Author: hqt

The design of open and closed export progressive tool has only one, but very significant difference. The former have a special gap that receives excess metal squeezed out of the progressive tool strands.

This gap allows export progressive tool without the need to calibrate the mass of work pieces with high accuracy: excess metal (if any) is simply released into the flash and then removed.

Advantages and disadvantages of export progressive tool

Firstly, progressive tool in open dies is good to use much more frequently. In technological terms, Secondly, it is simpler, and the range of parts produced with its help is wider.

This type of hot die forging has no restrictions - neither in terms of the shape of the products, nor in terms of their mass, or in terms of the physical and chemical characteristics of the steels good to use, nor in terms of the technological complexity of the production process.

The disadvantages of export progressive tool are the increased consumption of metal and the need to perform the technological operation of trimming the flash.

Fleshless production of forgings

Closed export progressive tool have no gaps. The engravings of the stamp are connected tightly, excluding any possibility of releasing excess metal.

This means that the work piece must calculate as accurately as possible, otherwise the die simply will not close. Eventually, accuracy in fleshless progressive tool plays a very important role!

If the work piece needs complex processing, each next technological transition should begin only after trimming the flash. This increases the cost of products and slows down production.

To reduce the wear of fleshless dies

Moreover, mechanical and thermal loads on dies good to use in fleshless progressive tool are extremely high. That is why the service life of closed dies is about 5000 forgings.

The introduction of alloying export progressive tool into the composition of die steel and the application of thermal hardening techniques to freshly cast dies makes it possible to slightly increase their service life, but inevitably increases the price.

The manufacture of parts in them is usually divided into two stages

• Preliminary
• Final

The first performs on a preliminary stamp, which has a rougher relief. Furthermore, he tells the export progressive tool the basic parameters of its dimensions and assumes the main wear. In addition, the final fleshless dies have a more complex relief - they complete the deformation transformations of the export progressive tool, processing it with high accuracy.

Stamps for trimming flash

Further, flash trimming is a high-precision technological operation. Export progressive tool that are both cold and hot subject to it. Subsequently, the technology for trimming the outer and inner flash is fundamentally different: the outer flash scraps off, while the inner flash (bridges) knocks out.

Flash trimming comes in three types of dies:

• Simple;
• Consecutive;
• Combined

In this case, the matrices of trimming dies can be both solid and composite. The latter designed to work with details of complex curvilinear configuration. Due to their design, such stamps very often warp from heating, eventually losing their ideal shape. This can lead to jamming of blanks and punches.

The main parameters that must calculate before trimming the flash are

As well as, the dimensions of the export progressive tool gaps between the punch and the matrix, due to the shape of the part;

• Design and method of fastening the punch;
• Design and method of fastening the matrix;
• Type of strippers (good to use to remove the stripped flash);
• Impact force on the flash

In addition, the latter depends not only on the thickness of the formed flash, but also on the mechanical properties of the export progressive tool of which it composes.

The punch is an integral part of the trimming die

In fact, not only the cutting edge of the matrix, but also the punch, which can be both pressing and cutting, is of great importance for the quick and most complete trimming of the flash. Punches of the second type are much less common and are good to use only with forgings of small thickness (up to 2 mm).

Like the matrix, the punch is made for a specific forging, acting on its most mechanically strong areas. If the punch is not designed correctly, it can damage the product, causing it to significantly deform.

Export progressive tool dimensions

The final finishing of the punch is made by a metalwork method. The standard for it is a part or a control casting. Fitting to the matrix ​​​​produces in a similar way, in compliance with the gaps provided for by the technology.

High surface quality of forgings achieves by their cleaning. Cleaning is a technological procedure for removing scale, traces of rust, as well as a variety of contaminants from stamped parts and blanks. At the same time, violations of the shape and dimensions of products or changes in their physical and chemical properties should not allow.

Forgings can be cleaned in the following ways

• Export progressive toolmechanical cleaning;
• Jet-abrasive cleaning (subdivided into pneumatic-abrasive and hydro-abrasive).
• vibro-abrasive cleaning
• tumbling in drums
• shot cleaning
• etching;
• Export progressive tool for Fire cleaning.

Of all these methods, mechanical cleaning is the most widely good to use, the simplest in technical terms. However, this method is not acceptable in all cases. Pickling (chemical cleaning of forgings with sulfuric, hydrochloric or phosphoric acid) has the greatest versatility, although it is more expensive.

General information about the methods good to use today for cleaning forgings

Method name	Equipment for cleaning	Application area
mechanical cleaning	Stationary roughing and grinding machines, wearable electric grinding hand tools, as well as a variety of scrapers and brushes	· The method is universal for small, medium and large workpieces of simple shape and without recesses.
Hydro-abrasive cleaning	Drum and continuous conveyor hydraulic installations	· The method is optimal for removing surface defects of different depths, cleaning scale and dirt
Pneumo-abrasive cleaning	Sand throwers of various capacities	· export progressive tool Can be good to use for removing small surface defects and fine grinding

Conclusion export progressive tool

Lastly, there are also combined export progressive tool that simultaneously push the part through the die edge and extrude the webs. The calculation of such punches is especially difficult. The punch is fastened in two ways - directly on the press slide or on the adapter.

The first is preferable when working with large-sized work pieces, the second - with medium and small ones.

Types and methods of modern metal stamping

Firstly, metal stampings is a controlled deformation process in which a body changes its shape under the influence of excess pressure.

Thanks to this processing, metal products are given a wide variety of forms that they need to fulfill their functional duties. Parts of small thickness lend themselves to stamping, since it is very problematic to bend thick products.

COLD STAMPING OF METAL

There are two types of metal stamping: cold and hot. The first option involves processing the work piece without preheating it.

Metal stampings method is cheaper in terms of industrial production, since it does not require energy to bring the metal to a certain temperature. In this way, mainly thin sheets are processed, which are well affected even without heating.

The sheet metal cold forming process divides into several stages, each of which plays an important role in obtaining the final result.

At the initial stage

A compaction process performs, which reduces the ductility of the metal so that the product better holds the shape obtained as a result of stamping. Technologically, the process is a pressing of a metal blank under high pressure.

At the second stage

Products are annealed at temperatures of 550-620 degrees Celsius in special furnaces. This makes it possible to carry out the procedure of recrystallization of the metal lattice and the introduction of carbon atoms into it at the molecular level, which can significantly increase the strength of the metal.

The annealing time depends on the composition of the alloy and the dimensions of the work pieces. When the preparation is over, the product is sent to a cold metal stampings press, which will give it the desired shape.

The procedure method takes how many times?

In terms of time, the procedure takes a few seconds and does not require human intervention. The presses use special dies made of hard grades of steel, less often of other alloys. They design for long-term operation, during which they retain their original shape to the nearest millimeter.

This is very important, since metal stampings cold stamps for specific needs, and deviations in the shape of the finished product are unacceptable, as this can lead to mismatches with other parts.

This method is harmless to the operating personnel, since they do not have to be in an area with high temperatures. In addition, the absence of the need for preheating makes it quite easy to automate the workflow.

HOT METAL STAMPING

Hot metal stampings allows you to process thicker work pieces, since in a hot alloy intermolecular bonds are much weaker, and it lends itself better to bending. Before starting the procedure, metal products go through the same preparatory stages as in the case of cold stamping.

But metal stamping equipment is already significantly different. It consists of two main parts:

 

A furnace and a press 

The furnace is good to use to preheat the work piece to the red heat temperature. In this form, the alloy lends itself well to physical impact and at the same time there is no risk of burnout.

To create optimal conditions inside the furnace, modern machines equip with a high-precision automated control system. It only requires setting the initial parameters, which depend on the type of work piece.

