Demystifying Metal Stamping Parts: A Comprehensive Summary for Beginners
Contents:
Part 1: what is a metal stamping
Part 2. the principle of metal stamping
Part 3. the features of metal stamping
3.1 High production efficiency
3.2 High precision:
3.3 Low cost:
3.4 Complex shapes
Part 4 The basic knowledge of metal stamping parts
4.1 Stamping process
4.2 Punching
4.3 Bending
4.4 Deep Drawing
4.5 Forming:
Part 5 : Common metal stamping materials
5.1 carbon structural steel
5.2 High-quality carbon structural steel
5.3 Alloy steel
5.4 Alloy structural steel
5.5 Stainless steel
5.6 Aluminum alloy
5.7 Series aluminum alloy
5.8 Brass
5.9 Bronze:
Part 6 : Common types of die for metal stamping parts
6.1 Classification by process properties
6.1.1 Blanking die
6.1.2 Punching die:
6.1.3 Bending die:
6.1.4 Drawing die
6.1.5 Flanging die
6.2 Classification by mold structure
6.2.1 Single-process mold:
6.2.2 Compound mold:
6.2.3 Progressive die:
6.3 Classification by mold material
6.3.1 Steel mold:
6.3.2 Carbide mold
6.3.3 Zinc-based alloy mold
Part 7 : The equipment for metal stamping
7.1 Mechanical press
7.2 Hydraulic press
7.3 Punch press
7.4 High-speed punch press
7.5 CNC stamping equipment
Part 8 : Metal stamping parts Quality inspection
8.1 Surface defect inspection:
8.2 Dimensional accuracy detection
8.3 Shape accuracy detection
8.4 Position accuracy measurement:
8.5 Performance testing
8.6 Material testing
8.7 Assembly performance testing
Part 9 : Common problems in metal stamping
9.1 Cracking
9.2 Mold problems:
9.3 Process problems:
9.4 Wrinkling
9.5 Material problems:
9.6 Mold problems:
9.7 Dimension deviation
9.8 Equipment problem:
9.9 Process problem:
9.10 Wear
9.11 Fracture
9.12 Material jam
9.13 Equipment problem
Part 10 : Metal stamping parts Application
10.1 Automobile manufacturing industry
10.2 Electronic and electrical industry
10.3 Electronic components
10.4 Home appliance industry
10.5 Hardware products industry
10.6 Aerospace industry
10.7 Medical device industry
10.8 Construction industry
Part 11 : Conclusion
Part 1 : What is a metal stamping?
Sheet metal pressing or metal stamping is a metal forming process to transform the sheet metal into a specific shape and dimension, utilizing indentation. A shape-specific die and design-suited press are used to stamp the sheet metal into various forms. The pressure applied by the press deforms the sheet metal and shears it into the die shape. Flat metal sheets that are fed into the machines are referred to as blanks.
Part 2 : The principle of metal stamping
Based on the deformation characteristics of metal materials, when the external force applied to the metal material exceeds its yield strength but is less than its tensile strength, the material will undergo plastic deformation. After the external force is removed, the material can still maintain the deformed shape. Metal stamping is to apply this external force precisely to the metal material through the stamping mold/die and stamping pressing machine, so that it deforms according to the shape and size of the mold/die.
In some stamping processes that require separation of materials, such as blanking, the pressure applied by the stamping equipment is used to generate shear force at the edge of the mold. When the shear force exceeds the shear strength of the material, the material is separated, thereby obtaining the required part shape.
Metal stamping parts are made by using the power of conventional or special stamping equipment to directly subject the sheet metal to deformation force in the mold and deform it, so as to obtain product parts with certain shapes, sizes and performances.
Part 3 Features of metal stamping
3.1 High production efficiency: Stamping processing can complete a large number of parts production in a short time. General stamping equipment can perform dozens or even hundreds of stamping operations per minute, which is particularly suitable for large-scale batch production.
3.2 High precision: Through the precisely designed and manufactured stamping dies, the dimensional accuracy and shape accuracy of the stamped parts can be guaranteed. The dimensional tolerance of the general stamped parts can be controlled within a few wires (0.01mm), and the surface roughness can also reach a high level.
