Sheet Metal Stamping Fabrication

Sheet Metal Stamping Fabrication refers to the bending and shaping processes of Sheet Metal Stamping techniques. Sheet Metal Stampings can be given all sorts of complex hollow shapes and sections, and the equipment used for these processes, range from simple hand tools, to sophisticated power-operated automatic machinery.

Sheet Metal Stamping work usually starts with a preliminary operation such as cutting, perforating or slitting etc. with tools that exercise some type of shearing action. These may be simple hand scissor like cutting tools, or power operated bench shears for heavier gauge materials. There are several kinds of power-driven shearing machines, and such machines comprises of a fixed blade and a moveable blade. The process of 'punching' refers to operations carried out with the use of a punching machine (or press) and this means to pierce a hole in the metal article, with the appropriate tool fitted in the machine, and clipping (the removal of surplus metal).

Another type of Sheet Metal Stamping fabrication is shaping. A wide range of shaping operations known as folding or bending, are done on presses and similar machines, as well as operations such as

Grooving

Seaming Stamping

Crimping & Beading

These processes are used for the stiffening and shaping of Sheet Metal Stampings, the forming of tubular sections for circular shapes, and other numerous purposes.

Angles and sections can be formed by bending or folding. Coiling is the process of coiling over the edge of a Sheet Metal Stamping component, to increase the strength and provide a suitable edge, and is applied by a rolling or coiling tool on a press. Circular or cylindrical shapes such as tubes are performed and produced on a roll-forming machine. Press forming operations can include

Cupping

Embossing

Cupping refers to the conversion of a blank into cup form. Embossing refers to a particular design applied for strengthening purposes, and can be produced on a partly finished component. Cupping is usually the first stage in an operation known as forming, in which the appropriate tool is used to give the article its final shape. Seaming is generally used for joining Sheet Metal Stamping parts and is for example, often used for joints in metal roofing. Flanging is the process of forming a flange on a Sheet Metal Stamping component. Beading is the process of making depressions for the purpose of embellishment or stiffening, etc, and it may be done by the use of suitable or specifically shaped rollers. There are many other techniques used in Sheet Metal Stamping fabrication and some of these can include:

Deep Drawing

Marforming

Flow Forming

Spinning

With the advancement of today's technology, many of these techniques are now applied with the use of computer controlled machinery.

Metal fabrication is a process of producing a metal component by modifying a raw piece of material in a machine shop. These materials are processed on different temperatures and depending on the range of temperatures; the process is classified as cold, warm and hot. Precision Sheet Metal Stamping fabrication describes various different processes that form Sheet Metal Stamping into finished products. Objects that are fabricated and used for machinery and other instruments are among the daily used objects like paper clips, computers, bolts, nails, automotive parts and many more.

There are various factors like rate of production, desired geometry, and other physical requirements that influence the fabrication process. The benefits of the metal fabrication process are far and wide because it is used by all industries. Every precision Sheet Metal Stamping fabrication process undergoes three primary processes that include forming, cutting and finishing. Forming is a process that alters the form of the flat metal sheet.

Sheet Metal Stamping Tools

Sheet Metal Stamping is nothing but a metal rotated into a sheet having a thickness between the plate and the foil. It is one of the basic forms utilized in metal working and it can be bent and cut into different shapes. The thickness of this material varies from thin foil to thick plate. They are obtainable as coiled strip or as flat pieces. Coiled strips are nothing but the continuous running of the sheet.

Different metals like brass, titanium, and aluminum, and copper, nickel, tin and steel are converted into sheets of metal. Sometimes, even precious metals like platinum, gold and silver are converted into Sheet Metal Stampings for decorative purposes. Every day different objects like car bodies, wings of airplane, building roofs, medical tables and tools are manufactured with the help of sheets of metal. The tools used for cutting the Sheet Metal Stamping differ according to the purpose for which the sheets of metal is going to be used.

Different tools like metal rollers, tip snips, etc. are being used to cut the Sheet Metal Stamping. The difficulty level in using Sheet Metal Stamping tools can be hard or easy; this depends on the tools being used. For instance, for the process of deep drawing, metal rollers can be used and thick sheets can be bent by using a tool called press-brake.

For the purpose of stamping designs and images in the Sheet Metal Stamping a tool called machine or stamping press is being used. Thus, each tool makes its own effect on the metal. The most important benefit of using these tools is that a tool available for one purpose need not be used for some other purpose. For instance for deep drawing of sheets of metal, the tool called rollers would be the best option, instead if the tool called press-brake is used for this purpose the desired result cannot be attained. So different tools can be used for different purpose, this helps the technician to shape the metal according to his desire.

Sheets of metal tools are used for different purposes like wheeling, deep drawing, ironing, cutting, bending, perforating, stamping, spinning, rolling, press-brake forming, roll forming, etc.

Sheet Metal Stamping tools must be used with utmost care. It is better to use the Sheet Metal Stamping tools only after getting training in using them. If an inexperienced person uses the tools he may get some injuries and it is also safe to keep the sheet tools out of the reach of the children.

Sheet Metal Stamping Tools are very helpful when trying to fix things around the house that involve metal plating, sheeting or otherwise. They might even be useful when fixing your car ports as they sometimes get dents from other vehicles or your own.

Automotive Muffler Parts Production by Metal Stamping

The private car has been a crown jewel of public consumption over the past hundred years since the notorious Henry Ford got wealthy from the Model "T" that gave people freedom of movement. In turn, a metal stamping factory turns the aluminum and steel into the necessary parts for the muffler factory.

In the last half of the 20th century and in the first decade of the 21st century the auto industry grew to be 10% of North America and Europe's GDP, employing around 9 million people directly and five times that total in associated sectors. That means that 5% of the working population are employed by automotive companies and almost everybody is affected by the automobile in one way or another.

One part of a car wears out quickly and needs replacement on a regular basis is the muffler. The one that came with the car is long forgotten, now just part of a garbage mountain of fellow rusty mufflers on the outside of town. The automotive giant doesn't make these directly but contracts from other manufacturers for a supply.

The die that produces a flat piece of metal and cuts the outer contours in one operation is known as a blanking die. In the case of muffler parts, sheet metal would be formed using a die that consists of the punch, which performs the blanking operation while the other part, known as the die block clamps the work piece securely for accuracy. Lubricants are used to reduce friction between the working material and the punch and die. They also aid in removing the part from the punch. Some examples of lubricants used in drawing operations are heavy-duty emulsions, phosphates, white lead, and wax films.

Punches and dies are typically made of tool steel, however carbon steel is cheaper, but not as hard and is therefore used in less severe applications, it is also common to see cemented carbides used where high wear and abrasive resistance is present. Alloy steels are normally used for the ejector system to kick the part out and into durable and heat resistant blank holders. When the parts to be made are of unusually deep dimensions, special dies and casts are used in a procedure known as "deep drawing". An example of this would be the shape of a deep-fryer in a restaurant where stainless steel or aluminum is formed deeper than it is wide to insert the basket of french fries into the oil.

Car mufflers are specially shaped with in inlet and an outlet with perforated tubes inside leading to a measured resonator chamber where sound waves are lined up in order to interfere with or cancel each other out. Without them, car engines would make an unbearable noise - the sound waves would go higher in frequency as the car goes faster. The roads would be chaos, as the engines would sound like thousands of "choppers" - motorcycles with mufflers removed to draw attention to the manliness of the rider through noise pollution.

The metals are formed into the various parts through the process of metal stamping whereby coil, bar, or sheet metal working materials undergo die forming to shape the part. A die is a specialized tool that is used to press the material into the desired shapes.