Hot metal stamping is made from?

The computer will take care of the rest. Hot metal stampings presses are made from hard, high-alloy steel grades that undergo additional processing to increase resistance to thermal stress.

They must withstand a certain number of technological operations without losing their original characteristics, so it is very important to use the highest quality material for their production.

Hot metal stampings requires the direct participation of a person in the production process. The work piece cools quickly under normal conditions, so it must quickly deliver from the furnace to the metal stamping machine.

This is done by a worker who, with the help of blacksmith tongs, transfers the product to the right place.

Subject to the galvanizing procedure

Working in an environment with a constantly high temperature regime negatively affects the body, so it is necessary to correctly calculate the duration of shifts in order to minimize the harmful effects of conditions on workers.

Process automation also faces great difficulties and requires high costs, so it is practically not good to use anywhere.

No additional equipment is good to use to cool the parts, they cool down naturally. In most cases, after metal stampings, no additional processing of parts requires. The exception is products for the automotive industry. Sometimes when stamping sheet metal, it becomes necessary to cut off excess elements. For this, a special machine with a high-precision cutter is good to use.

LIQUID METAL STAMPING

In addition to the two listed methods, there is another one that is good to use much less frequently. It implies liquid metal stampings of metal or so-call pressure casting, when the alloy pours into a closed die in a liquid state, and the final formation of the product takes place already in solid form.

This makes it possible to obtain ideally shaped parts with improved mechanical properties. The high cost and complexity of the technological process prevent the widespread use of the method at this stage.

Metal stamping equipment

Metal stampings technology is good to use to produce a wide range of products for various industries. In this way, car body parts, various panels and finishing materials, housings for household appliances obtain.

Stamping is one of the oldest methods of metal processing that survives to this day. The technology change, but the principle remains the same as many years ago.

With the help of volumetric Metal stampings, products of the most diverse shapes obtain. These are special corners that are good to use in anchor bolting, and various elements for equipment, and parts good to use in the manufacture of devices, assemblies and assemblies for all industries.

Conclusion

Metal stampings products allow you to get a part of almost any shape, which cannot achieve with other types of processing. This has been successfully good to use in steel mills. It can quickly adapt to new market needs. You just need to make a stamp of the required shape and you can start producing new products.

All You Need to Know About Aluminum Stamping, Stainless Steel Stamping, Pressure Die Casting, and CNC Bending

The metal stamping process converts flat sheets of metal into different shapes. Stamping is also known as pressing. To obtain a new shape out of a flat sheet, the flat metal sheet is placed in either blank or coil form into the stamping press. Forming tools and the die surface helps convert metals into a specific shape in the stamping press. Aluminum is one of the most common materials used for stamping. Aluminum is known for its workability and strength. We can find various use cases of aluminum stamping components in almost all industries.

Aerospace, marine, medical, electronics, and automotive industries need OEM aluminum stamping the most. In this comprehensive guide, you will learn about the aluminum stamping process, its use cases, properties, etc. We will also take a look at other options, like stainless steel stamping. You will also learn about other things like pressure die casting, CNC bending, diffusion welding, and high precision CNC machining.

Aluminum Stamping and the Most Common Aluminum Alloys

Usually, untreated aluminum is blended with other types of metals for enhancing or adding specific metal properties. It helps in improving the final product’s performance. The most common alloying materials are iron, magnesium, copper, zinc, silicon, and magnesium. All alloys have unique 4-digit numbers. The primary blending element determines the first alloy digit.

For instance:

• 1xxx for 99% untreated aluminum without alloying elements
• 2xxx for the aluminum blended with the copper
• 3xxx for aluminum blended with the manganese
• 4xxx for aluminum blended with the silicon
• 5xxx for aluminum blended with the magnesium
• 6xxx for aluminum blended with silicon and magnesium
• 7xxx for aluminum blended with the zinc
• 8xxx for aluminum blended with others

There may also be one letter at the end of the 4-digit number. This letter shows the temper designation of the metal alloy. For instance, aluminum stamping factories use F for ‘fabricated’, O for ‘annealed’, H for ‘strain hardened’, W for solution heat-treated, and T for heat treated.

What Are the Most Common Aluminum Alloys That Metal Stamping Companies Use?

Let’s take a look at the most common aluminum alloys that an aluminum stamping factory prefers for their use cases:

1100

This is a commercial untreated aluminum with high ductility, workability, and material softness. It is the perfect choice for applications that involve complex product or part design. These may include decorative or flatware components.

3003

It is an aluminum-manganese alloy. It is better than 1100 aluminum in strength. Moreover, 3003 also exhibits better workability and corrosion resistance. The most common use cases of 3003 include chemical handling items, cooking instruments, and kitchen equipment.

5052

It is an aluminum-magnesium alloy. 5052 exhibits better strength than all other non-heat-treated variations. Moreover, it offers better corrosion resistance, good finishing and workability characteristics, and improved fatigue strength. The most common use cases of 5052 include home appliances, heavy-duty cooking apparatuses, and aircraft parts.

6061

It is a heat-treatable aluminum alloy. Various advantageous chemical and mechanical properties of 6061 make it highly versatile. It is known for its exceptional weldability, formability, and corrosion resistance. 6061 is an ideal choice to make structural parts, like frames and bodies of automobiles.

What are the Common Aluminum Alloys Properties?

Aluminum stamping alloys may exhibit dissimilar properties according to their composition. However, the material group has a few shared properties that include:

• Higher strength-to-weight ratio
• Malleability and flexibility
• Low-temperature resistance
• Corrosion resistance
• Thermal and electrical conductivity
• Shiny and smooth finish with no or a little maintenance

Various manufacturers create aluminum alloys for different use cases. Some also offer wholesale aluminum stamping for different industries.

Stainless Steel

Stainless steel is tight to cut and form. However, it also depends on the stainless type you are working with and also what shape you want to make. For example, you must know the unique behavior of stainless steel for stainless steel stamping. Most stampers failed to cut and form stainless steel engineered for the flat carbon steel. A stainless steel stamping manufacturer must understand the material’s mechanical ability. The process design must be according to the behavior of the material.

Here, it is important to remember that high-temperature and corrosion-resistant steel is known as stainless steel. The oxide film rich in chromium is the reason behind the good resistance. The normal carbon steel, when you expose it to moisture, will corrode and form rust or an iron oxide brownish layer.

There are hundreds of specialty stainless steel types. Some stainless steels are ideal for high corrosion resistance. However, many others are known for withstanding higher heat. Some offer both benefits. A stainless steel stamping parts factory also adds alloys like nickel to the stainless steel for achieving specific desired properties.

Stainless Steel Use Cases

There are thousands of use cases of stainless steel. From marine screws to pocket knives to kitchen sinks, stainless steel is almost everywhere. Flatware is the most common stainless steel item that you can find in every retail store. The three grades are ‘good’, ‘better’, and the ‘best’. The nickel amount is what separates these three grades, giving it brilliance and luster. Take a quick look at the following details for stainless steel grating.

• Good stainless steel: Usually 18% chrome and 0% nickel
• Best stainless steel: Usually 18% chrome and 10% nickel

You will get different stainless steel stamping quotes depending on the stainless steel grade. Stainless steel is a perfect choice for products like surgical tools and pocket knives because of its higher carbon composition. Carbon helps the steel become hardened with the heat-treating process.

Other stainless steel types, like kitchen sink stainless steel, have little carbon content. Low carbon results in more stretchable, softer material. The automotive industry is one of the most common industries using stainless steel. An automobile’s exhaust is a classic example of high-temperature stainless steel grade.

Basic Types of Stainless Steel

The stamping industry uses three basic steel types, martensitic, ferritic, and austenitic. Let’s take a quick look at these types for a better understanding.