3.3 Low cost: In the case of mass production, the cost of stamping processing is relatively low. Because once the stamping die is manufactured, there is almost no other additional cost increase in the subsequent production process except for the raw materials and a small amount of equipment maintenance costs.
3.4 Complex shapes: it can be processed various parts with complex shapes, such as car body covers, precision connectors in electronic equipment, etc. These parts may be difficult or impossible to achieve with other processing methods.
Part 4 : metal stamping process:
4.1 Stamping process
Compared with castings and forgings, stamping parts are thin, uniform, light and strong. Stamping part can produce workpieces with reinforcing ribs, undulations or flanging that are difficult to manufacture by other methods to improve their rigidity. By the precision molds/Die, the workpiece accuracy can reach micron level, with high repetition accuracy and consistent specifications, and holes, bosses, etc. can be stamped out.
Cold stamping parts generally no longer undergo cutting processing, or only require a small amount of cutting processing. The accuracy and surface state of hot stamping parts are lower than those of cold stamping parts, but they are still better than castings and forgings, and the amount of cutting processing is small.
Stamping part is an efficient production method. With the use of composite dies, especially multi-station progressive dies, multiple stamping processes can be completed on one press machine, realizing fully automatic production from unwinding, leveling, punching to forming and finishing. It has high production efficiency, good working conditions, low production costs, and can generally produce hundreds of pieces per minute.
In production, multiple processes are often applied to one workpiece in combination. Punching, bending, shearing, drawing, bulging, spinning, and straightening are several major stamping processes.
4.2 Punching: A stamping process that uses a die to separate part of the material or process parts from another part of the material, process (sequence) parts or waste, including blanking, punching, trimming, etc.
4.3 Bending: a stamping process that bends sheet materials, bars, tubes or profiles into a certain angle, a certain curvature, and a certain shape, such as V-shaped bending, U-shaped bending, etc.
4.4 Deep Drawing: a stamping process that turns flat sheet materials into various open hollow parts, or further changes the shape and size of hollow parts, such as cylindrical drawing, box-shaped drawing, etc.
4.5 Forming: a stamping process that changes the shape of blanks or process parts through various local deformations, such as bulging, flanging, shrinking, etc.
Part 5 : Common metal stamping metal materials
The blanks for stamping are mainly hot-rolled and cold-rolled steel plates and steel strips.
60-70% of the steel in the world is sheet material, most of which is stamped into finished products. The car body, chassis, fuel tank, radiator fins, boiler drum, container shell, motor, electrical core silicon steel sheet, etc. are all stamped. There are also a large number of stamped parts in products such as instruments, household appliances, bicycles, office machinery, and daily utensils. Commonly used metal materials for hardware stamping mainly include ferrous metal materials and non-ferrous metal materials. The following is a specific introduction to their types and properties: Ferrous metal materials The surface and internal properties of stamping sheets have a great influence on the quality of stamped finished products. The thickness of the stamping materials is required to be accurate and uniform; the surface is smooth, without spots, scars, scratches, surface cracks, etc.; the yield strength is uniform and has no obvious directionality; the uniform elongation is high; the yield strength ratio is low; and the work hardening is low. In actual production, process tests similar to the stamping process are often used, such as deep drawing performance tests, bulging performance tests, etc. to test the stamping performance of materials to ensure the quality of finished products and a high pass rate.
5.1 carbon structural steel
Q195, Q215: With high plasticity and toughness, relatively low strength, easy to stamp and form, can withstand large deformation without breaking, often used to manufacture stamping parts that do not require high strength but require good forming performance, such as some simple daily necessities, small stamping parts, etc.
Q235: With good comprehensive performance, it has certain strength and hardness, good plasticity, toughness and welding performance, and is widely used in hardware stamping. It can be used to manufacture various structural parts, mechanical parts, building hardware, etc.
5.2 High-quality carbon structural steel
08F: It belongs to boiling steel, with low carbon content, excellent plasticity and toughness, excellent stamping performance, good surface quality, and is often used to manufacture parts that require high surface quality and good stamping performance, such as automotive covers, deep drawing parts, etc.
10 steel, 20 steel: slightly higher strength than 08F, still has good stamping performance and welding performance. After proper heat treatment, it can obtain certain strength and hardness, and can be used to manufacture some stamping parts that require certain strength, such as mechanical parts, standard parts, etc.