Air duct made from sheet metal stamping

A sheet metal stamping forming an air duct for use in heating and cooling systems and the like. The stamping has a generally rectangular shaped body portion and a protruding tongue portion extending from at least one side thereof. The stamping is foldable along its end edges and the tongue portion whereby two such stampings may be cooperatively engageable with a pair of side panels to form an air duct section having an inlet, outlet and a diverter or secondary outlet formed by the tongue portions. The tongue portions are adapted for connection to standard conventional take-off fittings.

Sheet metal duct section having an inlet and outlet comprising in combination:a prestamped upper and lower spaced panel interconnected by spaced side panels, at least one side panel being shorter in length than said upper and lower panels and defining an opening through which at least a portion of flow through said inlet isdiverted, said upper and lower panels having end edges and a central body portion extending the length and width of said duct section from said inlet to said outlet and formed tongue portions extending laterally beyond said shortened side, said stampingsbeing folded along their end edges and cooperatively engaged with said side panels to form the air duct section, and said tongue portions cooperatively forming a diverter outlet to divert flow through said inlet from said outlet, said duct having adiminishing cross section from said inlet to said outlet.

The prior art has recognized the advantages of a main conduit or trunk duct having reductions in cross sectional area along its length to provide generally equal air flow at each outlet. Such systems are however, relatively expensive andaccordingly have not found commercial acceptance. Partially prefabricated air duct fittings have been proposed for use in heating and ventilating systems, however, in each case a great number of separate component parts are required including top andbottom panels, take-off sections, side panels and the like. In some of prior art systems the top and bottom panels and the side walls are provided with spaced longitudinally extending marginal tabs and corresponding slots. The tabs, when inserted inthe slots are bent over to secure the plate and wall together in a rigid assembly. Such systems, however, require careful handling since the tabs are easily deformed during such handling. Additionally, if an ar tight seal is required, the tabs and slotmust be sealed with putty, or similar sealing substances.

In another system known in the prior art, prefabricated assembled components of the duct system are provided. Each component is reduced in cross sectional size from the previous adjacent component whereby they may be nested for shipment andstorage. In the above systems, however, separate provision must be made for the connection of take-off ducts and other fittings to registers or wall stacks or the like. In these cases either elaborate tab and slot combinations must be prefabricated orotherwise provided or in the case of the nestable preassembly an opening must be cut in the duct work in each position where it is desired to connect the take-off section.

While the above described systems are known in the art, it yet remains necessary to provide a totally standardized system which is readily assembled, relatively inexpensive and which utilizes standardized parts. The system of the presentinvention is designed for the least restriction of air from the heating or cooling system through the main ducts and into the take-off or leader pipes. A generally standard shaped fitting based on a modular construction concept is provided having astandard length and a variable width based on a preestablished range of sizes. A single fitting which provides top and bottom plates of a duct system is adapted for utilization with side panels and includes at least one outwardly extending tongue memberthereon forming a diverter or take-off section on which any of a large number of standard take-off fittings may be attached. Since the system is based on a standard length for each preformed fitting, layout is considerably simplified, and in fact quickand relatively accurate calculations to determine the total length of the system may readily be made simply by counting as for example, in a residential building, the number of floor joists to lay out the entire system. In the preferred embodiment ofthe invention, each panel section is fabricated from a stamping and has a lip or other fastening means formed at the ends and edges thereof. Each section has a standard length of 16 inches or multiples thereof which correspond to the conventionalspacing between floor joists.

The standardized system of the present invention is applicable to generally all heating installations and specifically adapted for home heating situations. The expense of custom-made installations is reduced. Each section formed in accordancewith the present invention has an inlet side and a diminished outlet side thereby providing, when assembled, a heating system in which the main trunk line is decreased at each take-off junction to thus proportion and reduce the cross sectional area ofthe main trunk line along its length.

Basically, the invention provides a sheet metal duct section having an inlet and an outlet and includes prestamped upper and lower spaced panels interconnected by spaced side panels. At least one side panel is shorter in length than the upperand lower panels thereby defining an opening through which at least a portion of the flow of air through the inlet portion is diverted. The upper and lower panels are prestamped and have a central body portion extending the length and width of the ductfrom the inlet to the outlet and a tongue portion is formed thereon extending laterally beyond the shortened side. The tongue portion is folded for connection to a diverter or take-off duct section. Finally, a secondary side panel joins the tongueportions to form the diverter duct.

The many advantages of the present metal stamping invention will become apparent to those skilled in the art upon reading the following description with reference to the accompanying drawings illustrating the preferred embodiment of the invention.

Reconfigurable variable blank-holder force system and method for sheet metal stamping

A reconfigurable variable blank-holder force system (and method) for producing sheet metal stamping comprises a portable hydraulic unit, controlled by a digital control system and a knowledge-based expert system to enable reconfigurability and an easy transition from the try-out stage to production.

The knowledge-base has a hierarchical structure and includes stored information about part geometry, material properties and press parameters. The expert system enables an operator to determine optimal blank-holder forces, and to fine-tune through a graphical interface unit. The optimal blank-holder forces are generated by hydraulic force actuators, using a controller running a nonlinear algorithm that accounts for valve nonlinearities, variable flow-rate and numbers of operational cylinders.

The portable hydraulic unit preferably comprises hydraulic cylinders with quick disconnect hoses, a manifold, servo-valves and a pump unit. A structured method to utilize this system to produce sheet metal stampings is also described. An article embodying the method is included.

Method of achieving reconfigurability in a blank-holder variable force system for producing stampings from sheet metal blanks, comprising: using movableblank-holder force actuators and variable blank-holder forces to hold and support said sheet metal blank at a first set of blank-holder force actuator locations; monitoring a first set of parameters selectively including punch force, blank-holder forceactuator numbers and locations, and blank-holder force magnitudes at said movable blank-holder force actuators; inspecting a sheet metal stamping work piece produced using said first set of parameters; noting differences between characteristics of asample work piece fabricated using said first set of parameters, and requirements of an acceptable sheet metal stamping work piece; and, using said differences and knowledge-based inputs from an expert system to arrive at a second set of newreconfigurable parameters.

A variable blank-holder force system for performing sheet metal stamping operations, comprising: movable blank-holder force actuators to hold and support said sheet metal stamping at a first set of locations; sensors associated with saidmovable blank-holder force actuators for monitoring parameters associated with the blank-holder force actuators including blank-holder force actuator locations and force magnitudes at the blank-holder force actuator locations; a user interface forviewing and using a first set of parameters for a trial run and for recording differences between a stamped sheet metal from a trial run compared with requirements in an acceptable stamped sheet metal work piece; and, a controllable arrangement forarriving at a second set of parameters based on said differences, knowledge-based software controlled by an expert system and knowledge-based hierarchy.

Sheet metal stamping is an indispensable and significant process because it is well suited to mass production of a wide variety of parts. In the automotive industry, it is used to make several body parts such as doors, hoods and lift-gates. Several other industries such as the consumer appliance industry and the aerospace industry use sheet metal stamping extensively. It is highly desirable to ensure high quality standards for sheet metal stampings so as to avoid problems during subsequentassembly stages and to ensure that the form and finish meet requirements.

A publication by Ananthakrishnan S., Agrawal S., Venugopal R., and Demeri M., entitled "RCS Based Hardware-in-the-loop Intelligent System Design and Performance Measurement," inProceedings of PerMIS 2002, NIST, Gaithersburg, Md., 2002, teaches design of an intelligent system with applications to manufacturing, based on a Real Time Control System (RCS) architecture. The Ananthakrishnan publication describes case studies on howthe RCS architecture can be used in a flexible automation scenario, where traditional industrial control cards (hardware) do not provide adequate measures of performance.

In addition, certain tooling concepts and blank-holder force actuator controlunits with individually controlled hydraulic cylinders have been developed to allow local control of metal flow into the die cavity during a stamping operation. Forces are applied on the sheet metal blank using hydraulic cylinders which are mounted onthe lower bolster of a hydraulic press.

