How to Choose custom precision metal stamping?

Metal stamping is a manufacturing process that employs a specialized press, as well as tool and die set, to form sheet metal into a specified shape and size. Industry professionals employ metal stamping processes to produce a wide range of industrial parts and products. When looking for a metal stamping partner, there are several considerations to bear in mind. You&#;ll want to vet a company that offers the greatest value for your project.

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The following piece provides an overview of some of the key factors to consider when choosing a metal stamping partner. In addition to metal stamping capabilities, qualities such as a broad selection of other fabrication and finishing services, extensive industry experience, and high quality standards are indicative of a high-value partner.

Partner vs. Supplier

When sourcing a metal stamping company, it is important to know the difference between a supplier and a partner. While a supplier has the metal stamping capabilities necessary to fulfill the project, a partner offers the required metal stamping services and more. The latter should be able to assist with all project needs, including design and engineering assistance, manufacturing, and/or finishing services. These offerings help shorten production timelines and reduce production costs.

Advanced Stamping Capabilities

While specialization is good, narrow specialization is not. For example, some projects may not overtly indicate which metal stamping process is appropriate. A metal stamping company that offers a wide range of in-house stamping capabilities&#;e.g., bending, blanking, coining, piercing, etc.&#;is better able to accommodate such projects. However, for projects that required advanced metalworking&#;i.e., deep draw stamping&#;it is essential to work with a specialist to ensure greater precision and accuracy in the finished parts.

Tooling Design and Development Services

Metal stamping companies that maintain an in-house tooling design and development team have greater control over part and process quality. As they have the ability to create custom tooling for every project, they are better able to ensure production proceeds as intended.

Secondary Services

As indicated above, a metal stamping partner should ideally offer more than just metal stamping capabilities. These secondary operations&#;provided in-house or through a network of reliable vendors&#;allow clients to receive a full-service stamping solution. Some of the other fabrication and finishing processes a partner may offer include:

• Heat treatment
• Forming and welding
• Painting and electrocoating
• Passivation and sterilization
• Pre-plating and post-plating processes
• Precious and non-precious metalwork
• Specialty edge cleaning and deburring
• Assembly
• Kitting & Custom Packaging

Industry Experience

Regardless of whether you [the customer] are in the aerospace, automotive, construction, appliance, or other industry, any potential metal stamping partner should have experience producing parts and products for your industry. This quality ensures the partner is familiar with any requirements or restrictions specific to the industry (e.g., using FDA compliant materials for medical devices).

Production Capacity

Both the type of equipment employed and the lead time for raw material orders estimated affect a company&#;s production capacity. A metal stamping partner should utilize metalworking equipment that allows them to complete projects efficiently without sacrificing precision or accuracy.

Quality Management

The International Organization for Standardization (ISO) develops and publishes standards aimed toward ensuring the quality, safety, and efficiency of products and services. The ISO family of standards focuses on quality management principles regarding a company&#;s products and processes. Companies certified to ISO comply with the ISO&#;s criteria for quality management systems, meaning they are knowledgeable about best practices regarding quality and sustainability, and are actively and adequately working to integrate them.

Metal Stamping Solutions From Keats Manufacturing

At Keats Manufacturing Company, we are an ISO- and ITAF-certified manufacturer of high-quality custom metal stampings, wire forms, and assemblies. Equipped with over 60 years of metalworking experience and three state-of-the-art facilities, our team has the knowledge, skills, and tools to meet virtually any small metal stamping need, ranging in size and design complexity. Our metal stamping capabilities include:

• Bending
• Blanking
• Coining
• Curling
• Drawing
• Embossing
• Piercing
• Punching

We also offer in-house tooling design and development services, which allows us to create die and tools sets that achieve up to ±0. inch tolerances throughout a metal stamping project.

The industries we serve include:

To learn more about our metalworking capabilities or partner with us on your next project, contact us or request a quote today.

Precision metal stamping is among the most common metalworking techniques utilized by various industries to turn sheet metal into custom parts.

Progressive metal stamping uses tooling called a progressive die, which contains multiple stamping stations to perform simultaneous operations on a sheet metal strip. A feeding system unrolls the strip from its coil and pushes it through each of the die&#;s different workstations until the final part is made.

Because this process uses various materials and techniques, it&#;s essential to understand the options available and factors to consider before getting started.

A progressive stamping die on the repair table

Precision Metal Stamping Challenges

According to a Research and Markets report, the global metal stamping market will grow to $250 billion in . With increased demand and evolving tools and materials for precision metal stamping, the industry must adapt to overcome challenges. Today&#;s metal rolling techniques are more advanced than traditional hand processes, but manufacturers still face some common problems during production.

One of these common problems is metal cracking, which can occur along the edges during hot and cold rolling. This is sometimes due to uneven heating or rolling, but there are also metallurgical factors to consider.

