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The Advantage and Disadvantage of Stamping

- Dec 27, 2017 -



The Advantage and Disadvantage of Stamping


Advantage:

Stampings and castings, forgings, compared with the thin, uniform, light, strong features. Stamping produces workpieces with stiffeners, ribs, undulations or flanging that are otherwise difficult to manufacture to increase their rigidity. As a result of precision molds, the workpiece accuracy of up to microns, and repeat the high precision, the same specifications, you can stamping holes, bosses and so on. Cold stamping parts are generally no longer by cutting, or only a small amount of cutting. Hot stamping precision and surface conditions lower than the cold stamping parts, but still better than castings, forgings, cutting less.

Stamping is an efficient production method, the use of composite molds, especially the multi-position progressive die, in a press (single or multi-station) to complete multi-punching process to achieve by the strip unwinding, straightening Flat, blanking to forming, finishing the automatic production. High production efficiency, good working conditions, low production costs, generally can produce hundreds of pieces per minute. Compared with other methods of machining and plastic processing, stamping has many unique advantages, both technically and economically. The main performance is as follows.

(1) Stamping production of high efficiency, and easy to operate, easy to mechanize and automation. This is because the stamping is to rely on the die and stamping equipment to complete the processing, the ordinary press the number of trips up to tens of times per minute, high-speed pressure to be hundreds or even thousands of times per minute or more, and each stamping stroke May get a punch.

(2) stamping die stamping due to ensure the size and shape accuracy, and generally does not damage the surface quality of stamping parts, and die life is generally longer, so stamping the quality of stability, good interchangeability, with "exactly the same" Characteristics.

(3) stamping Machinable size range, the more complex shape of the parts, such as the small watches to the stopwatch, large car beams, covers, etc., coupled with cold stamping material when the cold deformation hardening effect, the intensity of stamping and Stiffness is higher.

(4) The stamping is generally no chip scrap generation, less material consumption, and does not require other heating equipment, which is a material saving, energy-saving processing methods, the lower the cost of stamping parts.

Due to the superiority of stamping, stamping has a wide range of applications in all fields of the national economy. For example, in aerospace, aviation, military, machinery, agricultural machinery, electronics, information, railway, post and telecommunications, transport, chemicals, medical appliances, household appliances and light industry and other departments have stamping process. Not only is it used throughout the industry, but everyone is in direct contact with the stamping product. Like the plane, train, car, tractor there are many large, medium and small stampings. Car body, frame and rims and other parts are punched out. According to the survey statistics, bicycles, sewing machines, watches, 80% of the stamping parts; TV, tape recorders, camcorders 90% of the stamping parts; there are food metal shell, steel boilers, enamel bowls and stainless steel tableware, All are the use of die stamping products; even the lack of computer hardware can not stamping parts.


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Disadvantage:

1, mold problems

Stamping molds used in general have special, and sometimes a complex part of several sets of molds can be formed, and the high precision mold manufacturing, high technical requirements, is a technology-intensive products. Therefore, only in the production of large stampings cases, the advantages of stamping can be fully reflected in order to obtain better economic benefits.

2, security issues

Stamping processing also has some problems and shortcomings. Mainly in the stamping process noise and vibration of two kinds of public nuisance, and operator safety accidents have occurred. However, these problems are not entirely due to the stamping process and the mold itself, but mainly due to the traditional stamping equipment and backward manual operation. With the progress of science and technology, especially the development of computer technology, with the progress of mechatronic technology, these problems will be solved as soon as possible.

3, high-strength steel stamping

Today's high-strength steel, ultra-high strength steel to achieve a good vehicle lightweight, improve the vehicle's impact strength and safety performance, it has become an important direction for the development of automotive steel. But with the increase of sheet strength, the traditional cold stamping process is prone to rupture in the forming process, unable to meet the processing requirements of high strength steel. In the case can not meet the molding conditions, the current international research gradually ultra-high-strength steel hot stamping forming technology. The technology is a new technology that combines the forming, heat transfer and microstructure transformation. It mainly uses the high temperature austenite state, the sheet plasticity increases, the yield strength reduces the characteristics, through the mold forming process. However, thermoforming needs further study on process conditions, metal phase transition and CAE analysis technology. At present, the technology is monopolized by foreign manufacturers and its domestic development is slow.


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Solution:

In the past in the production of deep red or redock the workpiece, we all think pressure type (EP) lubricant is the best choice to protect the mold. It has been a long time since sulfur and chlorine EP additives have been mixed into pure oil to increase the die life. However, with the advent of new metals, high-strength steels, and stringent environmental requirements, the value of EP-based lubricants has been reduced or even lost.

At high temperature, high strength steels are formed, EP oil-based lubricants lose their properties and can not provide physical mold protection diaphragms in extreme temperature applications. Extreme temperature type IRMCO high solids polymer lubricants can provide the necessary protection. As the metal deforms in the stamping die and the temperature rises, the EP oil-based lubricant will become thinner and in some cases will flash or burn (smoke). IRMCO water-based stamping lubricants generally start spraying consistency is much lower. As the temperature rises during forming, it becomes thicker and tougher. In fact, the extreme temperature polymer lubricant has a "hot search" and will stick to the metal, forming a membrane can reduce friction. This protective barrier allows the work piece to be extended to control friction and metal flow without breaking and adhering when the most demanding work piece is molded. Effective protection of the mold, extending the service life of the mold and improve the strength of the stamping.




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