In the known type of hydraulic or mechanical press, a ram depresses the piston of each of the hydraulic cylinders via the blank and tooling in a blank-holder force actuator area to raise the pressure inside thecylinders. The pressure is transferred to the blank. A closed-loop control system modulates the flow of hydraulic fluid from the cylinder. In known arrangements, pressure within the cylinder is difficult to control using commercially available PID(Proportional-Integral-Derivative) control cards.

The few systems that are available presently are systems of hydraulic cylinders installed in the bed of the press (under the die). The hydraulic cylinders used to provide force actuation in knownsystems are placed in fixed locations in the bed of one particular press, and the force actuators are configured for operation in that press. In essence, these systems are not flexible and are customized for one particular press and thus tend to be veryexpensive.

The production of sheet metal stamping parts involves two distinct phases, namely, try-out and production. In the try-out phase, the die design is validated, and required process parameters (blank-holder force actuator forces, punch force etc.)are determined. Try-out is conducted by attempting to make the part and modifying the die and process parameters, until a part is consistently made within the required design tolerances. After successful try-out, the final die design and processparameters are transferred to a production unit that mass produces the part. In practice, try-out and production are typically conducted by different companies in different locations.

It is desirable to provide a system and method for sheet metal stamping that would offer reconfigurability utilizing a knowledge-base, as well as the most economy and flexibility in design, and in doing so, address the needs of both try-out andproduction.

Metal Stamping Materials and Processes

Little is known about this process, what type of machinery it uses or how it benefits our lives. The truth is simple. The process of metal stamping and the products it produces are virtually unlimited. Today, this process helps your car operate, medical equipment function and supplements other key components of our daily life.

Metal stamping operations utilize leading precision stamping presses including Bruderer, Kyori, Ingyu, and Minster with sizes ranging from 5 tons - 220 tons. Materials used in the process include Beryllium Copper, Phosphorous Bronze, Stainless Steel & Copper and Cold Rolled Steel with thickness ranging from 0.002" to 0.180". As a result, manufacturers have the capability to provide services and products for a wide variety of industries.

The Metal Stamping Process is put to use for a number if industries, including:

* Automotive parts stamping

* Medical stamping

* Stamping for mobile devices

* Stamped and drawn shields for industrial and electronics industries

* Bandolier

* Bandolier wire

* Header pins

* Contact pins

* Terminals

* Sleeved terminals

* Reel to reel

* Precision miniature stamping

* High speed

* Micro

* Stainless steel

* Medical Stamping

In addition, several types of metals are used in the process, including:

* Aluminum

* Beryllium

* Brass

* Bronze

* Cold Rolled Steel

* Copper

* Mylar

* Phenolic

* Stainless Steel

* Teflon

* Titanium and more!

The process of bandoliering involves the use of a delivery member (a "band", or "carrier") that conveys components from one point to another. In the precision metal stamping arena, bandoliering has been used extensively for manufacturing components such as pins assembled into electronic connectors. Bandoliered components are formed by a special type of precision metal stamping die (referred to as a progressive bandolier die), which is operated in a mechanical press (typically 60 ton, or greater). Raw material in the form of wire (ferrous or nonferrous) is fed into the die to be formed (stamped) into the final desired component, and raw material in the form of strip is introduced into the die to be formed into the bandolier to carry the final component. This article expounds on the use of the bandoliering technique for manufacturing various types of precision metal components. Specifically, the following will be discussed: (1) the benefits of bandoliered components, (2) examples of various applications that can employ bandoliering, and (3) various manufacturing options that can be incorporated into this process.

First, the benefits of producing a precision metal component in a bandoliered configuration (mainly for high volume applications) are threefold: (a) reduced unit cost, (b) repeatable quality, and (c) in-line post-processing. Unit cost can be reduced due to the fact that the stamping operation is performed in a progressive precision metal stamping die, and also because of the fact that the bandoliering process allows for time-saving secondary operations (such as assembly), which reduce overall unit cost. Quality is inherently repeatable in a progressive stamping die. The most significant benefit of the bandoliering process is related to the fact that the stamped components all exit the die in an "ordered" configuration, ready for an assembly process (either manual or automated) or for other secondary operations while still on the band (carrier). Related to this benefit is the fact that this process also lends itself to other manufacturing operations that can be performed inside the die (discussed later).

Second, the types of applications for which bandoliering may be employed are numerous. The following are examples of various industries that could employ this process: Medical devices (e.g., surgical components), Orthopedic components (e.g., pins), Electronic connectors (e.g., connector pins), Military components, as well as many other industries/applications.

Lastly, a bandoliered process can provide for various manufacturing operations to be performed either inside the precision metal stamping die, or outside of the stamping die (while the components are still located on the bandolier). Some examples of in-die operations that can be performed include: coining, sharpening, machining, assembly, and welding. Examples of secondary operations performed outside of the die (while the precision formed components are still on the band) include: cleaning, coating, heat-treating, and automated assembly.

High volume applications for stamped metal components should be evaluated to see if a bandoliered application could be used, especially if the need is present for secondary operations such as assembly, or other operations as discussed above.

The parts manufactured during the metal stamping process vary from tiny parts in material as thin as .05mm to larger frames and heavy duty metal components. Precision presses vary in size from 5 tons to 220 tons, and with speeds up to 1,500 per minute. Stamping services also have skiving equipment to contour metal thickness and configuration as required.

Metal Stamping Quality Control

Metal stamping is a form of metalworking that is completed using various levels of difficulty. Almost anyone can form their own jewelry, flowers, numbers and letters out of metal using metal stamping kits or other tools. The higher the quality of the metal used, the longer these personal things will last. Metal stamping is also an industrial fabrication process used to create weaponry, vehicle components, dollar bill changers, vending machines, decorative sheet metal parts, medical life-saving devices, and many other items.

Stamping includes a variety of sheet-metal forming manufacturing processes, such as punching using a machine press or stamping press, blanking, embossing, bending, flanging, and coining. This could be a single stage operation where every stroke of the press produce the desired form on the sheet metal part, or could occur through a series of stages. The process is usually carried out on sheet metal, but can also be used on other materials, such as polystyrene.

When working with metal stamping in the industrial world, material quality is very important. A metal stamping company may work with aerospace or medical industries creating products that can save lives-if the metal used is of low quality, lives can be destroyed instead.

Stamping simulation is a technology that calculates the process of sheet metal stamping, predicting common defects such as splits, wrinkles, springback and material thinning. Also known as forming simulation, the technology is a specific application of non-linear finite element analysis. The technology has many benefits in the manufacturing industry, especially the automotive industry, where lead time to market, cost and lean manufacturing are critical to the success of a company.

Recent research by the Aberdeen research company (October 2006) found that the most effective manufacturers spend more time simulating upfront and reap the rewards towards the end of their projects.

Stamping simulation is used when a sheet metal part designer or toolmaker desires to assess the likelihood of successfully manufacturing a sheet metal part, without the expense of making a physical tool. Stamping simulation allows any sheet metal part forming process to be simulated in the virtual environment of a PC for a fraction of the expense of a physical tryout.

Results from a stamping simulation allow sheet metal part designers to assess alternative designs very quickly to optimize their part for low cost manufacture.

Quality control is important, from verifying the metal when it's received to complete testing and inspection once the product is completed. Metal stamped parts can be made into fuel injectors for an automobile, engines in an aircraft, bayonet assemblies, and navigation systems used by the military. With components that can take lives if they fail, it's important to ensure the company you're working with takes quality control very seriously.

First inspection of the material when it is received is an important quality control process. If the metal company can verify where the materials that will be used in production come from, it is likely they take care to make sure your components do not fail on you. Material identification provides documentation as to where the metal has been before being used in fabrication; it shows where it's made and how it's transferred. By using metals from reputable sources, metal stampings are more durable, smoother, and last longer than questionable materials.

