Sheet metal stamping originated many centuries ago as a method of producing household utensils, ornaments, and weapons of uniform shape and size. The technology and manufacturing methods of sheet metal stamping advanced in the second half of the 19th century in connection with the mass production of parts of weapons, vessels, and other items. Improvements in technology resulted in a marked increase in the rate of production and the operating efficiency. In the early 20th century, sheet- metal stamping played a prominent role in the automotive industry (especially in the production of motor vehicle bodies); in the 1930's, in aviation and the shipbuilding and appliance industries; and in the 1950's, in the aerospace industry.
Parts produced by sheet metal stamping have high strength relative to weight and are distinguished by the efficiency of their shape. Through the use of highly plastic materials.
Sheet-metal stamping makes possible the production of both thin-walled parts of complex shape and large durable parts that cannot be produced by other processes (for example, the process can be used to produce hands for wristwatches or truck spars 5 m long). Sheet-metal stamping of parts, in conjunction with welding, makes possible the production of one-piece assemblies of virtually unlimited size (in railroad-car construction and shipbuilding).
Ribbon, strip, or sheet metal is used as the stock in sheet-metal stamping; the stamping is usually cold. If the material being worked is of low plasticity, or if the power of the equipment is insufficient, hot stamping is used. The main operations in sheet-metal stamping are separation and forming. As a result of the separation process, the part to be formed is separated during movement of the material according to a preset pattern
. The separation process includes the cutting-off, punching, piercing, trimming, notching, deburring, and cleaning of the part. In the forming operations, the shape and dimensions of the part are changed. The material is shaped but does not fracture. Among the forming operations are bending, twining, winding, expansion, reduction, beading, drawing, and molding of relief.
Sheet-metal stamping is done Indies that usually consist of stationary and movable have scant aiming the working parts (the matrix mold and the punch). Apart is formed from the sheet metal when the two halves come together. The halves of the die are secured in the press
. The stationary half is on the table, and the movable half is in the slide block (the working mechanism). The working parts of the die are made from tool steel. In the small series production of parts from aluminum or other soft materials, tool steel is replaced by various other materials (plastics, pressed wood, and so on).
To reduce production costs in the small-scale production of parts from sheet metal (particularly large parts), the matrix is made from iron, steel, or concrete, and the punch is replaced by water or another fluid in a container or located on the matrix above the sheet stock. Detonation of a powder charge in the wat or creates pressure on the sheet stock and shapes it according to the matrix. This is called explosive forming.
Another method of stamping, in which the action of an electrical discharge on water is transmitted to the stock (electrohydraulic forming), is also used. The stock may be stamped inside that has one working part (matrix or punch). In this case, the discharge of high-voltage capacitors, which results in a strong and rapidly changing magnetic field, is used to create pressure on the strip (the method of electromagnetic forming).
The precision of parts manufactured by sheet-metal stamping (in most operations) is the third or fourth class (Soviet standard). Some operations, such as deburring and special methods of punching, piercing, drawing with ironing, and calibration, provide the precision of the second class. In cold sheet-metal stamping the surface quality of the part is maintained in most cases. Thus, in stamping from cold-rolled materials the surface roughness of the product is of the sixth to eighth class. The specific strength characteristic of products produced from rolled metal is not decreased by stamping but rather increases during certain forming processes as a result of the strengthening of the material that accompanies the processes.
The cost of parts is determined by the cost of the material used and the expenditures for production. In sheet-metal stamping, material cost accounts for 80–85 percent of the cost of the part; production costs account for the remaining 15–20 percent. The variety of stamping methods, the use of dies of various designs (specialized and all-purpose), and the use of various materials to produce the dies make profitable the production of the same articles by sheet-metal stamping in any quantity.
Sheet metal stamping is a highly productive process. For example, presses with a force of 1meganewton (100 tons-force) and manual feed of the strip stock have a production rate of 600–800 units per hour. With mechanical feed, the rate increases to 3,000-4,000 or more.
Sheet-metal stamping makes possible the reduction of complex production procedures to simpler processes (the blows of a press), produces uniform precision of the stamped parts, and makes possible the production of parts with a small number of operations and changes and with low production costs. In some cases, the material not only retains but increases its strength. In addition, the cost of stamping equipment is low. Parts and finished products produced by methods of sheet-metal stamping are used in various branches of the national economy, such as instrument-making, shipbuilding, motor-vehicle and aircraft construction, and the clock and watch industry.
The further improvement of the sheet-metal stamping process requires greater mechanization and automation of small series production, the use of automatic lines of presses in mass production, an increase in the durability and ease of replacement of dies, in the effective use of stamping equipment, and the speed of forming operations, and a reduction in the consumption of metal.
Hueibin Enterprise Corp.