5.3 Alloy steel
Low alloy high strength steel: such as Q345, etc., has high strength and good toughness, and also has good corrosion resistance and welding performance. Under the same load-bearing capacity, the use of low alloy high strength steel can reduce the weight of parts, and is widely used in the manufacture of stamping parts in the fields of automobiles, bridges, and construction.
5.4 Alloy structural steel: such as 40Cr, 35CrMo, etc., has high strength, hardness, good wear resistance and toughness. After heat treatment, it can obtain good comprehensive mechanical properties. It is often used to manufacture stamping parts that bear large loads and require high strength and wear resistance, such as automobile transmission parts, mold parts, etc.
5.5 Stainless steel
Austenitic stainless steel: such as 304, 316, etc., has good corrosion resistance, high temperature oxidation resistance and excellent stamping performance, non-magnetic, excellent plasticity and toughness, but relatively low strength, and difficult processing. It is often used to manufacture stamping parts with high requirements for corrosion resistance and appearance in food machinery, medical equipment, kitchen utensils, decorative hardware, etc.
Ferritic stainless steel: such as 430, etc., has good corrosion resistance and higher strength than austenitic stainless steel, but slightly worse plasticity and toughness, and the stamping performance is not as good as austenitic stainless steel. It is suitable for manufacturing stamping parts that have certain requirements for corrosion resistance and are more sensitive to cost, such as home appliance housings, building decoration materials, etc.
Non-ferrous metal materials
5.6 Aluminum alloy
aluminum alloy: such as 5052, belongs to aluminum-magnesium alloy, has medium strength, good corrosion resistance, weldability and stamping performance. It is often used in the automotive, aerospace, electronics and other industries to manufacture some structural parts, housings and other stamping parts, such as automotive body covers, electronic equipment housings, etc.
5.7 Series aluminum alloy: such as 6061, is a heat-treated aluminum alloy that can be strengthened. It has high strength, good corrosion resistance and processing performance, and good stamping performance. It is widely used in the manufacture of stamping parts in the fields of automotive parts, building profiles, mechanical parts, etc.
5.8 Brass: such as H62, H65, etc., has good electrical conductivity, thermal conductivity, corrosion resistance and stamping performance, beautiful color, and easy processing and molding. It is often used to manufacture stamping parts in the fields of electrical components, hardware accessories, plumbing equipment, etc., such as wire plugs, faucets, door handles, etc.
5.9 Bronze: such as tin bronze, aluminum bronze, etc., has high strength, hardness and wear resistance, and also has good corrosion resistance and casting performance. It is widely used in some occasions with high requirements for wear resistance and corrosion resistance, such as the manufacture of stamping parts such as mechanical parts, bearings, gears, etc.
Part 6 : Common types of mould/Die for metal stamping parts
The precision and structure of the mold directly affect the forming and precision of the stamping parts. The manufacturing cost and life of the mold are important factors affecting the cost and quality of stamping parts. The design and manufacture of molds requires a lot of time, which prolongs the production preparation time of new stamping parts.
The standardization of mold bases, mold frames, guide parts and the development of simple molds (for small batch production), compound molds, multi-station progressive molds (for mass production), as well as the development of fast mold change devices can reduce the workload and preparation time of stamping production preparation, and can make the advanced stamping technology suitable for mass production reasonably applied to small batch and multi-variety production.
6.1 Classification by process properties
6.1.1 Blanking die
Blanking die: mainly used to separate the material from the sheet along the closed contour to obtain flat parts of the required shape and size, such as gaskets, stamping sheets of electronic components, etc.
6.1.2 Punching die: used to punch holes of various shapes on the formed workpiece or sheet, such as heat dissipation holes, mounting holes, etc. In automobile body manufacturing, various holes on parts such as doors and engine hoods are usually completed by punching dies.
6.1.3 Bending die: used to bend sheet materials, strip materials, etc. into certain angles and shapes, such as U-shape, V-shape, Z-shape, etc. In the manufacture of electronic equipment, some metal brackets, springs, etc. are often formed by bending dies. The bending die can achieve bending at different angles and radii by adjusting the structure and parameters of the die.
