Countermeasures for Various Process Issues in Stamping Part Manufacturing

Shenjia Hydraulics

Release Date:

2020-06-08

The majority of steel products are manufactured through stamping, a process that can produce components with stiffening ribs, flanges, corrugations, or hemming—features that are difficult to achieve by other methods—thereby enhancing their structural rigidity. Moreover, compared with castings and forgings, stamped parts are characterized by thin walls, uniform thickness, light weight, and high strength; dimensional accuracy can reach the micrometer level, with excellent repeatability and consistent specifications, and they can even be stamped with holes, recesses, bosses, and other features. Stamping is a forming process in which a press and dies apply external forces to sheet metal, strip stock, tubing, and structural profiles, inducing plastic deformation or separation to produce workpieces with the desired shape and dimensions. In this process, certain challenges are inevitably encountered—so how should they be addressed?

The majority of steel products are manufactured through stamping, a process that can produce parts with stiffening ribs, flanges, corrugations, or hemming—features that are difficult to achieve by other methods—thereby enhancing their structural rigidity. Compared with castings and forgings, stamped parts are characterized by thin walls, uniform thickness, light weight, and high strength; dimensional accuracy can reach the micrometer level, with excellent repeatability and consistent specifications, and they can readily accommodate features such as holes, recesses, and bosses. Stamping is a forming process in which external forces are applied to sheet, strip, tubular, and structural materials using presses and dies, inducing plastic deformation or separation to produce workpieces with the desired shape and dimensions. In the course of this process, certain challenges are inevitably encountered—how should these be addressed and managed? When stamping operations demand high cross-sectional quality and dimensional accuracy, an additional trimming operation may be added after the blanking stage, or precision blanking can be employed directly. To enhance the stability of precision stamping processes, it is sometimes necessary to increase the number of operations to ensure part quality. In many cases, the number of operations required for bending parts depends primarily on the complexity of their geometry, specifically on the number of bend angles, their relative positions, and the direction of bending. If the bend radius of a bent part falls below the permissible limit, a shaping operation should be performed after bending. Similarly, the number of operations for deep-drawn parts is influenced by material properties, drawing height, number of drawing stages, drawing diameter, material thickness, and other factors; these must be determined through detailed deep-drawing process calculations. When the corner radii of deep-drawn parts are small or when stringent dimensional tolerances are required, a shaping operation should be added following the drawing process. On top of this, the determination of the total number of stamping operations must also take into account the enterprise’s existing tool-making capabilities and the condition of its stamping equipment. Tool-making capacity must be sufficient to meet the corresponding requirements for improved die machining and assembly accuracy; otherwise, the number of operations will have to be increased. For workpieces with simple blanking geometries, a single-operation die can be used; conversely, for complex stamped parts, due to limitations in die design or strength, the internal and external contours must be divided into multiple sections for separate blanking, necessitating a multi-step stamping sequence.

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