently, Friction Stir Welding (FSW) has begun its journey in shipbuilding and food processing engineering.

We have covered such a process as friction welding. As you can see, this welding process is different from others, and has many advantages. However, it is quite specific and not suitable for all tasks. Nevertheless, in many cases its use is justified.

 

The technology demonstrates efficiency and a tendency to replace traditional welding methods in such areas as:

• to replace soldered and riveted joints;
• Replace contact electric welding;
• to restore products and complex tools;
• for welding workpieces to prepared surfaces

How aluminum is helpful to create automotive parts?

Today Aluminum is considered one of the best alloys to use in metal stamping. And Aluminum Stamping is getting utmost popularity for its outstanding reasons. Basically, aluminum is an ideal metal to use because of its durability. Moreover, it is extremely light weight.

Hence, because of these fantastic benefits, aluminum has ability to transport the energy to the very long distances. Aluminum is really cost efficient. Moreover, it is best for getting maximum items with great accuracy.

So, it will be an ideal and flawless choice for your bulk productions. Let’s check out 5 amazing reasons to choose aluminum in metal stamping. And also check some additional benefits of Aluminum Stamping in automotive industry.

What is Metal Stamping?

Basically, stamping is a special technique which manufacturers use to form their required shapes. There are various materials which manufacturers use to form their specific shapes. However, metals have most beneficial advantages in comparison to any other material.

Hence, the process of stamping by using metals is called metal stamping.

Types of metals to use in Metal Stamping

There are various kinds of metals to use in metal stamping. All of them have their own benefits. Each type of metal has different strength and unique properties. So, it is very important for you to choose the best metal for your special needs.

Furthermore, all types of metals are good and beneficial. But it totally depends on you to select the right one for your requirements. Here are some most common and advantageous types of metals.

For example:

• Aluminum
• Stainless-steel
• Copper
• Brass
• Nickel and many more.

What is Aluminum Stamping?

Aluminum Stamping is actually metal stamping in which manufacturers use aluminum alloy. Moreover, aluminum is extremely suitable in stamping because it is very strong kind of alloy. Additionally, it has great workability as well as has extreme strength.

Aluminum not only allows to produce quality products but there is low chance to occur any weakness in your production. Nowadays you can easily notice the components which have stamped by aluminum in your daily routine. Most popular uses of aluminum include,

• automotive
• medical
• aerospace
• marine
• electronics and many more industries which depend on Aluminum Stamping.

Aluminum components are ideal to use because they are low in weight. So, they are best option to use in automotive industry where low weight parts are necessary elements.

6 types of elements which manufacturers add in pure aluminum

In fact, manufacturers use 6 other important elements in the pure aluminum to get best aluminum parts. These 6 elements have ability to increase the essential properties of aluminum. Moreover, these elements are also helpful to improve the actual strength of aluminum.

Basically, manufacturers add them only 15% of the total weight of aluminum. They have to use in a very small quantity but are essential for greater performance.

However, these 6 important elements are:

1. Iron
2. Copper
3. Silicon
4. Zinc
5. Magnesium

5 wonderful reasons to use aluminum in Aluminum Stamping

Today aluminum alloy has become one of the most popular metals in all over the world in Aluminum Stamping. Aluminum becomes ideally flexible when it has processed in metal stamping. With the help of stamping you can create complex geometrical shapes of aluminum.

If we compare aluminum with steel, we find that it is more costly. But in spite of the cost aluminum is much light in weight. Moreover, it is natural corrosion resistance and its products have long life span.

Actually, aluminum becomes more flexible during the special process of stamping. Hence, in metal stamping you can form greatly complex geometrical shapes of aluminum products.

In addition, here are 5 amazing reasons to use aluminum in Aluminum Stamping.

1. Greatest Strength Even in Low Temperature:

Aluminum alloy has not to face the problems like brittle cracking. It is greatly strong in very low temperatures. For example, when the environment's temperature reduces, it cannot leave bad effect on the aluminum products.

In fact, in low temperature, aluminum has ability to maximize its strength. The change in temperature can’t leave bad effects on the aluminum parts. Hence, aluminum components are highly suitable for low temperature.

2. Highly Resistant to Corrosion:

One of the best qualities of aluminum alloy is that it is highly corrosion resistant. Basically, it can generate a natural protective layer. Hence, when the aluminum objects come in the oxidizing environment this protective layer truly save it.

Actually, this protective layer has capability to save the Aluminum Stamping products' surface from corrosion. When you paint your aluminum objects, their corrosion resistance ability further improves.

3. Great Conductivity for Thermal and Electricity:

Aluminum products actually have great conductivity for thermal and electricity. In fact, it is less conductive in comparison to copper. For example, it is only 60% conductive like copper. Aluminum alloy is best metal for the power transmission lines.