Austenitic

This stainless steel type is a perfect grade for use cases, such as deep drawing. Typically, this grade comprises lower carbon, making it perfectly suitable to make items like fat fryers, kitchen sinks, and deeply formed components or parts.

It is not possible to harden austenitic grade in stainless steel stamping with treating. However, it is possible to achieve this through cold treating the metal. This grade contains nickel and chromium, and also alloys in small amounts. It exhibits the best formability among all grades.

304L and 304 (normally extremely low carbon) and 316L and 316 (marine grades) are the most common austenitic grade stainless steel types. This stainless type is annealed state.

Ferritic

The automotive manufacturing industry requires a grade that is both heat and corrosion-resistant. Therefore, the ferritic grade becomes the most ideal choice for this industry. Ferritic grades may also exhibit exceptional formability according to the availability of alloys and carbon. Dissimilar to the austenitic grade, the ferritic grade doesn’t contain nickel.

These grades are magnetic and appropriate for drawing. The most common use cases of the ferritic grade include dryers, dishwashers, and exhaust systems of the automobile. 409, 430, and 439 are the most typical ferritic grade stainless steel types.

Martensitic

This stainless steel type is very much like the ferritic grade. However, there is one big difference. The martensitic grade stainless steel comes with a greater carbon amount. Because of this, it becomes possible to heat-treat the steel. With heat treatment, the stainless gets hardness. As a result, the steel becomes perfect to make surgical tools, knives, and cutting tools.

Unlike austenitic and ferritic grades, this stainless steel grade isn’t appropriate for stretching and drawing. It is hard and strong, but difficult and brittle to weld and form. The most common use cases include pocket knives, razor blades, plastic injections, ball bearings, and tweezers. 420 is a common example of this material type.

Three Tempers

It is possible to either heat-treat or cold-work all stainless steel grades to achieve the desired strength. Many stainless steel stamping manufacturers label the hardness of stainless still in the following ways:

Dead Soft: Completely annealed condition (maximum soft).

Quarter Hard: Partly heat-treated or cold worked, with a little strength and toughness increase.

Half Hard: Achieving greater hardness through further heat treatment or cold working, and great strength and toughness.

Three-Quarter Hard: Almost completely hardened. However, very tough and had a little malleability left.

Full Hard: Poor formability, but borderline brittle and fully hardened.

To perfectly form and cut stainless steel, it is essential to have a reliable understanding of the formability, hardness, and type. If you don’t know materials well, it will affect your process design in the wrong way.

What is Pressure Die Casting?

If you are after high-volume production, you should choose pressure die casting. It is also the most cost-effective and highly reliable process for net-shaped metal components with tight tolerances. Many China pressure die casting manufacturers inject molten metal alloys into the steel tool (or mold) under great pressure to complete the process of die casting. It gets hardened quickly, forming the net-shaped part. Then, it is extracted automatically.

Pressure Die Casting Benefits and Types

It costs low than other processes. Moreover, it is economical as you can produce millions of components before the replacement. It also ensures casting with a reliable surface finish and closer dimensional control. It is also possible to achieve thin walls castings, and therefore they are also lightweight.

There are two types of pressure die casting; high pressure and low pressure. High pressure is the most used type with approximately 50 percent of all casting productions of light alloys. On the other hand, the low pressure accounts for approximately 20 percent of the entire production. However, the use of low-pressure type is on the rise.

The high-pressure type is suitable for castings with detailed geometry and tight tolerance requirements. On the other hand, the low-pressure type is an ideal choice for non-critical and larger parts. Machine dies and the machine itself is extremely expensive. Therefore, the pressure die is suitable only when you are after high-volume production.

Let’s take a deeper insight into the two die casting types for a better understanding.

High-Pressure Die Casting

In this type of die casting, manufacturers inject liquid metals with high pressure and high speed into metal molds. The basic gear consists of a couple of vertical platens. They place bolsters on platens, holding die halves. One of the platens is movable, while the other one is immovable. It allows the bending die to close and open.

Metal, in a certain amount, is drizzled into shot sleeves. Afterwards it is introduced into mold cavities. The hydraulically-driven piston helps complete this function. After metal solidification, the die opens and eventually, the casting removes.

The high pressure die casting has two different types. Let’s take a closer look at both.

1. Hot Chamber Procedure

This procedure is valid only for alloys with low melting points, including zinc that doesn’t erode and affect metal pots plungers, and cylinders. For casting, molten metals are positioned into a holding furnace. It requires a specific temperature nearby the machine. A holding furnace holds the mechanism of the injection. Most of it is constantly touching molten metals.

An injection piston transmits the pressure to force the metal into the bending die via gooseneck. For another shot, metals are sent towards the gooseneck on another stroke. With this procedure, there is the least contact between the metal you want to inject and the air

2. Cold Chamber Procedure

We don’t have to submerge injection systems in molten metals, making it a different procedure than the hot chamber. In contrast, the metal transfers via a ladle, automatically or manually. A hydraulic plunger helps push metal into the bending die. With this process, the contact duration between molten metals and injector parts is at a minimum. As a result, it helps in maximizing the component life.

However, entertaining the air into metals usually linked with the high-speed injection may result in gas porosity within the casting. We can obtain over 70,000KPa or 10,000psi injection pressures in a cold-chamber machine. This is a perfect method to produce steel castings with copper and aluminum alloys.

Low-Pressure Die Casting

Low pressure die casting is the appropriate casting procedure if you are after the most reliable castings of aluminum alloys with low melting alloys, including magnesium. Aluminum castings in 2kg to 150kg weight are normal features. First, we position the metal die above the sealed furnace that contains the molten metal. Then, a refractory-lined riser emerges into molten metals from the die’s bottom.

After that, the introduction of the air with low pressure (2-15psi, 15-100KPa) occurs into a furnace. As a result, molten metals enter the cavity of the die by rising with low turbulence. The pressure of the air is released once the metal solidifies. Due to this, the molten metal in a riser tube goes into the furnace. The casting extracts once the die opens after the subsequent cooling.

It is possible to evade the riser requirement by ensuring the appropriate die design. The reason behind it is the casting’s directional freezing. After the establishment of the sequence, you can control the process automatically through pressure controllers and temperature. It helps in overseeing the multiple die casting machines operation.

Casting the yield is remarkably high since there are normally no feeders and just one ingate.

Pressure Die Casting Use cases

Take a look at the following use cases of the pressure die casting:

• Aerospace castings
• Housings of electric motors
• Electronic industry cabinets
• Kitchenware, like a pressure cooker
• Hardware appliances, such as plumbing parts and pump parts

It is also suitable for automotive parts, such as manifolds, cylinder heads, blocks, wheels, etc.

CNC Bending and CNC Forming

It is a process to re-shape metals with the help of machine presses, including brake presses. With computerized-numerical-control (CNC) presses this process becomes precise and versatile. It is also possible to automate it with CAM/CAD drawings to achieve better efficiency in minimum lead times. CNC machining and bending involve the implementation and development of special computer programs for controlling presses operations. It results in enhanced accuracy in the final product.

The CNC bending process involves programming press brakes for accepting metal sheet part plane bank at certain distances by the area where the bend formation will occur. Press brakes fundamentally clamp workpieces between the punch and matching die. A press brake’s sides consist of a couple of C-frames. These C-frames connect to the table’s bottom and upper beam’s top tool.

CNC Bending and CNC Forming Advantages

CNC bending machine manufacturers opt for CNC bending/forming for various reasons. It helps ensure the best performance while facilitating enhanced control and precision. You can achieve high-accuracy bending in sheet metal by using high-quality bending equipment. Therefore, it is essential to buy the best quality equipment from a reliable aluminum CNC bending machine manufacturer. Moreover, it also minimizes the chances of damaging the workpiece through the wrong fit.

