In the manufacturing industry there are different processes used to shape metallic materials and one of the most used is metal stamping. Find out what it is here.
What is metal stamping?
A die is a tool or mold used to cut or punch materials in an industrial production operation.
Metal die cutting, as the name implies, refers to the process of using a die to shape metal sheets or plates.
It is used in a wide variety of industries and its purpose is to provide an efficient and precise alternative to producing metal components in high volumes.
Components of metal stamping
● Die. It is the tool that gives composition to the metallic material. At the bottom it has the design of the piece to be produced; in addition to a punching machine, located at the top, which performs the cutting or shaping.
● Press. It is the machine that applies the necessary force on the die and the material to be die-cut. It can be of different types, such as mechanical, hydraulic or pneumatic.
● Material to be die-cut. It is a metal sheet or plate that is placed between the die and the press. It can be made of different metals, such as steel, aluminum or copper, depending on the requirements of the component to be produced.
Working principle of metal die cutting
The die is placed in the press and the material to be die cut is placed between the die and the press. When this is activated, a force is applied to the die which, in turn, cuts or shapes the metallic material according to the desired shape.
By using dies designed specifically for each component, it is possible to quickly produce identical parts, reducing costs and production time.
Importance of die cutting in the production of metal components
Metal die cutting is an essential process in the production of large-scale metal components, as it provides:
● Efficiency and speed. Once the die is set up and adjusted, the die cutting process
can be repeated many times without losing precision or quality.
● Accuracy and consistency. Thanks to the exact design and manufacturing of dies, metal die cutting ensures consistency in component production. This is especially important in industries such as electronics, automotive or aerospace, where a perfect fit of parts is required.
● Reduced costs. High-volume production and process efficiency allow economies of scale, which translates into a lower cost per component produced.
● Flexibility and versatility. Thanks to the variety of dies available, it is possible to produce metal components with unique shapes, sizes and characteristics.
● Waste reduction. It allows you to optimize the use of material by minimizing waste and cuts, a great advantage from an economic and environmental point of view.
As demand for custom metal components continues to grow, metal die cutting will continue to play a critical role in modern manufacturing.
Metal die cutting process steps
The operation of metal stamping is composed as follows:
- Design of the component to be produced, with the shape and dimensions previously defined.
- Design of the corresponding die to shape the metal material according to specifications.
- Selection of the material to be used for the component, for subsequent cutting into sheets or plates of the appropriate size.
- Configuration of the die and press for the specific process (pressure, speed, temperature, etc.).
- Die-cutting of the piece in the press.
- Finishing and quality checking, such as polishing or painting.
Machinery involved in metal stamping
Metal stamping requires specialized machines to carry out the cutting or shaping operations of the material. The most commons are:
1. CNC (Computer Numerical Control). Systems that precisely control the movement of tools and optimize the production process. They are characterized by their ability to follow computer programs, which allows them to make complex cuts
and shapes with great accuracy.
2. EDM machines. They are used during the electrical erosion process to remove material and shape parts. They are particularly useful for punching hard and resistant materials, such as steels or corrosion-tolerant metals. They use graphite or copper electrodes to erode the material using controlled electrical discharges.
3. Milling machines. They remove the material in different directions using a rotating cutting tool called a milling cutter. They are ideal for die-cutting two-dimensional and three-dimensional shapes in metal components. They can be operated manually or
using CNC systems to achieve greater precision.
4. Grinding machines. They are used to achieve smooth surfaces on die-cut components. They integrate abrasive wheels to grind and polish the surface of the material. They can be manual or automatic and are available in different types, such as cylindrical, surface and centerless, depending on the die-cutting needs.
5. Lathes. They rotate the workpiece while a cutting tool performs the die-cutting process. They are widely used for drilling, tapping and slot cutting. They are controlled manually or by CNC systems to achieve greater repeatability.
These machines are used in combination with dies designed specifically for each process and component to be produced. Choosing the appropriate machinery depends on the specifications and technical requirements of the die-cutting project.
Key factors influencing die cutting accuracy
As we mentioned earlier, the success of metal die cutting is a result of the precision of die design and manufacturing, as any errors or imperfections in the shape can affect the quality and consistency of the components.
Likewise, both the metal material and the press must be of high quality and equally important is to perform regular maintenance and adjust the equipment to avoid additional costs or pauses in production.
Types of die cutting and their applications
Selecting the correct die-cutting technique depends on the specific production needs.
Cold Die Cutting Vs Hot Die Cutting
Cold die cutting involves the application of a mechanical force on the metallic material at room temperature. This process is suitable for soft metals and thin sheets, it is used to produce smaller and simpler components. It is also faster and cheaper, while producing less material waste.
On the other hand, hot die cutting involves heating the metal material before applying mechanical force. This technique is used to produce larger and more complex components, it is suitable for hard and resistant metals.
Progressive Die Cutting Vs Transfer Die Cutting
They are techniques used to manufacture larger components by interconnecting multiple die-cutting operations.
Progressive die cutting requires a single die to produce components with multiple shapes and sizes. It is more efficient and profitable for large volumes.
Transfer die cutting, meanwhile, uses several separate dies, which are connected by a chain or conveyor to produce larger, more complex parts. Each die performs a specific cutting or forming operation at a stage of production, providing greater precision and control.
Applications and advantages of metal stamping in industry
Some of the sectors that benefit from metal die cutting include:
● Structural components for automobiles, including body parts, engine mounting, suspension and braking.
● Electronic products such as circuit boards, device cases, connectors and heat sinks.
● Consumer products which can be metal packaging, labels and customized packaging components for various products such as food, beverages and pharmaceutical items.
● Aeronautical components of airplanes, propellers, engine and fuel systems.
● Manufacture of metal furniture such as chairs, tables and shelves.
KLUMEX, a comprehensive solution for tool manufacturing
At KLUMEX we offer you a complete design, manufacturing and supply service of molds and dies for a variety of applications.
Contact us to learn more about our metal die cutting solutions. Maximize the economy and efficiency of your production!
