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What is stamping manufacturing
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Stamping is a forming processing method that relies on presses and molds to apply external forces to plates, strips, pipes and profiles to make them plasticly deform or separate, so as to obtain the desired shape and size of the workpiece (stamping part). Stamping and forging are both plastic machining (or pressure processing), collectively known as forging pressing. The stamped blanks are mainly hot-rolled and cold-rolled steel plates and steel strips. Of the world's steel, 60 to 70% are plates, most of which are stamped into finished products. The body, chassis, fuel tank, radiator sheet, boiler drum of the car, the shell of the container, the iron core silicon steel sheet of the motor and electrical appliances are all stamped and processed. Instrumentation, household appliances, bicycles, office machinery, living utensils and other products, there are also a large number of stamped parts.
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Stamping is a forming and processing method that applies external force to sheets, strips, pipes and profiles by means of presses and dies to cause plastic deformation or separation to obtain workpieces (stampings) of desired shape and size. Stamping and forging are both plastic processing (or pressure processing), collectively called forging.
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The stamped blanks are mainly hot-rolled and cold-rolled steel sheets and strips. 60-70% of the world's steel products are sheets, most of which are stamped into finished products. The body, chassis, fuel tank, radiator sheet of the car, the steam drum of the boiler, the shell of the container, the iron core silicon steel sheet of the motor and electrical appliances, etc. are all stamped. There are also a large number of stamping parts in instruments, household appliances, bicycles, office machinery, living utensils and other products.
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There are many types of stamping. Common ones are cold stamping, hot stamping (red stamping) and cold extrusion. Its working principle is to apply pressure through special stamping equipment to make the metal plastically change to obtain a certain shape and size design parts.
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Three necessary conditions for stamping processing: mold, sheet and stamping equipment. Different molds have different structures and manufacturing costs. They also work differently. The thickness of the sheet determines the tonnage (pressure) of the stamping equipment, and different dies determine the production efficiency. Efficiency, in turn, is related to the number of products, which in turn is related to manufacturing costs.
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The die used for stamping is called a stamping die, abbreviated as a die (tool). A die is a special tool for batch processing a material (metal or non-metal) into the desired parts. Dies are very important in stamping. Without a die that meets the requirements, it is difficult to carry out mass stamping production; without an advanced die, advanced stamping technology cannot be achieved. Stamping process and dies, stamping equipment and stamping materials constitute the three elements of stamping processing, and stamping parts can be obtained only when they are combined with each other.
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The process of stamping die is divided into: punching blanking die, punching bending die, punching drawing die, cold stamping die, cold extrusion die, hot stamping die, bending die, continuous die and so on.
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Among them, the continuous mold is the mold with the highest production efficiency in the current industrial manufacturing. But it has one basic condition, MOQ requirement. Products with less than 50,000 pieces are basically not suitable for continuous mold manufacturing. Advantages of Continuous Die: Low cost to manufacture parts. High production efficiency and high dimensional accuracy. No matter how complex the parts are, basically all production processes can be completed on one set of molds. Its disadvantage is that the mold manufacturing cost is expensive.
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The production efficiency of the single-process mold is low, and it needs to be processed one by one manually or by a robot. This situation is only suitable for demand between a few hundred pieces to a few thousand pieces. However, this kind of mold has low manufacturing cost and strong applicability. Because each process requires manual operation. Therefore, the unit price of the product is high, but it is suitable for small batch production.
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1. The most commonly used materials in stamping production are metal materials (including ferrous metals and non-ferrous metals), but sometimes non-metallic materials are also used. Among them, ferrous metals mainly include ordinary carbon structural steel, high-quality carbon structural steel, alloy structural steel, carbon tool steel, stainless steel, electrical silicon steel, etc.; non-ferrous metals mainly include pure copper, brass, bronze, aluminum, etc.; non-metallic materials There are cardboard, laminate, rubber sheet, plastic sheet, fiberboard and mica, etc.
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The supply status of metal materials for stamping is generally sheets and strips of various specifications. Sheets can be used for the production of engineering molds, strips (coils) are used for the production of continuous molds, and can also be used for the production of engineering molds. The size of the sheet is larger. Conventional material specifications are: 2440*1220mm, and thicknesses from 0.05 to 5mm are commonly used materials. For the stamping of large parts, the sheet can also be cut into strips according to the layout size and used for stamping of small and medium-sized parts; strips (also known as coils) have various widths, and the unfolded length can reach tens of meters~ Hundreds of meters, supplied in rolls, suitable for automatic feeding of continuous mold mass production.
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2. Reasonable selection of stamping materials
The selection of stamping materials should consider the use requirements of stamping parts, stamping process requirements and economy.
(1) Reasonable selection of materials according to the use requirements of stamping parts
The selected material should enable the stamping to work properly in the machine or component and have a certain service life. To this end, the selected materials should meet the requirements of the corresponding strength, stiffness, toughness, corrosion resistance and heat resistance according to the use conditions of the stamping parts.
