What do I need to start metal stamping?

Answer

To start metal stamping, you need:

 

  • Equipment: Press machine (mechanical/hydraulic) and stamping dies;
  • Materials: Metal sheets (e.g., carbon steel, aluminum alloy);
  • Auxiliary tools: Feeder, lubricants, measuring gauges;
  • Workspace: Load-bearing floor (presses can weigh tons) and safety protections.

Expansion

1. Core Equipment Selection

  • Press Types:
    • Mechanical presses: Suitable for medium-speed stamping (100–300 strokes/min), 30–2,000 tons, ideal for automotive sheet metal (e.g., door panels).
    • Hydraulic presses: Low-speed high-pressure (20–50 strokes/min), 500–5,000 tons, for thick plate forming (e.g., construction machinery bases).
    • Servo presses: High-precision control (adjustable speed/pressure), for micro-stamping of electronic components (e.g., 0.1mm copper foil forming).
  • Die Composition:
    • Upper/lower dies: Made of Cr12MoV tool steel (HRC58–62), requiring heat treatment for wear resistance;
    • Guiding mechanism: Guide pillars/sleeves (clearance ≤0.02mm) to prevent die misalignment;
    • Unloading device: Elastic stripper plate (prevents scrap adhesion).

2. Materials and Pretreatment

  • Common Metals:
    Material Type Thickness Range Typical Applications
    Low-carbon steel (Q235) 0.5–4mm Brackets, structural parts
    Aluminum alloy (5052) 0.3–2mm Phone casings, heat sinks
    Stainless steel (304) 0.1–3mm Kitchenware, medical casings
  • Pretreatment Requirements:
    • Sheet flatness: Warpage ≤1mm/m (to avoid feeding jams);
    • Surface cleanliness: Degreasing (stamping oil residue affects plating), burrs ≤0.05mm.

3. Auxiliary System Configuration

  • Feeding Automation:
    • Roller feeders: Suitable for regular sheets (10–50 strokes/min);
    • Robotic feeders: For multi-stage progressive dies (e.g., continuous stamping of terminals).
  • Lubrication & Safety:
    • Lubricants: Extreme pressure emulsions (for thick plates) or solid lubricants (stainless steel anti-sticking);
    • Safety devices: Photoelectric protection (prevents finger entry) and emergency stops (response time <0.1s).

4. Cost and Capacity Planning

  • Initial Investment:
    • Small production line (30-ton press + simple die): ~$28,000–$70,000;
    • Automotive-grade line (800-ton servo press + progressive die): $1.4M–$4.2M.
  • Capacity Calculation:
    • Single-operation die: 50–200 parts/hour (e.g., simple punching);
    • Progressive die: 500–1,500 parts/hour (e.g., continuous drawing).

5. Compliance and Quality Control

  • Industry Standards:
    • Dimensional tolerance: Follow ISO 2768-mk (medium precision), custom tolerances for precision parts (e.g., ±0.03mm);
    • Safety certifications: CE (EN 693 for presses), OSHA (workshop safety regulations).
  • Testing Tools:
    • Routine: Calipers (0.01mm accuracy), projectors (contour inspection);
    • Advanced: Coordinate measuring machines (CMM, 0.005mm accuracy) for aerospace parts.

6. Typical Startup Process

  1. Requirement analysis: Confirm batch size (e.g., 100,000 pieces), material (SPCC cold-rolled steel), precision (±0.1mm);
  2. Die design: 3D modeling (UG/NX) → die factory machining (4–8 weeks);
  3. Tool trial and debugging: First-piece inspection (dimensions/burrs) → die optimization (adjust punch-die clearance);
  4. Mass production: Set stamping parameters (150 strokes/min, 80-ton pressure) → first inspection + patrol inspection (every 2 hours).

 

Notes:

 

  • For low-volume trials (500 pieces), use Simple mold (zinc alloy dies, 70% cheaper than steel);
  • Environmental requirements: Stamping oils must meet VOCs standards, and waste should be sorted (metal recycling rate ≥95%).

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