Austenitic stainless steel has a high cold hardening index (0.34% for SS). Austenitic stainless steel is a meta-stable type, which will transform deformation, thus inducing a martensitic phase. The martensite phase is brittle and easy to crack. During plasticity deformation, with the increase of extension, the martensitic content will then increase, and the residual stress will also be increased. The greater the relationship between residual stress and martensite content there is, the greater the residual stress, and the easier cracking can occur during processing.

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Like most challenges that occur during precision metal stamping, the best way to navigate cracking is to determine and address the root cause. Partnering with a precision reroll mill with metallurgical expertise can be a tremendous help for stampers in performing root cause analysis and resolving issues such as these.

Types of Steel Used for Precision Metal Stamping

Manufacturers can use a variety of metals in precision metal stampings. However, some processes and types of metals perform better in the precision metal stamping process or are a better fit for a particular use case.

Hot rolled steel is roll-pressed at high temperatures and cooled quickly, which leaves a rough surface. For purposes that require closer dimensional tolerances and accuracy, sheet metal is processed further at room temperature through cold finishing techniques.

During the cold rolling process, when the metal is put under mechanical stress, it causes a permanent change to the crystalline structure of the metal. This causes an increase in its strength and often improves corrosion resistance. A cold-rolled stainless steel coil can be precision manufactured, allowing the metal to be produced to extremely tight tolerances. Precision stamping itself uses stamping dies to form metal. This typically occurs at room temperature, making it a cold process.

Compared to hot rolled steel, cold-rolled steel has the following characteristics, making it ideal for the growing needs of precision metal stampers:

• Smooth finished surfaces
• Precise edges and flatness
• Dimensional Uniformity (width, thickness)
• Greater strength and hardness
• Uniform and predictable material properties

When choosing a metal to use, consider the benefits and limitations of each and the requirements for your part.

For example, aluminum is lighter than stainless steel, softer, and a good conductor of electricity. But stainless steel can handle much higher temperatures and more corrosive environments.

Titanium, on the other hand, is also light but much stronger and more durable than aluminum. This makes titanium particularly suited for aerospace, military, and defense applications where a high strength to weight ratio is needed. Titanium is also corrosion-resistant and safe to use in medical implants within the human body.

It&#;s all about matching the alloy and its properties with the needs of the application being manufactured.

Alloys used in Precision Metal Stamping:

Key Factors to Consider When Choosing a Material for Precision Metal Stamping

Some of the key factors to consider when choosing a material for precision metal stamping are the metal&#;s ductility & formability, tensile strength, machinability, and work hardening rate.

Ductility & Formability

Forming occurs somewhere between the yield strength and tensile strength of the material. If yield isn&#;t exceeded, forming doesn&#;t occur but exceeding the tensile strength results in a material fracture. In higher-strength materials, the window between yield and tensile is very small.

The grain size of a material is commonly used to indicate its formability, and consistent grain size is highly desirable for forming operations. Grain size can be controlled by a rerolling mill within a very close range by monitoring the temperature of the annealing furnace and the speed at which the strip passes through the line.

Tensile Strength

Tensile strength measures the amount of force a material can withstand without breaking. Some metals are stronger than others, and the strength varies depending on the component materials in a metal alloy. You should consider the tensile strength of the metal you choose to ensure that it can withstand the amount of force applied during use.

Machinability

Machinability measures how easily the material can be cut or shaped. Because properties that improve a material&#;s performance often reduce its machinability, you should consider the machinability of the metal you choose after satisfying other requirements for your part. A machinable material can be cut quickly with a good finish, which reduces costs. However, it&#;s more important to choose a material that meets the requirements of your part rather than choosing a machinable material.

Work Hardening Rate

As metal is worked or stamped, the temper changes, and the metal either becomes harder and more brittle. The rate that this occurs is work hardening. Depending on how much work is done to the metal and how much it needs to be deformed in a particular operation, the material may require annealing to reset its properties to prevent cracking, breaks, and other material imperfections.

Precision CNC sheet metal stamping

Forming Operations in Precision Metal Stamping

In precision metal stampings, manufacturers use metal forming operations to make parts from metal and metal alloys. It is highly versatile and can be used to create complex, detailed components with an exceptional degree of accuracy and repeatability. What's more, deep-drawn parts are exceptionally strong due to the extreme amount of compression exerted on the metal during the forming process. The fundamental structure of deep-drawn metals is often highly compressed into a very hard crystalline structure.

A design guideline can help you decide the optimal materials and processes.

These are some of the most common forming operations used in precision metal stamping:

• Beads
• Bulging
• Coining
• Curling
• Dimpling
• Embossing
• Extruding
• Flanges
• Holes
• Ironing
• Marking
• Necking
• Notches
• Ribs
• Threading
• Trimming

Options That Fit Your Needs

Engineer-to-engineer collaboration between stampers and precision re-rollers is highly beneficial, especially during new product and process development.

Ulbrich&#;s metallurgical experts and wide alloy selection allow us to match precision metal stampers with the ideal material for their applications and equipment.

Contact us to learn how our solutions could help you reduce scrap and die wear.

If you are looking for more details, kindly visit custom precision metal stamping.