Month: January 2022

Types and methods of modern metal stamping

Metal stamping: technology features. It is an alternative method of plastic deformation of metal: cold and hot sheet and die forging. Moreover, this includes cold stamping technological operations.

Used Press Equipment and Automatic Lines.

Stamping is a technological operation that controls process of changing the shape and size of a work piece under the influence of pressure. Moreover, the process comes by high productivity, and therefore is widely common in various industries.

The technology has a rich history, but its mechanization began in the 50s of the XIX century: machines began to connect to the process. Furthermore, it increases productivity and improved the quality of products. Metal stamping equipment makes it possible to produce various parts: from small elements of the clockwork to the components of aircraft.

Basically, sheet stamping is actively common in serial production. Using this technology, metal, plastic and other materials process is important. Furthermore, the process comes by high productivity, stability and accuracy.

Generally, cold forming is the most advanced forming method. As the name suggests, these are manufacturing operations without preheating the workpiece. Similarly, this approach improves the strength and surface finish of the stamping.

Table of contents

• 1Types of metal stamping technologies
  • 1Sheet stamping
  • 2Forging
  • 3Technology of hot die forging (Essaii)
  • 4Cold die forging method
• 2The essence and purpose of cold stamping of sheet metal
  • 1Cold forming operations
• 3Classification of punching equipment
  • 1Crank presses
  • 2Hydraulic presses
  • 3Radial forging presses
  • 4Electromagnetic presses
• 4Automatic stamping lines

Types of metal stamping technologies

During its existence, many stamping methods have appeared. Similarly, mass production requires a special approach, where the speed and quality of product manufacturing are in the first place. In addition, hand stamping is now common exclusively privately, to create one-off pieces.

Before considering the methods of forming by pressure, consider other types of stamping:

1. Magnetic pulse. To change the shape of the parts, short-term pulses of electric current are common.
2. Isothermal stamping of parts. It is common for deformation of alloyed and heat-resistant steels. The peculiarity of the isothermal process is that the contact mold heats to the deformation temperature of the workpiece. Simultaneously, hydraulic presses are common as working equipment.
3. Explosion metal stamping. A kind of impulse method. It is actively common in the field of aircraft production. The principle of operation comes on the transmission of the impact of the blast wave through air or water. As a result, the workpiece deforms, acquiring the shape of the common matrix.

In addition to production functions, the energy of the explosion is common as a drive for moving parts of equipment.

The technological process in which a product obtains by pressure on molten metal is called liquid stamping. Due to the high cost of matrices and punches, it is advisable to use the method only in mass production.

Sheet metal stamping

Stamping of sheet metal parts is common in mass production for the manufacture of three-dimensional or flat structures. Furthermore, the process of forming a finished product takes place using a special tool called a stamp. The technology of sheet stamping was common by ancient people. With its help, dishes, decorations and agricultural supplies appeared.

The workpiece processing process divides into two categories, which differ in operating temperature:

Cold stamping: This method is considered the most effective. It is common for the manufacture of vehicle body parts. Competent cutting helps to rationally use the main material. The best performance is easy to achieve using carbon and alloy steels, as well as copper and aluminum sheets.

Hot stamping: As the name suggests, this method involves preheating the workpiece. For this, flame or electric ovens are common. Technological operations of this method do not differ at all from the cold production method. The only caveat is the thickness of the sheet metal:

Using this method, hull elements are produced in the shipbuilding industry.

Bulk metal stamping

A kind of processing of parts by pressure. The peculiarity of the process lies in the use of blanks of the simplest geometric shape. This technology makes it possible to obtain a more complex product as a result of volumetric plastic deformation.

Hot stamping is characterized by an elevated temperature at which the process takes place. The degree of heating depends on the materials common. Unlike metal stamping liquid metal, the state of aggregation of the workpiece remains unchanged.

Let's consider the features of each process.

Hot die forging technology (Essaii)

Hot volumetric deformation of parts performs under the influence of temperature and pressure on the workpiece. Moreover, to obtain the required shape, the material heats and place in closed dies. Similarly, there is no gap between the common molds. Thus, the finished product forms in a closed cavity called a stream or engraving.

The approach comes by a low percentage of flash, but requires attention at the procurement stage. In addition, finished products differ in dimensional accuracy and surface quality.

Essaii technological process:

1. The type of metal stampingis determined.
2. A detailed drawing is being developed.
3. Technologists calculate the number of transitions from the workpiece to the finished product.
4. Moreover, an individual drawing is prepared for each intermediate stage.
5. Similarly, select molds for transitions.
6. Determine the parameters and method of heating the workpiece.
7. Based on the requirements for the part, the necessary finishing procedures are determined.

Upon completion of the metal stamping project development, economists calculate the cost of the work. Compared to hot forging, Essaii has a much higher productivity and accuracy of work.

Furthermore, the requirements for the training of the equipment operator are not very strict. Similarly, the average training time for a specialist is 6 months.

The disadvantages include the limitation on the weight of the final product and the high cost of metal stamping equipment.

Cold die forging method for metal stamping

Calibrated rods or wire material are common as blanks for cold die forging. The technology makes it possible to obtain products of high precision and surface cleanliness. In addition, due to the absence of metal recrystallization, such parts are highly resistant to mechanical damage.

