Metal Stamping Manufacturing Explained
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If you&#;re not yet familiar with the manufacturing method known as metal stamping, you&#;ve come to the right place to learn! Dayton Rogers pioneered the practice of short run metal stampings back in , and we have now been in the metal stamping industry for almost a century.
One of our greatest contributions to metal stamping is our development and distribution of The Original Metal Forming Design Handbook- Cost Effective Design Principles, AKA The Red Book. The Red Book is a comprehensive guide to all the things you need to know when designing a part for metal stamping and other secondary manufacturing methods. In today&#;s blog we&#;ve gathered some of the most fundamental design information from the Red Book to share with you all, along with some other design considerations to keep in mind when designing a part for stamping manufacturing.
The first consideration to make when designing a part for metal stamping is the type of material you want your metal stamping to be made from. This selection will rely primarily on the physical and chemical properties of the metal- although in applications where your stamping will be exposed, it might be worth considering the visual appeal of your metal choice as well.
Below are a few of the metals that we stamp here at Dayton Rogers, along with the properties of each that will affect their viability as a metal stamping choice.
Ferrous materials like steel are highly durable, making them a good choice for use in rugged environments or demanding applications. Steel and stainless steel parts are commonly selected for metal stampings as steel is easily obtainable, takes well to forming, and is also compatible with secondary fabrication processes such as welding. Stainless steel in particular is a good choice for applications where corrosion resistance is critical.
Aluminum is known for its malleability, which makes it a great candidate for metal stamping manufacturing. It is also available at a fairly low cost compared to other metals. This lightweight material is a great selection for uses where weight is an important factor, such as in the automotive and aerospace industries. Aluminum is also a great conductor of heat and electricity, should your project call for either.
Another malleable family of metals, copper and copper based materials make excellent stamping candidates. Copper is resistant to corrosion, especially after going through stamping manufacturing processes. It is highly conductive and can be alloyed with many other materials to achieve a desired set of properties.
While brass is another copper-based alloy, the addition of zinc makes it a significantly harder material. This makes it well suited for stamping applications that demand a higher impact resistance compared to other copper alloys.
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While titanium&#;s low density and high strength make it an excellent material for aerospace applications, that same strength also serves as a drawback in stamping manufacturing. Stamping titanium is something that can be done, but it commonly requires secondary fabrication methods to achieve the desired result.
Deep drawn metal stampings can be classified into 3 categories, simple, average & difficult. Simple drawn parts usually have the following characteristics; Straight one diameter shell, no critical visual requirements, corner radius equal to 3 times material thickness or greater, an overall length of 1 ½ to 2 ½ times the diameter of the part, an overall length tolerance of plus or minus .005, a wall thickness of .010 &#; .020 and a tolerance for the outside or inside diameter of the part of plus or minus .002.
An average drawn part may be a two or three step diameter shell, average visual requirements, corner radius 3 times material thickness or greater, overall length 2 ½ to 3 ½ times the diameter of the part, an overall length tolerance of plus or minus .005, a .012 &#; .025 wall thickness and an outside diameter or inside diameter tolerance of plus or minus .001.
Moving forward with our examination of part characteristics, the next type of part would be classified as difficult. These parts typically have tapered drawn shells, average visual requirements, overall length of 3 ½ to 5 times the diameter of the shell, overall length tolerance of + or &#; .005, outside diameter or inside diameter tolerance of + or &#; .001 and material requirements of stainless steel, titanium or Monel.
Lastly, regarding the characteristics would be the most difficult part types. These parts could have features such as radial nose shaped shells, multiple pierced or formed shells and sides pierced or thread rolled shells. Parts classified as most difficult may also have involved secondary operations. The overall length of the part will be greater than 5 times the diameter of the shell, and tolerances will be critical.
Accurate Forming is a Deep Draw Metal Stamper who was established in . All of Accurate Forming&#;s operations take place in our 70,000 square foot facility located in Hamburg, NJ. Accurate Forming manufactures cylindrical shaped parts using transfer press technology. The size range for these parts ranges from .700&#; in length with a diameter of 1.562&#; all the way to 5.44&#; in length with a .400&#; diameter. Material thicknesses range from .007&#; thick up to .062&#; thick. Materials that are used in the deep draw manufacturing process are aluminum, cold rolled steel, pre-plated crs, stainless steel, copper, brass and other precious metal alloys.
Please contact Accurate Forming at (973)827- or at [ protected] or visit our website at www.accurateforming.com to learn more about what Accurate Forming can do for you.
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