Metal bending with CNC can also work with multiple smaller parts and large workpieces. Consequently, there will be reduced delivery times and better production efficiency. Therefore, you can ensure that your projects complete within your budget and on time.

CNC bending/forming is known widely for its automation benefit. The comprehensiveness of the CNC allows you to avoid many other machines that need more human interaction and time, such as shaping machines, vertical millers, routers, and center lathes.

This process requires less space. Moreover, it also allows for economical and faster working. Many other machines require regular upkeep and acquisition. However, you can avoid this hassle if you choose CNC bending. Additionally, you will also save more money for extra personnel because you will need just one operator to program/supervise various CNC machines.

Various CNC bending machine suppliers are available on the market. Therefore, you must choose the most reliable one to buy your CNC machines to ensure quality. You can also outsource a CNC bending machine factory or service provider to create a more efficient, streamlined production cycle.

CNC Bending/Forming Use Cases

High-quality CNC forming/bending equipment helps in providing a reliable solution for all material types, scope, and project sizes. For instance, RV manufacturers can manufacture the best-quality vehicle panels for vehicles. The automotive industry is using it for utility truck tool drawers. Moreover, CNC bending/forming is also an ideal choice to make lifting equipment, like truck cranes, boom components, and frame rails.

If you are using machine tools, such as a router, lathe, mill, or grinder for metal bending, you can replace it with CNC machines. These CNC metal sheets can perform metal fabrication jobs that need various cuts quickly at higher speeds. It is also possible when you need multiple angles or when your material is quite challenging. With CNC, you will ensure higher accuracy and fewer errors with minimum effort.

Specialized Capabilities

Some other metal bending capabilities include electronic and electrical products. Such products include control boxes, enclosures, light fixtures, computer cassis precision panels, and electrical cabinets.  Appliance panels and doors, and refrigeration equipment are some other use cases of CNC bending/forming.

It is also possible to produce furnishings, like metal desks and cabinets, drawers, lockers, shelving, and doors. The construction industry is also getting benefits from it. Ceiling systems and floors for offices, distribution centers, manufacturing facilities, stores, and homes are some common examples. So CNC bending service can benefit almost every industry where metal parts are required.

CNC Bending Techniques

CNC bending involves two techniques or methods. The first technique uses press brakes connected to the lower bed. Engineers utilize V-block tooling for the appropriate metal position and the higher beam goes through the V-blade tool’s force. It is known as ‘down forming’.

In the second procedure, it is a complete contrast, when the up-forming machine goes through the lower ben, while the higher beam sits in the place. We achieve a similar result with both approaches. Therefore, engineers have unlimited options for designs.

You can program press brakes to handle several metal sheet parts. Programmable backstops define the back flat distance. Dependable engineers program V-blades also, where V-blocks are critical for the bend angle in metals. The penetration of the V-block through the V-block affects the final product.

The positioning of the CNC program unites several bend angles and lengths with the metal sheet. It determines the angles and positions for all sheet metal pieces. The computerized numerical controls press brakes define the sheet metal piece length that you can bend.

The thickness of the material is lined up with the tonnage and tensile strength of the material that a machine can work with. The size of the metal sheet gauge depends on the lower V-block’s opening size. Remember that a more open V-block means a wider internal bend radius.

Diffusion Welding

Also called ‘diffusion bonding’, diffusion welding can be the solid-state welding approach for metalworking purposes.  It is an ideal strategy to join different and also comparable metals. It is based on the solid-state diffusion guidelines which demonstrate that particles of two metallic, solid surfaces strew with time.

Ordinarily, it often ends at the hoisted temperature of approximately 50% to 75% of the material’s super dissolving temperature. It is a common strategy for welding the lean metal’s thwart rotating layers and metal filaments or wires.

It is a popular strategy to join hard-heated metals and high strengths inside the atomic and aerospace businesses. Let’s go through a few diffusion welding types.

1. Solid-State Diffusion Welding

Diffusion bonding (welding) occurring in their rigid condition can be a knob to create solid links by arranging the bond. It can result in the coupling surfaces’ termination because the adjacent plastic may misshape when warm. It assists inter-diffusion at the joining fabric sheets’ exterior. Solid state diffusion welding is a common practice in many industries for welding.

2. TLP Diffusion Welding

The liquid-state diffusion bonding is based on the fluid stage arrangement at the line of the bond amidst isothermal bond cycles. The stage of fluid imbues the main fabric. It cements inevitably after the solute’s dissemination into the majority fabric. This procedure is known as TLP diffusion bonding.

Auto-Vacuum Welding: A couple of solid metals join through pressure in this strategy. It is also known as ‘pressure joining.

HIP: HIP (hot-isostatic-pressing) is the fabricating handle. It is useful in diminishing metals’ porosity with the assistance of diffusion welding, plastic misshaping, and crawl.

There are also a few other strategies apart from the above discussed. These include laser welding, forge welding, and electron beam welding.

Pros and Cons of Diffusion Bonding or Welding

There are various benefits along with some possible downfalls of using diffusion bonding. Let’s take a quick look at its pros and cons.

Pros

• The reinforced diffusion welding materialsexhibit similar mechanical and physical properties as base fabrics.
• Reinforced surfaces were tested via pliable testing.
• Diffusion bonding ensures clean joints. Joints are of high quality and there is no porosity and brokenness.
• You can join disparate and comparable materials with diffusion bonding. Because of this, it is high in demand.
• Because of exceptional measurement resilience, it is a perfect choice to deliver complex shapes and accuracy.
• Due to plastic distortion, there is a decrease in beneath diffusion.
• It is a simple method to approach and there are no running expenses.

Cons

• Even there are no running expenses, the initial setup will cost high.
• Diffusion bonding takes a lot of time.
• Workpieces plans are basic and somewhat tough.
• The accessible equipment limits the weld estimate.
• There is no use case for diffusion bonding in mass production.
• The result will be intensely subsidiary to welding parameters, such as temperature, fabric wrap-up, welding material, and weight.

Use Cases of Diffusion Bonding

There are many use cases of diffusion bonding or welding. Atomic diffusion welding is a classic example in the atomic industry. The aviation industry also uses this technique bonding factory materials. It is also suitable for welding beryllium, zirconium, and titanium metals as well as their alloys. Diffusion bonding can also bond nickel combinations, such as Udimet and Inconel. Another utilization of diffusion welding is bonding disparate metals, like Cu-Ti and Cu-AI, etc.

Ultrasonic Welding

Ultrasonic bonding has its use in workpiece liquefying through ultrasonic vibration touch warm and using the warm grinding vitality. The warm vitality depends on the workpiece responding development on other surfaces with specific sufficiency or relocation under a specific weight.

After a desired heat holding degree comes, the vibration halts, while there will be a specific weight on workpieces simultaneously. Such workpieces cool and set warm components to shape an adjacent bond.

Friction Welding

It is also known as ‘FRW’. It can be the solid-state welding approach to create warmth through automated grinding among work parts. The plastically upset (sidelong drive) is growing to merge and diminish fabrics. No dissolving occurs, so grinding bonding isn’t the fusion welding technique.

However, the solid-state bonding strategy is much similar to forge welding. It has its use with thermoplastics and metals in an array of car and flying applications. This type of welding is useful to work with wood.

Forge Welding

Also known as FOW, forge welding is an inelastic welding strategy. It joins two fabric parts by providing warmth up to a specific temperature. It may also comprise constraining and warming metals alongside presses, making adequate weight for plastic misshaping.

If you want to link fabrics, then this is the only method you can use. It is a flexible strategy you can use to join different and comparable metals. Transformation, mechanized forge, and manual forge welding can be the most common handle for fabrication.

