In industrial metal processing, different methods are used to process the metal sheets into useful finished products. Different approaches to metal processing are required to serve various industries and the styles to be adopted depends on the nature of the finished parts required. The conversion of flat sheets to form specific shapes is an integral aspect of the manufacturing industry, from large mechanisms to small components required to form a whole, understanding the basic processes involved is necessary to achieve the right finished product.
What is Metal Stamping?
One critical aspect of the material processing industry is metal stamping and it involves a cold-forming process that utilizes stamping presses and dies to convert sheets into different shapes as required. It involves passing flat sheets known as blanks through a stamping press and utilizing die surfaces and tools to form the desired metal shape. The use of pressure is necessary to be able to shear and shape the material to form the shape needed to complete the component.
Also referred to as pressing, metal stamping is a low-cost and effective approach to manufacturing identical high-volume components needed in industrial processes. It could be done as a stand-alone process or combines other metal forming processes such as bending, embossing, blanking, or punching which aids to achieve the specific shape required to form the part.
Understanding Assembled Components
Assembling individual components to form a segment or whole is an important part of the manufacturing process. With the individual components already manufactured through processes such as stamping, bending, embossing, punching, blanking, and others, it becomes necessary to combine them to form a unit. Different methods are used in the assembling process and the right one to use depends on factors such as the type of material, the design requirements, and the cost of the procedure.
In the assembling of wood, the two common methods are flat-frame construction and carcase construction. They both involve the use of joints made from woodwork, adhesives, and fittings like screws and nails. In the case of metal assembling, joining the components and parts together involves processes such as riveting, welding, threaded fasteners, adhesive binding, and many others. Human effort and automation processes are both essential in the industrial assembly of machine parts. This link https://xplorexit.com/benefits-adding-automation-manufacturing-processes/ has more on the usefulness of automation in manufacturing.
Metal Stamping Concepts
Stamping operations can be ideal for both short and long-run productions and will need to be properly planned by identifying the specific processes that will be required to achieve the finished part. Some of the common techniques used in stamping include
In punching, a die is required to cut the metal sheet into a specific part. The punch is run through the die and the scrap parts of the material are removed and this leaves behind a hole in the workpiece. When it comes to creating a recessed or raised design in a material, embossing is the go-to technique. It involves the pressing of the flat sheet against a die with the design of the desired shape. The flat sheet could also be passed through a roller die which also creates a recessed or raised design.
Blanking is the concept that involves removing a workpiece from the primary material and the removed workpiece becomes the desired part needed for the component. When it comes to forming metals into different shape profiles, bending is the technique employed. It begins with the deformation of the metal with the use of high stress beyond the yield point just under the tensile strength and should be done on a single axis.
In coining, the metal is first placed between the press and die and then stamped. This causes the tip of the press to pass through the metal resulting in accurate and repeatable bends. The deep penetration makes it possible to relieve the internal stress in the material which results in a no spring-back effect. Flanging utilizes a press or dies to introduce a flare onto the workpiece resulting in the desired shapes. Special flanging machines are also employed to yield accurate pieces that are identical to the desired parts.
Different Methods of Assembling Metal Components
Different techniques are used in the assembly of metal components to achieve the desired design. And as stated earlier, the type of material, nature of design, and cost of operation play a role in determining the technique to use. The basic metal assembling techniques include
This involves fusing different parts with the use of a welding machine to form a single unit. This technique is best employed in cases that require assemblies that meet the right structural construction, a permanent attachment and that needs to meet a high degree of strength. This website has more on welding operations that occur in the machine shop.
In soldering, a filler metal is melted and used to bond different machine parts together. This technique is usually employed in jewelry making, plumbing pipes, flashing, gutters, and electronic parts.
This involves the use of different fasteners to join or assemble separate parts to form a whole. The common fasteners used here include bolts, screws, and nuts. This technique is best employed in machine forming where adjustments may be required and will also benefit from routine maintenance of the individual components.
This is similar to welding as it is employed in forming parts that require a great deal of tensile strength. It is cheaper than welding and is best for processes that encounter unstable temperature and pressure in forming the desired part.
How Stamped and Assembled Components Are Used Industrially
For every machine part used in engineering construction, they will have to first pass through the stamping press which is where a flat sheet of metal is processed to achieve the desired part required in the design. The next step will be to assemble the separate materials derived from the stamping process to form the required design part needed for the manufacturing.
All metal pieces used in electronic, machine, plumbing, and other manufacturing parts pass through both processes in the construction stage in the factory. For example, in the UHI Group – Metal Components Machine Shop, a faster cutting, and precision technique is used to deliver complex and high precision parts for aerospace, military, medical, heavy trucking, automotive, and many other industries.
The technique to be used will depend on the sensitive nature of the manufacturing process and the design needs of the client. When it comes to making the right machine parts, it is important to employ the services of a production facility that understand the individual needs of specific materials and the best methods of achieving the desired design.
When it comes to the industrial applications used in forming machine parts, the stamping and assembling process plays a critical aspect and works side by side to achieve the right output. Different types of stamping operations and presses are used to ensure a smooth design and meet the manufacturing requirement of the finished parts. A lot of consideration is given to determine the right material type to use the same goes for assembly processes.