6.1.4 Drawing die: used to draw flat sheet materials into hollow parts of various shapes, such as cups, boxes, and automobile fuel tanks. The design and manufacturing requirements of the drawing die are high, and the flow and thinning of the material need to be considered to ensure the quality and precision of the drawn parts.
6.1.5 Forming die: to make the sheet material plastically deform without damage to obtain the desired shape and size, including 6.1.5 flanging die, shrinking die, bulging die, etc. Flanging die can be used to form flanges on the edge of the part to increase the strength and rigidity of the part; shrinking die is used to reduce the mouth of the hollow part; bulging die is used to expand the diameter of the hollow part.
6.2 Classification by mold structure
6.2.1 Single-process mold: a mold that only completes one stamping process in one stroke of the press, such as a simple blanking mold, a punching mold, etc. The single-process mold has a simple structure, a short manufacturing cycle, and low cost, and is suitable for small-batch production of simple-shaped parts.
6.2.2 Compound mold: a mold that completes two or more different stamping processes at the same position of the mold in one stroke of the press, such as a blanking-punching compound mold, a blanking-drawing compound mold, etc. The compound mold has high production efficiency and high precision of stamped parts, but the mold structure is complex, the manufacturing difficulty is high, and the cost is high, which is suitable for mass production.
6.2.3 Progressive die: it also known as continuous die, in one stroke of the press, multiple stamping processes are completed at different positions of the mold at the same time, and the sheet metal is fed in the mold in sequence according to a certain step distance, and each process is gradually completed to finally obtain a complete stamping part. The progressive die has extremely high production efficiency and is easy to realize automated production. It is suitable for large-scale, high-precision stamping parts production, such as multi-pin connectors in electronic components.
6.3 Classification by mold material
6.3.1 Steel mold: Made of high-quality carbon structural steel, alloy tool steel and other materials, it has the advantages of high strength, high hardness, good wear resistance, etc. It can withstand large stamping loads and has a long service life. It is the most commonly used mold material and is suitable for various batches of stamping production.
6.3.2 Carbide mold: Mainly made of cemented carbide, it has extremely high hardness, wear resistance and compressive strength, and can maintain high precision and long life of the mold. It is particularly suitable for high-speed stamping, high-precision stamping and mass production. However, cemented carbide materials are expensive and difficult to process.
6.3.3 Zinc-based alloy mold: An alloy mold based on zinc with aluminum, copper, magnesium and other elements added. It has good casting performance, processing performance, certain strength and toughness, low cost, short manufacturing cycle, and is suitable for the production of small batches and simple shape stamping parts, as well as the trial production of new products.
Part 7 : The equipment for metal stamping
Except for the use of hydraulic presses for forming thick plates, stamping equipment generally uses mechanical presses. With modern high-speed multi-station mechanical presses as the center, it is equipped with machinery such as unwinding, leveling, finished product collection, and transportation, as well as a mold library and a quick mold change device, and is controlled by computer programs to form a high-productivity automatic stamping production line. Common equipment for metal stamping includes mechanical presses, hydraulic presses, punching machines, etc. The following is a detailed introduction:
7.1 Mechanical press
Working principle: The flywheel is driven by an electric motor, and then the power is transmitted to the crank slider mechanism through the clutch, transmission gear, etc., so that the slider moves up and down, thereby applying pressure to the metal material placed in the mold to complete the stamping operation.
Features
High production efficiency: It can perform stamping operations quickly, and can complete multiple stamping strokes per minute, which is suitable for mass production.
High precision: The movement accuracy of the slider is high, which can ensure the dimensional accuracy and shape accuracy of the stamped parts.
Easy operation: It is easy to realize automated operation, and can be equipped with automated feeding and unloading devices to improve production efficiency and safety.
Applicable scenarios: widely used in the production of metal stamping parts in the automotive, electronics, home appliances and other industries, such as automobile body covers, stamping and forming of electronic components.
7.2 Hydraulic press
Working principle: Based on the Pascal principle, hydraulic oil is used as the working medium, the mechanical energy of the motor is converted into hydraulic energy through the hydraulic pump, and then the hydraulic energy is converted into mechanical energy through the hydraulic cylinder to push the slider for stamping.
Features
High pressure: It can generate greater pressure and can be used to process large and thick plates and other metal stamping parts that require greater pressure.