Final inspection of the completed component is just as important as material identification. By performing non-destructive testing and other inspection methods on the product, any defaults or other issues will be noticed. A company with high quality standards keeps their rejected products to less than 1%. This shows that quality control is completed during every step of the fabrication process.

Metal stamping prototypes are a great way to ensure that the final fabrication of all parts will be correct in tolerance, size, durability, and design. Whether the prototype is a working part or not, working with companies who offer this as an option can mean the difference between getting exactly what you want and a completed order that doesn't match your needs.

Metal stamping process using a wire preform

Metal parts can be economically fabricated by a metal stamping that comprises preforming a piece of wire to have a shape corresponding to the 2-dimensional configuration of a desired product workpiece, flattening the wire to form a metal blank, and subjecting the metal blank to metal stamping to obtain the desired product workpiece. The process can significantly reduce the amount of scrap material and thereby reduce manufacturing costs.

Metal parts are fabricated by a variety processes such as casting, die casting, and forging. One of the more common processes used for manufacturing metal parts is called metal stamping, which has been in use for over 150 years. Metal stamping,which in general involves taking a flat metal sheet and converting into a shaped article (i.e., a metal part) using a die and press, is a cost-effective process because it permits metal parts to be manufactured at high production rates.

In a conventional metal stamping process, a sheet of metal stock material, such as aluminum, copper, zinc, steel, stainless steel, nickel, titanium, or the like, is introduced into a stamping press such as a mechanical or hydraulic stampingpress. The stamping press has a die means and a punch means which together are used to form blanks from the initial sheet of stock material. These blanks are then subjected to further stamping procedures to form metal parts.

A disadvantage of conventional metal stamping processes is that the formation of the blanks from the initial sheet of stock material and the subsequent further processing of the blanks into metal parts can result in generation of excessiveamounts of scrap material, thereby adding to the cost of manufacture due to both loss of material and cost of waste disposal.

After the preforming stage, the shaped wire or preform is then subjected to a flattening process to achieve a "blank" from which the desired product workpiece will be obtained via a stamping process. The term "wire" as used herein is not to belimited to wires having circular cross sections. Wires of other cross sections such as square, rectangular, etc can also be used. Further, the effective diameter of the wire can vary widely depending on the desired thickness of the metal part and theflattening process. The wire can be flattened by any typical process suitable for applying the requisite pressure to a piece of metal. For example, a shaped section of wire having an effective or nominal diameter of, for example, 3 to 50 mm, preferably5 to 20 mm, can be flattened to a preformed piece of metal having a thickness of, for example, 1 to 30 mm, such as 1 to 25 mm or 8 to 30 mm, preferably 2 to 8 mm, by passage through a mechanical or hydraulic press that applies a pressure of, for example,60 to 1000 tons, preferably 100 to 600 tons. The dimensions and tonnage listed above are merely provided as examples and are not intended to limit the invention.

Thus, the width and thickness of the blank are determined by the selection of the nominal diameter of the wire and the amount of pressure imposed during the flattening process. The length of the blank is determined primarily by the performingstage, by selecting the length of the wire and it's perform shape prior to the flattening step, although the flattening step will also influence the overall length of the blank.

This procedure, in which the blank is made from a flattened preformed wire, results in considerable savings in material costs as the blank obtained from the flattened preformed wire requires far less material than a conventional blank obtainedfrom a metal sheet. In other words, in a conventional procedure blanks are cut and formed from a sheet of flat rolled metal. This procedure inherently imposes material costs due to the resultant scrap material. Yet, in the process according to theinvention, the blank is formed with little or no material loss.

After the preform is converted into a blank, the blank can then be subjected to one or more further conventional metal stamping procedures. In such procedures, the blank can, for example, be "stamped" in a die and press arrangement such as in amechanical or hydraulic press whereby excess material is trimmed from the blank to form a desired product workpiece, either a final product or an intermediate thereof. A typical metal stamping machine is a Minster.RTM. 200 ton mechanical press.

Method for Finishing Characteristics of Metal Stamping Dies

A method for improving the release and finish characteristics of metal stamping dies includes shot peening the interior die cavity walls with substantially spherical shot having a hardness value at least equal to the hardness value of the die cavity walls.

Optimizing the parameters of the peening process, such as the Almen intensity and the shot type, size, hardness and uniformity, maximizes the improvement to the release and finish characteristics of the die. Optionally, the initial shot peening is followed by a second shot peening with substantially spherical glass beads. Metal stamping dies shot peened in accordance with the present method exhibit substantial improvement in their release and finish characteristics over unpeened dies.

The present invention relates to metal stamping dies, and, more particularly, to a method for improving the release and finish characteristics of metal stamping dies through shot peening.

The use of metal stamping to produce a wide variety of metal parts is widespread. While there are variations of the metal stamping process, such as forming, piercing, deep drawing and the like and combinations thereof, and different types ofdies, such as single and multiple cavity dies and progressive dies, most of the principles and techniques are the same. The problems are also often the same.

One of the major problems which is common to virtually all metal stamping operations involvingdrawing or deformation of the workpiece,whereby the workpiece contacts the interior die cavity walls during the stamping operation, is a poor release characteristic between the workpiece and the die cavity walls. Poor release characteristics, whichcauses problems both during the stamping downstroke and the upstroke and workpiece removal stage, invariably leads to problems such as machine jams or smashups, misformed and non-uniform parts and poor finish characteristics on the workpiece surfaceproximal to the die cavity walls, such as scratches, galling, scoring, random shiny spots and the like. Although a poor release characteristic is most often the cause of a poor finish, poor finish can also be caused by other factors, such as heatbuildup, improper lubrication, surface flaws and the like.

Because of the high cost of rejected parts and the down time due to die maintenance and reconditioning, as well as the potential very high cost occasioned by a machine or die jam or smashup, constant efforts are being made to improve the releaseand finish characteristics of metal stamping dies. These efforts range from varying the composition of the die material to coating the interior die cavity walls with release agents, plating and the like. Even the die designer continually attempt toimprove the release and finish characteristics of dies by experimenting with variations of draft angles and the like.

While there has been steady improvement over the years, there is a continuing need for further improvements, especially improvements that are economical, reliable and durable.

The present invention was the result of the surprising discovery that shot peening metal stamping dies with generally spherical shot dramatically improves the release and finish characteristics of such dies, as well as substantially increasingdie life. Heretofore, the accepted rule in die construction and maintenance and reconditioning, with respect to achieving satisfactory release and finish characteristics, was to provide the interior die cavity walls with as smooth and uniform a surfaceas possible. Although shot peening has been in widespread use for years to increase the fatigue life and prevent stress corrosion cracking of metal parts, an irregular peened surface on the interior die cavity walls would predictably adversely affectthe release and finish characteristics of the die. Since any improvement in fatigue life or the prevention of stress corrosion cracking through shot peening would not be worth the sacrifice of having to accept poor release and finish characteristics ofthe die, shot peening has never been seriously considered for treatment of the interior die cavity walls of metal stamping dies.

In the broader aspects of the present invention, conventional shot peening techniques and equipment are utilized, i.e., the surface of the part is bombarded with shot by a peening apparatus under controlled conditions. However, in the preferredembodiment, optimum results are achieved by utilizing specific combinations of parameters with respect to shot type, size, hardness and Almen peening intensity. Examples of suitable conventional peening apparatus include air blasting equipment whichpropel the shot media at the part under air pressure, utilizing either suction, direct pressure or gravity feed, and airless or centrifugal wheel equipment which propels the shot media at the part by a rotating wheel. There are also freefall peeningmachines, where the shot media is dropped upon the part from various selected heights.

