Stamped metal
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Stamping (also known as pressing) is the process of placing flat sheet metal in either blank or coil form into a stamping press where a tool and die surface forms the metal into a net shape. Stamping includes a variety of sheet-metal forming manufacturing processes, such as
punching Punching is a forming process that uses a punch press to force a tool, called a ''punch'', through the workpiece to create a hole via shearing. Punching is applicable to a wide variety of materials that come in sheet form, including sheet meta ...
using a
machine press A forming press, commonly shortened to press, is a machine tool that changes the shape of a work-piece by the application of pressure. The operator of a forming press is known as a press-tool setter, often shortened to tool-setter. Presses ...
or stamping press, blanking, embossing, bending, flanging, and coining. This could be a single stage operation where every stroke of the press produces the desired form on the sheet metal part, or could occur through a series of stages. The process is usually carried out on
sheet metal Sheet metal is metal formed into thin, flat pieces, usually by an industrial process. Sheet metal is one of the fundamental forms used in metalworking, and it can be cut and bent into a variety of shapes. Thicknesses can vary significantly; ex ...
, but can also be used on other materials, such as polystyrene. Progressive dies are commonly fed from a coil of steel, coil reel for unwinding of coil to a straightener to level the coil and then into a feeder which advances the material into the press and die at a predetermined feed length. Depending on part complexity, the number of stations in the die can be determined. Stamping is usually done on cold metal sheet. See Forging for hot metal forming operations.


History

It is believed that the first coins were struck by the Lydians in what is modern-day Turkey in the seventh century B.C. Until 1550, the hammering method of coins remained the primary method of coin-making. Marx Schwab in Germany developed a new process for stamping that involved as many as 12 men turning a large wheel to press metal into coins. In the 1880s, the stamping process was further innovated. Stamped parts were used for mass-produced bicycles in the 1880s. Stamping replaced die forging and machining, resulting in greatly reduced cost. Although not as strong as die forged parts, they were of good enough quality. Stamped bicycle parts were being imported from Germany to the United States in 1890. U.S. companies then started to have stamping machines custom built by U.S. machine tool makers. Through research and development, Western Wheel was able to stamp most bicycle parts. Several automobile manufacturers adopted stamping of parts.
Henry Ford Henry Ford (July 30, 1863 – April 7, 1947) was an American industrialist, business magnate, founder of the Ford Motor Company, and chief developer of the assembly line technique of mass production. By creating the first automobile that ...
resisted the recommendations of his engineers to use stamped parts, but when his company could not satisfy demand with die forged parts, Ford was forced to use stamping. Over the history of metal stamping, forging and deep drawing, presses of all types are the backbone of metals manufacturing. The processes continue to improve in moving more metal in one press stroke. Press and interconnected automation devices increase production rates, reduce labor costs and provide more safety for workers.


Operation

*
Bending In applied mechanics, bending (also known as flexure) characterizes the behavior of a slender structural element subjected to an external load applied perpendicularly to a longitudinal axis of the element. The structural element is assumed to ...
- the material is deformed or bent along a straight line. * Flanging - the material is bent along a curved line. * Embossing - the material is stretched into a shallow depression. Used primarily for adding decorative patterns. See also
Repoussé and chasing ''Repoussé'' () or ''repoussage'' () is a metalworking technique in which a malleable metal is shaped by hammering from the reverse side to create a design in low relief. Chasing (French: '' ciselure'') or embossing is a similar technique ...
. * Blanking - a piece is cut out of a sheet of the material, usually to make a blank for further processing. * Coining - a pattern is compressed or squeezed into the material. Traditionally used to make coins. * Drawing - the surface area of a blank is stretched into an alternate shape via controlled material flow. See also
deep drawing Deep drawing is a sheet metal metal forming, forming process in which a sheet metal blank is radially drawn into a forming die by the mechanical action of a punch. It is thus a shape transformation process with material retention. The process is c ...
. * Stretching - the surface area of a blank is increased by tension, with no inward movement of the blank edge. Often used to make smooth auto body parts. *
Ironing Ironing is the use of a machine, usually a heated tool (an iron), to remove wrinkles and unwanted creases from fabric. The heating is commonly done to a temperature of 180–220 °Celsius (356-428 Fahrenheit), depending on the fabric. Ironing wor ...
- the material is squeezed and reduced in thickness along a vertical wall. Used for beverage cans and ammunition cartridge cases. * Reducing/Necking - used to gradually reduce the diameter of the open end of a vessel or tube. * Curling - deforming material into a tubular profile. Door hinges are a common example. * Hemming - folding an edge over onto itself to add thickness. The edges of automobile doors are usually hemmed.
Piercing Body piercing, which is a form of body modification, is the practice of puncturing or cutting a part of the human body, creating an opening in which jewelry Jewellery ( UK) or jewelry ( U.S.) consists of decorative items worn for personal ...
and
cutting Cutting is the separation or opening of a physical object, into two or more portions, through the application of an acutely directed force. Implements commonly used for wikt:cut, cutting are the knife and saw, or in medicine and science the scal ...
can also be performed in stamping presses.
Progressive stamping Progressive Die is a metalworking method that can encompass punching, coining, bending and several other ways of modifying metal raw material, combined with an automatic feeding system. The feeding system pushes a strip of metal (as it unrolls ...
is a combination of the above methods done with a set of dies in a row through which a strip of the material passes one step at a time.


