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What is the Metal Stamping Process?
Metal stamping is a cold-forming process used to shape metal strips or sheets, typically made from materials like cold-rolled steel, stainless steel, aluminum, copper, or brass.… The process takes place on various types of presses, including eccentric presses, hydraulic presses, and press brakes.To manufacture a precisely shaped component, a custom stamping die (or cutting die) must be designed and produced based on the technical drawing and client requirements (including volume and quality expectations). The die is then installed on a press, allowing the production of even complex geometries with tight dimensional tolerances.
Common metal stamping operations include: Cutting, Trimming, Bending, Forming, Punching, Coining, Marking
Each metalworking facility specializes in specific production techniques, depending on its machine park and expertise.
At DAGA, we focus on eccentric and hydraulic presses with a pressing force of 80-250 tons. We have extensive experience in processing not only standard materials like carbon steel but also coated materials (e.g., galvanized steel, tin-coated copper) and high-grade stainless steels.
Our expertise extends to demanding automotive projects, where we’ve been manufacturing: Copper electrical circuit components for heavy-duty vehicles Oil level indicators stamped from rolled stainless steel wire for passenger cars Read Full Answer
How to Choose the Most Effective Method for Manufacturing Metal Components?
The method used to manufacture a specific component is determined by a process engineer, based on your requirements. … From a technical perspective, a single part can often be produced in several different ways. To select the most optimal method, the manufacturer must understand the total production volume expected over the entire lifespan of the project. The most cost-intensive aspect of production setup is the construction and long-term maintenance of the stamping die.For medium and high-volume production, the most cost-effective solution is typically the use of a progressive die. Thanks to its specialized design, it allows for the execution of multiple operations simultaneously while maintaining tight drawing tolerances. This ensures consistent quality and high efficiency, resulting in the lowest possible unit cost.
For smaller production volumes, DAGA typically recommends alternative methods to progressive die stamping. From an economic standpoint, it may be more advantageous to use one or more single-stage dies, or to combine laser cutting with bending processes (using press brakes or dedicated tooling). Read Full Answer
How to Protect Small Metal Components from Environmental Conditions?
Corrosion protection of stamped metal components is one of the key elements of quality assurance in sheet metal forming – … particularly when working with carbon steel grades (e.g., DC01, DC04, DD11), which are highly susceptible to oxidation. The risk of corrosion is greatest with these materials.Preventive measures start at the steel service center level, where raw material is processed. Coil strips are cut to size and delivered with an oil film coating, which serves as the first layer of protection against rust.
Additionally, as is standard practice at DAGA, finished parts are stored in enclosed warehouses until transferred to the next production stage, minimizing exposure to humidity and temperature fluctuations. If your process requires additional corrosion protection of the finished part (such as galvanic coating, chemical treatment, or painting), DAGA can also arrange these services through trusted external suppliers. Read Full Answer
How to Select the Best Material for Production and Ensure Its Quality During Serial Manufacturing?
The material used in stamping must meet both functional and operational requirements of the final product. Additionally, it must comply with technological constraints to ensure smooth processing… The material used for metal stamping must meet both functional and environmental requirements of the final product, as well as the technological demands related to deformation during forming. To select the most suitable material for stamping from a technological standpoint, we recommend focusing first on its formability indicators – such as tensile strength (Rm) and yield strength (Re).Based on their plasticity and elasticity, stamping materials can be grouped as follows:
- Low-formability materials – high-carbon structural steels
- Medium-formability materials – chrome-nickel steels, heavily cold-worked aluminum
- High-formability materials – low-carbon steels (such as DC01, DC04), brass, aluminum
- Very high-formability materials – copper, titanium alloys
When components must withstand harsh environmental conditions, exposure to acids or alkaline solutions, it is worth considering materials from the broad family of special steels. Stainless and acid-resistant steels are ideal for applications in home appliances, medical instruments, and components used in the food industry.
In addition to proper technical specification, the material’s availability and cost must be considered. Low-volume production based on rare or expensive materials can make it difficult to find reliable suppliers and may negatively affect the project’s return on investment. Read Full Answer