Die Stamping: Steps, Operations and Processes

Chapter One ' What is Die Stamping?

Die stamping is a cold forming process that begins with a strip of metal, known as a blank or tool steel. Through the use of one or multiple dies, this method cuts and shapes the metal to achieve a desired shape or profile. The force applied to the blank alters its geometry, inducing stress that renders the workpiece suitable for bending or shaping into intricate forms. Parts produced through this method can vary greatly in size, from exceptionally small to extremely large, depending on the specific application.

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Die stamping, also referred to as pressing, encompasses various techniques such as punching, blanking, piercing, coining, and several other operations. Precision in design is essential to ensure each punch achieves optimal quality.

Dies used in die stamping are specialized tools tailored to produce specific designs, ranging from simple everyday items to intricate computer components. They can be designed for single-function operations or as part of a sequential series of functions performed in stages.

There are three common forms of die stamping manufacturing processes:

1. Line: a single operation process
2. Transfer: stamping completes several operations in one cycle
3. Progressive: the most common and widely used

(These three processes will be further explained below in Chapter 3: Production Methods).

Chapter Two ' Die Stamping Operations

Stamping dies serve two primary functions: cutting and forming, with some dies capable of performing a combination of these functions. Each operation is intended to either separate the material or shape it through plastic deformation.

Forming Dies Are

• Bending
• Flanging
• Drawing
• Stretching
• Coining
• Ironing

Cutting Dies Are

• Shearing
• Blanking
• Trimming
• Notching
• Piercing

Forming dies compress metals into precise shapes, functioning akin to stencils.

Bending

Bending forms shapes such as L, U, or V, using plastic deformation that stresses the material below its tensile strength along a single axis.

Flanging

Flanging involves bending the workpiece along a curved axis, with two primary types: stretching and shrinking. Tension and compression are typical in the flanging process, influenced by the length of the tab. It can create curves or corners and involves a straightforward downward movement of the press.

Drawing

Drawing is a metal forming process that displaces the surface of the workpiece to conform to another shape while maintaining the same surface area. The reshaped metal retains its original thickness. The direction of drawing is crucial as it determines how the part can be manipulated, cut, and ejected.

A variation of drawing is deep drawing. It is non-directional, meaning the direction can be up, down, or vertical.

Stretching

Tension and thinning increase the surface area of the workpiece, resulting in a smooth surface ideal for painting and finishing. Dies apply high-pressure binding to control the metal flow. Stretched metals are typically resistant to dents in most cases.

Coining

A pattern is created by applying intense pressure to the workpiece, thereby reducing the metal's thickness.

Ironing

Ironing is like coining. Its purpose is to reduce the wall thickness of the workpiece by squeezing it at a depth that is 30% of the workpiece's thickness. Ironing unifies wall thickness and increases its drawn vessel length.

Below is a description of cutting dies: Cutting, also referred to as shearing, involves separating a piece of metal by applying force until the metal fails.

Blanking

Blanking removes a portion of a metal strip along a specific contour line or shape. Simply put, it involves cutting out one part of the strip from another. The cut-out part becomes the workpiece, while the remaining material is considered scrap, as illustrated in this diagram.

Shearing

Shearing results in a linear cut and is typically used for creating parallel cuts, although it can also accommodate angled cuts. The diagram below illustrates a parallel cut.

Piercing

Piercing is akin to blanking in process. The distinction lies in blanking where the punched-out piece becomes the usable part, whereas in piercing, the removed piece is scrap, leaving behind the desired part. The dimensions of the punch dictate both the size of the removed part and the resulting hole. Below is a basic diagram illustrating this process.

Trimming

During the die stamping process, excess material around a form, known as flash, is trimmed away to achieve the desired profile by cutting along the perimeter edge of the form.

Notching

Notching can be used to assist in the bending or cornering processes. It is performed on the outside of the workpiece to create a specific profile.

The twelve dies described here are just a small sample of the many available options. Consulting with a die stamping manufacturer can offer you a comprehensive selection of various die types.

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Chapter Three ' Production Methods

When selecting a die stamping method, considerations such as cost, time, and required geometric tolerances play crucial roles. Below, we describe the three common production types: line, transfer, and progressive.

Line Production

Line dies are employed for low-volume part production or for very large parts that cannot fit on a single press. The workpiece progresses from station to station, with each station adding a single feature. Combination dies, on the other hand, execute multiple operations in a single stroke during pressing.

