What is Stamping Process ?
A stamping process is a method of forming a work-piece (usually metal) by pressing it with a die. It is related to forging, except that in forging, the work-piece is usually heated before it is shaped. In stamping, the work-piece is usually cold. The advantage of stamping over forging is that it is easier to produce complex shapes with stamping.
Stamping Process is often done as a final step in the manufacturing process, but it can also be used to create a prototype or sample of a product. In this process, a die is used to create a raised impression on a work-piece. The die is usually made of hardened steel (or) any metal and is mounted on a press. The press applies force to the die, which transfers the force to the work-piece, creating the impression.
The stamp may be made of any material, but is usually made of a metal or other hard material. The design or pattern may be impressed on the surface by means of a die, which is a raised image on the stamp, or by means of a plate, which is a flat surface on which the design or pattern is impressed.
To ensure the metal piece turns out the way it is supposed to be, the stamping professionals need to use the design tools which comes along with CAD/CAM engineering technologies. These designs must be as accurate as possible for each component to come out of the process, looking and operating how it should be.
Since,the metal stamping process can manufacture a high volume of similar components in a short amount of time, it is used in a variety of industries.
CONCEPTS OF METAL STAMPING PROCESS:
There are more processes or techniques available in stamping process used to shape a metal.
Each type of stamping has its own advantages and disadvantages, and the best type of stamping for a particular project or work-piece depends on the desired requirements.
1) Die Cutting – Die cutting is a process where a die is used to cut out a shape from a piece of paper.
2) Embossing is a type of stamping procedure that raises the design or image above the surface of the work-piece. This can be done using a die or a punch, and the resulting image is often three-dimensional. Embossing is commonly used to add a decorative element to a product, and it can also be used to create a raised surface that can be felt or grasped.
3) Debossing is the opposite of embossing, and it involves pressing the die or punch into the surface of the work-piece to create an indented design or image. Debossing can be used to create a negative image of a design, and it can also be used to create a raised surface.
4) Punching is one of the stamping techniques, which is used in the process of separating the waste or unwanted materials from the work-piece, along with the closed contour to obtain the part which contains the holes.
5) Bending is quite a special technique that uses specially designed die or general die in folding (or) bending a sheet metal along a straight axis based on the customer’s requirement. This is a high precision and consistent process used for product development, but certain things like bending angle, radius, Applied force, etc. must be monitored and controlled accordingly.
6) Blanking is the process of cutting a piece of sheet metal into a desired shape or size.
7) Coining – Coining is a process where the metal is deformed by force, usually using a punch, to create a desired shape.
8) Heat stamping is a type of stamping that uses heat to transfer a design or image onto a work-piece. Heat stamping is often used to create a permanent image on a variety of materials, including paper, plastic, and metal. This is a versatile process that can be used to create a wide range of results, from a simple design to a complex image.
9) Cold stamping is a type of stamping that uses a cold die or punch to transfer a design or image onto a work-piece. Cold stamping is often used to create a temporary image on a variety of materials, including paper, plastic, and metal. Cold stamping is a versatile process that can be used to create a wide range of results, from a simple design to a complex image.
TYPES OF STAMPING PRESSES:
a. MECHANICAL PRESSES – Mechanical presses use a flywheel to store energy and then release it in a rapid, controlled manner. This type of press is versatile and can be used for a variety of stamping operations.
b. HYDRAULIC PRESSES- Another type of stamping press is the hydraulic press. Hydraulic presses use hydraulic cylinders to generate the force needed to operate the press.These presses are specifically used for high-force applications such as deep drawing and forging.
c. PNEUMATIC PRESSES – Pneumatic presses use compressed air to generate the force needed to operate the press. They are typically used for lighter-duty applications such as stamping small parts.
d. MECHANICAL SERVO PRESSES – It uses servo motors to drive the various components of the press. The servo motors are controlled by a computer program that regulates the speed, pressure, and position of the stamping process. Servo-type stamping presses are used in a variety of industries, including the automotive, aerospace, and electronics industries.
Each type of stamping press has its own advantages and disadvantages. The type of press that is best for a particular application depends on the nature of the application and the desired results.
The steps involved in stamping are as follows:
Step 1: The first step is to establish the blank shape, which is the material used to create the part. The material is then cut and formed into the shape and size of the part, and is typically done with a shearing and blanking press.
Step 2: This next step is followed by the forming stage, which includes operations like drawing, embossing, and coining to shape the blank by stretching it around a metal punch.The die transfers the force to the work-piece, creating the impression. This stage is typically made up of a series of presses and rollers, specially designed tools that push, pull, fold, and bend the material.
Step 3: After the metal is formed, additional operations such as punching, notching, and bending may be used to refine the shape and accuracy. And the work-piece is removed from the die.
Step 4: The final step is finishing, which involves trimming off any excess material and polishing it for a clean, professional look. The surface of the part is also often treated for corrosion resistance.
One of the most important finishing operations in the stamping process is the de-burring or de-flashing process. This is the process of removing the burrs or flash created by the stamping process, which are often sharp and may be hazardous.