What is High Precision CNC Machining?

In the industry, high precision CNC machining normally refers to components with some micrometer’s tolerances. Precision machining procedure states several machining procedures whose surface finish and machining accuracy are greater than parallel machining procedures.

The processes of precision machining include high-brightness and high-brightness grinding and precision cutting. Generally, the precision machining accuracy is 10~0.1μm, the Ra surface roughness is under 0.1μm, and the level of tolerance is more than IT5.

Precision machining’s real art is the blend of human engineering and computer control design. It can create high output and unique functions via the development of chemical control, fluid dynamics, extreme weather, machinery, and the longevity needed by the latest hardware and technology.

High precision CNC machining part factory engineers consider precision machining very critically to manufacture parts and tools in a stable and precise manner. They ensure that they can repeat the process with accuracy, durability, and consistency.

Precision Machining Applications

The precision machining process is useful when you want to remove material from the original item or product for making the end product. You can use it to create an array of items, parts, and products for various materials and objects. These parts normally need strict tolerance changes among the nominal parts and size. It means that the margin for error is very low in the parts’ production.

It is useful for composing many small and large objects as well as components in daily lives. If an object composition involves several small components, it normally requires precision machining for ensuring that it fits together precisely and operates properly.

Parts, finished products, and components designed for maintaining high durability and tight tolerances are deciding factors for using precision CNC machining. For instance, parts that must work simultaneously like machine components may require aligning within a specific range of 0.01-0.005mm. Precision machining and engineering not only ensure accurate parts manufacturing, but they also help produce parts repeatedly with precision.

Repairing components and tools might as well be another common use case of precision engineering. With time, the components or tools of an object might need welding, grooving, or machine calibration for restoring them to the original condition. A high precision CNC machining part manufacturer always knows its importance. This is again something that they can achieve through precision machining.

Moreover, precision machining also plays an essential role in automating production lines or test fixtures, particularly in high-precision industries. Automotive, medical equipment production lines, automation industry, and electronic industry are a few prominent examples.

Precision Machining: Materials and Essential Tools

High precision CNC machining suppliers use several raw materials for precision CNC machining. Those may include plastics, stainless steel, titanium, metals, steel, tungsten, steel, etc. For complex raw material removal and precise cutting, several tools are available. A diffusion welding rod is one of the essential tools in the industry. These tools are dependent on different raw materials. You can use milling machines, grinders, lathes, and various CNC machines for many materials.

All of them are CNC-controlled machines that a highly experienced and qualified operator can operate. These tools have unique functions. Therefore, parts size, parts complexity, surface treatment, materials, etc. decide which tool(s) you should choose.

What are the Different Types of Machines?

For the most optimal precision machining results, it is essential to follow certain blueprints accurately. CAD (computer-aided design) or CAM (computer-aided manufacturing) procedures are helpful in this regard. You can use CAM or CAD for creating 3D drawings essential for producing parts. It is essential to ensure that well-trained technicians create files according to exact specifications. After that, the CNC machining picks the CAM or CAD file for obtaining optimal results during the machining procedure.

To high precision CNC machining part suppliers or manufacturers, these high-precision and complex parts, complex machinery is essential for effectiveness. Below is the list of the different CNC machine type capabilities:

• 3-axis CNC machining
• CNC turning
• CNC milling
• Wire EDM and EDM
• 5-axis CNC machining
• CNC indexed machining 3+2-axis
• Precision grinding

Quality holds significant importance in precision machining. Therefore, an inspection machine also plays a critical role. Normal includes:

• Microscope
• CMM
• Calipers
• Micrometer
• Hardness checking machine
• Altimeter

Precision Machining Benefits

There are various benefits of precision machining. Let’s take a closer look at the most important ones.

Operational Efficiency

The process of precision machining depends largely on automatic CNC machines capable of running at higher speeds without manual interventions. It means that most China pressure die casting suppliers and manufacturers would require less labor for processing parts. It also results in minimum productions costs, while enhancing product quality. As a result, it can enhance the factory floor’s operational efficiency. However, operating complex systems and machines require experienced and skilled labor.

Increased Speed

Equipment that utilizes animated computer drawings for interpreting blueprints and executing them accordingly is an essential part of precision machining. Such machines can overtake humans for accuracy, overall output, and speed. Most significantly, machines don’t require sleep. They can operate for many hours.

Steady Product Quality

High precision CNC machining tools ensure steady output time. Consistent production of high-quality products or parts builds customer confidence while increasing brand visibility. Therefore, it is another massive benefit you will get with precision machining.

Minimum Risk Factors

Mechanical or human errors increase the costs of production and slow down the whole production process. However, we can use smart machines to eliminate human errors. Computers follow predefined operations very strictly. Therefore, there are almost no chances of them going wrong.

Low Error

CNC machining tools will implement an automated machining process after you provide precise specifications. The probability of errors is very low when we compare it with manual processing.

Minimized Production Costs

Usually, we use CNC machines for manufacturing precision parts. This manufacturing procedure has a comprehensive nature. Therefore, it reduces waste, errors possibility, and labor. Because the productions costs are low, automated systems are rising in popularity in the manufacturing field.

Fast Production

Last but not the least; fast production is another huge advantage that comes with CNC machining. Fast automatic manufacturing machines can perform tasks repeatedly with high accuracy. Humans cannot compete with precision engineering when we talk about accuracy and speed. The less turnaround time assists companies to attain sustainable growth and meet their market expectations.

Final Words

High precision CNC machining is playing a great role in the manufacturing industry. Various industries are using CNC machining for tasks like stainless steel lost wax casting. Aerospace & optics, automotive, transportation, and military are the most prominent industries using CNC machining. It ensures fast production, minimum risk factors, steady product quality, and improved speed and efficiency.

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.

What is metal stamping processing?

Metal stamping supplier provides the process of forming metal sheets in a desired shape using different manufacturing methods. The completion of a product usually involves many steps, from cutting and bending to surface treatment and assembly.

Often, fabrication techniques are easy to use to achieve similar end results, but the right choice should base on cost and need.

Metal stamping fabrication process

The journey from metal stamping to metal products begins with CAD, after which the models go through the necessary metal stamping fabrication processes. The most popular are:

Laser cutting

Laser cutting is the preferred choice for Metal stamping supplier. A very fast and precise cutting method that guarantees good results. For thicker materials, plasma cutting is easy to use because of its quickness. But this advantage is only apparent with metals up to 10mm thick.

Cut 

Cutting refers to a process of cutting metal stamping without melting. In essence, it's not too different from cutting with scissors. When cutting, the hammer presses the workpiece into the fixed die or blade, the gap causes the Metal stamping supplier cut. This is a great and effective method for cutting large metal sheets into other sizes (no complex engineering required).

Metal stamping Punching

Punching is another way to cut holes in sheet metal. A punch will deform the metal stamping into the desired shape or punch a hole in it. Punching is suitable for large-scale production but not cost-effective for small jobs. The reason is that punching requires separate tools for different shapes.

Curling

When it comes to actual engineering, there aren't many metal components that don't use bending techniques. Some bending shapes are complex and make manufacturing difficult.

Assemble

Assembly is the last or penultimate step when you want to build a product. If the assembly includes welding then cleaning and painting must accompany it. On the other hand, products that have been powder coated will be assembled together by other methods such as riveting, screwing...

Metal stamping supplier Powder Coating

Powder coating is a process in which an electrostatic powder is applied to an electrically charged metal component. This is the preferred surface treatment when there are no special requirements, such as acidic environments, which are common to the construction industry.

Advantages of sheet metal

• Flexible in design and use
• Production from prototype to bulk is possible
• There are many surface treatment options available: powder coating, painting, galvanizing, plating... allowing for a variety of looks and protection under different circumstances.

