Precision Metal Stamping: Guide to Materials & Modifications

Precision metal stamping is among the most common metalworking techniques utilized by various industries to turn sheet metal into custom parts.

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Progressive metal stamping uses tooling called a progressive die, which contains multiple stamping stations to perform simultaneous operations on a sheet metal strip. A feeding system unrolls the strip from its coil and pushes it through each of the die&#;s different workstations until the final part is made.

Because this process uses various materials and techniques, it&#;s essential to understand the options available and factors to consider before getting started.

Precision Metal Stamping Challenges

According to a Research and Markets report, the global metal stamping market will grow to $250 billion in . With increased demand and evolving tools and materials for precision metal stamping, the industry must adapt to overcome challenges. Today&#;s metal rolling techniques are more advanced than traditional hand processes, but manufacturers still face some common problems during production.

One of these common problems is metal cracking, which can occur along the edges during hot and cold rolling. This is sometimes due to uneven heating or rolling, but there are also metallurgical factors to consider.

Austenitic stainless steel has a high cold hardening index (0.34% for SS). Austenitic stainless steel is a meta-stable type, which will transform deformation, thus inducing a martensitic phase. The martensite phase is brittle and easy to crack. During plasticity deformation, with the increase of extension, the martensitic content will then increase, and the residual stress will also be increased. The greater the relationship between residual stress and martensite content there is, the greater the residual stress, and the easier cracking can occur during processing.

Like most challenges that occur during precision metal stamping, the best way to navigate cracking is to determine and address the root cause. Partnering with a precision reroll mill with metallurgical expertise can be a tremendous help for stampers in performing root cause analysis and resolving issues such as these.

Types of Steel Used for Precision Metal Stamping

Manufacturers can use a variety of metals in precision metal stampings. However, some processes and types of metals perform better in the precision metal stamping process or are a better fit for a particular use case.

Hot rolled steel is roll-pressed at high temperatures and cooled quickly, which leaves a rough surface. For purposes that require closer dimensional tolerances and accuracy, sheet metal is processed further at room temperature through cold finishing techniques.

During the cold rolling process, when the metal is put under mechanical stress, it causes a permanent change to the crystalline structure of the metal. This causes an increase in its strength and often improves corrosion resistance. A cold-rolled stainless steel coil can be precision manufactured, allowing the metal to be produced to extremely tight tolerances. Precision stamping itself uses stamping dies to form metal. This typically occurs at room temperature, making it a cold process.

Compared to hot rolled steel, cold-rolled steel has the following characteristics, making it ideal for the growing needs of precision metal stampers:

• Smooth finished surfaces
• Precise edges and flatness
• Dimensional Uniformity (width, thickness)
• Greater strength and hardness
• Uniform and predictable material properties

When choosing a metal to use, consider the benefits and limitations of each and the requirements for your part.

For example, aluminum is lighter than stainless steel, softer, and a good conductor of electricity. But stainless steel can handle much higher temperatures and more corrosive environments.

Titanium, on the other hand, is also light but much stronger and more durable than aluminum. This makes titanium particularly suited for aerospace, military, and defense applications where a high strength to weight ratio is needed. Titanium is also corrosion-resistant and safe to use in medical implants within the human body.

It&#;s all about matching the alloy and its properties with the needs of the application being manufactured.

Alloys used in Precision Metal Stamping:

Key Factors to Consider When Choosing a Material for Precision Metal Stamping

Some of the key factors to consider when choosing a material for precision metal stamping are the metal&#;s ductility & formability, tensile strength, machinability, and work hardening rate.

Ductility & Formability

Forming occurs somewhere between the yield strength and tensile strength of the material. If yield isn&#;t exceeded, forming doesn&#;t occur but exceeding the tensile strength results in a material fracture. In higher-strength materials, the window between yield and tensile is very small.

The grain size of a material is commonly used to indicate its formability, and consistent grain size is highly desirable for forming operations. Grain size can be controlled by a rerolling mill within a very close range by monitoring the temperature of the annealing furnace and the speed at which the strip passes through the line.

Tensile Strength

Tensile strength measures the amount of force a material can withstand without breaking. Some metals are stronger than others, and the strength varies depending on the component materials in a metal alloy. You should consider the tensile strength of the metal you choose to ensure that it can withstand the amount of force applied during use.

Machinability

Machinability measures how easily the material can be cut or shaped. Because properties that improve a material&#;s performance often reduce its machinability, you should consider the machinability of the metal you choose after satisfying other requirements for your part. A machinable material can be cut quickly with a good finish, which reduces costs. However, it&#;s more important to choose a material that meets the requirements of your part rather than choosing a machinable material.

Work Hardening Rate

As metal is worked or stamped, the temper changes, and the metal either becomes harder and more brittle. The rate that this occurs is work hardening. Depending on how much work is done to the metal and how much it needs to be deformed in a particular operation, the material may require annealing to reset its properties to prevent cracking, breaks, and other material imperfections.

Forming Operations in Precision Metal Stamping

In precision metal stampings, manufacturers use metal forming operations to make parts from metal and metal alloys. It is highly versatile and can be used to create complex, detailed components with an exceptional degree of accuracy and repeatability. What's more, deep-drawn parts are exceptionally strong due to the extreme amount of compression exerted on the metal during the forming process. The fundamental structure of deep-drawn metals is often highly compressed into a very hard crystalline structure.

A design guideline can help you decide the optimal materials and processes.

