Stamping includes a variety of sheet-metal forming manufacturing processes, such as
punchingPunching in metalworking is the process of using a punch press to push a punch through the material and into a die to create a hole in the workpiece. A scrap slug from the hole is deposited into the die in the process. Depending on the material being punched this slug may be recycled and reused or...
using a
machine pressA press, or a machine press is a tool used to work metal by changing its shape and internal structure.A forge press reforms the work piece into a three dimensional object—not only changing its visible shape but also the internal structure of the material...
or
stamping pressA stamping press is a metalworking machine tool used to shape or cut metal by deforming it with a die.A press has a press frame, a bolster plate and a ram. The bolster plate is a large block of metal upon which the bottom portion of a die is clamped; the bolster plate is stationary...
, blanking, embossing, bending, flanging, and coining. This could be a single stage operation where every stroke of the press produce the desired form on the sheet metal part, or could occur through a series of stages. The process is usually carried out on
sheet metalSheet metal is simply metal formed into thin and flat pieces. It is one of the fundamental forms used in metalworking, and can be cut and bent into a variety of different shapes. Countless everyday objects are constructed of the material...
, but can also be used on other materials, such as
polystyrenePolystyrene , sometimes abbreviated PS, is an aromatic polymer made from the aromatic monomer styrene, a liquid hydrocarbon that is commercially manufactured from petroleum by the chemical industry...
.
- Bending
Bending is a common metalworking technique to process sheet metal. It is usually done by hand on a box and pan brake, or industrially on a brake press or machine brake...
- Blanking
Blanking is a shearing process where a punch and die are used to create a "blank" from sheet metal or a plate. The process and machinery are usually the same as that used in piercing, except that the piece being punched out in the piercing process is scrap....
- Coining
- Drawing
Drawing is a metalworking process which uses tensile forces to stretch metal. It is broken up into two types: sheet metal drawing and wire, bar, and tube drawing. The specific definition for sheet metal drawing is that it involves plastic deformation over a curved axis...
- Deep drawing
Deep drawing is a sheet metal forming process in which a sheet metal blank is radially drawn into a forming die by the mechanical action of a punch. It is thus a shape transformation process with material retention. The flange region experiences a radial drawing stress and a tangential compressive...
- Repoussé and chasing
Repoussé or repoussage is a metalworking technique in which a malleable metal is ornamented or shaped by hammering from the reverse side. There are few techniques that offer such diversity of expression while still being relatively economical. Chasing is the opposite technique to repoussé, and...
(embossing)
- Forming
- Piercing
Piercing is a shearing process where a punch and die are used to create a hole in sheet metal or a plate. The process and machinery are usually the same as that used in blanking, except that the piece being punched out is scrap in the piercing process...
- Progressive stamping
Progressive stamping is a metalworking method that can encompass punching, coining, bending and several other ways of modifying metal raw material, combined with an automatic feeding system....
Stamping simulation is a technology that calculates the process of sheet metal stamping, predicting common defects such as splits, wrinkles, springback and material thinning.
Discussion
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Stamping includes a variety of sheet-metal forming manufacturing processes, such as
punchingPunching in metalworking is the process of using a punch press to push a punch through the material and into a die to create a hole in the workpiece. A scrap slug from the hole is deposited into the die in the process. Depending on the material being punched this slug may be recycled and reused or...
using a
machine pressA press, or a machine press is a tool used to work metal by changing its shape and internal structure.A forge press reforms the work piece into a three dimensional object—not only changing its visible shape but also the internal structure of the material...
or
stamping pressA stamping press is a metalworking machine tool used to shape or cut metal by deforming it with a die.A press has a press frame, a bolster plate and a ram. The bolster plate is a large block of metal upon which the bottom portion of a die is clamped; the bolster plate is stationary...
, blanking, embossing, bending, flanging, and coining. This could be a single stage operation where every stroke of the press produce the desired form on the sheet metal part, or could occur through a series of stages. The process is usually carried out on
sheet metalSheet metal is simply metal formed into thin and flat pieces. It is one of the fundamental forms used in metalworking, and can be cut and bent into a variety of different shapes. Countless everyday objects are constructed of the material...
, but can also be used on other materials, such as
polystyrenePolystyrene , sometimes abbreviated PS, is an aromatic polymer made from the aromatic monomer styrene, a liquid hydrocarbon that is commercially manufactured from petroleum by the chemical industry...
.
Operations
- Bending
Bending is a common metalworking technique to process sheet metal. It is usually done by hand on a box and pan brake, or industrially on a brake press or machine brake...
- Blanking
Blanking is a shearing process where a punch and die are used to create a "blank" from sheet metal or a plate. The process and machinery are usually the same as that used in piercing, except that the piece being punched out in the piercing process is scrap....
- Coining
- Drawing
Drawing is a metalworking process which uses tensile forces to stretch metal. It is broken up into two types: sheet metal drawing and wire, bar, and tube drawing. The specific definition for sheet metal drawing is that it involves plastic deformation over a curved axis...
- Deep drawing
Deep drawing is a sheet metal forming process in which a sheet metal blank is radially drawn into a forming die by the mechanical action of a punch. It is thus a shape transformation process with material retention. The flange region experiences a radial drawing stress and a tangential compressive...
- Repoussé and chasing
Repoussé or repoussage is a metalworking technique in which a malleable metal is ornamented or shaped by hammering from the reverse side. There are few techniques that offer such diversity of expression while still being relatively economical. Chasing is the opposite technique to repoussé, and...
(embossing)
- Forming
- Piercing
Piercing is a shearing process where a punch and die are used to create a hole in sheet metal or a plate. The process and machinery are usually the same as that used in blanking, except that the piece being punched out is scrap in the piercing process...
- Progressive stamping
Progressive stamping is a metalworking method that can encompass punching, coining, bending and several other ways of modifying metal raw material, combined with an automatic feeding system....
Simulation
Stamping simulation is a technology that calculates the process of sheet metal stamping, predicting common defects such as splits, wrinkles, springback and material thinning. Also known as forming simulation, the technology is a specific application of non-linear finite element analysis. The technology has many benefits in the
manufacturingManufacturing is the use of machines, tools and labor to make things for use or sale. The term may refer to a range of human activity, from handicraft to high tech, but is most commonly applied to industrial production, in which raw materials are transformed into finished goods on a large scale...
industry, especially the
automotive industryThe automotive industry designs, develops, manufactures, markets, and sells the world's motor vehicles. In 2008, more than 70 million motor vehicles, including cars and commercial vehicles were produced worldwide....
, where lead time to market, cost and
lean manufacturingLean manufacturing or lean production, which is often known simply as "Lean", is a production practice that considers the expenditure of resources for any goal other than the creation of value for the end customer to be wasteful, and thus a target for elimination...
are critical to the success of a company.
Recent research by the Aberdeen research company (October 2006) found that the most effective manufacturers spend more time simulating upfront and reap the rewards towards the end of their projects.
http://www.aberdeen.com/summary/report/benchmark/BM_Simulation_driven_Design_3591.asp
Stamping simulation is used when a sheet metal part designer or toolmaker desires to assess the likelihood of successfully manufacturing a sheet metal part, without the expense of making a physical tool. Stamping simulation allows any sheet metal part forming process to be simulated in the virtual environment of a PC for a fraction of the expense of a physical tryout.
Results from a stamping simulation allow sheet metal part designers to assess alternative designs very quickly to optimize their part for low cost manufacture.