Application of sheet Metal stamping supplier

Metal stamping has many applications. It's not easy to find home appliances, construction... that don't use any Metal stamping supplier. However, different groups of metals have specific uses.

Cold rolled steel is used in home appliances, furniture, lockers, cabinets...Cold rolled steel is also used in warehouses and steel structures.

Do you know how the metal stamping process works?

Imagine producing your own detailed geometries using just a plate, a press and a few seconds. No welds, no chips, no mess and record time. This is Stamping!

Stamping is the manufacturing process for stamping metals, which through the pressing operation, plastically cuts or deforms metal sheets, generating a final product with an excellent finish. The process is very useful in industries with serial production and with large batches such as automotive and household appliances, for example.

Materials most used in Metal stamping

Of course, not all materials easy to use in Metal stamping supplier, you can only use those that are able to acquire the format of sheets or tapes, the main ones are:

• Steel
• Copper
• Aluminum
• Nickel
• Zinc

 

Metal stamping supplier high tooling cost

Although this type of manufacturing has a high tooling cost, making it impossible to apply for small batches, the advantages make it very attractive for several industries, because they can offer:

• high production
• Also, Low cost
• Moreover, great finish
• Furthermore, Greater strength of parts due to hardening of the material
• In addition, Production uniformity: Quality

 Specific application of Metal stamping

Stamping has its strands and each one has its specific application, among them are: Cutting, Mechanical Conformation, Dip and Deep Metal stamping supplier. In all cases, the press exerts pressure on the sheet that, supported on a matrix, defines the profile of the part.

cut in stamping

The compression force exerted by the press is converted into shear force, cutting or perforating the material, thus producing profiles in flat pieces.

Some parts usually produced by this means of manufacturing are: IT components, cabinets, rulers, photo panels, washers or flat discs.

Mechanical Conformation of Metal stamping

In this category, the material does not necessarily need to undergo rupture, among the operations are the bending and bending, winding, ribbing and forming of tubes.

Examples of mechanical forming applications are the production of shallow parts such as car body components such as the hood and doors.

Drawing in the stamp

During this operation, the material undergoes a more intense conformation so that the material undergoes stretching, that is, its thickness is reduced so that it can be molded into the desired profile. It is important to remember that to be subjected to drawing, the material must meet certain specifications so that it does not break. An example of application are the sinks for kitchen sinks.

deep stamping

Following the same line of reasoning as in Shallow Stamping, in Metal stamping supplier the cup is deeper than half its diameter. An example of application of this stamping is in the production of pans.

Fine-Blanking or Fine Cut

Fine Cutting and Forming of Metal stamping supplier

it is the technology for the cost-effective production of precision-cut parts.

The fine cutting process offers state-of-the-art technology for the cost-effective production of parts with cutting precision and surfaces free from edges or burrs (cutting overflow). We can use them without any need for rework or second operation or process.

The development of projects

Of course, to produce the parts with the desired profiles, you will need the entire mechanical assembly and not just the die itself. Metal stamping supplier are composed of common elements (Base, head, guide columns and tenon) and specific elements, responsible for the profile of the part that will be produced ( dies and punches ).

Metal stamping supplier Dies and Punches

Dies and Punches are the fundamental elements of die tooling. In the matrix, the negative shape of the piece's profile is cut out and rigidly fix on a reinforce base, forming a solid set, whose material is of high quality and fine finish. Some characteristics that should consider in the design of cutting dies are:

• Exit angle to facilitate the flow of cut material;
• Also, Gap between punch and die that is responsible for cutting the desired piece;
• Moreover, they must not have sharp corners or very small rounding radii;
• Furthermore, they must not contain sudden variations in sections or blind holes.

Conclusion

In the fine cutting process, parts appear on a press with three active forces and on cutting tools with minimal clearance, at right angles with sharp surfaces that leave no burrs or edges and are extremely flat.

Along with nonmetals and nonmetals, metal forming tools are also distinguished by their degree of ionization. In the periodic table of chemical elements, metals make up about 80% and nonmetals and nonmetals make up about 20%.

• Classify
• Physical and chemical properties of metals
• Physical properties
• Chemical properties
• Applications of metals in today's life

What is metal? Metal properties and structure

Specifically, metals are chemical elements that generate positive ions and have metallic bonds.

In nature, non-metals are more abundant, although on the periodic table, the positions of metals are the majority. The most common metals is easy to mention as iron (Fe), aluminum (Al), copper (Cu), gold (Au), silver (Ag), zinc (Zn) ...

Classification of the Metal forming tools

Metals have 4 types, each with different structures and applications, serving different production purposes.

Basic Metal forming tools

These are metals that easily react with the external environment, causing corrosion and oxidation. In addition, they have a chemical reaction with HCl (dilute hydrochloric acid). Some typical base metals are iron, lead, zinc... Particularly, copper, although it does not react chemically with hydrochloric acid, is easily oxidized, so it is also classified as basic metals.

Black Metal forming tools

These are metals that contain iron (Fe) and are magnetic. For example, cast iron, steel and other iron-based alloys, are made up of two main elements, iron and carbon. Ferrous metal is very common and one of the metals that gets recycled over and over again.

High quality stainless steel twigs produced by Dai Duong Factory

Despite metal forming tools strength and flexibility in forming, this is a metal that is susceptible to rust, because it is composed of iron. To eliminate this defect, metallurgists will add some chemical elements such as chromium, nickel... to increase corrosion resistance. The typical material for this alloy is stainless steel, also known as stainless steel.

Non-ferrous forming tools

Nonferrous metal forming tools are the remaining metals that are not ferrous. They are not black, neither iron nor ferroalloy. They have their own distinctive color and are produced from primary or secondary color ores. Non-ferrous metals resist corrosion better than ferrous metals, and conduct heat and electricity quite well. The lower melting point makes casting easier than ferrous metals.

Physical and chemical properties of metals

Like other materials, metals also have specific mechanical, physical and chemical properties.

Physical properties of Metal forming tools

Metal is hard, metallic color, easy to laminate and machined into a variety of shapes. Thanks to the ions, they conduct electricity well. In addition, the metal is also magnetic and conducts heat well, has a high melting point.

Thermal expansion is also characteristic of metals, when visible to hot temperatures they tend to expand, conversely, when visible to low (cold) temperatures, they will contract. Or Most, at ambient temperature, metals are solid, except mercury and copernicus (which are liquid).

Terms of mechanical properties of Metal tools

In terms of mechanical properties, metal forming tools and its alloys are malleable, elastic, and have a certain tensile and compressive strength. Depending on the structure, each metal has a higher or lower degree of mechanical and physical properties.

In addition, metal is the material that has the most advantages in processing such as casting, forging, cutting, punching, stamping, bending, welding... Especially, with heat treatment technology, the hardness of metals and alloys easy to change, to create many different types of materials.

Chemical properties of Metal forming tools

Metals can react with nonmetals, acids, water, and salts to form compounds. The chemical reaction of metals with these substances may or may not be accompanied by a catalyst.

React with acids

When metal reacts with acid, it produces salt and hydrogen gas. In case the reactant is a hot, intense acid, the reaction produces nitrate salts and gases (such as N ₂, NO ₂, NO ...) or sulfate salts and gases (SO ₂, H ₂ S).

Effects on nonmetals

metal forming tools are elements on the right side of the periodic table, which are non-conductive (except for Carbon, graphite), and readily accept electrons (except for Hydrogen). Some nonmetals: oxygen, nitrogen, phosphorus, sulfur, carbon, hydrogen...

