What Is The Metal Stamping - Advantages and ...

Metal stamping is a manufacturing process that uses a metal stamping die or a series of metal stamping dies to form a metal sheet into a three-dimensional workpiece. So under what circumstance, we should select the metal stamping, what are the advantages and disadvantages?

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What Are the Advantages of Stamping?

1. One of the advantages of the stamping process is that the cost of using dies is low and the automation level is high.

The production and maintenance costs of metal stamping dies are often relatively lower than those used in other common processes. Secondary costs, such as cleaning and electroplating, are also cheaper than similar treatments in other metal manufacturing processes.

2. The dimensional accuracy of stamping parts is good.

The dimensional accuracy of stamping parts is guaranteed by the die, which has identical features. And the service life of the mold is generally long. Therefore, the stamping quality is stable and the interchangeability is good.

3. Stamping can process parts with large size range and complex shape.

Because of the mold processing, parts with thin wall, light weight, good rigidity, high surface quality and complex shape that are difficult to manufacture by other processing methods can be obtained.

4. The cost of stamping parts is low.

Stamping generally does not need to heat the blank, nor does it cut a lot of metal like cutting. Therefore, its material consumption is less, which not only saves energy, but also saves metal.

5. High stamping efficiency.

For ordinary presses, dozens of pieces can be produced per minute, while high-speed presses can produce hundreds of or thousands of pieces per minute, and each stamping stroke may result in one stamping part. Therefore, it is an efficient processing method. The stamping machine is relatively easy to be automated, and can use high-end computer control programs to provide higher precision, faster production and faster turnaround time. The improvement of automation level also reduces the labor cost.

What Are the Disadvantages of Stamping?

1. One of the disadvantages of stamping is that the cost of production die is high.

The dies used in stamping process are generally special, and most stamping products are completed by multiple different stamping processes. The die needs to be newly built, and the production of customized metal stamping die is a long pre production process. Mold manufacturing requires high precision. And the mold manufacturing needs long manufacturing cycle, large investment, many unpredictable problems, and high requirements for mold technicians&#; experience. It is a technology intensive product. If the design must be changed in the production process, then the mold is also difficult to change.

2. Unfriendly to single piece and small batch production

As the stamping process must have the corresponding mold, it is most suitable for large batch production. There are certain restrictions on single piece and small batch production. Only when the production batch is large, the stamping processing method will be considered. The advantages of stamping can be fully reflected, so as to obtain better economic benefits.

3. The design of stamping die focuses on classical theory and experience, requires strong imagination and creativity, and has high requirements for die designers and manufacturers.

4. Large noise and vibration during production.

5.If the precision requirements of parts are too high, stamping production is difficult to meet the requirements.

6. Material bottleneck

It is a direction of international efforts to develop and research the cold forming of high-strength steel. At present, the research on hot forming process and equipment technology has been relatively mature internationally, but the cold forming field still needs to continue to develop.

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High strength steel and ultra-high strength steel have well realized the lightweight of vehicle body and improved the crash strength and safety performance of vehicles, so they have become an important development direction of vehicle steel. However, with the improvement of the strength of the sheet metal, the traditional cold stamping process is prone to crack during the forming process, which is difficult to meet the processing requirements of high-strength steel plates.

KENENG can provide you with metal stamping, CNC machining processing and other molding services, whether small or large batches or mold production can meet your needs. If you need, please contact us.

Related Products

It may be the default metal forming method for many manufacturers, but the disadvantages of die stamping are worth considering. As manufacturers search for ways to bring new products to market as quickly as possible, it's easy to lose sight of the importance of quality, accuracy, and repeatability. In this article, we'll touch on a few of the most significant disadvantages of die stamping.

Disadvantages of die stamping

• Poor accuracy and repeatability.
• High tooling costs.
• Cannot accommodate rapid prototyping.
• Not suitable for small or mid-size production runs.
• Not an iterative process.
• High scrap rates.
• High post-fixturing costs.

#1: Poor accuracy and repeatability

Although progressive die stamping can yield accurate parts with complex shapes, material thinning is highly likely and part repeatability is poor. It also requires incredibly expensive permanent, progressive steel tooling.

Advantage of FluidForming

Thanks to incredibly high forming pressures, FluidForming is a Six Sigma metal forming process that uses a single die to produce components with minimal warping, unparalleled accuracy, and high repeatability rates.

#2: High tooling costs

Die stamping requires significant upfront, hard tool and die costs. Not to mention ongoing tool maintenance. Because both a punch and a die are required, tooling costs are significant with die stamping. If tooling changes are required or tools are damaged, additional costs are inevitable. Where possible, designs should be based on the use of existing dies for standard shapes and bends. The need to create a custom die for stamping will further increase initial tooling costs (Thomas).

Advantage of FluidForming

Because just one tool is needed from prototype through production, tooling costs are reduced by 50-90%. And, with 3D printed tooling, it's easy to make changes to your product design without incurring significant delays or prohibitive expenses. Furthermore, because water is the forming force, tool wear is also minimized.

#3: Cannot accommodate rapid prototyping

Outdated metal stamping methods &#; like die stamping &#; require costly and time-consuming tool development. Because of this, rapid prototyping is prohibitively expensive and ineffective with die stamping.

Advantage of FluidForming

All of FluidForming Americas' FormBalancer metal forming machines are compatible with 3D printed, metal sintered, steel, aluminum, and composite tools. In other words, it's possible to move from design to production in a matter of days.

#4: Not suitable for small or mid-sized production runs

For the same reasons die stamping isn't suitable for rapid prototyping, it just doesn't cut it for low-volume, or short-run productions, either. It's simply too expensive and tooling development and set-up take too much time.

Advantage of FluidForming

FluidForming is ideal for low- to medium- volume production runs. Our process can easily accommodate anywhere from 1 to a million parts per year. Because just one tool is needed, tooling costs are slashed. And as an added benefit, FluidForming uses the same tool from prototyping through production &#; which saves time and money.

#5: Not an iterative process

Product developers and product innovators are hampered by the inherent restraints that die stamping metal forming process imposes. Because tool development is so time-consuming and costly, product designers cannot innovate and iterate products as freely as they should.

Advantage of FluidForming

Not only do 3D printed tools save time, but they're dramatically less expensive. Plus, FluidForming Americas offers customers detailed pre-production Finite Element Analysis (FEA) reports which means we're iterating before production even begins.

#6: High Scrap Metal Rates

Although die stamping produces less scrap than machining, for example, scrap rates and non-conforming rates are high with die stamping.

Advantage of FluidForming

More and more manufacturers are focusing on reducing scrap because it's better for the environment, lowers production costs, and because it can result in faster turnaround times. FluidForming's 99.996% accuracy rate virtually eliminates non-conforming scrap and our nested tooling capabilities make the most of every inch of sheet metal.  

#7: High Post-Fixturing Costs

Die stamping is a primitive stamping process that relies on brute force to deform metal into a predetermined shape. The process requires substantial post fixturing work like deburring, clamping, painting, and polishing. All of which adds time and cost to the process.

Advantage of FluidForming

&#;Because the forming force &#; water &#; comes in contact with just one side of the material, post-fixturing costs are all but eliminated. The process is compatible with pre-finished, textured, painted, or polished materials.

Are you designing for tomorrow with yesterday&#;s metal forming technologies? Find out how our 21st Century technology can revolutionize the way your product design teams dream, innovate, and produce. Contact FluidForming Americas today at (800) 497- or us at . Let&#;s start designing for tomorrow with today&#;s technologies.

FluidForming Americas, Inc. is a member of the Precision Metal Forming Association and is AS Rev D, ISO : certified.

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