Advantages

1. Faster production ' Multiple cuts can be made from several dies.
2. Positioning of blank ' Loading and repositioning of the blank is easy. It can be turned, flipped, and shifted with little effort.
3. Complex geometries ' Produces complex geometries without the need of special calculations or adjustments.
4. Handling of dies ' Dies are lighter and less expensive to handle.
5. Tooling ' Tooling is smaller and conveniently accessible.

Disadvantages

1. Machine limitations ' Not all presses have the capability of loading combination dies.
2. Slow production ' Unlike progressive die stamping, line die processing produces one part at time making it slower and more time consuming.
3. Turnaround times 'Turnaround times and volume of production are both low.
4. Costs ' Machines have to be maintained and controlled by an operator, increasing labor costs when and several machines are needed to complete a process.

Transfer Production

Transfer dies operate similarly to line dies, but they synchronize multiple dies together. Parts are evenly spaced on a single press, known as pitch, and are automatically moved between presses on side-by-side rails or manually. Once a cycle completes, the workpiece is gripped and transferred to the next die.

Advantages

1. Multiple motions ' Two and three-axis motions can be performed during a single cycle. Three-axis motion lifts the workpiece for the next operation.
2. Part placement ' Using gauges or locators, each part is automatically positioned perfectly for each operation.
3. Faster production ' Large parts are rotated, turned, and positioned easily, and moved rapidly from station to station.
4. Computerization ' Servo drive transfers program the types of parts, press speeds, and length of press strokes.
5. Turnaround times ' High volumes of parts are completed with less handling, lower waste, and decreased labor costs.

Disadvantages

1. Technical planning ' Transfer die stamping requires highly sophisticated and technical equipment monitoring. The process has to be carefully planned, tested, and adjusted to ensure quality.
2. Cost ' Expertise for planning and design is expensive and time consuming. In general, the overall process is more expensive than progressive stamping.
3. Destacking ' A specially designed destacking mechanism is necessary to control the flow of blanks and time their insertion.
4. Process regulation ' Production happens quickly, making it impossible to check the status of dies. Die protection sensors are a necessity.
5. Restrictions of process ' In the two-axis process, workpieces slide from die to die, which slows down production.

Progressive Dies

Progressive die stamping has several dies that are activated together. The metal strip, as seen below, is fed through, producing a continuous stream of parts. The stress on the metal is distributed evenly over multiple operations. The equal distance between them is called the progression.

Advantages

1. Volume ' Produces large numbers of parts very quickly. It has the potential to produce seven or eight parts per minute, up to per hour.
2. Labor ' It operates automatically, unattended or monitored.
3. Equipment ' One machine can produce all of the parts.
4. Die configuration ' All die stations are mounted on a single die. Parts are produced together in a single pressing.
5. Speed ' Progressive dies are faster and run on less expensive equipment.

Disadvantages:

1. Technical considerations ' A complicated set of variables and calculations are necessary to determine and synchronize feed speed to protect the die and precisely time the feeding of the coil to be sure it is fed at a constant rate.
2. Cost ' It is more expensive than line or transfer die stampings. The calculations, multiple elements, and equipment are expensive and require significant expertise.
3. Equipment costs ' Equipment is very heavy and cumbersome.
4. Maintenance - Damage to a single station requires removal of the whole system and changeover, which can lead to days of delay.

Compound Die Stamping

Compound die stamping involves feeding strips of steel through a compound die, which cuts or punches out a part in one stroke. A knock-out mechanism ejects the part, and the steel strip continues through the die. This rapid process can produce parts within seconds, achieving rates exceeding per hour, thereby reducing labor costs and lead times.

Compound die stamping eliminates the necessity for multiple dies, which can inflate stamping costs. By using a single die, this process ensures consistent accuracy, flatness, and dimensional stability. The preference for compound die stamping stems from its capacity to decrease expenses and minimize waste, addressing critical concerns in contemporary manufacturing practices.

Advantages

1. Efficiency - Compound dies cut complicated parts in a single stroke avoiding the need for multiple dies.
2. Cost-Effectiveness - Compound die stamping manufactures parts quickly, saving time and money.
3. Speed -Compound die stamping produces parts in seconds and can produce over parts in an hour.
4. Repeatability -Using a single die in compound die stamping ensures that every part has the same dimensions and configuration.