With respect to the shot peening media, the media must be substantially spherical. Irregular, angular or abrasive media, such as employed in grit blasting and sand blasting, are unacceptable in the method of the present invention. While avariety of generally spherical peening media may be utilized, such as steel shot, ceramic media and conditioned cut steel wire shot, steel shot is preferred. In the case of cut steel wire shot, it must be conditioned prior to use, such as by blasting itagainst a steel plate until the particles are rounded. Whichever peening media is selected, it must have a hardness value at least equal to the hardness value of the die cavity walls to achieve the improvements of the method of the present invention.

The peening process should be conducted under conditions that will yield substantially 100% coverage and saturation of the interior die cavity walls. In addition, it has been found that increasing the depth of the compressive stress layerprovides additional improvement. A substantial improvement, especially in die life, is achieved when the compressive stress layer is about 0.02 inch or greater. This increase in die life is partly due to the fact that some surface metal is removedduring each periodic maintenance or reconditioning operation. Accordingly, the greater the depth of the compressive stress layer, the more the amount of metal that can be removed during maintenance and reconditioning operations before the benefits ofthe shot peening are negated.

The optimum shot peening intensity will vary depending upon the hardness of the dies and the type of die metal. Under the generally accepted Almen shot peening intensity standard, which was developed by the General Motors Research LaboratoriesDivision of General Motors Corporation, the various variables of shot peening are integrated into a single scale for measuring, specifying and duplicating shot peening intensities and results. All measurements are made on the standard Almen No. 2 gage,as shown in the SAE Manual on Shot Peening, AMS 2430 and MIL S-13165. Even though the exact optimum Almen intensity will vary as the die material and shot parameters vary, it has been found that when regular hardness steel shot, with a Rockwell hardnessof from about C45 to about C55, is utilized, the desired compressive stress layer of at least about 0.02 inch will be achieved with Almen intensities of from about 0.004 to about 0.014 C2.

Also, while the optimum size of the shot peening media will vary, steel shot with a Mil Spec size of from about SAE 70 to about SAE 230 is preferred for most applications. For optimum reliability and uniformity of the peening media, cast steelshot certified to Mil Spec 13165 is especially preferred.

Finally, it has been found that yet further improvement is achieved by following the initial shot peening with a second shot peening utilizing substantially spherical glass beads. The optional second peening procedure provides primarily acleaning function and enhances the uniformity of the peened die surface.

The improvement achieved in the die release and finish characteristics by the present method is consistent and dramatic over a wide range of varying die constructions. One of the clearest gages of improvement is to monitor the frequency of diecleaning and reconditioning that is required. Comparison testing between untreated dies and dies shot peened in accordance with the present invention at various stamping work stations at a major automotive assembly plant revealed consistent improvementwith the shot peened dies. From large steel quarter panel dies to smaller front fender steel insert dies, the results are the same. The shot peened dies experienced far less down time and required far fewer periodic maintenance and reconditioningoperations. The improvement as a function of reduced down time and periodic maintenance and reconditioning ranges from a factor of several fold to a factor of over 30. In addition, the surface finish of the stamped parts is consistently uniform andfree from flaws.

In addition to the improvements that the present method provides with respect to release and finish characteristics and the reduction of down time and the need for periodic maintenance and reconditioning, additional advantages are achieved. Costwise, the present method is less costly than most other surface treatments and coatings which are applied to the interior die cavity walls. Moreover, additional cost savings are realized during die reconditioning or modification. Coatings, such asplating, tend to chip and flake and eventually must be replaced at high cost. In the event that the die needs modification due to an engineering change or the like or requires a repair operation such as welding, only the immediate area that is alteredor repaired may require repeening. In sharp contrast, such an isolated modification or repair in a plated die most often requires the entire die surface to be replated.

Thus, the surprising discovery that shot peening metal stamping dies in accordance with the present method dramatically improves release and finish characteristics, instead of adversely affecting them as would be predicted, has resulted in asimple, reliable and economical method which can benefit the entire metal stamping industry.

The Custom Metal Stamping Process

Today, manufacturing has embraced a wide range of advanced technologies that have enabled the reduction of turnaround time considerably. As a result, demand on the metal stamping industry has also increased as the components have to be made to be exactly suitable to the final product. This has made precision and custom metal stamping much more important in the manufacturing industry.

Custom metal stamping is the process of creating metal products according to the required sizes and shapes through a method called stamping. It involves the pressing or stamping of the metal in dies or press tools to give it the right shape. In custom metal stamping, the final products are made according to customer's precise requirements and conditions. Custom metal stamping is used in various industries like construction, electrical, bearing, automotive, medical and janitorial, among others.

Metal stamping typically involves the normal process of metal stamping but with certain changes. These can be the change in the kind of metal to be used, changes in the size and shape of the final product, the need to produce many kinds of sizes and shapes, high quality of the tools used, the volume and the number of units to be produced, the kinds of presses required and the number of presses and dies required. Some producers are changing their processes to accommodate any volume, up to thousands of tons.

There are several challenges to be met by the custom metal stamping companies. These are producing a high quality product, designing new products or re-engineering existing products to suit customers' needs while also meeting delivery requirements. The company has to be involved in every stage right from product design assistance to the final delivery. Additionally, the costs also have to be kept low even as the scope of offerings is increased.

Sheet metal stamping is the system wherein metal sheets are used for producing final products. When a metal sheet is inserted into the die or the press, it is molded into the required shape and size. Metal sheets of only a certain thickness can be inserted into metal stamping machines. The maximum limit for most metal stamping machines is ? inch. However, machines can be designed to accommodate sheets of greater thickness also. Even the kind of metal sheets that can be processed in metal stamping are also specific. Only certain metals or alloys can be used like aluminum, brass, steel (hot rolled or cold rolled), galvanized steel, stainless steel, copper, zinc and titanium.

Before the metal sheet is inserted into the machine, the customer provides the prototype or at least a diagram of the final product. In case the customer doesn't have a clear idea of what the final product should look like, most metal stamping producers also offer engineering services for designing the products as well. Even some secondary services such as deburring and plating are provided by the metal stamping companies after the metal sheet is stamped.

There are three main components in sheet metal stamping -- the die, the punch and the binder/blank holder. The sheet is kept between the blank holder and the die and the punch is driven into the die wherein the sheet spreads over the die because of the drawing and stretching. The blank holder provides the restraining force that is required to control the sheet flow into the die. This force prevents wrinkling and tearing of the sheet as the quantity of material going into the machine can be controlled. For some processes where the blank holder force is too high for the material, draw beads are used to create the restraining force.

Sheet metal stamping is also known as thin stampings. Sheet metal stamping is used most primarily in the case-building process. It is also the most important part as each of the panels has to be stamped one by one. First the motherboard tray is stamped, then one-side panels on the right and left from bottom to top and back.

Sheet Metal Stamping In The Automotive Industry

Historically, sheet metal stamping has been used extensively to produce automotive body panels. Although sheet metal stamping use has decreased with the advent of fiberglass body panels, sheet metal stamping is still the most popular material for manufacturing automobiles today. The addition of lasers and robotics to the automobile manufacturing process has further expanded the way that sheet metal stamping is processed.

Lasers

Lasers have been used in production facilities since the 1960's. Today, they are used to cut, form holes, engrave, weld or heat treat sheet metal stamping for use in automotive production.

Lasers are used in applications that rely on precise measurements and exact alignments.

The adjustment of lasers is measured in micrometers, or millionths of a meter.

There are many different types of lasers used to alter sheet metal stamping and plastics in the automotive industry.

