The stamping process is accomplished by applying tremendous pressure to metal sheets. These sheets/billets are placed into a die press and stamped into the desired shape.
During this process, many factors come into play that can lead to errors in the finished product. Complicated metal parts have small dimensions that are often very difficult to achieve. Because of this, it becomes crucial for stampers to consider several things when processing complicated metal components. These considerations should include whether the press can run at total capacity and how many tons of force can be applied without damaging the component during the production run. Other considerations may include use of the correct dies, misalignment of tools, etc.
Complicated metal stamping is frequently required to produce highly finished parts for various industries, including the aerospace, military, automotive, and appliance industries. Because these are intricate components, they must be produced with utmost precision. This means close attention must be paid to avoid errors during the stamping process. It is essential to consider whether the press has been checked for accuracy and how smoothly it runs before using it on complicated metal components.
Complicated metal parts include components made from a variety of materials, many of which can be difficult to stamp. For example, titanium requires different procedures from aluminum, because titanium is a strong material that requires more stamping force, whereas aluminum can be stamped with less tonnage. Tooling also needs to be precisely designed, manufactured, and aligned to ensure accuracy when processing complicated metal components.
We ensure precision stamping for complex metal parts in the following ways.
By using high-grade, strong metals
We use strong metals because thin metals cannot withstand the pressure necessary to stamp complicated shapes. Stamping complex shapes requires the use of durable alloys. For example, aluminum is well known for its use in cans, but aluminum is too soft for intricate metal parts. Complex metal components require strong metals.
High-grade metals are essential for metal stamping because they maintain their characteristics even after multiple heat treatments. Complex metal components require high-grade metals that can retain their characteristics, such as thickness and strength, after repeated processing.
By checking the press and its capabilities
Before complicated metal components can be stamped, we ensure that the equipment and tools are ready for use. Tools must be examined and tested for alignment.
It is necessary to check the equipment before production begins so as not to damage or mis-align parts during stamping. Having this information available beforehand ensures there are no complications during this process.
By using accurate dies
Dies used for stamping metal parts must be extremely accurate to avoid exerting too much pressure on thin metals or they will not fit together correctly.
Achieving pressure on specific points depends on both sides of a die aligning perfectly with one another. A high degree of precision is needed to ensure proper alignment. The life span of a die can be extended by ensuring that no excessive forces are applied during its production and checking for any misalignment.
By choosing the correct tonnage and speed
Stamping complicated metal parts is a balancing act. You need enough force to produce them accurately, but not so much force that components are damaged during production.
Achieving that balance will avoid overstressing or deformation caused by too much pressure. It is also
important to choose the correct so the part suffers no damage from heat buildup.
By having well-trained employees
Having well-trained employees who possess the right skill set will ensure that complicated metal components are stamped correctly. It is necessary to familiarize employees with quality control best practices, as well as how the stamping equipment operates.
Following established guidelines produces high-quality parts, correctly marked, with accurate dimensions and tolerances. Making sure all the specs are correct before production begins ensures there won’t be any issues during the process.
By using computer numerical control technology
It is essential to use CNC to maintain the quality and tolerances of complicated metal components because it automates this process.
In stamping, there are multiple steps involved, such as punching, bending, forming, and trimming. This requires a great deal of work from employees, making it difficult to meet high-quality standards when they have many tasks to complete.
CNC machines reduce the chance of human error during production by orienting parts based on their printed blueprints. This technology ensures that tolerances are considered, dimensions are exact, and all requirements are met before production begins.
By stamping at the correct temperature
Temperature plays a significant role in stamping because it can alter how metals behave. The heat treatment of metal components can affect whether ductile or brittle, their yield strength, and how much stress they will take before breaking. We consider these traits before stamping complicated metal parts because if these properties change, the part could break during production.
If excessive pressure is applied to a brittle material, it may cause cracking, prohibiting further production. Too much heat could cause deformation if the material becomes too soft; thus, it is essential to use temperatures to control these effects and ensure no damage.
By using data throughout the manufacturing process
Relevant data throughout the manufacturing process is essential for the accurate production of complicated metal components. For example, getting data on the material’s properties beforehand will give employees an understanding of how it will behave during production.
We establish a blueprint for each part, including the dimensions and tolerances necessary for its creation. Other information, such as the required finish, curvature, and any tools needed for this process must also be determined to ensure success.
We record critical dimensions, like overall length and width, before any processing begins, and these can be referenced if problems arise. We mark all stamps, cuts, holes, or other features appropriately using stencils or similar devices.
By examining each part
Before we use any parts, we should first check and inspect to ensure no damage occurred during production. If there is a problem with the part, it should be sent back to the supplier or discarded if it was manufactured in-house. Inspection ensures that all parts meet specifications and can be used as intended. In addition, we create assembly instructions, so workers on the receiving end know how to assemble them correctly.
This process ensures that complicated metal components are manufactured correctly and that all specifications are met.
Material preparation with spare parts can also ensure accuracy
Spare parts ensure accuracy when stamping complicated metal components with high tolerances and specifications for companies such as Boeing, Airbus, and GM. In this method, our operators use spare parts in place of the actual product, then heat treat each part accordingly.
This will allow them to know exactly how accurate their production process is without having to wait until heat treatment is complete on every individual part. After that, operators can adjust their processes if any deviation from the standard size is found at this stage.
Certification after production
Our operators also use certification after production so they can ensure products are stamped at the correct tolerances. This ensures product quality. They will stamp a few parts with certifications needed before mass production to know how their process is working out because the certification part is very expensive. Simultaneously, these parts will be heat treated depending on the tolerance required for the customer’s request. These parts are then used for certification purposes to balance out the cost.
Certification stamping after production is essential in ensuring the quality of complicated metal components because it shows how accurate the parts are with our customers’ specifications or tolerance levels.
Quality Assurance with testing for functionality
Another way they ensure accuracy is through quality assurance testing, which includes material, geometry, and heat treatment testing. Complicated metal components require strong materials that can withstand stamping pressure. They also need to be heat treated accordingly. If any deviation from the correct size or specification is found, then we adjust heat treatment, so no cracks form in part and it remains within tolerance.
Complicated metal components stamping differs from other metalworking operations because it requires machine operators, certified machinists, to use measurement equipment such as micrometers and gauges. Measurement accuracy is just as critical as part functionality in complicated metal component manufacturing.
Conclusion
Complicated metal components are typically produced by stamping. This process uses sheet metal and creates various shapes with distinct features. To ensure that these complicated pieces are stamped correctly, it is necessary to understand how to manage specific variables such as material properties, temperature, data throughout the manufacturing process, appropriate data on dimensions, critical information like overall length and width of parts, stencils, or other devices used for marking purposes, curvature for some designs, pressure applied during production, and any tools needed.
