Stamping Technology

Introduce

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Stamping is a forming and processing method that relies on a press and mold to apply external forces to plates, strips, pipes, and profiles, causing plastic deformation or separation, in order to obtain the required shape and size of workpieces (stamped parts). Stamping and forging belong to plastic processing (also known as pressure processing), collectively known as forging. The stamping blanks are mainly hot-rolled and cold-rolled steel plates and strips. 60% to 70% of the world's steel is made of sheet metal, most of which is stamped into finished products. The body, chassis, fuel tank, radiator, boiler drum, container shell, iron core silicon steel sheets of motors, and electrical appliances of automobiles are all stamped and processed. There are also a large number of stamping parts in products such as instruments, household appliances, bicycles, office machinery, and household utensils.

characteristic

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Compared with castings and forgings, stamped parts have the characteristics of being thin, uniform, light, and strong. Stamping can produce workpieces with reinforcing ribs, ribs, undulations, or flanges that are difficult to manufacture by other methods to improve their rigidity. Due to the use of precision molds, the workpiece accuracy can reach the micrometer level, with high repeatability and consistent specifications, and can be punched out with holes, protrusions, etc. Cold-stamped parts generally do not undergo cutting or require only a small amount of cutting. The precision and Surface states of hot stamping parts are lower than those of cold stamping parts, but they are still better than castings and forgings, with less machining.

Stamping is an efficient production method that uses composite molds, especially multi-station progressive molds, to complete multiple stamping processes on a single or multi-station press, achieving fully automatic production from strip uncoiling, leveling, and punching to forming and finishing. High production efficiency, good labor conditions, low production costs, typically producing hundreds of pieces per minute. Compared with other methods of mechanical processing and plastic processing, stamping processing has many unique advantages in both technical and economic aspects. The main manifestations are as follows.

• The production efficiency of stamping processing is high, and the operation is convenient, making it easy to achieve mechanization and automation. This is because stamping relies on dies and stamping equipment to complete the processing. The number of strokes of a regular press can reach tens of times per minute, and high-speed pressure can reach hundreds or even thousands of times per minute. Moreover, each stamping stroke may result in a stamping part.
• During stamping, because the die ensures the size and shape accuracy of the stamping part and generally does not damage the surface quality of the stamping part, and the life of the die is generally long, the stamping quality is stable, the interchangeability is good, and the stamping is "exactly the same".
• Stamping can process parts with a wide range of dimensions and complex shapes, such as the second hand of a clock, the longitudinal beam of a car, and covers. Coupled with the cold deformation hardening effect of the material during stamping, the strength and stiffness of stamping are both high.
• Stamping generally does not generate chips or debris, resulting in less material consumption and no need for other heating equipment. Therefore, it is a material-saving and energy-saving processing method, and the cost of stamping parts is relatively low.

Process classification

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Stamping is mainly classified by process and can be divided into two categories: separation process and forming process. The separation process, also known as punching, aims to separate the stamped part from the sheet metal along a certain contour line while ensuring the quality requirements of the separated section. The purpose of the forming process is to cause plastic deformation of the sheet metal without breaking the billet and to produce the required shape and size of the workpiece. In actual production, it is often a combination of multiple processes applied to a workpiece. Punching, bending, shearing, deep drawing, bulging, spinning, and straightening are several main stamping processes.