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metal stamping process
Sheet metal parts are all around us: motor-parts, metal desks, LED parts, building-hardware, 3C-products, auto parts, aircraft fuselages and so on. They are lightweight, strong, and can take on complex shapes. The sheet metal stamping process is characterized by very high production rates, low labor costs, but high equipment and tooling costs Thus, this process is ideally suited for high-volume production.
The sheet metal blanks used in stamping are typically made of low-carbon steel, because of its low cost, good strength and excellent formability. The formability of various sheet metals is typically determined by marking the sheet with a grid of small circles and then stretching it over a punch. The deformation of the circle's ins measured in regions where tearing has occurred and used to construct a forming-limit diagram.
In applications where lightweight is important, aluminum, or alloys of steel with magnesium and titanium are also used, these lighter-weight materials are typically more expensive and less ductile and harder to from. Thus, developing tooling to produce defect-free parts using these lightweight materials is difficult.
A typical stamping press consists of a punch (upper of stamping mold), a stamping mold, and blank holder (binder), which holds the sheet metal in place during the punch stroke (i.e., while the punch is lowered into the stamping mold). The stroke (e.g., 50~80 mm) depends on the desired part geometry.
The stamping mold design will often include appropriately placed draw beads to help regulate the material flow into the stamping mold.
Commercial stamping operations are typically done at high pressure and high speed, thus, leading to short duration. The sheet metal material is plastically deformed, and flows into the stamping mold cavity and conforms to its shape. Proper design of the stamping mold allows complex shapes to be produced rapidly and cost effectively. Blank holder force and punch force must be properly selected to hold the sheet metal blank in place, through friction forces, while still allowing the sheet metal to plastically deform and flow into the stamping mold cavity.
Typically, stamping mold design, and selection of nominal process parameters is based on a finite element analysis (FEA). A variety of presses (e.g., mechanical or hydraulic) can be used, and nitrogen cylinders are typically placed under the stamping mold as a cushion to absorb the energy of the punch stroke and provide blank holding forces. For complex parts, a stamping line with several presses and stamping molds is used. Stamping molds can be quickly removed from the press to enable the production of a variety of different parts on the same press line. A more detailed discussion of the stamping process and equipment used.
Typical quality problems in sheet metal stamping include wrinkling (due to compressive stresses), tearing (due to tensile stresses) and spring back (due to elasticity). If the binder force is too high, locally in a particular area of the stamping mold, then the flow of material into the stamping mold is restricted and tearing is likely to occur in that region. If the binder force, again locally in a particular region, is too low then excessive material flow can lead to wrinkling. Spring-back can be accounted for in the design of the stamping mold, as well as by varying the punch force during the stroke to set the part geometry.
Mechanical presses typically allow the operator to set the desired stroke, speed, and blank holder force. The blank holder force typically cannot be adjusted around the stamping mold, and it is not possible to control the binder or punch force during the short time in which the part is formed. Hydraulic presses, depending on the design, do provide some additional flexibility in setting the blank holder and punch forces during operation. Thus, the control capabilities of stamping presses are limited, and they require significant trial and error during the stamping mold tryout process to establish the best settings for use in a production run. Furthermore, during production, factors such as blank material thickness and formability variations, and changes in lubrication, can act as disturbances and lead to quality problems
Oct. 2016 Hueibin Enterprise Corp. / Taiwan Stamping Parts of KueiShan Township, Taoyuan County in Taiwan, R.O.C has received its new Certificate of Registration for ISO 9001: 2015 (CNS 12681) The scope of the work at Hueibin Enterprise Corp. is the following: Stamping Parts for Automotive, Electronic and Hardware Componemts. The date of issue was Sept. 22, 2016 and it will expire on 21-Sept-2019
If you like to know more about Hueibin Enterprise Corp. of Taiwan please visit our website at www.taiwanstampingparts.com
Stamping industry is a long-established, widely used industrial process for economical high-volume production. It is used extensively in the automotive industry/building hardware industry/LED parts / Motor parts/3C parts ,
As well as for production of white goods and many other products.
We would like to present an approach, based on process control, to improve stamped part quality at reduced cost by eliminating tearing, wrinkling and springback. The concept is straight-forward: measure punch forces and then adjust the blank holder forces at various locations around its periphery and at various times during the stamping process to properly control the draw-in of blank material into the die. Of course, how to do this is the challenge! We would like to show in detail how this simple goal can be achieved through real-time control technology.
A reconfigurable set of hydraulic actuators is placed under the die to enable the control of the bland holder forces at various locations around the die periphery. These blank holder forces at each actuator are varied during the short duration of the press stroke. The careful design of a controller, termed the machine controller, is needed to ensure that the desired blank bolder forces are achieved at each hydraulic actuator and at each instant in time during the press stroke. Furthermore, we also measure the punch force during stamping, and design another controller, termed the process controller, to ensure that the desired punch force values are achieved during stamping despite the presence of disturbances. Maintaining the desired punch force leads to consistent draw-in of blank material and improves stamped part quality by eliminating wrinkling, tearing and springback.