(2) Reasonable selection of materials according to stamping process requirements
For any kind of stamping part, the selected material should be able to stably form a qualified product without cracking or wrinkling according to the requirements of its stamping process, which is the most basic and most important material selection requirement. To this end, the following methods can be used to select materials reasonably.
① Try punching. According to the previous production experience and possible conditions, several kinds of sheet materials that can basically meet the requirements of stamping parts are selected for trial punching, and finally the one that has no cracks or wrinkles and has a low rejection rate is selected. The results of this method are more intuitive, but with greater blindness.
② Analysis and comparison. On the basis of analyzing the properties of stamping deformation, the maximum deformation degree during stamping forming is compared with the limit deformation degree allowed by the sheet metal stamping forming performance, and based on this, the sheet metal suitable for the stamping process requirements of this kind of parts is selected. . In addition, there are cold-rolled and hot-rolled sheets of the same grade or thickness. Among the domestically produced plates in my country, thick plates (t>4mm) are hot-rolled plates, and thin plates (t<4mm) are cold-rolled plates (also hot-rolled plates). Compared with hot-rolled sheet, cold-rolled sheet has precise dimensions, small deviation, less surface defects, brighter, denser internal structure and better stamping performance. (Note: t generally represents the thickness in the mold. For example, the thickness of the template and the thickness of the material can be represented by t.)
(3) Reasonable selection of materials according to economic requirements
The selected materials should be as low in price, convenient in source and economical as possible on the premise of meeting the performance and stamping process requirements, so as to reduce the cost of stamping parts.
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Kamikawa Precision has its own stamping factory and tool shop. We are equipped with stamping equipment of different tonnage, ranging from dozens of tons to hundreds of tons. Our large and small stamping equipment has more than 120 sets, which can well meet the needs of different customers for stamping processing.
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We have 6 professional stamping die design engineers. 22 mold manufacturing engineers. Among them, there are 15 mold manufacturing engineers with more than 10 years of work experience. From mold design to mold making, to tryout and mass production, every ring is guaranteed to be foolproof.
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Kamikawa Precision has its own mold manufacturing workshop. Equipped with a variety of advanced CNC mold manufacturing equipment: 5 sets of large CNC machining centers (maximum processing range: 2000*1000mm), 2 sets of CNC lathes, 5 sets of EDM wire cutting, 2 sets of EDM EDM, 15 sets of fast running wire cutting. Mold testing equipment quadratic element imager and CMM. These are the necessary conditions for guaranteeing mold manufacturing.
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Kamikawa Precision follows standard molding processes. Analyze the manufacturing process from the product drawings provided by the customer. Its flow mold manufacturing flow sum is: product process analysis - mold design - drawing review - mold manufacturing - mold testing - sample confirmation - mass production.
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It is divided into medium mold manufacturing: material preparation - machining - heat treatment - grinding - wire cutting - EDM - assembly - tryout - mass production.
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Generally, simple molds take 7-10 days to complete, and complex continuous molds take 25-30 days to complete the manufacturing work. It depends on the complexity of the product.
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Kamikawa Precision thinks from the customer's point of view from the beginning. First, we will analyze the customer's product drawings before designing the mold. Discuss the feasibility of mold manufacturing and select the optimal mold manufacturing scheme. Thereby avoiding the additional manufacturing cost caused by repeated modification of the mold.
The quality of stamping products is completely determined by the quality of the mold. A set of well-designed molds can ensure the product shape is stable, the tolerance size is consistent, and there are many advantages such as no burrs.
Kamikawa Precision's molds are made of Swedish ASSAB high-quality cold stamping mold steel or Japanese imported KD11 mold steel. After vacuum heat treatment, its hardness can reach HRC60~62 degrees. It is an ideal mold material and can easily punch out stainless steel sheets. The punches and knife edges of the molds are all EDM wire-cut with a maximum precision of 0.002mm. We can also carry out titanium plating on the punches and cutting edges of the molds according to different needs. in order to achieve a more durable effect.
The minimum die life of stamping dies manufactured by Kamikawa Precision can reach more than 50,000 punches. Precision continuous mold can reach more than 300,000 to 500,000 times. By replacing the punch and cutting edge, the die life can also be extended by more than 80%.
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Different products have different surface treatment requirements. Kamikawa Precision can do a variety of different surface treatments. Common surface treatments are: electroplating, electrophoresis, polishing, spraying, wire drawing, sandblasting, passivation, blackening, QPQ, PVD, heat treatment, anodizing. Of course, we can also customize according to customer requirements;
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We have a complete surface treatment supply chain and are excellent in the surface treatment of metal materials. All electroplating, electrophoresis, spraying, blackening and anodizing are made of anti-UV materials, which can ensure that the outdoor does not fade for 5-10 years.
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Kamikawa Precision can manufacture various stamping parts, common products are: metal brackets, metal panels, chassis casings, shrapnel, terminals, auto parts, furniture parts, various electrical metal parts, metal deep drawing parts, etc.
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You just need to send me the drawings. We will be able to provide you with the answer, and provide a quotation service in as little as 2 hours. Welcome new and old customers to consult and understand.