The main disadvantage of the technology considers being the excessive efforts that must come to obtain the finished metal stamping.

High-precision stamping part is the shaping of a material under the action of an external force in order to obtain the desired part. It takes a lot of effort to machine the work piece in this way. Moreover, for this, there is equipment that comes with an effort of 16 to 500 tons.

The tooling installed in the press is a stamp. In it, there is a direct contact of the working tool with the precision. Similarly, for 1 stroke of the machine, a part of a high degree of accuracy is obtained.

High-Precision Stamping Part

The history of the process

Stamping of precision products started in the 16th century. This was due to the development of weapons production, where it was required to obtain a large number of identical parts. In the 19th century, the rapid development of stamping production began.

In addition, household items are produced. There is a need to manufacture high-quality serial products.

With the advent of the automotive and shipbuilding industries, precision forming has taken a key position in the development of these industries. With the help of high-precision stamping part, dimensional parts began to be produced.

High-Precision Stamping Part Areas of Use

Industrial production is not complete without cold and hot stamping. Using these methods, you can create both small and large parts in a short period of time. Furthermore, hot stamping is common where three-dimensional parts need to be obtained.

When stamping flanges, 2 methods are common:

1. Hydraulic presses are common in the forging high-precision stamping part, Here, under the influence of pressure, the precision flows into the cavity, which comes in the striker. This space corresponds to the shape of the resulting part.
2. When using sheet precision as a work piece, crank presses are common. Moreover, a stamp inserts into them and sheet precision is fed. Similarly, the flange draws under pressure.

 

The essence and purpose of sheet high-precision stamping part

Cold stamping is the most popular technology for manufacturing Keyword: high-precision stamping part and polymers. The versatility of the method lies in the fact that it allows the production of structures of any size: from kitchen utensils to elements of large ships.

Cold sheet plastic deformation is appreciated for the following benefits:

1. Endless possibilities for mechanization and automation of the process.
2. Low production cost.
3. High utilization rate of the material.
4. In the manufacture of thin-walled elements, the strength of the structure does not reduce.
5. There is no need for finishing the finished product.

High quality and manufacturability have a downside: it requires qualified specialists to set up equipment. In addition, designing a high-precision stamping part is a time consuming operation.

Stamping technology

The technology of manufacturing parts by stamping both hot and cold presupposes the presence of tooling. Similarly, for both types, stamps have certain differences. Hence, they are good for metal that has a different degree of thickness.

Cold forming operations

Any working operation of high-precision stamping part can attribute to the group of separating or shaping actions. Let's consider the main procedures:

Cutting: The operation involves cutting the material along a straight or complex line. Moreover, various types of scissors or guillotines are common as working equipment. Cutting is easy to perform both at the start and at the finish stage of high-precision stamping part.

1. Get a free-form hole.
2. Cutting down. Cutting the structure along a closed contour. In this case, the separated part is a part, and not a waste, as when punching.
3. The operation of creating a side along the outer or inner contour. Most often, the procedure carries out on the end of the pipes, in the places where the flanges install.
4. Convert a flat product to a hollow volumetric part. Moreover, the process comes by a change in wall thickness.
5. Reducing the size of the end part by crimping in a conical die.
6. Giving a curved shape to flat parts. Similarly, the most common are V and U bends.
7. Change the local shape of the part while maintaining the dimensions of the outer contour.

High-Precision Stamping Part Equipment Classification

Basically, the stamping press is a machine with a crank or hydraulic drive. Moreover, there is a wide variety of equipment on the market. The characteristics of stamping lines differ in strength and dimensions of the processed materials. Similarly, high power machines are not required for soft precisions.

Stamping production and equipment for it are regulated by the requirements of interstate standards. In addition, GOST establishes the maximum permissible consumption of materials and approves the rules for the development of projects.

Consider the equipment that is common in High-Precision Stamping Part.

Crank Presses

The principle of operation of the equipment comes on the conversion of the crank mechanism of the torque into the reciprocating movement of the slide.

Such equipment classifies as a simple type of mechanism. Moreover, they can be double or triple acting.

Hydraulic presses

The most powerful equipment capable of developing an effort of up to 2 thousand tons. The principle of operation is based on the movement of two hydraulic cylinders of different diameters. The magnitude of the difference in size determines the degree of impact on the surface. Similarly, the fluid moves in special electrically driven pumps.

Radial forging presses

They are a molding press for the production of parts of a cylindrical configuration. The complete set of the machine includes an induction furnace for preheating blanks.

The High-Precision Stamping Part is common to produce square, round or rectangular forgings.

Electromagnetic High-Precision Stamping Part presses

This is a product of modern technology. Furthermore, the driving force is the energy of the electromagnetic field, which presses on the wire-wound core. In the process of moving, it acts on the executive part of the machine.

Automatic stamping lines

Modern machine tool enterprises offer a wide range of automatic High-Precision Stamping Part lines and complexes for solving various problems.  Similarly, the machines are high-tech equipment manufactured under the guidance of qualified process engineers.

Modern complexes come with CNC systems with a central touchscreen display, which reduces the operator's functions to a minimum.

High-Precision Stamping Part is a popular technology that allows the production of parts with high performance characteristics. Do you think semi-automatic machines can compete with numerical control or such equipment outdate? Hence, you can share your opinion in the comment section.