Stamping (metalworking)

Forming metal sheets with a stamping press

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Stamping is a manufacturing process involving the transformation of flat metal sheets, either in blank or coil form, into desired shapes using a stamping press with specially-designed tools and dies. This process comprehensively covers sheet-metal forming techniques such as blanking, punching, flanging, bending, embossing, and coining. Essentially, stamping can be a one-time operation where a single stroke leads to the desired metal shape, or it may necessitate multiple stages, depending on the complexity of the component being produced.

Commonly performed on cold sheet metal, while occasionally extending to other materials like polystyrene, stamping generally employs progressive dies that are fed from coils of steel. The coil is unwound, straightened, and then forwarded into the feeder that guides it into the press and die at a predetermined increment. The precise number of stations in a die correlates with the complexity of the part designed.

History

The origins of stamping can be traced back to the Lydians in modern-day Turkey around the seventh century B.C., where the world first witnessed coin-based currency formed through striking. Relying on hammering for conventional coin-making persisted for centuries until novel methods surfaced in the early 19th century with innovations in mass production. Stamping became a game-changer for the bicycle and automotive industries, offering significant production efficiencies and cost reductions.

Operation

• Bending - material is formed along a straight axis.
• Flanging - bending material around a curved shape.
• Embossing - imparting a raised design by forming material against a die.
• Blanking - removing a piece from a larger sheet to create a blank.
• Coining - imprinting patterns into the material.
• Stretching - expanding the area of a blank while keeping its edge fixed.
• Ironing - reducing thickness of metal along a vertical edge.
• Curling - forming material into tubular shapes.
• Hemming - folding an edge over itself for added thickness.

Lubricant

Friction arising from the stamping processes necessitates lubricant usage to avert damage to tooling and finished pieces. These lubricants enhance metal flow and minimize damage during stamping, with options ranging from traditional oils to modern polymer-based synthetic lubricants.

Simulation

Sheet metal forming simulation technology computes the stamping processes, predicting common issues like splits and wrinkles. This simulation is invaluable for designers assessing the feasibility of part manufacturing without incurring the costs of physical tooling, thus enabling cost-effective and timely evaluations.

Microstamping

The rise of microstamping techniques complements the traditional stamping approaches by focusing on minuscule components for sectors like healthcare and electronics, emphasizing the importance of precision in shaping metal parts on a microscopic scale.

Industry-specific applications

Metal stamping finds its ethos across many industries, including automotive, aerospace, and electronics. Each sector benefits from the capability to manipulate various metals and alloys engineered for specific performance characteristics, making stamping a crucial component in modern manufacturing processes.

See also

References

• Don Hixon, 1997, "Alternative Lubricant Offers Advantages for Stamping", Precision Metal, page 13
• William C. Jeffery, 2010, "Non-Oil Drawing Compounds Make Dollars and Sense", Metal Stamping, pages 16-17
• Phillip Hood, 2011, "Environmental Compliance - A Lawn and Garden Manufacturers’ Approach to Stamping Lubricants and Environmental Change", Stamping Quarterly, Pages 24-25
• Marilyn Claessens, 2012, "At 75, IRMCO still a pioneer - Lubricants go down the drain by design", Pioneer Press, page 33
• Bradley Jeffery, 2013, "Environmental Solutions for Metal Stamping", MAN, pages 31-32

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