When metals react with non-metals, they will produce oxides (when reacting with O ₂ ) or create salts when reacting with other non-metals such as Cl, S

Effect with water on Metal

At normal and high temperatures, when metals react with water, they can give out bases, alkali metals or oxides and hydrogen.

Effect with salt

When a metal is combining with a salt of a weaker metal, the reaction produces a new salt and metal.

Applications of metals in today's life

Metal appears a lot in life, applies extremely diversely in many fields from industry to civil.

Some common applications of metals mention below

• In production:metal is widely common in metallurgy and manufacturing, mechanical processing, machinery and equipment manufacturing. Iron, steel (and their alloys such as stainless steel) or aluminum, zinc ... are mostly common to create many details, accessories, fabrication of billets, casting molds...
• In construction:ferrous metals, base metals are often common to serve construction works such as houses, buildings, bridges and roads, different large and small architectures...
• In transportation:application in making vehicle shells, machine parts, equipment and accessories, joints in most vehicles from bicycles, motorbikes, cars, trucks, airplanes or bicycles. ship.

Metal forming tools in household

• metal is common to create products for life such as tables and chairs, kitchen utensils, stairs, doors, gates...
• Decoration – design:In addition, non-ferrous metals are also common a lot in interior decoration. Thanks to the shape and ease of processing, metal bends and cut according to many unique textures and patterns, making the product both practical and beautify the space.
• In chemistry:Metal forming tools are common to study and analyze chemical reactions, from which scientists develop many other useful materials based on metallic elements to serve modern life. Grand.

Conclusion

In metal forming processes, friction between the workpiece and the tools has both negative and positive effects. In the cases where friction opposes the flow of the workpiece material during forming, it may cause defects in the formed parts.

Turning a part: using metal stamping kit and solving the problem

I am often asked about the secrets of making metal stamping kit. Turning process of a part despite having many years of experience as a turner, this question baffles me.

You cannot answer with one sentence, and I don’t want to turn the dialogue into a scientific treatise. In the turning business, many different operations are practiced, so for now we will focus only on turning.

Parts that are difficult or impossible to make by stamping or welding are made on lathes by machining. The advantage of turned parts is their ability to withstand high pressure.

How to choose metal stamping kit?

Everyone knows that there are different brands of metal in metal stamping kit. For novice operators, I can give a general recommendation: choose the cutting mode and the amount of removal with an eye not on the grade, but on the way it is machined.

Further, you will not change the composition of the metal: you have to work with what you have. But such parameters as annealing, nit riding, carburizing and hardening, tempering or stress relief, the turner can easily control.

Depending on the task at hand, we machine specific areas of the part. I would like to draw the attention of operators to the problem of tightening the metal stamping kit during part turning, in particular when processing the outer diameter of the work piece,

Smart tips for easy work

So, let's talk about how to surprise, not only customers, but also ourselves with our work.

• Turned pipeline parts to ensure rigidity; regularly check the bolts and nuts, which should be tight to the maximum
• Know when to stop and do not rip off the bolts, otherwise you will not be able to readjust the machine
• Always adhere to the stock removal rates, cutting speed and feed rates indicated in the standard tables
• Do not use deformed stamping kits or stripped-off thread hold-down bolts.
• Change plates in time. Their wear and tear provokes the tightening of the metal stamping kit

What is the importance of shape?

Manufacturing parts from steel does not imply savings on working equipment. It is important to select a stamping kit with a suitable edge shape. It is necessary to monitor the strength indicators, which must exceed the strength of the processed material, in this case steel.

The expediency of using this or that stamping kit largely determines the speed and productivity of work. For example, a straight and bent tool is suitable for machining external surfaces. When you need to cut off a part of a work piece or turn a groove, a metal stamping kit comes to the rescue.

Is metal stamping process long?

Furthermore, the process of processing a product by grinding is quite long. It takes about 70% of the total work piece time. This type of protective and decorative finish is half the cost of the finished part! In mass in-line production, the entire grinding process automates.

What is a turner in metal stamping?

A turner is a metal jeweler, since very often he has to work on complex parts of all possible thicknesses. Here you cannot do without milling machines and knowledge of all types of milling work.

Further, the surface can be anything: flat, threaded, or serrated. Milling today is extremely popular due to its high efficiency, so every novice turner should master its basic techniques.

What are the types of metalworking?

We list the main types of metal stamping kit of metalworking: 

• Horizontal and vertical type (according to the location of the working surface);
• Operations with passing and counter rotation of the stamping kit;
• End works (processing of undercuts, wells, grooves, windows);
• Shaped milling of profiles;
• Face processing of overall surfaces.

Furthermore, using all of the above types of work on milling machines, you can quickly and efficiently process casting molds and decorative elements, parts and instrument cases, door and cabinet numbers, letters for different plates. Also, the ability to produce clichés, badges, badges, and make advertising products will not be superfluous.

Milling recommendations for milling process

Now let me share some recommendations regarding the milling process itself:

1. For face milling, avoid machining planes with intersecting holes and slots.
2. The cutting process will be intermittent, which will disrupt the work of the cutting edges.
3. It is better to make the hole later or, in extreme cases, halve the feed amount;
4. If the work is going on with a large surface, the contact of the metal stamping kitwith the work piece must be continuous;
5. The radius of machining of the corner sections of the stamping kit must be larger than the radius of the stamping kit.

What is 3D milling?

As for the shaped type of milling work on metal, then on a conventional machine it is easy to do only in the case of a curved profile of the work piece in one section. When a part has a curved profile in two sections, then its processing is possible only on special equipment.

Moreover, if you are fortunate enough to be a numerically controlled machine operator, you have the opportunity to create complex three-dimensional products, that is, practice 3D milling. Typically, such devices are common in advertising, industry, instrument making.

What to buy a metal stamping kit?

When you decide to purchase metal stamping kit for personal use or professional activity, you should pay attention to the power and speed of the grinding machines. It is important that the manufacturer's stated wattage balances against the other specifications of the device.

The speed of the car should also be “in tune” with the torque. Smart electronics of the instrument and protection against overheating will become an excellent assistant in your work.

Therefore, in order for working on a lathe to provide you with income for your long and happy life, you must follow simple rules.

Bending die processing: principle of operation, advantages, application

Bending die of metal is carried out with a laser beam. Compared to conventional light, the laser is directional, monochromatic and coherent. Moreover, these properties provide the most accurate focus on a small metal surface.

Generally, the concentration of energy allows the material to get heat. Furthermore,  gas and solid-state lasers are commonly common.

The first ones are the most optimal in terms of price and quality of work.  The installation is a working table on which a beam with a laser head is attached. The work piece movement system operates on a linear drive. The installation of bending die is under the control of a computer. Furthermore, this works according to the cutting programs embedded in it.

How to work properly and professionally with bending die?

In order for the process to be of high quality, the required cutting width is observed, so that the work takes place strictly in the heat-affected zone, it is important to observe the technological parameters:

• Generally, repetition frequency, duration of pulses when operating in a pulsed mode;
• Radiation power and cutting speed;
• Similarly, diameter of the laser- spot;
• Furthermore, auxiliary gas pressure.

Each of the above factors affects different materials in different ways. Similarly, it is important to consider whether you are working with stainless steel, titanium, aluminum, copper or brass, mild steel. The correct bending die will ensure a smooth and smooth bend.

How to choose bending die quality?

One of the most frequently asked questions to me is how to determine the die quality. The main criterion is the degree of surface roughness. As you move deeper into the metal, the quality will decrease. In addition, it is important to monitor oxygen pressure and cutting speed here.

Benefits of bending die metal

At one time, the principle of operation of bending die cutting and the attractiveness of the workflow prompted me to take up this particular cutting method.

