Common Problems in Metal Stamping Process
Jul 25, 2024
product definition
Punching Metal Stamping Copper Contact Parts (Punching Metal Stamping Copper Contact Parts) refer to metal parts obtained by using copper or copper alloy strips as raw materials and forming one or more times on a high-speed punch machine through precision stamping dies. Such parts are widely used in electrical products such as switches, sockets, relays, circuit breakers and connectors, and undertake the key functions of current conduction, signal transmission and mechanical contact. Compared with cast or machined parts, stamped parts have significant advantages of high production efficiency, high material utilization, good dimensional consistency and low cost. Switch Socket Precision Custom Metal Stamping Parts are precision custom metal stamping parts for switch sockets. They are various stamped copper parts used in household wall switches, sockets, industrial plugs and sockets and converters, including terminal blocks, contact pieces, elastic clips and grounding pieces.
Electrical Contact Metal Copper Stamping Parts are metal copper stamping parts for electrical contacts, emphasizing the contact function of the parts in the electrical circuit. It is usually necessary to compound or electroplating precious metals such as silver and gold on the stamped copper matrix to form a low and stable contact resistance. OEM Precision Copper Sheet Metal Stamping, that is, OEM precision copper sheet metal stamping, highlights the customized attributes of copper stamping parts - different customers' switch and socket products have different structure, size and performance requirements, which require targeted mold design and process optimization to meet specific needs. Copper Alloys Metal Stamping is copper alloy metal stamping, covering stamping processing using copper alloy materials such as brass, phosphor bronze, beryllium copper and chromium zirconium copper.
Different copper alloys have different conductivity, elastic modulus and stress relaxation resistance, and are suitable for different application scenarios - phosphor bronze is often used in switch contact springs because of its excellent elasticity, and brass is often used in terminal blocks because of its good cutting performance. Copper Stamping Contact For Electrical Switch refers to copper stamping contacts for electrical switches, especially the moving and static contact parts in wall switches, micro switches, travel switches and push button switches. This type of parts has high requirements on the material's conductive properties, arc erosion resistance and dimensional accuracy.
Material advantages
The materials selected for stamped metal stamped copper contact parts are mainly copper and copper alloys. Commonly used grades include brass (H62, H65), phosphor bronze (QSn6.5-0.1, QSn8-0.3), red copper (T2, C11000) and high-performance copper alloys (beryllium copper C17200, chromium zirconium copper C18150). The choice of different materials depends on the functional requirements of the parts - brass has good electrical conductivity (about 30-40% IACS) and good cutting performance, and the cost is relatively low. It is suitable for terminal blocks, brackets and shell parts that do not require high electrical conductivity. For terminal blocks in Switch Socket Precision Custom Metal Stamping Parts, H62 brass is the mainstream choice, with a copper content of about 62% and a zinc content of about 38%, and has good stamping formability. Phosphor bronze (also known as tin bronze) has high elastic limit and fatigue resistance, and is the first choice material for manufacturing elastic contact parts (such as switch springs, plug clamping claws, and relay moving reeds). For the moving contact shrapnel in Copper Stamping Contact For Electrical Switch, QSn6.5-0.1 phosphor bronze is usually used, with a tin content of about 6.5% and a phosphorus content of about 0.1%.
It maintains good conductivity (about 15-20% IACS) while having excellent elastic recovery capabilities. Copper has high electrical conductivity (up to 100% IACS or above) and is an ideal material for switches, sockets and terminals that carry large currents. For the high-current terminals in Electrical Contact Copper Metal Stamping Terminal, T2 copper is usually used, with a copper content of not less than 99.9% and excellent electrical conductivity. High-performance copper alloys are used in applications that require higher strength or greater heat resistance. For the high-demand elastic components in Custom Metal Brackets Spring, beryllium copper (C17200) is the top choice. After age hardening, its tensile strength can reach 1200-1500MPa, and it has excellent stress relaxation resistance. It is suitable for occasions where elasticity needs to be maintained at high temperatures for a long time. However, it should be noted that special safety protection measures need to be taken during the processing of beryllium copper (beryllium and its compounds are toxic). For high-strength brackets in Metal Copper Stamping Bracket Parts, chromium zirconium copper (C18150) is a good choice. While maintaining high conductivity (about 80% IACS), it has excellent resistance to high-temperature softening and can maintain high hardness and strength above 400°C.
