THE PROCESS OF STAMPING SHEET METAL

Introduction

A stamp is a mold used to design shapes on a metal. By extension, stamping is the associated process of imprinting a particular mold onto a metal plate.

Sheet metal stamping in essence involves placing a flattened metal sheet metal onto a metal press to create a desired mold

The processes involved include coining, emboss, bending, blanking, flanging or a simple metal press.

This entails a one stage procedure where a single stroke by the press imprints the desired mold on the metal sheet or multiple serial stages.

This process is commonly carried out on metal sheet, though other materials can be used like polystyrene.

Modes of stamping metal sheet

1. Stamping progressively

— The weight of the press needed is about 800 tonnes
 — For very large surfaces like automobiles, ships and jets and their parts
 — A breath of about 6mm for the raw material.
 — Maximum size of the tool is 270cm X 120cm

2. One stage stamping

— Preferred for smaller products or for several products that need stamping.
 — The press element weighs at most 400 Tonnes
 — Usually made with multiple units, about thirty two in number

Subassembly

Note: Subassembly is a process by which a part of the whole unit is separately formed to fit many other units like a puzzle to make a single large product.

In progressive stamping other process are:

1. Spot welds
2. Riveting
3. Machining
4. Tapping.
5. De greasing process
6. Gas wielding and shield
7. Subassembly as defined above.

The strengths of tools used in stamping are determined by:

— Stamping mold
 — A gauge for inspecting the automotive
 — Fabrication of tools for precision. 
 — A fixture that is non standard
 — 100% in house fabrication of tools used in stamping.
 — Consumer desires as the main focus of the design team
 — Manufacturing tools are.of high class

Finished unit quality assembly

There are sets of coordinate measuring machines (CMM) with profile scanning function that are used for accuracy establishment.

There is a projector that is digital and is used for quality assurance

Roughness of surfaces measured by Mitutoyo equipment

Rockwell hardness tester- using its defined scale of measuring hardness as slated by a materials indentation hardness.This test measures hardness via the indenter’s penetration depth.

Testing for corrosion by salt spray.

Applications

• Agricultural tools
• Automobiles
• Aerospace parts 
• Weapons.and ammunition
• Commercial wares
• Electronic industry
• Lighting systems
• Manufacture of locks
• Submarines
• Medical equipment 
• Plumbing tools 
• Equipment for power
• Other tools like power saws etc

Advantages of sheet metal stamping

1. Useful in large scale production of thin parts with complex shapes at a considerably lower cost.

2. Easy to play around with varied colors and finishes

Disadvantages of sheet metal stamping

1. Too heavy press on small parts (titanium amd steel alloys)
2. Expensive, bulky and noisy machines are needed.
3. To cut din costs, it requires large workloads.

About the author:

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