Uniform pressure: During the stamping process, the pressure applied by the slider to the workpiece is uniform, which can make the deformation of the stamping parts more uniform and improve the quality of the stamping parts.
Strong adjustability: Parameters such as pressure and stroke can be easily adjusted to adapt to the production of stamping parts of different materials, shapes and sizes.
Applicable scenarios: Commonly used in aerospace, shipbuilding, large-scale machinery manufacturing and other fields, such as the forming of aircraft wings and the stamping of large ship parts.
7.3 Punch press
Working principle: Similar to a mechanical press, it also drives the flywheel through an electric motor, and then makes the slider reciprocate through the transmission mechanism to generate a stamping force. However, the structure of a punch press is generally relatively simple, focusing on single or high-frequency rapid stamping actions.
Features
Simple structure: Compared with some complex presses, the structure of a punch press is relatively simple, with low cost and easy maintenance.
Fast speed: It can achieve a higher stamping frequency and is suitable for some simple stamping processes with high production speed requirements.
Flexible operation: According to different stamping requirements, the mold can be quickly replaced to adapt to the production of stamping parts of various specifications and shapes.
Applicable scenarios: It is widely used in small hardware processing enterprises, electronics factories, etc., and is often used to produce small stamping parts, such as gaskets, shrapnel, small brackets, etc.
7.4 High-speed punch press
Working principle: Similar to the principle of an ordinary punch press, but it has been optimized in terms of transmission system and slider motion control to achieve a higher stamping speed. High-precision gear transmission or cam transmission mechanism is usually used to ensure the accuracy and stability of the slider under high-speed movement.
Features
Ultra-high speed: The stamping speed is extremely fast, reaching hundreds or even thousands of stamping strokes per minute, greatly improving production efficiency.
High precision: Equipped with high-precision molds and advanced positioning systems, it can ensure the accuracy and quality stability of stamping parts during high-speed stamping.
High degree of automation: Generally equipped with advanced automatic feeding, unloading and detection devices, it realizes fully automated production, reduces manual intervention, and improves production reliability and consistency.
Applicable scenarios: Mainly used in fields with extremely high production efficiency and precision requirements in electronics, precision hardware and other industries, such as the production of precision stamping parts such as mobile phone parts and integrated circuit lead frames.
7.5 CNC stamping equipment
Working principle: Computer numerical control technology (CNC) is used to control the movement and processing of stamping equipment. By writing CNC programs, the stroke, speed, pressure and other parameters of the slider, as well as the replacement and positioning of the mold, can be accurately controlled to achieve automated and high-precision stamping processing.
Features
Highly automated: It can automatically complete stamping processing according to the preset program without frequent manual intervention, reducing the impact of human factors on processing quality, and improving production efficiency and product quality stability.
High processing accuracy: It can accurately control various parameters in the stamping process, achieve micron-level processing accuracy, and meet the production needs of high-precision metal stamping parts.
Strong flexibility: It can quickly adapt to the production of stamping parts with different shapes, sizes and process requirements by modifying the CNC program, without a large number of mold adjustments and equipment modifications.
Applicable scenarios: It is suitable for the production of various metal stamping parts with high requirements for precision and flexibility, especially in small batch and multi-variety production modes, such as personalized hardware products, precision instrument parts, etc.
Part 8 : Metal stamping parts Quality inspection
Quality inspection of metal stamping parts is a key link to ensure that stamping parts meet design requirements and performance. It mainly includes appearance, size, performance and other aspects. The following is a specific introduction:
Appearance inspection
8.1 Surface defect inspection: It mainly checks whether there are cracks, scratches, burrs, pits, bulges and other defects on the surface of the stamping parts. Cracks may cause stamping parts to break during use, affecting the safety of the product; scratches may affect the appearance quality of the product, and may also become stress concentration points, reducing the strength of the product; burrs may not only affect the appearance of the product, but may also scratch other parts or cause harm to operators during subsequent assembly.
Surface flatness detection: Use flatness detection tools such as knife edge rulers and flat plates to detect the flatness of the surface of stamping parts. For some stamping parts with high requirements for surface flatness, such as automobile body covers, surface flatness directly affects the appearance and aerodynamic performance of the car.