Undeniable advantages of bending die technology: 

• You can cut any materials with different thermo physical properties;
• With a minimum heat-affected zone, it is easy to get a cut up to 1 mm wide;
• Parts during processing practically do not deform, therefore, this method of metal processing can be safely applied to products with low rigidity;
• It is possible to make complex parts of original shapes;
• Flat and volumetric parts along a complex contour are processed automatically;
• You can change the shape of the part at any time, which eliminates the need for stamps;
• Low processing cost, which increases the demand for this bending die

Despite all its advantages, the technology is not at all universal. You should know that you can only achieve an ideal result with steel; the thickness is not more than 6 mm. For metal more than 40 mm thick, this method is generally contraindicated. Plasma or oxygen cutting is common there.

Reasons for the popularity of the bending die method

Based on my own, fortunately, successful, experience, I can say with sovereignty that having mastered bending die, you will never be left without work. This technology is moving forward to a leading position among various bending die processing methods.

Scope of bending die:

• Shaped cutting of sheet steel;
• Execution of complex shapes in design (decorative elements, stencils, etc.);
• Manufacturing of complex parts for commercial equipment;
• Release of products for the production of advertising products;
• Use in small-scale production of parts.

For laser technologies, not only the future, but also the present, so it never hurts to master promising, demanded knowledge and skills.

Why is bending die not complete today without milling work? 

This modern and very successful technology has significantly expanded the possibilities of straight and true shape nesting.  Having learned how to deftly operate the machine, you will be able to:

• Carry out piece and serial orders;
• Make an accurate and even cut;
• Give it the desired shape, depth and even make shaped cuts;
• Work on inclined, vertical and horizontal surfaces;
• To make carved decorative elements.

Choosing a milling and engraving machine for the bending die is directly related to your ambition as a professional. The more advanced a technique is, the more options it has.

How is milling and engraving useful in bending die?

Modern machines are models with CNC and the ability to manufacture products for various purposes. They allow you to carry out complex orders, to do artistic work. The universal machines behave very well, on which you can mill at various angles, in any position and with a variety of tools. To cope with any kind of work, you should use certain types of cutters.

The use of several methods of milling and engraving work on metal will help to get the desired result for bending die. If you move the cutter in the direction of rotation of the work piece, you get a very smooth and clean surface.

In this case, you need to fill your hand, since the work piece can fly out when a large layer of metal is removed. To improve productivity, cut towards the work piece. These techniques are often combined.

How to choose bending die tools?

Of course, everyone wants to achieve maximum results by reducing the cost of the work process. Nothing is impossible.

For example, if you work with end mills, remember that imported counterparts are more expensive. When choosing a tool for bending die, you should pay attention to the pitch of the plates. Each manufacturer places its own price on products, so you should choose carefully.

The quality of milling work is also affected by:

1. High rigidity of the bed;
2. Decrease in the power of the machine during finishing work;
3. The use of a large number of inserts (also for finishing);
4. Shallow cutting depth (helps to avoid chip problems).

Summary

The need of professional bending die company is crucial for long-term projects. That is why in this article we have tried to convey you the modern ways of doing ending projects for metal industry.

Progressive stamping tool is the finishing of a work piece. It is necessary to obtain a smooth surface of the part. With the help of grinding, minor defects of previous operations are eliminated.

This process is subdivided into several types:

• Rough
• Flat
• Round grinding
• Sharpening
• Polishing

I must say that this process is quite laborious. This requires special tools and abrasives.

Recommendations for completing the surface treatment of metal parts

In every metalworking job, it's important to pay attention to the many things like progressive stamping tool. There are no formulas and axioms for success. In order for the result of the work done to match your idea or the customer's project, I advise you to choose the right materials and type of processing. It will not hurt to practice to fill your hand.

What are the important things to consider while sanding metal parts?

Here are some things to consider when sanding metal parts:

Abrasive type. Coarse-grained materials are common for hard metals, and for soft alloys, analogs with fine grain are suitable.

Grinding type. For example, roughing is necessary to remove rust, dirt and other foreign matter from the metal.

The need for manual processing. This technique gives the metal an aesthetic look with the help of progressive stamping tool. For its implementation, waterproof skins with micro abrasives are common. To make it convenient to manipulate the skin, it is attached to a wooden block.

 

Specificity of polishing: Usually this super finishing carries out using special wheels and skins. In order for the surface to become completely perfect, you should not neglect powders and pastes.

Why metal grinder is selected more consciously?

The use of a good modern metal grinder ensures a high quality finish. An important selection criterion is the number of possibilities for a particular type of equipment. It is great when the unit allows you to process parts of various shapes, configurations, and sizes.

Moreover, only manual processing progressive stamping tool is indispensable for a professional. For example, products made of hardened steel are ground exclusively on machines.

How to evaluate the result of the progressive stamping tool?

The surface of the work piece or product must be completely smooth: without traces of feed and other defects that can often comes by vibration of the table or vibration of the grinding wheel. After high-quality machine grinding, polishing is no longer necessary. Also, do not remove the finishing shavings.

Useful and simple guidelines for bending reinforcement

Manual bending of rebar is only possible in third-rate Hollywood action films. In reality, this laborious process will require a special machine and a certain qualification. To cope with this task, it is necessary to have knowledge of the characteristics and properties of the starting material.

Moreover, as well as the operator must be able to correctly set up the equipment for progressive stamping tool, know how it works and apply the appropriate bending techniques.

Why modern device are common?

Modern devices make it possible to simplify and mechanize work with metal as much as possible. Rebar bending machines are of various modifications:

• manual;
• metal;
• hydraulic;

They are common for making staples and hinges, billets with a double bend, embedded parts.

Equipment for metal bending: getting started

Learning to operate the machine is not difficult. I will say from my own experience that it is important to follow two rules: follow the instructions and not neglect safety precautions. I present to everyone interested in the success of their work the following recommendations:

• Make sure you are using the correct set of rollers for the selected rebar thickness
• Delve into the characteristics of the progressive stamping tool
• Work only with protective gloves
• Start by bending one metal bar.
• Stand in a comfortable position so that you can quickly move away from the equipment
• When removing the reinforcement, it is important not to hook the pedal.

How to do when a drawing is there?

If you have a drawing in front of you and clearly understand the purpose of all the components of the device, as well as the principle of their operation, then “do it yourself” model can be easily assembled from scrap materials. To do this, you need ordinary channels, steel corners, bolts and nuts.

In order for a homemade manual rebar progressive stamping tool to fulfill its purpose, its strength must exceed the strength of the rods and rods. All fasteners must be absolutely secure. Moving parts must not have any play.

Why is organization of work place important?

The correct organization of the workplace is also important when working with any type of machine. The supply of blanks and storage of finished parts are carried out from opposite sides. It is impossible that there are foreign objects nearby.

Stamping tool is the process of removing a thin layer of shavings using abrasive wheels and skins. The operation has high accuracy; it is the final stage of the part processing. Grinding and polishing processes

How does grinding work?

The abrasive wheel rotates and moves in a specific way relative to the work piece. The result of such progressive stamping tool is a smooth surface without the slightest defects.

Each abrasive wheel has its own grain size. Do not use coarse abrasives when sanding soft metal products. The choice of wheel or pelt is dictated by the type of sanding.

What are the types of grinding?

I will say a few words about the features of each type of grinding.

Rough grinding is common to remove a metal layer containing dirt and rust. Here you need a circle with large grains. The complexity of the process involves the use of power tools.

Surface grinding carries out around the periphery with the end of the wheel.

The round grinding comes with a transverse, longitudinal, axial feed, it can be center.

Special works are common on carved surfaces, when machining shaped parts.

Internal grinding of the holes of the rotating part takes place with a longitudinal or transverse feed; the process can also be center less. When the part is static, planetary feed is important.