We would like to show the methods for designing these controllers, and present experimental validation results from die try-out tests, the proposed system has also been evaluated in pilot tests in production and has also been shown to improve the formability of hard-to-form materials, such as lightweight alloys.
Hueibin Stanzteile aus Taiwan / Taiwan Stamping Parts
Die Hueibin Enterprise Corporation produziert seit 1976 Stanzteile, Pressteile, Umformungen und Ziehteile. Die Produkte finden Verwendung als Ersatzteile, Maßteile und Prototypen für mittelständische Unternehmen, als Zulieferer für die industrielle Großfertigung, wie auch für private Anwender. Vor allem die Serienfertigung von Rahmen und Stanztechnik für Computergehäuse und Autoteile, haben Hueibin zu einem der wichtigsten taiwanesischen Hersteller für Stanzteile gemacht. Die Importeure der Spezialteile aus Taiwan kommen heute vorwiegend aus den USA, Europa, Japan und China.
Stanz- und Formteile vom Profi aus Taiwan
Die Hueibin Enterprise ist Experte bei der Herstellung individuell gefertigter Präzisionsteile aus Metall, für alle Arten von Maschinen und Zwecke. Die Produktpallette des Herstellers umfasst nahezu alle bekannten Arten von Stanzware und Formteilen. Im laufenden Programm finden sich Maschinenteile, Autoersatzteile, Autozubehör, OEM Parts, Computerteile und Komponenten für Elektrogeräte. Ein weiteres Betätigungsfeld sind die vor kurzem eingeführten Formteile zum Einsatz beim Einbau von LED Beleuchtung. Auch mit dem Bau von Prototypen und der Herstellung von Kleinserien, hat sich die Firma in den vergangenen Jahren einen Namen gemacht.
Stanzteile von höchster Qualität
Hueibin Taiwan steht für Qualitätsteile und hervorragenden Service. Das Einhalten der exakten Spezifikationen und Fertigungstoleranzen ist dabei genauso wichtig wie die Möglichkeiten zu Änderungen und Optimierung in jedem Stadium. Dank kurzer Kommunikationswege und ausgezeichnet geschultem Personal, können selbst im laufenden Fertigungsprozess noch Modifikationen vorgenommen werden. Auch die Produktion von Vorserien, vor dem Beginn einer Massenfertigung, ist kostengünstig und unkompliziert möglich. Neben der Verwendung erstklassiger Qualität bei der Auswahl der Rohstoffe wie Stahl, Zink, Titan, Nickel oder Aluminium, beschäftigt Heuibin nur hervorragend ausgebildete Techniker.
Nicht nur in Taiwan und China, dank schneller und genauer Umsetzung der Kundenwünsche, ist Hueibin heute international bekannt. Vom Design bis zum fertigen Stanzteil, unterstützt Hueibin seine Kunden mit vollem Einsatz. Statt dem Kauf von gleichartigen, kompatiblen Ersatzteilen, kann Hueibin seinen Kunden maßgefertigte Teile anbieten, die den Originalteilen zum Bestücke ihrer Maschinen perfekt entsprechen. Einer der größten Vorteile in der Zusammenarbeit mit Hueibin ist jedoch die Flexibilität des Unternehmens bei der Herstellung von Stanzteilen und anderen Metallwaren. So können Aufträge jeder Größenordnung bearbeitet werden. Ob maßgefertigte Stanzteile für die Großindustrie, eine Kleinserie für mittelständische Unternehmen oder ein einzelnes Stanz- oder Formteil für Privatanwender, die Mitarbeiter von Heuibin machen es möglich.
Ausstattung und Reputation
Mit hoher Kundenzufriedenheit und bewährter Qualität, hat Hueibin sich seit der Gründung einen stetig wachsenden Kundenstamm gesichert. Die Stanzteile des Unternehmens werden heute international als Custom Stamping Parts und Metal Stamping Parts vertrieben. Das Label „Made in Taiwan“ sowie die Zertifizierung nach ISO 9001, haben dabei geholfen das Ansehen der Firma zusätzlich zu stärken. Die Fertigung der Metallstanzteile und Maßanfertigungen erfolgt heute in den Hueibin Werkshallen, auf über 3000 Quadratmetern Fläche. Nach dem Umbau und Erweiterung des Geländes im Jahr 2006, wurden viele neue Maschinen für die Serienproduktion angeschafft. Zum Inventar der Firma zählen heute unter anderem Fräsen, Stanzwerkzeuge, hydraulische Pressen und Lötapparate für die Großproduktion. Mit viel Erfahrung, den richtigen Werkzeugen und dem außerordentlichen Service ist Hueibin in der Lage, nahezu alle Kundenwünsche zeitnah und zuverlässig zu erfüllen.
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