Disadvantages

1. Costly Tool Development - Tool development requires time and cost.
2. Unsuited for Small Runs - The cost of tool development makes it unsuitable for small part runs.
3. Post Process Finishing - The force of compound die stamping requires extensive after-process finishing, such as deburring, clamping, and polishing.

Lubricants

Regardless of the production process, die stamping requires the use of lubricants for:

• Protection of tools and dies
• Providing hydrodynamic film to prevent surface abrasions
• Assisting material flow
• Preventing rips, tears, and wrinkles
• Reductioning friction

When punching dies exert force against a metal strip, friction can lead to scratches, burning of the piece, or damage to the die itself. To mitigate these issues, a lubricant is applied to form a protective layer on the metal workpiece. This helps reduce damage to the die and lowers defect rates during the stamping process.

The three methods for applying lubricant are drip, spray, and roller.

Manufacturers use lubricants made from plant, animal, and mineral oils in addition to graphite, soap, and acrylic ones. Modern lubricants are synthetic and do not contain any oil.

Chapter Four ' Types of Die Stamping Presses

There are four main types of die stamping presses: mechanical, hydraulic, servo, and pneumatic, named according to the force-generating mechanism they employ. Each type is categorized into C-frame and straight side varieties, where C-frame presses feature three open sides, while straight side presses have two. The ram or slide, where the upper die is mounted to apply force, can have single or double connectors.

The image below shows a straight side press, equipped with four to eight guideways. These guideways enable it to manage off-centered loads effectively while safeguarding against deflections.

Stamping Press Terminology

Stamping press manufacturers utilize specific terminology to describe the operation of their equipment, with individual companies often employing proprietary terms. Below is a comprehensive diagram listing all the terms associated with a die stamping press.

Below are selected stamping terms from Sutherland Presses Auto Stamping based in Malibu, CA. For a complete list of their die stamping terminology, please visit their website at https://www.sutherlandpresses.com/news/press-terminology

• Capacity ' the tonnage of pressure the slide can produce
• Continuous on Demand ' meaning the press runs in continuous mode
• "Counter Balance" ' a system that equalizes the weight of the upper slide
• Daylight ' opening in a hydraulic press between the slide and bolster
• Die Blocks ' a safety measures inserted when working on the press
• Eccentric ' a disk used on an eccentric press to drive attachments
• Flywheel ' a wheel that provides rotational energy to prevent excessive or sudden speed changes
• Gibs ' guides that ensure proper sliding fit between two machine parts

When communicating with a die casting company, it's advantageous to be familiar with the vocabulary to understand the terminology used.

Die Stamping Presses

Hydraulic and pneumatic die stamping presses are widely used, with mechanical presses remaining the cornerstone of the industry. Each type of press employs a distinct method to achieve similar functions with varying types of force. Some models integrate both hydraulic and pneumatic methods. Motor presses represent a recent advancement under evaluation and exploration by major manufacturers.

Pneumatic Stamping Press

A pneumatic press utilizes air pressure to drive the downward stroke of the ram, while springs facilitate its upward movement. When activated by the controller, air fills the cylinder, expanding to generate pressure. At the end of the cycle, the air is released, allowing the ram to return to its starting position at the top.

Benefits

1. Moving parts ' Fewer moving parts enables pneumatic machines to reach full ram velocity quickly and require little maintenance.
2. Precision ' Ram pressure is uniform with low deflection. Since it reaches velocity rapidly, it has an increased flow rate.
3. Fast stroke cycles ' Stroke speeds can be as high as 400 strokes per minute (spm) without the need for extra framing.
4. Automation ' Can be fitted with robotics and special transfer units.

Hydraulic Stamping Press

Hydraulic presses provide force using static pressure over a finite and small area. They use pressurized incompressible fluid in a cylinder or cylinders to drive the ram. They are used for metal forming, shallow stretching, and bending. There are three parts to a hydraulic press: machine, power system, and control system.

Benefits

1. Weight of parts ' Parts produced have a light-weight structure with strong rigidity.
2. Mold or die ' Only one mold is needed to complete forming.
3. Strength ' Parts have increased fatigue resistant and exceptional strength.
4. Cost ' It is a cost effective method that significantly lowers the costs of individual parts compared to other stamping methods.
5. Stroke ' Delivers a shorter stroke with maximum tonnage throughout the stroke.