Moreover, it also has extreme conductivity for heat. And aluminum has got great popularity to use for heatsinks in several applications. Such as,

electronic devices

LED lights

computer motherboards and much more.

4. Extremely Flexible and Greatly Workable:

The ideal metal of Aluminum is highly flexible. Aluminum Stamping makes it more elastic in comparison to steel alloy. So, because of this great flexibility you can create even more complex shapes much easily. Moreover, aluminum has great workable quality than any other metal.

5. Incredibly Lightweight:

Aluminum is actually much lower in weight in comparison to several other metals. Basically, its fixed weight is almost 2.71 g/cm3. This great feature makes it cheaper than any other popular metal, like steel.

So, all these great characteristics of aluminum like,

• corrosion resistant
• very easy in order to create products
• naturally low in weight, etc.

makes it ideal to use in automotive industry.

Why Aluminum Stamping consider ideal in automotive industry?

Aluminum Stamping components has become the world's first choice for their natural properties. All of its good features have essentially needed in automotive industry. Since, aluminum is lightweight and corrosion resistant, so it is ideal to make parts for automobile sector.

Aluminum metal has ability to increase performance. This special alloy can generally improve fuel economy of auto industry. In spite of all these, it is really strong and durable metal. Among all other metals steel and aluminum are popular to use in motor vehicles.

Nowadays, by using aluminum, manufacturers are rapidly introducing most efficient vehicles. Furthermore, its great features have made it the world's second most famous metal in car industry.

So, all in all Aluminum Stamping can provide you,

• Safer and strong
• Greatly energy effective
• Corrosion resistant

auto parts. Moreover, aluminum metal can easily provide you smooth and shiny excellent finish for latest models of auto vehicles. Aluminum has perfect weldability and remarkable strength. Hence all these amazing advantages make this metal ideal for automotive industry.

  Important applications of Aluminum Stamping

When we talk about radiant energy, aluminum is incredibly reflective. In fact, its perfect quality of nonmagnetic make it highly suitable to use in all industries.

Hence some important applications of aluminum metals are:

For Construction:

• doors
• windows
• building wires
• siding, etc.

Electronics devices:

• CPUs
• fin stock
• transistors and many more.

Aluminum Stamping for Transportation:

1. Automotive
2. Trucks

• Railroad cars

1. Aircrafts
2. Marine vessels
3. Bicycles

Cooking utensils:

• Mixers
• Mixing pots
• Pots
• Blender parts
• All residential parts
• In whole equipment which manufacturers use in food and beverage processing.

Conclusion:

All in all, aluminum has great properties than many other metals which manufacturers use in metal stamping. Moreover, it is best for,

• Treating of heat ability
• Great level of weldability
• Strength
• Corrosion resistant
• Cost effective and so on.

So, choosing aluminum for your bulk productions will be your great and beneficial decision.

Because aluminum stamping is a wise choice for several mass projects.

How stainless-steel is best metal to use in metal stamping?

Nowadays we can see the different objects that have created with the help of Stainless-Steel Stamping. From our household items to industrial goods there are hundreds of kinds of objects which manufacturers are creating using stamping.

Although all materials have their specific features but stainless steel is best among all the other metals and materials. Moreover, Stainless-Steel Stamping has become the world’s best technique from small gauge components to large and heavy products.

Additionally, stainless steel has extremely great features and provides precision parts whether they are complex or simple. Let’s have a deep look about the stamping and its benefits while using the metal of stainless steel.

What is stamping?

Stamping is actually the process of creating the products of different materials. This is also known as pressing. Basically, it is the process of putting the flat or plane sheets of specific materials inside a stamping press. In this stamping press these special materials have shaped into particular designs.

So, stamping is the process of forming some particular shapes of different materials according to your needs and demands. Although manufacturers most commonly use metals but there are also different kinds of materials which have used in stamping. For example, polystyrene.

However, metal stamping has got popularity among all the other materials because of their fascinating benefits.

What is metal stamping? Stainless-Steel Stamping

Metal stamping is the same process of manufacturing different shapes by using the metal with the help of stamping. Basically, it is a complicated process which has included several types of metal techniques. Furthermore, these complex forming techniques are,

 

• Bending
• Blanking
• Piercing

Stainless-Steel Stamping is actually the famous type of metal stamping. However, there are several types of materials which have used in metal stamping.

5 most common metals which have used in metal stampings?

Although there are numerous metals which manufacturers are using in stamping machines to create different items. And these 5 most common metals stampings are:

• Steel Stamping
• Aluminum Stamping
• Brass Stamping
• Polystyrene Stamping
• Automotive Stamping.