forming process

• Bending: A plastic forming method of bending metal plates, pipe fittings, and profiles into a certain angle, curvature, and shape. Bending is one of the main processes widely used in the production of stamping parts. The bending of metal materials is essentially an elastic-plastic deformation process. After unloading, the workpiece will undergo directional elastic recovery deformation, known as rebound. Rebound affects the accuracy of the workpiece and is a technical key that must be considered in the bending process. 
• Stretching is the process of applying tension to the sheet metal through a stretching die, resulting in uneven tensile stress and strain. As a result, the bonding surface between the sheet metal and the stretching die gradually expands until it fully adheres to the stretching model surface. The main application object of stretching is to manufacture hyperbolic skin with certain plasticity, large surface area, gentle and smooth curvature changes, and high-quality requirements (accurate appearance, smooth streamline, and stable quality). Due to the relatively simple process equipment and equipment used for stretching, the cost is low and the flexibility is high, But material utilization and productivity are relatively low.
• Spinning is a metal rotary machining process. During the machining process, the blank actively rotates with the spinning die or the spinning head actively rotates around the blank and the spinning die. The spinning head moves in feed relative to the core mold and blank, causing continuous local deformation of the blank and obtaining the required hollow rotating parts.
• Shaping is the secondary modification of the product's appearance using a predetermined grinding tool shape. Mainly reflected in the pressure plane, spring feet, etc. When some materials have elasticity and cannot guarantee the quality of one-time molding, re-processing is used.
• Bulging is a processing method that uses a mold to thin the sheet metal and increase the local surface area to obtain parts. Commonly used methods include undulating forming, bulging of cylindrical (or tubular) blanks, and stretching forming of flat blanks. Bulging can be achieved using different methods, such as rigid die bulging, rubber bulging, and hydraulic bulging.
• Flanging is a plastic processing method that bends the edge of a thin plate blank or the narrow band area of the preformed hole edge on the blank into a vertical edge along a curve or straight line. Flanging is mainly used for strengthening the edges of parts, removing cut edges, and making parts that are assembled and connected with other parts or three-dimensional parts with complex and unique shapes and reasonable space on the parts while improving the stiffness of the parts. It can also be used as a means to control cracking or wrinkling during large-scale sheet metal forming. So it has been widely used in industries such as automobiles, aviation, aerospace, electronics, and household appliances.
• Shrinkage is a stamping method that reduces the diameter of the open end of a stretched flangeless hollow part or tube blank. The diameter change at the end of the workpiece before and after necking should not be too large, otherwise, the end material will wrinkle due to severe compression deformation. Therefore, shrinking the neck from a larger diameter to a very small diameter often requires multiple necking operations.

Application Fields

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• Automotive Industry: Stamping parts are extensively used in the automotive industry to produce components such as body panels, chassis parts, brackets, hinges, and engine components.
• Electronics and Electrical Appliances: Stamping parts are crucial in manufacturing electrical contacts, connectors, switches, and components for consumer electronics like smartphones, computers, and household appliances.
• Aerospace and Aviation: The aerospace industry relies on stamping parts for producing aircraft structural components, interior fittings, and various aircraft hardware.
• Home and Office Furniture: Stamping parts are used to manufacture furniture fittings, brackets, hinges, and decorative components for both residential and commercial settings.
• Construction and Architecture: Stamping parts play a role in producing building components, such as metal roofing, wall panels, and structural elements for construction and architecture projects.
• Industrial Equipment: Many industrial machines and equipment utilize stamping parts for gears, shafts, brackets, and various mechanical components.
• Renewable Energy Systems: Stamping parts are used in the production of components for renewable energy systems, including solar panels, wind turbine structures, and energy storage systems.
• Medical Devices: Stamping parts are employed in medical equipment and devices, such as surgical instruments, implantable components, and diagnostic equipment.
• Telecommunications: Stamping parts are essential in manufacturing telecommunications equipment, including antennas, enclosures, and connectors.
• Appliances and HVAC Systems: Stamping parts are found in various household appliances and heating, ventilation, and air conditioning (HVAC) systems, including refrigerators, air conditioners, and furnaces.
• Lighting Fixtures: Stamping parts are used in the production of lighting fixtures and fittings, including lamp holders, brackets, and decorative elements.

Our company is focused on top quality Copper End Cap, Fuse Terminal Contacts, (ELECTRICAL VEHICLE) EV Film Capacitor BusBar, (SOLAR POWER) PV Inverter BusBar, Laminated BusBar, Aluminum Cases for new energy batteries, Copper/Brass/Aluminum/Stainless Steel Stamping Parts, and other electrical products Metal Stamping and Welding Assembly for over 18 years in China. We started as a small operation, but now have become one of the leading suppliers in the EV and PV industry in China.

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