All About Metal Pressing

Metal Pressings

What is metal pressing?

Metal pressing, also known as metal stamping, is a low-cost, high-speed manufacturing process that helps to convert flat metal sheets into different shapes. This complex process includes techniques like punching, bending, blanking, embossing, piercing, and notching, to name a few.

What are the types of stamping press?

Stamping presses are connected to an automatic feeder that directs the metal sheets to either the coil or the blank form through the press. The most common types of stamping presses are:

  • Mechanical

Mechanical presses run on a motor that is linked to a mechanical flywheel, allowing for easy transfer and storage of energy. Depending on the press, the punch can range from 5mm to 500mm. The mechanical pressing speed varies from 20 to 1500 strokes per minute. These presses are considered to be faster than the hydraulic ones. Also, their size ranges from 20 to 6000 tons.

  • Hydraulic

Hydraulic presses apply force to the material by utilising pressurised hydraulic fluid. The fluid is displaced by the hydraulic pistons at a force that is proportionate to the piston head’s diameter. Such presses give better control over pressure as compared to mechanical presses and provide added flexibility due to the adjustable stroke length. They allow to create complex and deep stampings and are ideal for small production runs.

  • Mechanical Servo

A mechanical servo press makes use of a high-capacity servomotor to apply power as needed throughout the stamping operation. These presses are ideal for creating complex stampings quicker than the hydraulic presses.

What are the types of stamping operations?

Progressive Die Stamping

Progressive die stamping features a sequence of stamping stations, each having a different function to perform. First, a metal coil is fed through progressive stamping dies into a reciprocating stamping press. When the press moves down, the die moves with it and closes to stamp the metal. Whereas, when the press moves up, the metal moves horizontally to the next station. Every step in this process helps the metal achieve a unique cut, bend, or punch, making it easy to get the desired result.   

Four-Slide Stamping

Four-slide stamping, also known as multi-side stamping, makes use of four sliding tools to shape the workpiece. This process involves no dies and relies on four different tools to attain various bends simultaneously. Four-slide metal stamping is considered to be a versatile type as it allows you to attach a different tool to each slide. Moreover, it gives you more flexibility to make changes in the design.

Metal Pressings

Transfer Die Stamping

This type is similar to progressive die stamping. However, it involves the separation of the metal trip early, so it can get transferred from one station to the other by another mechanical transport system.

Various metal stamping design processes?

Metal pressing or metal stamping includes many metal forming processes and not all processes are necessary or required. It is best to understand these processes as much as possible, so you can use the ones that best suit your project. Picking the right processes can help save on cost and time.

Some of the stamping design processes are as follows.

Blanking – This forms the first step of the stamping process that involves the cutting of a rough outline of the product. At this stage, the aim is to reduce burrs to prevent adding another step to the process and increasing the overall time and cost involved.

Corners – This step involves including a radius of at least half the material’s thicknesses to remove sharp edges.

 Burrs – This step reduces the intensity of burrs and sharp edges. It is carried out only if the need be. If your design is such that even dull burrs will create a problem, you need to carry out this procedure.

Piercing – This step helps in creating holes or slots in the parts. When piercing, it is essential for the hole diameter to be at least 1.2 times the thickness of the material. Smaller diameters may require additional stages like punching or drilling. Also, there should be a considerate amount of space between the edge of the hole and the edge of the component to prevent.

Bending – This step usually occurs towards the end of the cycle. To ensure this stage is carried out smoothly, you need to design the part and its blank correctly.

Industries using metal stamping?

Metal stamping is required by manufacturers that use metal components in production. It benefits a range of industries, thanks to its versatility. Some of the industries that require metal stamping are:

  • Power Tools
  • Plumbing
  • Construction
  • HVAC
  • Automotive
  • Medical
  • Marine
  • Aerospace

Industries requiring metal pressed parts in bulk rely on industrial metal stamping machinery the deliver consistent and accurate results at an affordable cost. However, it is important to use the right type of mechanism to produce efficient metal fabrication parts.

Making tools for metal pressing process

The metal pressing process involves blanking, piercing, bending, and lots more, and this calls for the need of different types of press tools. Also, the thickness of every metal is different, and hence, the type of tool required to work on it would be different too. For example, hard and thick metals require shallow pressing tools, whereas thin metal sheets require deep pressing tools.

The metal pressing process involves the use of a number of tools, and these tools need to be designed as per the project’s requirements. This is why there is a need for toolmaking, the process of making tools that can help produce products.

There are many standard tools available in the market that you can use for your project, if suitable. However, unique nature work calls for the need for designing customised tools or modification of the standard tools. It is essential to know that only if you have the right type of tools available to yourself, you will be able to perform the different metal pressing processes perfectly.