Servomotor Stamping Presses

Until recently, the primary method to increase tonnage was by constructing larger motors. However, press manufacturers have now replaced motors, clutches, and flywheels with servomotors. These servomotors provide precise energy delivery at specific locations, enhancing control over the ram.

Servo presses enable operators to program the dwell time at the bottom of each stroke, ensuring the workpiece settles perfectly before forming. This capability significantly extends the lifespan of the die. Additionally, programming the dwell allows for advanced in-die functions, such as pre-heating the metal before forming. This pre-heating prevents tough materials like stainless steel from tearing during deep draws. Moreover, programmable functions facilitate the use of water-soluble lubricants instead of oil-based lubricants, eliminating the time-consuming and environmentally problematic oil-removal step in subsequent processes. These features make servo forming a compelling alternative to mechanical presses.

Benefits

1. Flexibility ' Ram motion can be controlled throughout its stroke. It is possible to always know the position of the ram. The stroke can be matched to fit the application.
2. Speed ' The speed can be set to the needs of production and the application.
3. Forming ' Progressive forming can be accomplished with one die.
4. Designing ' Engineers are able to see when fractures will occur and make the proper adjustments.
5. Space ' The machines are small and take up less manufacturing floor space.

Mechanical Press

All mechanical presses produce force by stored energy from a flywheel. Punches can be 5 mm up to 500 mm at stroke speeds of 20 to spm. They are categorized by their type of drive, which can be single gear, double gear, double action, linked, or eccentric geared.

Energy stored in the flywheel is discharged using one of the drive types. As the flywheel completes each rotation, it gradually loses energy, reducing its speed by 10 to 15 percent per turn. This lost energy is replenished by an electric motor.

Benefits

1. Speed ' They run at a higher production rate producing more parts per minute efficiently with superior quality.
2. Consistency ' The tonnage at the bottom of a stroke is consistent.

3. Tonnage ' They can vary in size from 20 tons to tons with the ability to supply substantial force.

   Press Energy Chart Press Type: Flywheel (Direct drive) SPM In.-Tons of Energy 5 5 10 19 15 43 20 76 25 119 30 171 35 285 40 285 45 285 50 285
4. Accuracy ' Larger, more complex parts that are thinner and made of stronger material can be produced as well as complete assemblies.
5. Larger materials ' The large bed size allows the processing of parts up to 24 feet.

Chapter Five - Leading Die Stamping Machines

There is a wide range of die stamping machines available across the United States and Canada. These machines are indispensable in modern society, playing a pivotal role in manufacturing industries by facilitating the mass production of precise metal components used in diverse products like automotive parts, electronics, and appliances. Below, we explore several popular die stamping machines, highlighting their unique features and characteristics that contribute to their widespread adoption.

Bliss Presses - C Series

Manufacturer: Bliss Clearing Niagara (now part of Aida Engineering)

Features: Bliss C Series presses are known for their robust construction and high precision.

They provide a broad spectrum of tonnage capacities tailored to diverse die stamping applications. Bliss Presses' C Series presses feature advanced control systems aimed at enhancing productivity and user-friendliness.

Komatsu Presses - E2 Series

Manufacturer: Komatsu America Industries LLC

Features: The E2 Series of Komatsu Presses has gained acclaim for its energy efficiency and environmentally friendly design. These machines incorporate advanced servo technology, enabling fast and precise stamping operations. The press controls in the E2 Series are user-friendly and provide extensive monitoring and diagnostics capabilities.

Minster Presses - P2H Series

Manufacturer: Nidec Minster Corporation

Features: The P2H Series of Minster Presses are celebrated for their exceptional precision and productivity. They integrate advanced servo-driven technology to enhance control during the stamping process. Minster Presses are highly regarded for their durability and minimal maintenance needs.

Seyi Presses - M1 Series

Manufacturer: Seyi America, Inc.

Features: The Seyi M1 Series presses are recognized for their versatility and efficiency in die stamping operations. They offer customizable features tailored to meet specific production requirements.

The M1 Series presses feature intuitive interfaces and enhanced safety measures to optimize the operator experience.

