Metal stamping is a fabrication process used to create unique sheet metal designs. It entails using one or more stamping dies to shape the metal by cutting, piercing, or forming the metal in a certain way. It may involve a single process with at least one die, multiple sequential dies in one machine, or moving the metal material between dies across multiple machines in a process known as transfer stamping.
Regardless of the method used, metal stamping uses multiple techniques and materials, which is why you must find the right setup for your required metal stamping process.
Common Problems in Metal Stamping
Without the right setup, several potential metal stamping issues can arise, but they also have a variety of potential solutions. Knowing what these problems and solutions are will help keep the metal stamping process smooth, efficient, and cost-effective.
Here are some common metal stamping problems.
Poor-Quality Stamping
Low-quality stamping is one of the most common reasons for stamped sheet metal defects. Cracking is one of the biggest issues seen with poor-quality stamping, usually on the edges of stamped parts during cold and hot rolling. Poor-quality stampings can also have:
- Inconsistent sizes
- Scratches
- Fewer holes
- Deformations
- More burrs
There are certain factors that result in poor-quality stampings, such as worn tools, improper tool design, inadequate maintenance, and selection of the wrong materials.
Tool Wear
Metal stamping issues could also involve tool wear, making it important to repair or replace equipment as needed. Over time, tools experience a degree of wear that renders them less efficient and effective, which can contribute to poor-quality stampings.
Some of the potential causes of tool wear include incorrect selection of materials, inadequate maintenance, and overusing the tools.
Material Selection
You must also select the right metal to use in your metal stamping process. Different types of metals come with different benefits and disadvantages, influencing their ability to meet certain performance requirements. For instance, you might need a durable and corrosion-resistant material like stainless steel for one application, whereas another application may benefit from using more lightweight aluminum to meet lower weight requirements.
If you neglect to choose the right materials for your metal stamping application, the process may result in premature tool wear, poor-quality stamping, and other potential problems.
Solutions to Issues in Metal Stamping
You can use the following solutions to help avoid the problems discussed above.
Proper Tool Design
Tools should have the proper designs and engineering behind them to prevent potential issues with wear and incompatibility with other equipment and workpieces. Proper tool design entails selecting the appropriate tool materials and geometries.
Correct Material Selection
You will need to select the right materials for each stamping process to prevent issues like poor-quality stamping. Consider materials based on the ideal properties the part should have, the part’s intended use, and the budget available to spend on stamping materials.
Regular Maintenance
Prevent potential tool wear and other common metal stamping issues by performing regular maintenance on equipment. Proper maintenance will involve regularly inspecting, lubricating, cleaning, and replacing any equipment if necessary. Through proper, consistent maintenance, you will expand the life of all equipment and minimize the risk of poor-quality stamping.
Appropriate Use
Reduce the risk of overuse in metal stamping by facilitating the proper use of all tools and other equipment. In addition to avoiding tool overload, be sure to use the right metal stamping techniques and refrain from using the tools for anything other than its intended use.
Metal Stamping Services From Manor Tool & Manufacturing Company
Choosing the right materials and techniques as well as properly maintaining stamping equipment can help you reduce the risk of potential issues. In turn, you’ll benefit from more efficient processes and high-quality metal stamping parts.
If you require help with your next metal stamping project, turn to the professionals at Manor Tool & Manufacturing Company. As an ISO 9001:2015 certified manufacturer, we deliver precision metal stamping, deep drawn stamping, progressive die stamping, punching, bending, and more.
Contact us today to learn more about our metal stamping capabilities, or request a quote to get started on a new project.