Carbon dioxide laser- uses a mixture of carbon dioxide, nitrogen and helium to produce a continuous laser output

Continuous-wave laser- this type of laser produces light beams continuously rather than in controlled pulses

Excimer laser-emits light in a UV spectrum that is used for producing high quality edges on parts that are prone to cracking or thermal damage; it falls into the category of pulsed-gas lasers

Gas laser-any laser that uses a gas mixture as the lasing medium; common gases are argon and carbon dioxide

Pulsed laser-emits light in controlled pulses and is preferred for thin materials ; it can be used to create intricate details and work in tight corners without burning

Ruby laser-a solid state laser that uses a synthetic ruby crystal with a chromium impurity as the lasing medium

Solid-state laser-a type of laser that uses a crystal or glass as the host for an impurity to produce the lasing action; especially useful for precise measuring and spot welding

Yttrium aluminum garnet (YAG) laser-ranges in power from a few milliwatts to more than 400 watts; used for cutting, drilling, heat treating and welding operations

Robotics

Robotics are often used for repetitive tasks, monotonous jobs or those parts of the manufacturing process that are physically difficult or take place in environmentally unpleasant conditions. They are directed by computer programs and perform precise operations without human intervention.

Lasers and robotics have significantly increased the speed at which sheet metal stamping can be processed in the automotive manufacturing process. Continued technological advancements in these two areas will further increase the cost effectiveness and productivity of automotive manufacturing facilities.

Metal Stamping Tools and Die Hot Sheet Metal Stamping

Metal Stamping tools are hard tools made with hard materials like steel. Usually hot stamping die is used for stamping metal surfaces. Die is the tooling used to produce a stamped part. A die set assembly has male and female components that actually produce the shaped stamping. Stamping die stamps the design on the metallic surface by using moulding process.

Stamping can be fun when done right. But, you have to have the right stamping tool for precision metal stamping. Latest stamping methods are affordable and provide creative stamping solutions. Stamping tools can be used for stamping metal, foils, wood, leather and plastic. Stamping tools companies usually provide.

Stamping tools and dies servicesIn-house die designClean & organized tools roomFast tooling modificationsTry-out, first-run and capability Studies.

Whether you need a different part for a vehicle or for a roof of a building, is the ability to get the right shape through metal bending. The procedure that is used for bending can provide you with a custom fit and will help you to get the right results through the shape that is formed from this process. The different procedures that are used will create an alternative look to the metal and can help with the right formation of the metal for any need.

When beginning to look into metal bending, you will notice that there are several expected results from the procedures that are used. Different types of bending are divided according to the shape that you need with the metal. The most common types of bends are the V - shape, U - shape or channel shape. The other differences in the bends will depend on the length of the metal that is needed as well as the specific area that the metal will be used in. For instance, if the metal is going to be used for an air duct, it will need a different type of bend from the use of an automobile part.

The common shapes that are used with metal bending then move into several processes to make the correct design. Each of these is designed to create the right shapes of the metal while providing a convenient fit for different needs. One of the common types is known as the three point bend, which will fold the metal in several different places. Rotary bending and folding are other common procedures, each which are developed to create specific width, designs and measurements for different areas.

To formulate the type of metal bending that is used, manufacturers will use specific equations that determine the results of the metal. The processes used will begin with a determination of the thickness of the material. If the metal is thicker, then processes with more compression and air may be used.

There are also factors such as how much allowance can be used for the metal as well as what the deduction is for the metal. The angle in degrees will also be measured in relation to this. All of the metal bending will then fit together into a process that combines air compression and pressure to make the right look to the material.

The procedures and types of metal bending that are used by manufacturers create a different set of materials that can be used in various processes. After metal has been bent to the right shape, it will lead to a different set of uses. The result will be sturdy parts used for transportation, buildings and other areas that require extra support through the use of metal.

Metal Stamping:

Metal stamping tools and stamping dies are used to produce high volume sheet metal parts using press. Parts can be stamped from any ductile metal to create and achieve almost any desired configuration.

Metal stamping is generally performed on materials .020" to .080" thick with tolerances to ±.001. The process also can be applied to foils as thin as .001". Stamping is also done by machine press. The metal is placed between the press plates and pressed against each other. This deforms the metal into the desired shape.

Die Hot Sheet Metal Stamping:

The Die Hot Sheet Metal Stamping process is described as relief printing and as the name implies uses printing plates with raised images. Hot stamping is used in graphic arts, plastics and packaging industries. Die hot stamping is versatile. It can print onto all wettable materials - paper and board, thermoplastics and duroplastics, leather, textiles, wood and many other materials.

How to Become a Metal Stamping Press Operator

Factory work can be a thankless job most of the time without much of an opportunity for advancement, but the ability to become a metal stamping press operator can lead to bigger and better things.

In the metal stamping industry every employee looks for a more lucrative position in terms of pay, and to become a metal stamping press operator can provide an excellent learning opportunity that can result in promotion to a supervisory position or one that is at least less physically demanding. As far as the labor force in a factory goes tool and die makers usually make the most money, and many have started their careers as a metal stamping press operator.

To become a metal stamping press operator an unskilled person usually accepts a position as a laborer in a metal stamping plant. After a period of "paying your dues" an individual may be offered as position as a press tender, which encompasses any tasks that are necessary to keep a stamping press functioning at full capacity. These tasks may include bringing new steel to a metal stamping press operator or taking away the finished product.

After a period as a tender, the next step to become a metal stamping press operator is to assume the position of a "catcher" - the person that catches the pieces as they come from the stamping press and has the responsibility to check that there are no quality issues. The reason that time must be spent in each of these positions before an individual can become a metal stamping press operator is so that they can absorb the nuances of the job by watching and learning a skilled metal stamping press operator in action.

Eventually an individual will be promoted to become a metal stamping press operator and will initially be assigned a more simple stamping job on a press with a force of smaller size and tonage. Over time and with hundreds of thousands of repetitions, a metal stamping press operator will learn and rise in the factory heirarchy until they are considered competent enough to be assigned stamping jobs on 300 to 1,500 ton presses with a subsequent increase in salary based on experience and production.

A responsible employer will only allow an employee to become a metal stamping press operator after significant training has been completed. To become a sheet metal stamping press operator is not a tremendously difficult task, but when the job is performed incorrectly it can be an extremely dangerous situation for the metal stamping press operator as well as any other employee in the immediate vicinity.

Finding the Right Metal Stamping Manufacturer

Sheet metal stamping products could range from the simplest to the most complex mechanical parts that are used in industries like automotive, house ware, aircraft, medical and communications. Such industries are constantly looking for manufacturers that will provide them the best metal products at affordable prices.

For a manufacturer, metalworking is by far the most effective and economical method to produce different types of metals. The process involves cutting and forming sheet metal into shapes and sizes based on a client's design and specifications. They make use of special tools such as stamping dyes, as well as the most innovative technologies that not only speed up the rate of production but also produce high quality products at affordable cost.

Sheet metal stamping is used to produce a wide variety of items like automobile panels, rain gutters, restaurant equipment, road signs and heating ducts, fabricating. As a result, installing and maintaining these items can be a hazardous job.

Sheet metal stamping workers are subject to frequent cuts, scrapes, burns and falls from scaffoldings or ladders. Many times, the sheet metal stamping production process itself requires repetitive heavy lifting, bending and squatting, putting workers at risk for back, neck and muscle injuries. Knowing the proper safety procedures can help keep sheet metal stamping production workers safe on the job.

Safety Equipment is everyone's Friend

While safety equipment may feel like a cumbersome, frivolous waste of time, safety gear is designed to prevent and limit injury should an accident occur. Accidents can happen in a matter of seconds.

During an accident, safety equipment must already be in place in order to be effective. Hard hats, gloves and safety glasses left in a truck or tool box are useless during an accident.

Sheet metal stamping workers can be subject to flying debris and tiny shards of metal shavings, cuts from sharp metal edges, crushing injuries from presses and other sheet metal stamping forming equipment, and burns from metal heated during production, installation or repair.

Many of these injuries have the potential to be life threatening unless safety equipment is worn when working around sheet metal stamping.

Preventing Back Injury in sheet metal stamping Workers

Back and neck injuries are one the most common causes of Worker's Compensation claims. A serious muscle injury can keep a sheet metal stamping worker from the job for months while muscles, tendons, tissue and bones heal.

