How To Automate Metal Stamping Die Process?

Metal stamping is used in industries for converting metal sheets into destined shapes and sizes. It is a combination of various operations like stamping, folding, drawing, piercing, etc.

Materials used in Metal Stamping:

The material used in stamping is crucial for the functioning of the progressive tool based on the density of the metal, the force, and the strength of the tool.

Precious metals: Precious metals like gold, platinum, and silver are used in several industries that require the application of these expensive metals.

Ferrous metals: Ferrous metals include iron-based metals like stainless steel and other alloys like that. These are the most commonly used metals for their lower cost and convenient processing mechanism.

Non-ferrous metals: Metals other than iron, like bronze, copper, etc.

Specialty metals: Special metals like titanium, nickel, etc., are specially used for customized equipment.

 

Steps involved in Metal stamping:

• Punching: This is a process of making holes of different sizes and shapes.
• Blanking: Cutting the primary metal sheet into pieces of required shapes and sizes.
• Bending: Bending process is to fold a metal along an axis to form different shapes. This process creates finished products.
• Coining: Coining is a widely used process in metal stamping die.
• Drawing: It is the stretching of the metal sheet to obtain the required thickness.
• Embossing: This is a technique used to raise or shrink the metal sheet at required places.
• Flanging: Bending the metal at right angles is called Flanging.
• Shearing: Cutting the metal into square or rectangular shapes.
• Trimming: Trimming is a finishing process to cut the excess metal.

Automation in metal stamping die process:

Automation in metal stamping gives surprising results. It reduces the time drastically and also decreases the cost involved.

Since Metal Stamping is a complex process, the scope for automation is also more. Below are the top-most ways to automate metal stamping.

• Quick Die change: An efficient Quick die change setup must have an automated storage and retrieval system. The automation of die changes improves the production time by completing the process in the quickest possible time.
• Automated Loading/Unloading: Loading and Unloading of the dies can be automated using robots/cobots.
• Transfer systems for Progressive Die: In the progressive metal stamping process, each station has different functions. Automation of transfer systems allows quick travel of the metal through different stages. Many organizations still rely on hand transformers. However, automation reduces time and boosts productivity significantly.
• Quality Control: The quality of the press-line is essential for making the desired metal sheet. In modern days, press lines are equipped with viewing cameras to give a clear view to monitor the dimensions and shapes achieved in the stamping process. The automated quality control systems are unbiased, repeatable, and very fast.
• Machine Monitoring: Machine monitoring is the most significant process to ensure quality. Automation of machine monitoring gives smart data gathering and analysis. This will also help in storing the data for future analysis.

What is the right time to automate?

Although automation has tremendous benefits, it’s better to implement it at the right time. Automation provides benefits beyond saving time.

Invest in automation when you would like to increase productivity with assured quality.

You can achieve process variability through the use of sophisticated vision systems and monitor the machine’s functioning.

Automation may seem to be expensive, but it saves the cost involved in manual functioning.

Benefits of Metal Stamping:

• Increased production in lower turnaround time.
• Secondary costs are decreased, like cleaning, scrap collection, etc.
• High-end automation programs are used to provide further accuracy in a lesser turnaround time.

Industries that use Metal stamping:

• Agriculture: Metal stamping is used to produce stamped parts, deep drawn shells, etc
• Electronics: In electronics, metal stamping is used in the manufacture of certain components of machinery, like connectors, fitters, etc.
• Oil and gas: The oil and gas industry has metal stamping applications in producing parts like washers, handles, etc.
• Automobiles: In automobiles, metal stamping is widely used for producing bus bars, shields, etc.
• Aerospace: Metal stamping is used to create engine parts, connectors, terminals, etc., in the Aerospace industry.

Eigen is a leader in metal stamping. Many industries rely on Eigen for their customized products and share their testimonials to prove Eigen’s expertise and perfection.