Metal stamping is a widely used manufacturing process that involves shaping metal parts with the help of a press and dies. It’s an efficient way to manufacture precision components quickly and cost-effectively. In this article, we’ll overview the metal stamping process, discuss different techniques used, and explain the types of motor lamination stamping.
What is Metal Stamping?
Metal stamping is a popular manufacturing process for developing parts with tight tolerances using sheet metal, like steel, copper, stainless steel, and aluminum.
The process involves blanking the part, punching it to shape, bending it into position, drawing it to form the desired shape, and finally embossing it with a message or design.
During this process, we can press different materials into desired shapes using pressure or force applied through mechanical, manual, or other tools. This manufacturing method is often suitable for producing large quantities of components accurately and efficiently.
Process of Metal Stamping
Metal stamping encompasses multiple forming techniques, such as blanking, punching, embossing, and progressive die stamping. In bending, blanking, coining, and flanging processes, the shape of the part is defined by a die or template. In forging, the part is formed by hammering a flat piece of metal into shape.
Here’s a closer look at each step:
Designing The Parts To Be Stamped:
This first step involves creating a design based on customer specifications to make items efficiently with minimal waste when they reach later stages of production. This could involve creating CAD models or drawings to guide the rest of the fabrication work afterward.
Preparing The Materials For The Job:
This step includes prepping metals by cutting them into specified sizes using shears or laser cutters before being ready for further processing. During this time, an alloy may need to be hardened by heat treatment before being stamped into desired shapes via appropriate tooling sets.
Choosing The Best Tooling For The Job:
According to size (punch diameter), shape (die radius), hardness (tempered steel), etc., we select tool sets, ensuring optimal performance during stamping operations.
Setting Up And Operating The Equipment:
Tool and die-making are essential for setting up and operating the equipment for metal stamping. Stamping presses range in size from 10 to 250 tons and can be either mechanical or hydraulic. We use various tools and dies to form the desired shapes on the flat metal sheets fed into the press.
Once all the preparatory work is done, we must properly align the machine before running. This requires us to assemble the molds into the press and have it release enough pressure so that they don’t move. At the same time, we program the machine according to the specified type/size/shape specification.
Quality check and package:
It is essential to perform quality checks on metal stamping. Quality checks can be done with a check fixture or check gauge and involve testing the material, process, and finished part.
We ensure that products meet all requirements and package them according to customer specifications.
Types of metal stamping
Metal stamping includes a variety of types, including progressive die stamping, transfer stamping, four-sild stamping, and more.
Progressive die stamping
Progressive die stamping involves moving strip metal through a progressive stamping press, passing it from one station to the next.
The progressive die stamping process produces small, precision parts, such as medical and electronic stampings, metal clips, brackets, and spring clips. These pieces are made by pressing one metal die against a workpiece until finished.
It has the advantages of a quick turnaround without the need for multiple dies or welding steps and the creation of repeated, uniform pieces.
And progressive stamping is ideal for long runs since the dies last longer and do not sustain any damage due to the process. This makes them ideal for continuously producing small parts with high accuracy and precision.
Transfer die stamping
Transfer die stamping produces large parts and workpieces with lower tooling costs than progressive die stamping.
Unlike progressive die stamping, where the in-progress part remains on the metal strip and is moved between stations. Transfer die stamping removes the part from the strip and places it on a stationary platform for stamping.
This process allows for designs where the metal strip may interfere with complex design features.
Four-slide stamping is a versatile and cost-effective technique that can form complex components with multiple bends and twists. Instead of using a single vertical slide to shape the workpiece, four sliding tools are attached to each slide.
These tools allow precise control over the location and angle at which the workpiece is pressed between them. This process is controlled by a cam that rotates as the workpiece moves between the different tools.
Deep draw stamping
Deep draw stamping is a process that creates parts with complex shapes and designs in one step.
This type of stamping is commonly suitable for various industries, including the automotive, aerospace, and medical sectors.
Deep draw stamping forms metal parts by drawing them into a die with a punch, resulting in intricate details and a high surface finish.
Short-run stamping is a low-volume production run with limited tool revisions. Short runs can be cost-effective for parts requiring less flexibility, low volume, or entering a new market.
However, very short runs may have no changing factors, resulting in the lowest price per unit.
What types of metal stamping are used for motor lamination?
Progressive stamping is a type of metal stamping used for motor lamination. It involves cutting and forming metal sheets into specific shapes, with multiple operations performed in one pass. This process offers high speed, accuracy, and repeatability, which makes it ideal for producing motor laminations.
Compound stamping is another type of metal stamping used for motor lamination. With compound stamping, multiple operations are combined into one pass of the sheet metal. This technique also offers greater efficiency and accuracy compared to progressive stamping.
Rotary notching is yet another type of metal stamping used for motor lamination. It can create complex shapes in metal parts quickly and accurately.
It can also notch existing metal parts to create features such as grooves or cavities needed to improve performance. Therefore, it is an ideal choice for motor lamination applications.
Our Manufacturing Metal Stamping Die Capability
We are a manufacturing leader in metal stamping for motor core laminations and specialize in stamping dies. Our die shop offers high-precision stamping for motor cores and high-quality services for our client’s manufacturing needs.
We use cutting-edge technologies to create custom-made stamping dies for metal part manufacturing. Our die capability allows us to create motor core lamination stamping dies of various shapes and sizes.
Benefits of Metal Stamping
The main advantage of metal stamping compared to traditional machining processes is its cost-effectiveness since it requires minimal steps in the production cycle.
Additionally, it can produce complex shapes from thin sheets with high accuracy. Therefore, it is ideal for producing small parts like nuts, screws, rivets, and miscellaneous hardware.
Moreover, its high accuracy levels can also be suitable for intricate medical devices or consumer electronics parts.
Furthermore, due to reduced contact time between tool and material, it produces better quality parts with less scrap material than die casting or forging.
Applications of metal stamping
Metal stamping offers a cost-effective manufacturing solution with short lead times that can produce high volumes of highly precise parts in various sizes and materials.
It can produce parts and components across many industries, such as automotive, aerospace, medical, and electronics.
Examples of products made with metal stamping include agricultural parts, electronics, home appliances, and telecommunications products.
Other applications include decorative items, sheet metal enclosures, nuts, washers, rivets, fasteners, brackets, springs, and connectors.
Why use metal stamping for motor lamination?
– Speed, accuracy, and repeatability
– Cost-effective compared to other metal fabrication processes
– Allows for the production of complex shapes in shorter lead times
– Tool-free production, meaning less downtime due to wear on tooling and longer product life cycles
These benefits make metal stamping an excellent choice for motor lamination applications.
What are the materials used for motor core lamination?
Silicon steel is one of the most common materials for motor core lamination. This material is well known for its high permeability and low coercivity. Its excellent electrical properties and higher relative saturation point make it an ideal choice for electric motor cores.
Silicon steel reduces the size of motors and increases their efficiency, making them highly sought after in many industries. Additionally, silicon steel is easy to machine and provides a perfect winding and assembly surface without additional finishing operations.
Metal stamping is widely suitable for many industries, such as motor cores. And it is an efficient way to produce high-quality parts without additional processes. With careful planning and the right tools, metal stamping can yield quality components cost-effectively and with minimal setup time.
To learn more about motor lamination, design stamping dies, and material choices, click on our home page to read.