AIDA Presses - NC1 Series

Manufacturer: Aida Engineering

Features: The AIDA NC1 Series presses are renowned for their high-speed capabilities and precision. They incorporate state-of-the-art technology to deliver consistent and reliable stamping performance. The NC1 Series provides a variety of tonnage options to meet diverse metal stamping needs.

Keep in mind that advancements in technology and changes in the market often bring about the introduction of new machines or updates to existing models. For the latest information on the leading die stamping machines available in the United States and Canada, it is advisable to refer to industry publications, visit manufacturers' websites, and consult with industry experts or suppliers in the field.

Chapter Six ' Choosing Metals for Die Stamping

When selecting a metal for die stamping, several factors should be taken into account, such as its mechanical properties, lubrication requirements, press speed and capacity, magnetic attributes, and the type of steel used in die construction. Die stamping utilizes both ferrous and nonferrous metals, with aluminum being particularly favored for its strength, lightweight nature, and resistance to corrosion.

Two primary considerations must be evaluated when selecting a metal: ductility and tensile strength. Ductility is critical as it determines a metal's ability to be shaped and formed without cracking, tearing, or breaking. Tensile strength, on the other hand, measures a metal's resistance to breaking under tension and pressure. These factors are essential criteria for assessing a metal's suitability for die stamping.

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Tensile Testing

Tensile testing is a straightforward method used to determine how a sample responds under tension, revealing its breaking point when subjected to external forces. These tests provide designers and developers with material analysis reports to predict how a metal will perform in its intended application. The diagram below illustrates the testing process. Tensile strength reports typically include values in megapascals (MPa). For instance, mild steel has a yield strength of 247 MPa and ultimate tensile strength of 841 MPa, with a density of 7.58. In contrast, aluminum exhibits a yield strength of 241 MPa and ultimate tensile strength of 300 MPa, with a density of 2.7.

Benefits include:

• Achieving lean manufacturing
• The safety of materials, components, and products
• Providing design data
• Compliance with industry standards
• Product quality and consistency

Ductility Testing

Ductility describes a metal's capacity to deform without fracturing, as depicted in the diagram below.

Four factors contribute to determining a metal's ductility: elongation percentage, tensile strength, yield strength, and hardness.

Elongation Percentage:

Elongation percentage measures how much a metal can stretch within a specified distance, typically two inches. For example, a metal with a 38% elongation can stretch 38% of its original length before fracturing when elongated over two inches.

Tensile Strength:

Tensile strength refers to the maximum stress a metal can endure. A higher tensile strength indicates greater ability to withstand stress.

Yield Strength:

This measure quantifies the force required to shape and deform a metal. When a metal undergoes deformation, it experiences two stages: elastic and plastic. Elastic deformation occurs when it bends under its own weight, whereas plastic deformation involves permanent changes to the metal during processing.

Hardness:

The hardness of a metal is determined using the Rockwell hardness scale, which measures its resistance to penetration by applying weight until the metal surface yields.

Chapter Seven ' Metals Used in Die Stamping

Various metals can be utilized in the stamping process, categorized as either ferrous or nonferrous. Ferrous metals contain iron, while nonferrous metals do not. Steel exemplifies a ferrous metal, derived from iron ore, whereas aluminum, devoid of iron, originates from raw aluminum. In general, ferrous metals are magnetic, whereas nonferrous metals are not, with a few exceptions.

Because nonferrous metals lack iron, they are resistant to rust and oxidation. Nonferrous metals commonly used in stamping include aluminum, bronze, brass, gold, silver, tin, and copper. Among these, aluminum is preferred for its strength, lightweight properties, and corrosion resistance.

Of the ferrous metals, steel is the most used in stamping due to its strength and durability.

Steel in Die Stamping

Because nonferrous metals lack iron, they are resistant to rust and oxidation. Nonferrous metals commonly used in stamping include aluminum, bronze, brass, gold, silver, tin, and copper. Among these, aluminum is preferred for its strength, lightweight properties, and corrosion resistance.

Stainless Steel in Die Stamping

Stainless steel is another type of steel used in stamping, classified as a ferrous metal. The composition of alloys, primarily chromium and nickel, in stainless steel determines its grade. Each grade possesses specific properties and characteristics that make it suitable for diverse applications. For instance, stainless steel grade 316 is ideal for marine applications, whereas grade 304 is preferred for chemical and food processing industries.

Typical grades of stainless steel used for stamping are 301, 302, 304 & 304L, 316 & 316L, 321, 410, and 18-8.