What is Stainless-Steel Stamping?

Basically, stainless steel is a unique alloy of steel. Moreover, by mass it has minimum of 10.5% chromium content. Today it has become one of the most beneficial alloys because it is corrosion resistant.

However, Stainless-Steel Stamping also has the additional advantage of staining resistance. Stainless steel has become manufacturers favorite metal due to its extremely good gloss. In addition, by using stainless steel manufacturers can get their required shape more easily.

In fact, it has a perfect hardness which is ideal to shape it in desired shaped. Additionally, the stainless-steel products have great durability and get less damage even in tough using. I think most of us did not know that actually there are different variations in the stainless-steel alloy.

However, the most common type which industrialists use to create adorable items is 300 Series Stainless Steel. It is one of the best and most popular kind of stainless-steel series. Furthermore, stainless steel of series 400 is also available which also has exceptional advantages.

But manufacturers are rapidly using 300 Series of steel alloy for its awesome advantages.

Why manufacturers prefer Stainless-Steel Stamping?

Most of the industrialists are preferring Stainless-Steel Stamping as it is corrosion resistant and highly low in weight. But despite of all these, stainless-steel has ideal strength. Moreover, it is,

• easily available
• extremely cost efficient.

In order to make it more versatile and fascinating manufacturers make use of,

• steel blanks
• coil-fed steel.

Industrial manufacturers are highly preferring to use those components which have created by using stainless steel metal stamping. Because these components provide,

• better corrosion resistance
• greater life span (almost 10 to 12 years).

Furthermore, the most beneficial alloy of stainless-steel also has ability to bear the following important treatments. Such as,

1. wire drawing
2. sandblasting

• coating

1. polishing
2. electrolytic polishing and so on.

In fact, stainless-steel have great strength to bear the high temperatures. It also has the rich layer of chromium oxide on its surface. So, it is extremely corrosion resistant.

3 popular types of steel used for Stainless-Steel Stamping

Basically, in Stainless-Steel Stamping, manufacturers use different types of stainless-steels. All of them are important and favorable for several different industries. Automotive manufacturers are rapidly using high grade stainless steel for high temperature components.

 

Generally, the amount of carbon in stainless-steel makes it enable for different industries. For example, the manufacturers which make surgical tools and pocket knives mostly use stainless-steel that has great amount of carbon.

The good features of carbon make it specific for several uses. Moreover, carbon makes it highly hardened even in high heating processes. However, there are three basic kinds of stainless-steels which manufacturers are successfully using in Stainless-Steel Stamping. For instance:

1. Ferritic
2. Austenitic

Ferritic:

It will not wrong to say that ferric grade is ideal for automotive components. In fact, in automotive industry, we need both

• heat resistant
• corrosion resistant.

Actually, ferritic grades do not have any amount of nickel. Additionally, these are magnetic and consists very decent formability.

Famous applications of ferritic:

• dryers
• dishwashers
• automobile exhaust systems and many more.

Special types are:

• 409
• 439

Austenitic

Austenitic grades have become one of the most popular type for their deep drawing quality. This type of stainless-steel actually consists of lower carbon. So, because of this good quality it is ideal for Stainless-Steel Stamping to create household items.

In fact, Austenitic steel has greatest moldability. Hence, it is the best in comparison to any other grades of stainless-steel. Furthermore, it has ideal amount of nickel, chromium and many other important alloys.

It is highly stretchable, so Austenitic is ideal to use for kitchen or home items.

Famous applications of Austenitic:

• household items
• deep fat fryers
• kitchen sinks
• several other deep formed components, etc.

Special types are:

• 304
• 304L
• And 316

Martensitic:

If we compare martensitic stainless-steel with the above two steel grades, we find that,

1. This is not highly suitable for stretching
2. It is not perfect to use for drawing purposes.

Moreover, it is extremely strong and much harder. It is fragile, hard and brittle. In spite of all these facts, it is harder to weld and transform in specific shape during Stainless-Steel Stamping.

Generally, martensitic is similar in many features to the above grades but it has great amounts of carbon. In fact, it is highly heat resistance.

Famous applications of Martensitic:

• tweezers
• pockets knives
• razor blades
• surgical tools
• plastic injection methods
• ball bearings and much more.

Special types are:

Its greatly popular kind is 420.

Conclusion:

We have tried to explain you the most beneficial uses of stainless-steel alloy in metal stamping. Furthermore, it has really advantageous features to use in residential accessories as well as in industrial equipment. Actually, stainless-steel is extremely useful in Stainless-Steel Stamping. 

Additionally, stainless-steel metal is

• corrosion resistant
• cost effective
• has great durability
• and has long life spans.

So, for ideal metal stamping, stainless-steel is highly reliable.