Learning to lift with the large, strong muscles of the legs instead of the muscles of the neck, back and arms is crucial to preventing back injuries. A 100 pound woman can easily pick up a 150 pound weight with proper body mechanics.

Heavy lifting requires lowering the body's center of gravity. Bending at the knees improves balance and provides a stable, lowered center. Lifting is only begun after the neck and back muscles are relaxed. Upper body muscles should not bear the weight of the object being moved; they should only be used to hold the object near the body.

If at all possible, sheet metal stamping workers should plan and position their workstations and materials so that heavy items can be lifted from waist high in a standing position. Feet should be placed shoulder width apart, directly under the hips.

The body can also be positioned to take advantage pivoting movements that can reduce the chance of falls or improper body alignment during transfers of heavy objects. These lifting techniques can reduce muscle strain and prevent neck and back injuries in sheet metal stamping workers.

The best custom manufacturers spend enough time with their prospective clients discussing every aspect of the request, from the desired shape and size, as well as the end products' look and finish. They can also provide expert design and engineering services, as well as recommend the use of special materials and methods to further enhance the final product.

A reliable metalworking company conducts professional engineering with the help of a team of fully-trained personnel. The company should also be performing a series of quality checks and inspection procedures to ensure that every single product that leaves the production is of high quality and is able to meet the requirements of their clients. Doing a background check is the best way to determine which of the manufacturers can give you the best service when it comes to custom metal stamping.

Precision Sheet Metal Stamping Fabrication

Metal stamping fabrication is a process of producing a metal stamping component by modifying a raw piece of material in a machine shop. These materials are processed on different temperatures and depending on the range of temperatures; the process is classified as cold, warm and hot.

Precision sheet metal stamping fabrication describes various different processes that form sheet metal into finished products. Objects that are fabricated and used for machinery and other instruments are among the daily used objects like paper clips, computers, bolts, nails, automotive parts and many more.

There are various factors like rate of production, desired geometry, and other physical requirements that influence the fabrication process. The benefits of the metal fabrication process are far and wide because it is used by all industries.

Every precision sheet metal stamping fabrication process undergoes three primary processes that include forming, cutting and finishing. Forming is a process that alters the form of the flat metal sheet. Forming can be done using various different processes like annealing, bending, cold rolling, drawing, forging, mechanical working, press forming, roll forming and welding.

After forming, a metal sheet is cut to alter the shape by removing some unwanted material. The cutting process includes stamping, shearing, sawing, drilling, blanking and punching. Finally, the last stage is the finishing process. In this process, the shaped metal sheet is given a finished and soft surface using sanding and vibration techniques.

Aesthetic considerations like painting and visual design applications are also few of the method applied to give the finishing touch. Some of the latest techniques in metal fabrication involve laser cutting, electro discharge machining, water jet cutting and wire cut EDM. In some cases CNC machining is also used.

There are various products that are created during precision sheet metal fabrication. The most common objects produced are metal cabinets, enclosures, ventilation shafts, hoods, exhaust systems, tanks and prototypes. Metal fabrication is also used by various other industries for food dispensing, food storage, communications, automotive, computer, medical, electronics, aerospace, telecommunication, pharmaceutical, residential and construction.

Some of the types of Precision sheet metal stamping Fabrication include processes like Annealing (heating), Bending (straining), Cold forming, Cold rolling (shaping sheet metal using rollers), Drawing (material is forced into a die with a punch to form a cup-like shape), Forging (hammering or pressing), Rolling (reducing thickness of the material), Extrusion (producing cylindrical bars or hollow tubes by forcing round billets through one or more dies) and Spinning (forms axially symmetrical shapes).

The Process of Precision Metal Stamping

Precision metal stamping is the process of making 3-dimensional metal parts, lettering and other embossing. This is a kind of sheet metal stamping used mostly for decorative purposes. It is similar to normal metal stamping, which is the process of molding metal into different shapes and sizes.

The products obtained through metal stamping are used as components for some larger products in other industries. The most common metals and alloys used for precision metal stamping are copper, aluminum, brass, beryllium, nickel, nickel silver, steel, stainless steel, phos bronze and titanium.

Precision metal stamping is applicable to many industries like computers, electronics, electrical, dental, aerospace, instrumentation, military specs, defense, telecom and automotives. There are many methods in precision metal stamping for producing stamped prototypes. Blank creation is one such method. Blank creation involves the creation of a flat state of the component. The flat blank sheet is then used to make the part's features. In blank creation, there are many processes like nibbling, chemical etching, water jet cutting, wire EDM, punch and die.

There are also many methods for producing prototypes by precision stamping. The type of method used depends on the size and intricacy of the parts to be produced as well as the number of prototypes. Single part transfer is one such method in which single parts are transferred from one station to the next for blanking and metal forming.

The main advantage with this method is the cost effectiveness. One single, standard system can be maintained for designing, manufacturing and holding tooling inserts. However, this system is slow because it needs individual prototype parts. The other method is the progressive strip prototyping which involves the automatic transfer of the metal from one stage to the next.

Precision metal stamping can be done at very high speeds and even up to 1,200 strokes per minute. Precision metal stamping gives several advantages like the ability to use any metal or alloy and creation of components with very precise dimensions and shapes. Plating can also be very precise which is helpful when working with precious metals like gold and palladium.

An Introduction to Metal Stamping Machines

Metal stamping machines are used to give the exact shape and parameters to the metal products. When a metal sheet is inserted into the metal stamping machine, it can be molded into the exact shape.

The kind of shape that has to be given to the product should be pre-determined before putting the metal in the stamping machines. The customer provides a sample or a diagram of the product that has to be created. Sometimes, the customer may not even know what the final product will look like. He will come with a vague idea of what purpose the product would serve. Most metal stamping producers have designing capabilities to assist the customer with what the actual design and requirements of the product should be.

Metal stamping machines are of many kinds. They can range between the simplest manual presses to highly computerized progressive die processors that involve complicated parts. Depending on the kind of machine, the features of the product can be changed according to the customer's requirements. The more advanced the machine, the process also becomes much faster and more efficient.

Metal stamping machines can perform a variety of functions like fine blanking, wireforming, deep drawing, fourslide and multislide stamping. Fine blanking involves the shearing of the material for producing finished parts without secondary operations.

Wireforming is the stamping of metal wire into different shapes such as springs, clips, rings and pins. Deep drawing is a cold forming process in which a flat blank of sheet metal is formed by the action of a punch forcing the metal into a die cavity. Four slide and multislide stamping is for horizontal die applications from multiple directions, done either successively or simultaneously.

There are a variety of metal stamping machines from the simplest manual presses to computerized progressive die processors that are highly advanced and involve complicated parts. Depending on the type of machine, the features of a product can be changed based on the customer’s requirements. The more advanced a metal stamping machine, the faster and more efficient the processes.

Metal stamping machine functions

A metal stamping machine can perform a variety of functions that includes fine blanking, wire forming, deep drawing, four-slide and multi-slide stamping.

Fine blanking – Shears the material to produce finished parts without secondary operations.

Wire forming – The process of stamping metal wire into different shapes such as rings, pins, clips and springs.

Deep drawing – A cold forming process using a flat, blank sheet of metal that is formed by punch forcing the metal into a die cavity.

Four-slide and multi-slide stamping – This is for horizontal die applications from multiple directions, done successively or simultaneously.

Most sheet metal stamping companies also offer supplementary services like designing, material sourcing, prototyping, short run manufacturing, upgrading or re-designing, assembly services and specialty packaging.

The Important Function of Metal Stamping Dies

Metal stamping dies are the devices used in metal stamping machines. Each metal stamping machine can have one or more than one dies depending on the kind of machine. Dies are the main components in metal stamping machines that do the actual casting, punching, cutting and shaping of the metal sheet.