These are some of the most common forming operations used in precision metal stamping:

• Beads
• Bulging
• Coining
• Curling
• Dimpling
• Embossing
• Extruding
• Flanges
• Holes
• Ironing
• Marking
• Necking
• Notches
• Ribs
• Threading
• Trimming

Options That Fit Your Needs

Engineer-to-engineer collaboration between stampers and precision re-rollers is highly beneficial, especially during new product and process development.

Ulbrich&#;s metallurgical experts and wide alloy selection allow us to match precision metal stampers with the ideal material for their applications and equipment.

Contact us to learn how our solutions could help you reduce scrap and die wear.

Precision metal stamping is a versatile manufacturing process used to create a wide range of metal parts for various industries, including automotive, electronics, aerospace, and medical. It offers several advantages over other manufacturing processes, including :

You will get efficient and thoughtful service from greatlionparts.

• Cost-effectiveness: : Precision metal stamping can produce complex-shaped parts in a single step, reducing processing steps and lowering production costs.
  


• High production efficiency : We offer precise and reliable brackets for secure and stable stereo installation.
  


• High precision : Precision metal stamping can produce high-precision parts that meet strict quality requirements.
  

Read More : Advantages of Precision Metal Stamping in the 5G Communication Chassis and Intelligent Robots Era

Precision Metal Stamping Parts

Precision metal stamping parts are metal parts produced by precision metal stamping. They are widely used in various industries, such as automotive, electronics, aerospace, and medical.

• Applications in the Automotive Industry
  Precision metal stamping is a critical process in the automotive industry, used to produce a wide range of components, including :
  1.Automotive body panels
  2.Engine parts
  3.Transmission parts
  4.Electrical components
  5.Structural components
  
  
• Applications in the Electronics Industry
  Precision metal stamping is also widely used in the electronics industry to produce a variety of components, including:
  1.Electronic enclosures
  2.Heat sinks
  3.Shielding components
  4.Connectors
  5.Terminals

Read More : Industrial application of Precision Metal Stamping

Principles of Precision Metal Stamping

Precision metal stamping uses a press mold and a press machine to apply pressure to a metal sheet, deforming it into the desired shape. The press mold consists of an upper mold and a lower mold. The upper mold is fixed on the slide of the press machine, and the lower mold is fixed on the bed of the press machine. The press machine applies pressure to the upper mold, causing the upper and lower molds to approach each other, thereby stamping the metal sheet into the desired shape.

Precision Metal Stamping Material Selection

The selection of materials for precision metal stamping should consider the following factors :

• The shape and size of the part
  
• The performance requirements of the part
  
• Processing cost
  
• Common materials for precision metal stamping include :
  1.Steel sheets : Steel sheets are strong and durable, making them ideal for structural components and automotive parts.
  2.Aluminum sheets : Aluminum sheets are lightweight and corrosion-resistant, making them ideal for electronic enclosures and aerospace components.
  3.Copper sheets : Copper sheets are highly conductive, making them ideal for electrical components and heat sinks.
  4.Stainless steel sheets : Stainless steel sheets are strong, durable, and corrosion-resistant, making them ideal for medical devices and food processing equipment.
  

Read More : Material Selection Crucial : Elevating Metal Stamping Processes

Automotive Metal Stamping Process

The automotive metal stamping process generally includes the following steps:

• Material preparation :
  The metal sheet is first cleaned and prepared to remove any impurities or contaminants.
• Mold design and manufacturing :
  The press mold is designed and manufactured based on the specifications of the part to be produced.
• Stamping processing :
  The metal sheet is placed in the press mold, and the press machine is used to apply pressure to the upper mold, causing it to deform the metal sheet into the desired shape
• Post-processing :
  After stamping, the part may undergo additional processing, such as trimming, deburring, and heat treatment.

Read More : Mastering Metal Stamping: A Comprehensive Guide to Precision Manufacturing Processes

Challenges of Metal Stamping Miniature Components

Precision metal stamping of miniature components presents the following challenges:

• High precision requirements :
  Miniature components require high precision in terms of their dimensions and tolerances
• Difficult mold manufacturing :
  The manufacturing of molds for miniature components is more complex and challenging than for larger components.
• Prone to burrs and flash :
  Miniature components are more prone to burrs and flash, which require additional processing to remove.

Read More : Mastering Metal Stamping: A Comprehensive Guide to Precision Manufacturing Processes

How to Choose the Right Metal Stamping Service Company

When choosing a precision metal stamping manufacturer, consider the following factors:

• The qualifications and experience of the manufacturer : The manufacturer should have the necessary qualifications and experience to produce the required parts.
• The equipment and technical capabilities of the manufacturer : The manufacturer should have the necessary equipment and technical capabilities to produce the required parts to the required quality standards.
• The quality control system of the manufacturer : The manufacturer should have a robust quality control system in place to ensure the quality of the parts produced.
• The price and service of the manufacturer : The manufacturer should offer competitive prices and good customer service.

Precision metal stamping is a critical manufacturing process for a wide range of industries. By understanding the advantages, principles, and challenges of precision metal stamping, manufacturers can select the right materials, processes, and service providers to meet the specific needs.

Read More :
10 Challenges of Metal Stamping Miniature Components

Your 3-Minute Guide to the Automotive Metal Stamping Process

If you have any questions about precision metal stamping, please contact us at or contact us. We would be happy to discuss your specific needs and requirements.

The company is the world’s best high precision stamping parts supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.