Material seminar

STAMPING PROCESS

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 Stamping process
Stamping is usually done on cold metal sheet. Stamping (also known as pressing) is the process of
placing flat sheet metal in either blank or coil form into a stamping press where a tool and die surface forms
the metal into a net shape. Stamping includes a variety of sheet-metal forming manufacturing processes.

Single Die Progressive Die

Benefits of Metal Stamping

Process Parts
Precision and fast
Increasing the strength and other
Complex products can be created using mechanical properties
stamping
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 The elements for Stamping process.

1. Deformation of material 4. The clearance surface between parts and

It can predict the position or risk during the die It is a frictional area that resist
forming. It can be planning for the design to material flow (Lubrication or mold surface
find solutions to prevent. improvement may be used)

5 4 3 5. Die
2. Properties of materials before 2
forming Chemical composition, 1 a The good design can reduces the
Mechanical properties, Flowability residual stress from the forming
and Work hardening process.
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3. Properties of materials after forming 6. Machine
Mechanical properties ,Appearance, Size (In The force transmission of machine to
some cases, the stress on the material determine the size of the mold.
affect to usability)

The production by metal stamping process to obtain the complete part and meet the requirements.
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So you have to take into these elements.
 Material select
Parts characteristic Ductility - Elongation
- Yield stress
- Chemical composition
- Hardness
Formability
Properties of
*There are also other factors that affect the forming material.
materials to - Rolling direction.
forming Stretchability - Surface condition because dent or foreign matter can affect to formability.

Example stamping part for shock absorber

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 Stamping process
1.Shearing 2.Bending 3.Drawing

Punch and Die are tooling in Shearing process. That is Punch and Die. In the shearing process will
be fracture into. Therefore, the edges of the workpiece should be considered after cutting because the edge is
rough or burr, it can affect the next process. For important in shearing process are 1.shape of the punch and die
2. the clearance between the punch and the die.
Shearing operation Process parameter
- Shape of die and punch
- Speed and force to cut
𝑇 = Thickness
𝐹 = 0.7𝑇𝐿(𝑈𝑇𝑆)
𝐿 = Length
𝑈𝑇𝑆 = Ultimate Tensile Strength
- Lubricants
- Clearance between die and punch
𝑎= material constant
𝐶 = 𝑎𝑡
𝑡 = thickness

Clearance, the more area a large processing, which makes the surface
of part rough up.

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 Stamping process
1.Shearing 2.Bending 3.Drawing

The deformation occurs only within the radius of the bending. The stress occurring, the external is
tensile stress and the compressive stress on the inside. So, the damage caused by folding are cracks occur on
the outer surface and wrinkles have the potential to surface on the workpiece.

Shearing operation Process parameter

- Shape of die and punch
- Speed and force to cut 2
𝑊 = Engineering strain
𝑘𝑌𝐿𝑇 𝐿 = Length
𝑃=( )
𝑊 𝑌 = Yield strength
- Lubricants 𝑇 = Thickness
𝑘 = constant
- Bend radius
𝑒 = Engineering strain
𝑅 = Bend radius
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U - Bend 𝑒=
2𝑅 𝑇 = Thickness
𝑇 +1

- Springback 𝑅𝑖 𝑅𝑖 𝑌 3 𝑅𝑖 𝑌
= 4( ) −3 +1
𝑅𝑓 𝐸𝑇 𝐸𝑇

- Rolling direction
V - Bend
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 Stamping process
1.Shearing 2.Bending 3.Drawing

In this process, The raw material is ductile material. If the workpiece requires a lot of depth, it may
need to be formed more than one times. In the drawing process, there will be a problem with fracture and wrinkle.

Drawing operation Process parameter

- Shape or radius of die and punch
- Speed and force to cut
𝐹𝑚𝑎𝑥 = Maximum punching force
𝐷𝑜 𝐷𝑜 = Blank diameter
𝐹𝑚𝑎𝑥 = 𝜋𝐷𝑝 𝑇 𝑈𝑇𝑆 [ − 0.7]
𝐷𝑝 𝐷𝑝 = Punch diameter
𝑇 = Thickness
𝑈𝑇𝑆 = Ultimate tensile strength
- Lubricants
- Rolling direction
- Drawability
𝐷𝑜
Limiting drawing ratio 𝐿𝐷𝑅 =
𝐷𝑝

Good part Fracture Wrinkle 7

 Die and Machine
Die Machine

Structure of Die Mechanic press Hydraulic press

1.Single die

Machine characteristic Mechanic press Hydraulic press

2.Progressive die Production rate Fast Slow
Stroke length Short High
Change of stroke length Hard Easy
Speed setting No Yes
Force setting Hard Easy

Die and Machine can be forming according on usage

Force Factor for control Die and Machine Die height

Speed Other 8
 Conclusion
Metal forming is a high stress process in the material. Due to the deformation
of almost all materials at the time and in the solid state where the material is strong.
The mold must be high strength and high quality. Including machinery must be able to
pass enough force. It is a process where the cost of production is high and appropriate or
cost effective in the case of high production volumes. The workpiece from stamping
process is more hardness due to the Strain hardening properties of the material.
Therefore, in some workpieces where the production is not very high, but requires high
hardness properties, the metal forming method is also used.