The basic die operations are drawing, shearing and bending. In metal stamping, the metal sheets are placed in a die or a press tool which has a specially designed cavity that gives the preferred shape to the metal sheet.

The upper part of the die connects to the press slide while the lower component connects to the press bed. A specific component known as the punch pushes the metal sheet through the die, thus performing the actual shaping operation. The patterns on the dies can be used to emboss or give three-dimensional lettering on the final product.

Dies are placed in sheet metal panels either alone or as a series of presses in a press line. Metal stamping dies and presses can have different input variables on the bases of tonnage, press parallelism, shut height, nitrogen pressure in dies, counterbalance pressure and press speed. These variables can influence the quality of the stamping panel, particularly during die setup. The same stamping press can be reused by replacing one set of dies with another.

The placement of dies in a press is known as die setup. Die setup decides the shut height and binder force. The number of components produced in a die setup is known as a batch.

Sheet Metal is a flat shaped product made from metal that can vary in thickness between 0.015cm and 6.32cm. Very thin pieces would be considered foil/leaf pieces while thicker pieces are called plates.

The reason why sheet metal is widely used is because it can be easily changed in to a variety of shapes. Through a wide variety of processes sheet metal machinery and tools are used to do this.

Stretching

Sheet metal can be straightened by using a grip at either side of the sheet and stretching it. The sheet metal machinery and tools used to do this are able to pull the sheet metal beyond its elastic limit allowing it to come out flat. The affect of the stretching is that its temper will be slightly raised.

Stamping

This is a process that may involve one or more stamping stations to perform various actions on a metal sheet to create a final workpiece. As the metal sheet is passed through the work stations each one alters the shape by cutting, forming or drawing the piece. Each stamping station contributes to the final piece.

Cutting

There are a number of ways that Sheet metal can be cut, ranging from manually cutting the sheet using tin snips to using computer aided laser cutting. Tin snips can be extremely tricky - even frustrating to use, especially when the sheet curves. The use of computer controlled laser cutting allows for greater accuracy while at the same time reducing the amount of waste.

Laser cutting involves focusing a beam of laser light over the sheer metal heating and subsequently burning the metal. The edge of the sheet will be very smooth. Old Trumpf equipment laser cutters can be used to get a precision of around 0.01mm.

Bending

Bending can be carried out by sheet metal machinery and tools and is done to shape the sheet into various forms. A pressbrake is used to bend the metal into a shape that is determined by its die set.

Shearing

When the sheet metal is too big for use, then the sheet needs to be cut to size. This process is called shearing. This step needs to be carried out before any stamping can be started. Sheet metal machinery and tools 'shear' the sheet metal until the desired size has been achieved.

Deep Drawing

The deep drawing process involves sheet metal machinery and tools 'punching' blank sheet metal into a die set. It thus involves a transformation of the sheet metal into a desired shape.

There are many different kinds of dies such as single station dies, multiple station dies, compound dies, progressive dies and tandem press lines. Most dies are designed by the metal stamping companies who use advanced technologies like CAD to design them according to customer specifications. Another classification of dies is draw dies, trim dies and cam-pierce dies.

Metal Stamping Info provides detailed information about precision, custom, and sheet metal stamping, as well as metal stamping machines and metal stamping die.

How to Use Metal Stamping

Often found in hardware, craft, woodworking or jewelry making shops, metal stamping can be used for everything from industrial marking and stamping to property identification to adorning decorative materials like leather or metal jewelry.

With a basic set of metal alphabet stamps and a hammer, you can also create artistic bands or tags to use when designing home decor, gardening or even gift wrapping projects. Use the following steps to use metal stamps with ease.

Gather the materials you need to use metal stamps, including a set of steel stamps, a regular-sized hammer (smaller hammers designed for craft purposes like setting eyelets won't pack enough punch to create an impression with the metal stamps), a cushioning material (such as a self-healing cutting mat) to protect your work surface from scratches and something to stamp.

Consider creating imprints with the metal alphabet stamps on objects like aluminum plant tags (to identify seedlings in your garden, tack onto candles or use as gift tags), metal tags (to create pet, identification or gift tags) or paper tags with wide metal rims, for example.

Place the tag on the self-healing cutting mat atop a hard surface such as your garage's concrete floor. You don't want to run the risk of damaging a wood table or ceramic tile by hammering with the steel stamps on the fragile work surface. Tack small items down with a piece of double-stick tape to prevent the item from slipping as you work with the hand metal stamp.

Position the first metal alphabet stamp on the metal object where you'd like the letter to appear. Hold the stamp halfway down so your fingers don't get pinched below the stamp or the hammer.

Rap the back of the hand metal stamp firmly. Exert more pressure if you're trying to use metal stamps on more durable objects like heavy metal tags-items like aluminum plant tags will require little effort to make an impression with the steel stamps. If the letter isn't clearly defined, simply place the stamp back over the shape (it should fit into the partial letter easily) and hammer once again.

Add definition to your design once the entire word or message is engraved onto the metal with your steel stamps. Buff some metallic rub-ons, acrylic paint or even stamping ink onto the surface, letting the color get into the grooves made with the sheet metal stamping. Let dry a few seconds, then use a soft cloth to buff the excess paint or ink from the metal object, just leaving color inside the letters.

How to Unstop a Clogged Shower Drain

When the water starts creeping up the side of your toes when the shower is running, it's time to either call the plumber or take some action yourself. You might as well save yourself the time, embarrassment and money by attempting this simple remedy yourself--the same thing a plumber will do anyway. Read on to learn how to unstop a clogged shower drain.

Dry off and dress, then come back to this when it's convenient. First, scrape your hand or a sponge or clump of paper towel across the top of the shower drain grate to remove any hair that may be hanging in the drain. Continue scraping until you can't get anymore hair out.

Unscrew the two or more small sheet metal screws holding down the drain grate, being extremely careful to hold the screws when they're removed, and place them where they won't be pushed or tapped and roll down the drain.

Slowly and carefully lift the drain grate and lay upside down on a section of paper towel. Remove any debris and hair from both sides, careful not to allow any to drop down the drain. Scrape any soap or calcium residue from both sides of the grate using the putty knife.

Point the flashlight beam down the drain and inspect the sides of the drain pipe as far down as you can see. You will probably see residue and tangled hair clinging to the inside of the drain pipe, but if you don't, skip the next step.

Tear off a 2 foot strip of duct tape and insert it doubled into a sling down into the pipe with the sticky side up and toward the center. Make sure there are at least 4 to 5 inches of tape at each end outside the drain to stick to the shower floor so you don't risk losing the tape down the drain. Adjust the tape with one of the screwdrivers so that it covers as much of the pipe opening as possible. Then chisel and scrape the inside of the pipe and opening to remove any residue, pulling up the tape whenever a large piece of the residue falls onto the tape. Pull hair out using the pliers.

Leaving the grate off, remove everything from the inside of the shower, then let the shower run until it fills up the pipe and begins to collect in the bottom of the shower. Use warm water and let if collect until there is an inch or more of water in the shower, then turn it off.

Immediately place the plumber's friend over the drain opening and position the lips of the rubber head around the drain opening so that suction can be acquired. Plunge the tool gently and repeatedly, paying attention that suction occurs.

Check under the plunger continually for a clog. Normally there will be a clump of matter somewhere in the drain line causing the clog. You want to locate this and get it out of the drain as quickly and efficiently as possible.

Continue until you get the clog, then continue longer to remove any remaining parts of the clog. The pressure from the plunger will either raise the clog to the drain opening or force it out the drain pipe into the sewer or septic tank.

Be prepared to work the plunger for a half hour or more--hopefully it will take only a few minutes.Do not apply liquid or powder drain cleaners in the shower drain. They are harmful to pipes, and most likely your clog is not grease-based.