Application industry
The application industries of stamped metal stamped copper contact parts cover a wide range of fields such as household appliances, consumer electronics, automotive electrical, industrial control and communication equipment. In the home appliance industry, Switch Socket Precision Custom Metal Stamping Parts are the core internal components of wall switches, sockets, strips and converters. Each switch or outlet usually contains multiple stamped copper parts inside - the terminal block is used to connect the power cord, the contact blade is used to make the electrical connection to the plug pin, and the elastic clip is used to secure the plug pin. The annual output of household appliances is huge, and the corresponding demand for stamped copper parts is also extremely considerable.
In the consumer electronics industry, Electrical Contact Metal Copper Stamping Parts are used in mobile phone chargers, power adapters, laptop power interfaces and smart speaker power switches. Consumer electronics products have high requirements on the dimensional accuracy and surface quality of parts. At the same time, due to the rapid replacement of products, they also have high requirements on the rapid response capabilities of OEM suppliers. In the automotive electrical field, Copper Stamping Contact For Electrical Switch is used in automotive interior parts such as window switches, seat adjustment switches, light switches and horn switches. Automotive switches have strict requirements on the resistance to fretting corrosion and long-term reliability of the contacts. They usually require composite silver contacts on copper stamping parts or full silver plating. For Electrical Contact Copper Metal Stamping Terminal, it is widely used in automobile fuse boxes, relay boxes and wire harness connectors. The terminals are required to have good vibration resistance and plugging and unplugging life.
In the field of industrial control, Metal Copper Stamping Bracket Parts are used in contactors, circuit breakers, thermal relays and control buttons. Industrial control equipment usually works in relatively harsh environments (such as high temperature, dust, vibration), so it has high requirements on the material selection, coating type and mechanical strength of copper stamping parts. For the elastic elements in Custom Metal Brackets Spring, they are usually made of phosphor bronze or beryllium copper to ensure stable contact pressure after millions of operations. In the field of communication equipment, the stamped parts provided by China Copper Metal Stamping Manufacturer are used in base station power interfaces, antenna connectors, optical module housings and copper bus connectors in data center power distribution units. Communication equipment has extremely high requirements for signal integrity, so the contact resistance of copper stamping parts needs to be controlled at an extremely low level, which is usually achieved by gold or silver plating.
FAQ
Q: How to choose stamping material - brass, phosphor bronze or copper?
A: Select based on the function of the parts: brass is used for non-elastic parts such as terminals and brackets (high cost performance); phosphor bronze (good elasticity) is used for elastic parts such as switch shrapnel and clamping claws; red copper is used for terminals carrying large currents (high conductivity). If you need to maintain elasticity at higher temperatures, beryllium copper or chromium zirconium copper can be used.
Q: How to control burrs on stamping parts? What is the standard?
A: Burr is determined by the blanking gap, the sharpness of the mold edge and the stamping speed. Reasonable blanking clearance (3%-7% of material thickness) and regularly sharpened molds can control burrs within 3% of material thickness. For most electrical applications, burr height < 0.05 mm is acceptable; for contact surfaces, < 0.03 mm is required.
Q: What is in-mold riveting? What are the advantages compared to subsequent riveting processes?
A: In-mold riveting is a process in which the silver contacts are directly riveted onto the copper substrate through the riveting station in the mold during the progressive stamping process. Its advantages are: high contact positioning accuracy (one-time positioning, no need for secondary clamping); high production efficiency (completed simultaneously with stamping); stable riveting quality.
Q: What is the general coating thickness of stamped copper contact parts? How to detect?
A: Silver plating is usually 2-8 microns (switch contacts are recommended to be ≥5 microns; terminals can be 2-3 microns); tin plating is 3-10 microns; gold plating is 0.1-1 micron (for connectors). Detection method: X-ray fluorescence spectrometry (XRF) is the first choice for non-destructive testing and can quickly measure coating thickness and composition.
conclusion
We provide Punching Metal Stamping Copper Contact Parts services from material selection, progressive die design and manufacturing, high-speed precision stamping, in-mold riveting/spot welding to silver plating/tin plating surface treatment. The engineering team can quickly complete the solution design according to your conductive requirements, elastic parameters and assembly process. Welcome to submit drawings or samples for process evaluation and sample docking.