Aluminum

Aluminum, a nonferrous metal utilized in stamping, is valued for its lightweight nature, strength, and resistance to rust and corrosion. Typically, aluminum is alloyed with other metals to enhance its strength and augment specific properties and characteristics.

Aluminum's excellent formability makes it an ideal metal for stamping, as it can be shaped and molded into virtually any configuration.

Copper in Die Stamping

Copper, similar to aluminum, is a nonferrous metal known for its ease of forming and ability to be shaped into seamless components. It is low maintenance, highly resistant to corrosion, and naturally hygienic, making it suitable for medical, food, and beverage applications. While pure copper is used in stamping, it is often alloyed to improve its durability and strength. Its high ductility makes it well-suited for the stamping process.

Brass in Die Stamping

Brass is an alloy of copper and zinc, with the proportions of each metal defining its grade and ductility. It features a smooth, silky surface that is easily shaped, resistant to corrosion, and has excellent conductivity. Additionally, brass is chosen for its attractive appearance and superior aesthetic value.

C is among the most widely favored grades of brass, largely owing to its remarkable corrosion resistance. The hardness of brass correlates directly with its zinc content percentage.

Specialty Metals in Die Stamping

Specialty metals encompass a wide range of materials crafted to endure severe environmental conditions without corroding, degrading, or becoming brittle. This category includes diverse titanium and nickel-based alloys. Their extensive variety makes it challenging to generalize their characteristics, as they are specifically engineered to meet precise operational conditions.

Specialty metals commonly share two key attributes: corrosion resistance and heat resistance. Engineering these metals involves enhancing the base material's strength, durability, and resilience against impact and physical damage.

Chapter Eight ' Microstamping

Microstamping involves manufacturing parts that are nearly imperceptible to the naked eye, typically measuring fractions of a millimeter in size. The production of these micro-stamped parts demands highly precise technical procedures with strict tolerances and exceptionally accurate dimensions. These miniature components are created through processes such as line, transfer, or progressive die stamping, where they are pressure-formed at microscopic scales and may include even smaller integrated elements.

Microstamping compared to regular die stamping:

1. Process - Parts are formed in one stroke of the stamping press.

   
   

2. Technical requirements - Dies are specially designed for a single operation.

   
   
3. Cost ' The technology and expertise to design dies costs between $ and $30,000. The more complex the design, the higher the cost.

4. Lead times ' The complex nature of producing dies takes months to produce and configure.

   
   

5. Equipment ' Presses and other equipment are the same as in regular die stamping.

   
   
6. Tolerances ' Precision stamping produces tolerances of +/- ."

7. Metals ' Beryllium copper, phosphor bronze, and brass. The tensile strength of metals has to be precision controlled to ensure quality and proper performance.

   
   
   
   
8. Dimensions ' Dimensions within 5 mm, thicknesses of 0.1 mm, and diameters of 0.1 mm.

Microstamping products

The microstamping industry continually encounters new challenges in designing and producing increasingly smaller and more precise parts. Below are some recent advancements in this field.

1. Rivetless Nutplate ' Fastener for use in the aerospace industry.

   
   

2. Micro lumbar retractor ' Micro Lumbar Discectomy at 1.57 in (40 mm).

   
   

3. Micro USB Breakout Board ' Breakout board with USB Micro-B connector.

   
   
4. Ammunition Cartridges - Ammunition cartridges are normally made from brass. In an innovative development, ammunition cartridges are now being made from stainless steel, which makes the casings much lighter, offering a critical military advantage. The casings are tapered with a bottom shaped to form a rivet after which a primer base is attached. Using a specially proprietary process, the casings are formed under high pressure and come in caliber cartridges of 4.6, 5.56, and 7.62.

Chapter Nine ' Simulation

One challenge with the die stamping process is its inflexibility. Once a die is cast or a product is produced, there is limited room for reverse engineering or process corrections. However, new auto simulation software enables designers to conduct simulations in a seamless process, minimizing iterations and validating designs before they proceed to manufacturing.

Reducing Flaws in Die Stamping:

Simulation software is designed to compute the stages of the die stamping process, aiding developers in anticipating potential flaws and errors in designs, including those outlined below.

Necking

Tensile failure can occur due to excessive stitching of metal, resulting in deformation like smiling or elongation caused by stretching the metal to its maximum threshold.