This helps ensure that all parts meet the same exact specifications, and can help reduce overall costs through precise trimming which minimizes waste and minimizes how much material must be used.
| involves using dies and tools to cut and shape materials. |
| Mostly suitable for thinner materials |
| Faster process than forging, which makes it better suited for mass production |
| Can be used for variety of materials, including metals, plastics, and composites. |
| High precision process than forging, making it ideal for creating products with tight tolerances |
| This process can be done either by using hand or with help of machinery |
| involves using heat and pressure to shape materials. |
| better suited for thicker materials. |
| Comparatively slower process, but it results in a stronger product. |
| It is typically only done with metals. |
| Much less precise process,with possibilities of making more imperfections. |
| Forging is typically done with machinery. |
MATERIALS
In the Stamping Process, different materials can be used based on their properties and customer’s requirements. The type of material used in this process, mainly depends on its application of utilization.
Zastata uses a variety of materials in the Stamping Process namely
- Ferrous Metals such as Iron based Alloys, Alloy steel, Stainless steel, Carbon tool steel, High-quality carbon structural steel, etc.
- Non – Ferrous Metals like Brass, Zinc, Bronze.
- Along with them, Non-standard alloys, such as beryllium nickel and beryllium copper can also be used.
- Some precious metals like – Gold, Silver and Platinum are used to produce more precise products.
- Other lesser used materials are also available such as Titanium, Teflon, and Phenolic. The material used typically determines the type of die used, as a softer material will require a specific die to properly form.
Zastata is a professional and experienced casting option, we use a strictly controlled environment to offer high performance and high quality products. We have a wide range of premium casting materials to help you achieve the capability of your desired component requires.
Some of the finishing processes Zastata provide the customers to enhance material properties are
After the finishing operation, the coating process is done, which helps to seal the parts and also helps give them an attractive finish. This is usually done,
- Through painting or an electroplating process such as chrome plating or anodizing.
- Painting helps protect the parts against corrosion and oxidation.
- Anodizing and electroplating to help the parts look more attractive, and also makes them last longer.
Zastata also performs premium quality testing procedures such as
Inspection procedures after the stamping process includes,
- Visual and physical inspection, in addition to gauging and testing.
- Visual inspection is done to make sure that all parts meet the quality standards,
- Physical inspection involves checking for defects such as warpage and burrs.
- Gauging is used to check critical dimensions of each part, while testing is used to determine the strength and performance of each part. This process ensures quality control and helps catch any issues before production moves ahead.
- In addition, tests such as hardness tests, material properties tests and surface finish evaluations can also be used to validate product quality. These tests can be done in-house or sent to outside labs for further analysis.
- Final dimensional inspections, alloy test results, and NDT are validated authentically with expertise prior to shipment.
OTHER TYPES OF METAL FABRICATION
Whilst Pressure die casting is widely used casting method for high volume production, there are other casting methods which have their merits
OUR MANUFACTURER LOCATIONS
Over the years, Zastata has audited and worked with various die casting manufacturer across India for various casting types. Our pressure die casting company are selected and retained based on their quarterly quality performance on Cost, Delivery, Quality, Communication, Innovation and flexibility.
COUNTRIES WE EXPORT
Over the years, Zastata has audited and worked with various die casting manufacturer across India for various casting types. Our pressure die casting company are selected and retained based on their quarterly quality performance on Cost, Delivery, Quality, Communication, Innovation and flexibility.
UK
USA
AUS
Denmark
Germany
Canada
France
China
INDUSTRIES WE SERVE
Stamping Certifications
The parts manufactured in our plants are based on the quality certifications as, Certified in
- ISO 9001:2015, ISO 14001:2015, ISO 45001:2018
- Also, ISO 9001:2016 Certificate with ITAR Certification
Quality Management
The Quality Assurance also include documentations as
- FMEA – Failure Mode and Effects Analysis
- PPAP – Production Part Approval Process
- APQP – Advanced product quality planning
- FAI – First Article Inspection
- SPC – Statistical process control
- MPC – Multi-point constraints
Advantages
- Require much less Die cost and Secondary costs.
- Suitable for both Ferrous, Non-ferrous materials and wide range of alloys.
- Able to use high level of automation and computer programs,which provides greater level of dimensional accuracy than other processes.
- Smooth surface finish with great cost effectiveness.
- Faster production and enhanced customization, makes it great choice for mass production.
- Lesser labour cost.
Applications
- The stamping process can be used to create a variety of shapes, including holes, slots, and contours.
- In the appliance industry, stamping is used to create parts for a variety of products, including washers, dryers, and dishwashers.
- In the automotive industry, stamping is used to create a variety of parts, including door panels, fenders, and hoods.
- Aircraft parts like such as skin panels and structural members are made using this process.
Zastata is your best choice with high technical expertise and great knowledge in the Automation technology along with the computer technology for proper execution.
Zastata exhibits a self-owned production complex with state-of-the-art equipments, and skilled crew of engineers, complemented by a professional technical team. We also pride ourselves on high-quality part manufacturing with fast lead times. We are one of the prominent stamping sourcing companies in the global market, providing great Pre-ordering & Post delivery services.
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