Color uniformity inspection: Observe whether the color of the surface of the stamping part is uniform. Uneven color may be caused by uneven surface treatment of the material, local overheating during stamping, etc., which will not only affect the appearance of the product, but may also imply differences in material properties.
8.2 Dimensional accuracy detection
Linear dimension measurement: Use calipers, micrometers, three-coordinate measuring instruments and other tools to measure the linear dimensions of stamping parts such as length, width, height, aperture, and wall thickness. These dimensions are directly related to the assembly accuracy of stamping parts and other components. For example, in the assembly of mechanical parts, excessive dimensional deviation may cause the parts to be unable to be installed or affect the performance of the entire mechanism.
8.3 Shape accuracy detection: For some stamping parts with specific shape requirements, such as round, square, arc, etc., it is necessary to detect their shape accuracy. For example, a roundness meter is used to detect the roundness of a circular stamping part, and a contour meter is used to detect the contour shape of the stamping part. Unsatisfactory shape accuracy will affect the function and assembly performance of the stamping part. For example, the roundness of a circular stamping part may cause it to jump during rotation, affecting the stability of the equipment.
8.4 Position accuracy measurement: Detect the position accuracy between the holes, grooves, bosses and other features on the stamping part, as well as the positional relationship between these features and the reference plane and reference axis of the stamping part. Commonly used measuring tools include three-coordinate measuring machines, projectors, etc. Position accuracy is crucial to ensuring the assembly accuracy of stamping parts and the overall performance of the product. For example, the position accuracy of each mounting hole on the engine block directly affects the assembly quality and working performance of the engine.
8.5 Performance testing
Hardness testing: Use a hardness tester to test the hardness of stamping parts to determine whether they meet the hardness requirements of the material. Hardness is an indicator of the material's ability to resist local deformation. Failure to meet the hardness standard may cause premature wear and deformation of stamping parts during use.
Strength testing: Use tensile testing machines, pressure testing machines and other equipment to perform tensile tests, compression tests, bending tests, etc. on stamping parts to detect their tensile strength, compressive strength, bending strength and other mechanical performance indicators. Strength is a key performance indicator to ensure that stamping parts can withstand the corresponding loads during use. For example, automobile chassis stamping parts need to have sufficient strength to withstand various forces during vehicle driving.
Toughness testing: Use an impact testing machine to perform an impact test on stamping parts to test their impact toughness. Toughness reflects the ability of a material to absorb energy under impact loads. For some stamping parts that work under dynamic loads, such as gears and springs, good toughness can ensure that they are not prone to brittle fracture during use.
8.6 Material testing
Chemical composition analysis: Use spectrometer, chemical analysis and other means to analyze the chemical composition of the stamping parts to determine whether they meet the standard requirements of the materials. Chemical composition directly affects the performance of the material. For example, the content of carbon, manganese, silicon and other elements in steel will affect the strength, toughness and other properties of the steel.
Metallurgical structure inspection: Observe the metallographic structure of the stamping parts through a metallographic microscope to check its grain size, phase composition, and uniformity of the structure. The metallographic structure is closely related to the performance of the material. For example, uniform and fine grain structure usually has good strength and toughness, while coarse grains or uneven structure may cause the material performance to deteriorate.
8.7 Assembly performance testing
Assembly test: Assemble the stamping parts with other related parts to check whether they can be assembled smoothly, as well as the matching accuracy and overall performance after assembly. For example, in the production of automotive parts, the stamping parts are tested with other parts to check whether there are assembly interference, gaps that are too large or too small, etc., to ensure the assembly quality and performance of the whole vehicle.
Functional testing: Perform functional testing on assembled products to verify whether the stamping parts function normally in actual use. For example, for stamping parts in electronic equipment, electrical performance testing is performed after assembly to ensure that they can perform functions such as conduction and insulation normally.
Part 9 : Common problems in metal stamping
Metal stamping will encounter many problems during the production process. The following are some common problems and reasons:
Stamping parts quality problems
9.1 Cracking
Material problems: Insufficient ductility, too high hardness or internal defects such as impurities, pores, etc. of the material are prone to cracking during the stamping process.
9.2 Mold problems: If the gap of the mold is too small, the material will be subjected to excessive extrusion during stamping; if the mold edge is worn and not sharp, the material will be subjected to uneven force during the shearing process, which may cause the stamping parts to crack.