Splits

a tear or rip caused by too much stretching; happens after necking.

Springback

A geometric alteration in a part occurring at the conclusion of the forming process can illustrate the effects of springback, as depicted in the image below.

Cracking

a result of excessive cold working or strain hardening.

Benefits

AutoForm and Stamping Simulation technology have the capability to forecast and rectify intricate die stamping issues. The image below illustrates a solution for addressing a springback problem.

1. Examining the entire process, engineers can simulate each operation, such as drawing, flanging, or coining.

   
   
2. Tool design ' Complete design and analysis of tools.
3. Repeatability ' Once a design is made, engineers can refine and analyze it down to the finest detail.
4. Complete imaging ' The software produces 2D and 3D images, multi-axis machining, CNC programming, and areas for maintenance.

5. Formed parts ' The software provides an image of the completed part for close evaluation and determination of any flaws.

   
   

Conclusion

• Die stamping uses operations that include flanging, piercing, blanking, coining, and shearing.
• Die stamping is a method for cutting and forming metal into a specified shape.
• There are three types of die stamping production methods: line, transfer, and progressive. with progressive being the most used.
• Ferrous and nonferrous metals are used in die stamping. Metals should be tested for their ductility and tensile strength.
• The fastest-growing form of die stamping is microstamping, which produces miniature precision parts with exact tolerances.
• There are four types of die stamping machines: hydraulic, pneumatic, mechanical, and servomotor.

updated 8/31/

Sheet metal stamping dies are the parts responsible for cutting and shaping pieces made from sheet metal. Engineering diagrams provide specifications, and a trained diemaker creates the tool. The diemaker then attaches the die to the manufacturing equipment to produce the desired part.

The Sheet Metal Stamping Process

Sheet metal stamping produces uniform parts, called piece parts, according to exact dimensions. This process is ideal for simple components.

The first step of the sheet metal stamping process is engineering. A developer generates drawings of the piece part, often using computer-aided design (CAD). An experienced artisan interprets the drawings to fabricate a one-of-a-kind die required to manufacture the piece part. The artisan then attaches the die to the press.

Blanks ' manageable sizes of sheet metal ' feed into the machine to begin the production process. The die cuts, bends and forms the part into the exact size and shape specified by the engineering diagrams.

The most common process in sheet metal stamping is cutting, which may include techniques like piercing and trimming. Forming is another process, and it involves compression, tension or a combination of the two to force the metal into the desired shape. Bending is one method of forming.

Since the stamping is machine-assisted, metal fabricators can produce consistent parts at high volumes.

Types Of Metal Stamping

The two types of die stamping processes you may encounter are progressive die stamping and transfer die stamping. What do these different types of stamping entail, and what are the advantages and disadvantages of each? What types of applications are most common to transfer die vs. progressive die stamping and vice versa?

Progressive Die Stamping

In progressive die stamping, a coil of metal is fed through a machine that consists of a series of stamping stations that perform simultaneous operations. The metal strip moves through the drawing process, with each progressive die station altering the configuration on the metal from the previous station. Once the metal has gone through the entire machine and all the stamping stations, the piece will be complete.

Progressive die stamping is well-suited to operations needing to produce many small pieces quickly since you can perform multiple cutting and forming operations simultaneously. This combining of operations can also save on costs, although you will have to pay for permanent tool steel die sets. Progressive die stamping can also allow you to maintain close tolerances if you have the right tools.

You can find progressive die stamping in a variety of industries, including automotive, locomotive, heavy trucks and RVs, electronics, and agriculture.

Transfer Die Stamping

In transfer die stamping, rather than feeding the metal part through a series of stations, a mechanical transport system transfers the part from station to station. The transfer die can be a single die or part of several dies lined up in a row. Transfer die stamping is used to perform operations on the part free from the strip.

Transfer die stamping tends to be more economical than progressive die stamping. It is also much more versatile than progressive die stamping. If your part has features like cut-outs, pierced holes, ribs, knurls, or threading, you can use transfer die stamping to work these into regular press operations so that you don't need secondary operations at added cost.

You will use transfer die stamping when you have large parts you need to transfer between multiple presses to complete them, such as shells, tube applications, frames, and structural components. You can find transfer die stamping in all the industries where you find progressive die stamping. It all depends on the specific type of part you are stamping and your requirements for that part.

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