Lubricant

The
Tribology Tribology is the science and engineering of interacting surfaces in relative motion. It includes the study and application of the principles of friction, lubrication and wear. Tribology is highly interdisciplinary, drawing on many academic f ...
process generates friction which requires the use of a lubricant to protect the tool and die surface from scratching or galling. The lubricant also protects the sheet metal and finished part from the same surface abrasion as well as facilitate elastic material flow preventing rips, tears and wrinkles. There are a variety of lubricants available for this task. They include plant and mineral oil-based, animal fat or lard-based,
graphite Graphite () is a crystalline form of the element carbon. It consists of stacked layers of graphene. Graphite occurs naturally and is the most stable form of carbon under standard conditions. Synthetic and natural graphite are consumed on lar ...
-based, soap and acrylic-based dry films. The newest technology in the industry is polymer-based synthetic lubricants also known as oil-free lubricants or non-oil lubricants. The term "Water-Based" lubricant refers to the larger category that also includes more traditional oil and fat-based compounds.


Simulation

Sheet metal forming simulation Today the metal forming industry is making increasing use of simulation to evaluate the performing of dies, processes and blanks prior to building try-out tooling. Finite element analysis (FEA) is the most common method of simulating sheet metal for ...
is a technology that calculates the process of sheet metal stamping, predicting common defects such as splits, wrinkles, springback and material thinning. Also known as forming simulation, the technology is a specific application of non-linear finite element analysis. The technology has many benefits in the
manufacturing industry Manufacturing is the creation or production of goods with the help of equipment, labor, machines, tools, and chemical or biological processing or formulation. It is the essence of secondary sector of the economy. The term may refer to a ran ...
, especially the
automotive industry The automotive industry comprises a wide range of companies and organizations involved in the design, development, manufacturing, marketing, and selling of motor vehicles. It is one of the world's largest industries by revenue (from 16 % such ...
, where lead time to market, cost and lean manufacturing are critical to the success of a company. Recent research by the Aberdeen research company (October 2006) found that the most effective manufacturers spend more time simulating upfront and reap the rewards towards the end of their projects. Stamping simulation is used when a sheet metal part designer or toolmaker desires to assess the likelihood of successfully manufacturing a sheet metal part, without the expense of making a physical tool. Stamping simulation allows any sheet metal part forming process to be simulated in the virtual environment of a PC for a fraction of the expense of a physical tryout. Results from a stamping simulation allow sheet metal part designers to assess alternative designs very quickly to optimize their parts for low cost manufacture.


Microstamping

While the concept of stamping
sheet metal Sheet metal is metal formed into thin, flat pieces, usually by an industrial process. Sheet metal is one of the fundamental forms used in metalworking, and it can be cut and bent into a variety of shapes. Thicknesses can vary significantly; ex ...
components has traditionally focused on the macro level (e.g. vehicle, aircraft, and packaging applications), the continuing trend of miniaturization has driven research into micro- forms of stamping. From the early development of micropunching machines in the early to mid-2000s to the creation and testing of a microbending machine at
Northwestern University Northwestern University is a private research university in Evanston, Illinois. Founded in 1851, Northwestern is the oldest chartered university in Illinois and is ranked among the most prestigious academic institutions in the world. Charte ...
in the 2010s, microstamping tools continue to be researched as alternatives to machining and chemical etching. Examples of applications of sheet metal microstamping include electrical connectors, micromeshes, microswitches, microcups for
electron gun An electron gun (also called electron emitter) is an electrical component in some vacuum tubes that produces a narrow, collimated electron beam that has a precise kinetic energy. The largest use is in cathode-ray tubes (CRTs), used in nearly ...
s, wristwatch components, handheld device components, and
medical device A medical device is any device intended to be used for medical purposes. Significant potential for hazards are inherent when using a device for medical purposes and thus medical devices must be proved safe and effective with reasonable assura ...
s. However, key issues such as quality control, high-volume application, and the need for material research into mechanical properties must be addressed before full-scale implementation of the technology is realized.


