Full analysis of brass stamping industry knowledge

With its excellent ductility, corrosion resistance, electrical and thermal conductivity, and smooth and beautiful metal texture, brass alloy is one of the core raw materials in the fields of hardware precision stamping, electrical accessories, machinery manufacturing, and decorative components. It is suitable for the molding and processing needs of various precision structural parts and electrical functional parts. In the production process of brass stamping processing, the scientific selection of plate thickness is the core pre-process that determines the quality of the finished product, structural stability, processing yield and production cost. The stamping process, molding difficulty and application scenarios of brass plates with different thickness specifications vary greatly. The thickness range of conventional brass stamping sheets in the industry is concentrated between 0.2mm and 6mm. The actual selection cannot be determined based on experience alone. It needs to be comprehensively weighed based on the brass grade characteristics, stamping forming process, mold parameters and terminal working conditions. A reasonable thickness ratio can avoid common process defects such as cracks, wrinkles, deformation, and dimensional deviations from the source, ensuring that the overall performance of stamping parts meets standards. In the field of electrical accessories, Electric Brass Stamping Part for Wall Switch Socket, a special brass stamping part for wall sockets, has strict requirements on plate thickness accuracy and selection suitability. It is a typical category for thin and medium-thick material stamping process applications.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Brass is a binary alloy composed of copper and zinc. Its processing performance, mechanical properties and corrosion resistance are closely related to the zinc content in the alloy and the heat treatment state of the material. There are obvious differences in hardness, elongation and work hardening index of different grades of brass, so the specific grade must be analyzed when selecting thickness. Commonly used stamping brass grades include H62 (copper content is about 62%, zinc content is about 38%), H65 (copper content is about 65%), H68 (copper content is about 68%), and lead-containing free-cutting brass HPb59-1, etc. Among them, H68 brass has excellent cold working plasticity and an elongation rate of more than 40%. It is the preferred material for deep drawing forming and complex bent parts. It is suitable for structural parts that require multiple deformations in Plug Socket Brass Stamping. The strength of H62 brass is slightly higher than that of H68 but its plasticity is slightly lower. It is suitable for stamping parts that have certain requirements for structural strength but less complicated deformation, such as fixed brackets in switch bases. In terms of material state, soft state (that is, annealed state, code-named O state or M state) brass is usually used for stamping processing.

 

At this time, the material has been fully recrystallized and annealed, and the grain structure is uniform and fine, with low yield strength and high elongation. It has sufficient plastic reserves to cope with complex stamping deformation. For the stamping of thin materials with a thickness less than 0.5mm, the uniformity of the material state is particularly important - any local hardness differences may cause uneven rebound or distortion of the stamped parts at the bending corners. For parts such as Brass Stamping Switch Terminal Accessories that require both conductivity and elasticity, semi-hard brass is sometimes used, and the work hardening of the material is used after stamping to obtain the required contact pressure and stress relaxation resistance.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Different stamping processes have different requirements for the thickness adaptability of brass materials. Reasonable matching of process and thickness is the prerequisite for ensuring stamping quality and production efficiency. For processes based on blanking (blanking, punching), the thickness of brass mainly affects the selection of the blanking gap and the wear rate of the mold edge. The greater the thickness, the greater the punching force required, and the unilateral gap between the convex and concave dies also needs to be increased accordingly (usually 5%-8% of the material thickness) to reduce friction and lateral extrusion force during the punching process. For terminal parts in Electrical Metal Brass Stamping Parts, the thickness is usually between 0.3- 0.8 mm, and the punching gap control accuracy is required to be high, because any gap deviation will produce burrs on the punching section, which will affect the plug-in and pull-out fit of the terminal. For processes mainly based on bending and forming, the springback angle of brass increases as the thickness increases. This is because the material other than the neutral layer of the thick plate produces greater elastic recovery strain during the bending process. Therefore, when bending a brass plate with a thickness of more than 2mm at 90°, the bending angle of the mold needs to be set with a bending compensation of 1.5-3°, and the bending radius should not be less than 1.5-2 times the material thickness to prevent micro-cracks from appearing on the outside of the bend.

 

For processes mainly based on drawing (deep drawing), thickness selection is directly related to the flow behavior and defect tendency of the material. When thin materials (< 0.8 mm) are stretched, the flange area is prone to instability and wrinkling under the action of tangential compressive stress, which requires sufficient blank holder force to suppress. However, if the blank holder force is too large, it can easily cause side wall cracks. When thick materials are stretched, the material flow resistance is large, and the mold fillet radius and lubrication conditions are required to be high. For the shell parts in Electric Brass Stamping Part for Wall Switch Socket, the thickness is usually designed to be 0.5- 1.0 mm, taking into account the feasibility of stretch forming while ensuring sufficient strength. In addition, for composite processes that include punching, bending and shallow drawing on the same part, the thickness selection should be based on the intersection of the thickness requirements of each process. If necessary, when the thickness cannot be compromised, the process conflict can be resolved by increasing the number of process passes or intermediate annealing.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The thickness selection of brass stamping parts should be determined based on the stress conditions of the parts in actual use, environmental conditions and the assembly relationship with other parts. In the field of electrical connections, the thickness of the contact terminals or sockets in Electrical Contact Assemblies Brass Stamped Parts directly affects the contact positive pressure and current carrying capacity. For plug sleeves in standard household wall switch sockets, the thickness is usually 0.4- 0.6 mm, which not only ensures sufficient clamping force to maintain stable contact resistance, but also does not cause the plug-in and pull-out force to exceed the standard range due to excessive thickness (IEC 60884 requires that the maximum plug-in and pull-out force does not exceed 50N). For industrial connectors or high-current terminals, the thickness range is generally between 0.8 and 1.5 mm, and tin plating or silver plating may be required to reduce contact resistance and prevent oxidation of the copper matrix. For support parts that bear mechanical loads, such as the moving contact bracket inside the switch or the connecting rod in the conversion mechanism, the thickness selection needs to be based on the expected number of operating forces and fatigue life. Brass will work harden and gradually lose elasticity under repeated bending loads.

 

Therefore, for Stamping Riveting Electrical Brass Press Parts that require frequent movements, it is recommended that the upper limit of the thickness be adopted (1.0- 1.5 mm), and sharp corner transitions and sharp cross-sectional changes be avoided during design to reduce stress concentration. For stamping parts with high decorative or appearance requirements, such as panel trims, signboards, etc., thin materials with a thickness of 0.3- 0.5 mm can be selected to reduce material costs and facilitate subsequent surface treatment (such as polishing, electroplating, wire drawing, etc.). In such applications, uniformity of thickness is more important than absolute value, since thickness fluctuations can appear as color differences in the gloss of the surface after treatment. For brass stamping parts used in humid or corrosive environments, the thickness selection also needs to reserve a corrosion allowance, that is, add 0.1- 0.2 mm to the minimum thickness that meets the mechanical performance requirements to compensate for the uniform corrosion thinning that may occur during long-term use.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Welcome to send your Brass Sheet Metal Stamping Parts drawings or technical requirements to our engineering docking window, and a professional team will provide thickness optimization suggestions and process feasibility assessments. We use deep drawing process experience and mold technology to respond to each of your structural and electrical connection needs.