is Metal Stamping:
stamping is the process in which small, simple or complex shapes
are punched-out in a continuous sheet of metal (blank) by using
instruments such as punches and dies. Complex shapes are generated
by successively stamping the metal sheet with punches of different
shapes, starting with a rough shape, to the final punch. Stamping
is a high volume production method and machines called presses
that can generate 100 or more strokes per minutes are used.
By using metal stamping, pieces of metal can be made into a
three-dimensional object from a flat piece of metal. The object
will also be stronger than if it was machined by any other process.
Metal stamping can also be used on a piece of metal to make
a relief design.
is made of hardened casing or hardened steel, while the punch
is made of carbide or hardened, precision, ground, tool steel.
The stamping machine or press may be powered by hydraulics,
pneumatics or electric.
are various types of presses that are used in metal stamping.
A forge press is used to turn the metal piece into a three
dimensional object. A press brake is used to bend the metal
to force it to change its shape. A punch press is used to
punch holes into the metal sheet. A set of rollers may be
employed to make the metal pieces either thinner or wider.
This is done by feeding the metal through the set of rollers
to flatten it out. A set of plates can be used to stamp various
designs or reliefs into the metal pieces
clearance between the die and the punch is required for increased
tool life. Proper layout of the blank, punch and die must
be done to ensure the minimum waste of the blank material,
with just the right amount of wall thickness between adjacent
punched parts. In addition, edge beading and shoulder forming
can also be done. Metals such as brass, aluminum, bronze,
fiber, inconel and steel can be stamped. There is a maximum
sheet thickness up to which the metal can be stamped.
common type of metal stamping is called progressive die stamping.
In this method, the metal is fed through a number of different
dies, or stamping stations, at the same time. This process
enables the piece to receive an assortment of shapes or impressions
at once. The advantage of this is that it speeds up the procedure
as the metal sheet doesn't have to be taken out and reinserted
to a new die station each time.
is CNC Machining:
numerical controlled (CNC) machine tools are the best tools
to use for automated machining. The machines can be as simple
as a drilling machine that drills a hole repeatedly or they
can be huge complex devices that can machine large cylinder
blocks in multiple designs.
machines can be operated either unmanned or with a few operators
manning a production cell of many machines. Once the program
that is used to give the machining detail and the tools to
be used, etc. is given, then the machinery can run by itself.
They will change the tools in the ordered sequence; turn the
component around so that a fresh face is exposed, and so on.
Because these machines can run by themselves for hours at
a time, they save you manpower. Usually roughing operations
are done on other machines to save on productivity.
they are computer programmed, CNC machining is more accurate,
consistent and precise than human operated machining as this
system doesn’t require human adjustment for its settings.
There are no errors in CNC machining as the machinery operates
exactly as the computer programs it to. This enables complicated
machining tasks to be performed repetitively and the finished
product will be the same each time.
operation is relatively easy to learn and to set up as you
just have to enter the instructions into a computer program.
You can also recall the machine’s previous settings
instantly. This process allows you to save time as lengthy
manual changeovers are not required.
have two tables and an automatic pallet changer. This saves
valuable time as it allows components to be machined on one
table while a fresh component can be loaded on another. There
are various types of CNC machines available such as: turning;
drilling; grinding; and machining centers that perform milling,
drilling, boring, tapping, and contour operations.
is a metal joining process in which two pieces of metal, touching
each other, are melted at the edges by a welding gun to fuse
them together. When the metals cool down, a strong bond is created.
Welding can be done by using either pressure or by using a filler
material. The heat can be provided by an electric arc, a gas
flame, laser, electron beam, ultrasound, the electrical resistance
of the metals or through a chemical reaction. There are different
types of welding processes such as spot welding, mig welding,
tig welding, seam welding, projection welding, gas welding,
resistance welding, induction welding, thermal welding, and
forge welding, etc. Welding rods and electrodes are used in