Industry-specific applications

Metal stamping can be applied to a variety of materials based on their unique metalworking qualities for a number of applications across a wide range of industries. Metal stamping may require the forming and processing of base common metals to rare alloys for their application-specific advantages. Some industries require the electrical or thermal conductivity of beryllium copper in areas such as aerospace, electrical, and the defense industry, or the high strength application of steel and its many alloys for the automotive industry. Industries metal stamping is used for: *
Aerospace Aerospace is a term used to collectively refer to the atmosphere and outer space. Aerospace activity is very diverse, with a multitude of commercial, industrial and military applications. Aerospace engineering consists of aeronautics and astr ...
* Agriculture * Ammunitions * Major appliances * Small appliances * Automotive * Commercial *
Construction Construction is a general term meaning the art and science to form Physical object, objects, systems, or organizations,"Construction" def. 1.a. 1.b. and 1.c. ''Oxford English Dictionary'' Second Edition on CD-ROM (v. 4.0) Oxford University Pr ...
* Electronics * Fire arms * HVAC *
Jewellery Jewellery ( UK) or jewelry (U.S.) consists of decorative items worn for personal adornment, such as brooches, rings, necklaces, earrings, pendants, bracelets, and cufflinks. Jewellery may be attached to the body or the clothes. From a wester ...
* Lawn care and equipment * Lighting * Lock hardware * Marine * Medical * Plumbing * Power storage * Power tools * Small engine


See also

*
Circle grid analysis Circle grid analysis (CGA), also known as circle grid strain analysis, is a method of measuring the strain levels of sheet metal after a part is formed by stamping or drawing. The name itself is a fairly accurate description of the process. Lite ...
*
Forming limit diagram A forming limit diagram, also known as a forming limit curve, is used in sheet metal forming for predicting forming behavior of sheet metal. The diagram attempts to provide a graphical description of material failure tests, such as a punched dome t ...
*
Four-slide A four-slide, also known as a multislide, multi-slide, or four-way, is a metalworking machine tool used in the high-volume manufacture of small stamped components from bar or wire stock. The press is most simply described as a horizontal stampin ...
machine, a combination stamping, bending, and punching machine *
Progressive stamping Progressive Die is a metalworking method that can encompass punching, coining, bending and several other ways of modifying metal raw material, combined with an automatic feeding system. The feeding system pushes a strip of metal (as it unrolls ...
*
Shearing (manufacturing) Shearing, also known as die cutting, is a process that cuts stock without the formation of chips or the use of burning or melting. Strictly speaking, if the cutting blades are straight the process is called shearing; if the cutting blades are curve ...
*
Punching Punching is a forming process that uses a punch press to force a tool, called a ''punch'', through the workpiece to create a hole via shearing. Punching is applicable to a wide variety of materials that come in sheet form, including sheet meta ...


Footnotes


References

* Don Hixon, 1984, December, "Alternative Lubricant Offers Advantages for Stamping", ''Precision Metal'', page 13 * William C. Jeffery, 1985, November, "Non-Oil Drawing Compounds Make Dollars and Sense", ''Metal Stamping'', pages 16–17 * Phillip Hood, 1986, Spring, "Environmental Compliance - A Lawn and Garden Manufacturers' Approach to Stamping Lubricants and Environmental Change", ''Stamping Quarterly'', Pages 24–25 * ''Pioneer Press'', April 27, 1989, Marilyn Claessens, "At 75, IRMCO still a pioneer - Lubricants go down the drain by design", Evanston, IL, page 33 * Bradley Jeffery, 1991, August, "Environmental Solutions for Metal Stamping", ''MAN'', pages 31–32 * Robin P. Bergstrom, 1991, November, "Stamping Made Clean(er)", ''Production Magazine'', pages 54–55 * 1991, February, "Lubricants and Environment Mix", ''Manufacturing Engineering'', pages 52–59 * Brian S. Cook, 1992, January 6, "Appropriate Technology", ''Industry week'', pages 51–52, 58. * James R. Rozynek, 1995, Winter, "Case Study: Converting to Water-Based Metal Stamping Lubricants", ''Stamping Quarterly'', pages 31–33 * Philip Ward, 1996, July/August, "Water-Based Stamping Lubricant Washes Away Oil-Based Lube Problems", ''Forming & Fabricating'', pages 52–56 * Matt Bailey, UK, 1997, May, "Non-Oil Lubricants Offer Solvent Solution", ''Sheet Metal Industries'', pages 14–15 * Chris Wren, UK, 1999, June, "One Out - Oil Out" ''Sheet Metal Industries'', pages 21–22 * Brad Jeffery, 2003, April, "The Bottom Line - Getting your N-Values Worth", ''Modern Metals'', page 76 * Brad F. Kuvin, 2007, February, "Forming Advanced High Strength Steel Leaves No-Room for Error", ''MetalForming'', pages 32–35 * Brad F. Kuvin, 2007, May, "Dana's Giant Lube Leap of Faith", ''MetalForming'', pages 32–33 * Hyunok Kim PhD, 2008, March "Evaluation of Deep Drawing Performance of Stamping Lubricants with Dual Phase (DP) 590 GA", Part II in III part series, ''The Center for Precision forming (CPF), The Ohio State University'', pages 1–5 * Brad F Kuvin, January, 2009, "Deep-Draw Automation returns remarkable results", ''MetalForming'', pages 14–15 {{Metalworking navbox, formopen Metal forming Simulation software