9.3 Process problems: The stamping speed is too fast, and the material has no time to deform evenly; the drawing coefficient is too small, resulting in excessive deformation of the material, which will also increase the risk of cracking.
9.4 Wrinkling，some times, the metal stamping part will have the wrinkling problem, that caused by the materail or the processing issue.
9.5 Material problems: The thickness of the material is uneven, and wrinkling is prone to occur during the stamping process.
9.6 Mold problems: Insufficient clamping force, unable to effectively control the flow of the material, will cause the material to wrinkle during the stamping process; inappropriate surface roughness of the mold may also affect the flow of the material, leading to wrinkling.
Process problems: If the drawing ratio is too large, the material will deform too much during the drawing process, which is easy to wrinkle; if the stamping sequence is unreasonable, the material may also deform unstably during the stamping process, resulting in wrinkles.
9.7 Dimension deviation
Mold problem: Insufficient manufacturing accuracy of the mold, such as mold cavity size deviation and poor assembly accuracy of the mold, will lead to dimensional deviation of the stamped parts.
9.8 Equipment problem: The accuracy of the stamping equipment decreases, such as the flatness of the workbench exceeds the tolerance and the movement accuracy of the slider decreases, which will affect the relative position of the mold and the material during the stamping process, resulting in dimensional deviation.
9.9 Process problem: The rebound phenomenon during the stamping process will cause the size of the stamped parts to change after demolding; unreasonable process parameters such as material thickness tolerance and stamping gap will also lead to dimensional deviation.
Mold problem
9.10 Wear
Material problem: The high hardness and high surface roughness of the stamped material will accelerate the wear of the mold.
Mold problem: Improper material selection and unreasonable heat treatment process of the mold will reduce the hardness and wear resistance of the mold; poor surface treatment quality of the mold, such as no nitriding, hard chrome plating and other treatments, will also make the mold easy to wear.
Process problem: Too fast stamping speed and too many stamping times will increase the friction between the mold and the material and accelerate the wear of the mold; poor lubrication during the stamping process will also increase the friction between the mold and the material, causing mold wear.
9.11 Fracture
Mold problem: The structural design of the mold is unreasonable, such as insufficient strength and rigidity of the mold, which is prone to fracture during the stamping process; the mold has defects such as cracks. Under repeated stamping loads, the cracks will gradually expand and eventually cause the mold to break.
Process problem: The stamping pressure during stamping is too large, exceeding the bearing capacity of the mold; the stamping speed is too fast, which will increase the impact load on the mold, all of which may cause the mold to break.
9.12 Material jam
Mold problem: The unloading device of the mold is not designed properly, such as insufficient elastic force of the unloading spring, insufficient stroke of the unloading plate, etc., which will cause the stamping parts to fail to unload smoothly after the stamping is completed, resulting in material jam.
Process problem: Uneven stamping gap will cause uneven deformation of the material during the stamping process, resulting in material jam; excessive stamping speed may also cause the stamping parts to jam during unloading.
9.12 Equipment problem
Unstable pressure
Hydraulic system problem: Contamination of hydraulic oil, wear of hydraulic pump, failure of hydraulic valve, etc. will all lead to unstable pressure of hydraulic system, thus making the pressure of stamping equipment unstable.
Mechanical transmission problem: Wear of transmission gears, looseness of chains, slippage of belts, etc. will affect the transmission accuracy and stability of stamping equipment, resulting in unstable pressure.
Electrical control system problem: Aging and damage of electrical components, unreasonable parameter settings of control system, etc. will cause deviation in pressure control of stamping equipment, resulting in unstable pressure.
Unstable movement of the slider
Guide system problems: wear and tear of the guide column and guide sleeve, too large or too small guide gap, will affect the movement accuracy and stability of the slider.
Balance system problems: insufficient pressure of the balance cylinder, elastic failure of the balance spring, etc., will cause the slider to lose balance during movement, resulting in unstable movement.
Equipment installation problems: the installation foundation of the stamping equipment is not firm, the levelness is out of tolerance, etc., which will cause the equipment to vibrate during operation and affect the stability of the slider.
