A Handy Guide to Sheet Metal Die Stamping and 5 Key Die Categories
Die Stamping is a crucial, cold-forming metallurgical process. The required shape or profile is produced from plain metal sheets with single or multiple dies. To produce complex metallic parts/components, bending and shaping metal to gain the desired form is necessary.
Metal engineering experts ensure that the design and dimensions are analyzed for precision-based sheet metal die stamping. Be it for the automobile industry, aeronautics, electronics, or engineering, the accuracy of shape, size, and form is a must.
Common Metals Used in Sheet Metal Die Stamping
Since die stamping is a cold-forming procedure, the chemical reactivity of the metal is a secondary consideration. The primary consideration here is its tensile strength and ductility. Tensile strength refers to the maximum ability of the metal to sustain an external force before breaking apart.
Ductility is the quality of a metal to change shape/form upon physical impact by stretching or getting elongated. The higher the tensile strength and ductility, the higher is the suitability of the metal for the die stamping process. Both ferrous and non-ferrous metals and alloys are used in this process. The most common ones include: –
- Steel and Stainless Steel
- Copper
- Aluminium
- Brass
- Alloys with Nickel and Titanium
5 Key Types of Dies in Sheet Metal Die Stamping
To create the most basic metal parts, a simple die is used. Basic industrial metallurgical operations like cutting and forming make use of this die which operates in one single stroke.
Given the complexity and finesse of the metallic parts required nowadays, the simple die is almost obsolete. today. Let us understand the 5 key categories of dies that are most commonly used in sheet metal die stamping today: –
- Progressive Sheet Metal Dies
These advanced dies seamlessly perform multiple cutting operations in a single stroke. This process warrants several prerequisites on part of the Engineering team. A complex setup needs to be designed along with the razor-sharp alignment of dies.
What sets this die category apart from others is the reduction in force required with each successive punch or stroke. Highly complex metallic components can be smoothly created using the progressive die, provided that each stage is planned meticulously.
- Combination Sheet Metal Dies
As the name suggests, these dies are used for cutting and forming sheet metal in the same operation. This increases the production volume within a short span.
The only constraint here is the type/complexity of metal components required. Only those shapes, sizes, and dimensions can be created that warrant dual cutting and forming strokes.
If any other finishing is required, then this die will have to be used in conjunction with another type. Nevertheless, these are used by metal part manufacturers when fast turnovers and bulk outputs are required.
- Transfer Dies for Sheet Metal Die Stamping
The use of transfer dies is especially applicable when the metal forming operation needs to commence with blanking. This follows the assembly-line method wherein the blanked sheet metal is transferred to the next stage to complete the process.
Transfer dies are extremely popular when large metal components need to be produced with less finesse. The process is cost-effective and doesn’t warrant the kind of planning that is evident in case of progressive dies. It is also a versatile process, considering that a wide range of shapes and sizes can be produced.
- Compound Sheet Metal Dies
This is used when the production volume is high and the components require a high level of precision and finesse. Multiple cutting operations are performed in a single stroke.
In many ways, it is similar to the progressive die. But the key difference lies in yielding force with each successive operation. In case of progressive dies, the force reduces with each operation. However, in case of the compound sheet metal die, the force more or less remains constant.
- Use of Multiple Dies
So far we have discussed the use of a single category of die for sheet metal die stamping. But many complex metal parts involve the strategic use of multiple dies of different kinds.
The dies are arranged parallel to one another. A high level of metallurgical prowess is needed for the resulting components to have the exact shape and dimensions required.
Conclusion
Given the massive experience and expertise required in sheet metal die stamping, you need to be very discerning. Always opt for a metal stamping service provider with a distinguished track record and suitable infrastructure. Most importantly, they should have handled similar orders, both in terms of volume and component type in the past.
Also read : https://zoombazi.com/5-precision-metal-stamping-methods-for-optimal-production/
