Metal Stamping - Ways and Means to Increase Durability

Online, September 10, 2013 (Newswire.com) - Metal stamping is the process of transforming flat metal sheets into desired shapes using dies. It is and age-old method of producing home utensils, weapons and ornaments of uniform size and shape. In the second half of the 19th century, the technology and manufacturing of metal stamping developed widely due to the mass production of vessels, weapons and other things. Technology improvement has led to the increase in the production rate and operating efficiency.

Sheet metal stamping played a prominent role in the automotive industry in the 20th century followed by aviation, ship building and aerospace industry. The parts produced are vigorous and distinguished by the efficiency of their shape. Metal stamping, through the use of high plastic materials, produces both thin-walled parts of complex shape and large durable parts which cannot be produced by other processes.
In sheet metal stamping, the main operations are separation and forming. In the separation process, the part that is to be formed is separated according to the preset pattern during the movement of the material. This process includes cutting-off, piercing, punching, trimming, deburring, notching and cleaning of the part. The shape and dimensions of the part are changed in the forming process. This process includes winding, reduction, twining, beading, expansion, molding of relief and drawing.

In order to reduce the cost of production of parts from sheet metal in small scale industries, the matrix is made from steel, concrete or iron and the punch is substituted by water or any other liquid above the sheet stock. The power charge explodes in the water and thus creates pressure on the sheet stock and thereby shapes it accordingly. This is known as explosive forming.

Metal Stamping is done in a single step or several steps. The two types of stamping presses used are mechanical and hydraulic. Metal stamping involves various processes like punching, bending, embossing, blanking, coining and flanging. In a series of dies, Blanking is the first die that leads to one completed part. Metal coining on the other hand is used to create coins. The various metals that can be treated using this procedure are zinc, aluminium, titanium, nickel and so on.

The durability of the dies in the metal stamping process is equally important. While altering the shape, properties and dimensions of the metal, the functioning of the die is likely to slow down resulting in incomplete production. Also, due to huge consumption of dies, the production process usually fails. The dies on the other hand, due to stress and corrosion tend to crack. Therefore, it is absolutely necessary take effective measures to increase the durability of the dies. The Improvement in the durability of Sheet metal stamping requires

• Reducing consumption of metal
• greater mechanization
• In mass production use of automatic lines of presses
• effective use of stamping equipment,
• increase in the durability
• speed of forming operations
• ease of replacement of dies

Due to its low production cost, increased strength and more durability, metal stamping has been replacing other processes like forging and die casting. Also the development in the automotive industry has made the sale of metal stamping products more popular today.