Part 10 : Metal stamping parts Application
Metal stamping parts have the advantages of high precision, high production efficiency and low cost, and are widely used in many fields. The following are some of the main application areas:
10.1 Automobile manufacturing industry
Body structure parts: such as frames, door frames, engine hoods, etc. These stamping parts constitute the basic skeleton of the car and need to have high strength and good impact resistance to ensure the safety and stability of the car.
Automobile interior parts: car seat frames, instrument panel brackets, door interior panel frames, etc. These stamping parts must not only meet certain strength and rigidity requirements, but also have good comfort and aesthetics.
Auto parts: The cylinder block, cylinder head, oil pan of the engine, the housing of the transmission, and various automobile radiators, filter housings, etc., all need to be manufactured through stamping processes to meet the high precision and high performance requirements of automobile parts.
10.2 Electronic and electrical industry
Electronic equipment housing: The housings of electronic devices such as mobile phones, tablets, laptops, and televisions usually use hardware stamping parts. These stamping parts must not only have good appearance quality and heat dissipation performance, but also be able to provide reliable protection for the internal electronic components.
10.3 Electronic components: Such as electronic connectors, relays, switches, etc., many of these components are manufactured through stamping processes. The precision and performance of stamping parts directly affect the quality and reliability of electronic components.
Circuit board bracket: The bracket used to fix and support the circuit board is usually manufactured by stamping technology, requiring high precision and good conductivity and insulation.
Home appliance housing: The housings of home appliances such as refrigerators, washing machines, air conditioners, and microwave ovens usually use hardware stamping parts. These stamping parts need to have good corrosion resistance, appearance quality and strength to meet the use requirements and aesthetic requirements of home appliance products.
Internal structural parts of household appliances: such as the evaporator bracket of the refrigerator, the inner barrel bracket of the washing machine, the fan bracket of the air conditioner, etc. These stamping parts are important components of the internal structure of household appliances and need to have good strength and stability.
10.5 Hardware products industry
Daily hardware products: such as door locks, hinges, handles, faucets, etc. Many parts of these hardware products are manufactured through stamping processes. The quality and performance of stamping parts directly affect the use function and life of hardware products.
Tool hardware: such as pliers, wrenches, screwdrivers and other tools. The handles, jaws and other parts are also often made of hardware stamping parts to improve the strength and comfort of the tools.
10.6 Aerospace industry
Aircraft structural parts: such as wings, fuselage frames, landing gear, etc. These stamping parts need to have extremely high strength, lightness and reliability to meet the requirements of aircraft use in high-altitude flight and complex environments.
Aircraft engine parts: such as engine blades, combustion chambers, turbine discs, etc. These stamping parts need to have high temperature resistance, high pressure, high strength and other properties, and are key parts in aircraft engine manufacturing.
Medical equipment housing: such as X-ray machines, B-ultrasound machines, medical monitors and other medical equipment housings, usually use hardware stamping parts, these stamping parts need to have good corrosion resistance, hygiene and appearance quality to meet the use requirements and hygiene standards of medical equipment.
Medical equipment parts: such as surgical instruments, medical fixtures, medical implants, etc., many of these parts are also manufactured by stamping technology, requiring high precision, high reliability and good biocompatibility.
10.8 Construction industry
Building decoration parts: such as door and window frames, decorative lines, ceiling ceilings, etc., these stamping parts must not only have good appearance quality and decorative effects, but also have certain strength and corrosion resistance.
Building hardware: such as hinges, handles, door locks, latches, etc. used in buildings. These hardware are usually manufactured using stamping technology to meet the functional requirements of opening, closing and safety protection of building doors and windows.
Part 11 : Conclusion
During stamping, the machines will produce dozens or hundreds of stamping parts at per minute, the production time needs to be completed the relevant processes such as feeding, stamping, discharging parts, and waste removal in a short time. If you don't pay attention, personal safety, equipment problems, and quality accidents will be occurred. Therefore, safety production in stamping needs to be operated according to ISO 9001 safety standard guide, and employee training should be offer for every one. The safety issue is a priority at Dr. Solenoid metal processing workshop.
By the way Metal stamping part is a very complicated process. The entire project may turn into a disaster without experience expert guidance and observation. Here, at Dr. Solenoid Metal processing workshop, you will find a combination of expertise, experience engineer, manpower, and upgraded machinery. So, contact us and let us handle your project in the best way possible.