Longsheng

金属スタンピングに対する物質硬度の影響は何ですか？

Main Effect of Material Hardness on metal stamping

1.Mould wear rate

• High-hardness stamping metal (such as stainless steel and titanium alloys) accelerate mold wear, resulting in increased surface roughness (Ra value 0.5-1.0 μm).
• Alloy molds (such as tungsten steel) or surface coating techniques (such as TiN coating) are needed to extend service life.

2.Adjustment of stamping process parameters

• Harder materials require greater punching force (increasing the tonnage of the press by 20% to 30%) and lower punching speed to minimize the impact loss of the die.
• Low hardness materials (such as aluminum foil) is easy to wrinkle, need to adjust the edge pressure to increase the use of lubricating oil.

3.Quality of finished products and tolerance control

• When the hardness of stamping metal is greater than HRC 45, the tensile forming limit decreases decreases, cracks are easy to appear, and progressive stamping and additional annealing processes required.
• Low hardness materials suffer poor stability (±0.1mm fluctuation) and additional finishing processes are required to correct deformation.

4.Material Applicability Limitations

• Too much hardness (such as quenched steel) may cause mold blade breakage, so choose a composite mold structure (such as block mold).
• Ultra-low hardness materials (such as pure aluminum) require anti-adhesion treatment (such as nitrogenation of mold surfaces).

Comparison of stamping process of Different Hardness materials

• Material with high hardness: Priority should be given to alloy molds with slow stamping equipment (velocity ≤50spm) and annealing and softening should be added.
• Low hardness material: Optimize mold clearance (reduce by 5%-10%) and use polyurethane shock absorber to reduce rebound.
• General recommendation: Predicting process risk through material hardness testing (such as Rockwell hardness tester) and test pressure if necessary.

How to reduce the cost of metal stamping?

1.Improving accuracy and reducing waste

High-precision equipment and technology:

• Adopt ±0.005mm ultra precision machining technology (JS core technology) to reduce the scrap rate caused by size deviation and reduce secondary processing cost.
• The CAD/CAM system simulates stamping process, optimizes mold design and parameter setting in advance, and avoids material waste in actual production.

Automated production and intelligent detection: Automatic stamping equipment is combined with real-time quality control system to reduce manual intervention errors and improve yield rates.

2.Material management and selection strategy

Adaptability of a variety of materials: Use JS's metal material database of metal materials (such as stainless steel, aluminum alloy, copper alloy, etc.) to select the most cost-effective materials based on product performance and avoid overdesign.

Residual material recycling and nesting technology: Maximize board utilization (15%-20% increase in JS's material utilization rate) through intelligent typesetting algorithms, reduce corner material waste, and support the recycling of materials such as aluminum and steel.

3.Process efficiency and rapid response

Standardized and modular design: Provides a standardized metal punch library (connectors, casings, etc.) to shorten design lead times, and supports customers to customize quickly to existing templates to reduce development costs.

Agile production mode: Commit to 1-2 weeks of standard delivery time (including complex orders) and reduce additional costs for emergency orders through lean production management and priority scheduling.

4.Collaborative design and process collaboration

Early intervention in client design: The JS team provides pre-design review services to optimize the structural strength, tolerance fit, and assembly feasibility of metal punch to avoid additional costs associated with later modifications.

Mold sharing and lifecycle management: Provide long term maintenance and optimization services for high frequency order molds, extend the lifespan of molds (the average life of JS molds is 30% longer than industry standard), and dilute unit cost of individual products.

5.Sustainable production reduces costs and improves efficiency

Green manufacturing certification: Energy energy consumption has been reduced (JS energy consumption has been reduced by 15%) through the implementation of the ISO 14001 environmental management system and the introduction of energy-efficient stamping equipment and renewable lubricants.

Reduce process and logistics costs: Provide Design stamping surface processing one-stop service (JS integration capability covers the entire chain), eliminating intermediate costs.

How does JS company ensure the accuracy of metal stamping?

Cutting-edge equipment and precision machining technology

1.Ultra precision stamping equipment

• Equipped with a Germany/ Japan imported high-precision servo stamping machines with repeat positioning accuracy ±0.002mm and support tolerance ±0.005mm.
• Adopt ball screws, straight line guide rail and so on transmission systems, reduce mechanical error, guarantee the stability of shape and position tolerances of hardware punch.

2.Mold design and manufacture

• CAD integration software is used to simulate stamping process, optimize mold structure (such as convex die clearance, guidance accuracy), and reduce burrs and deformation risk.
• The mold material is made of SKD11. After heat treatment, the hardness reaches HRC60 or above, and the service life can reach millions of stamping cycles, ensuring consistency of mass production.

Intelligent process control systems

1.Real-time quality monitoring

• Integrated optical measurement system and automation equipment, real-time measurement of punch size, flatness, hole accuracy, automatic clearance of non-conforming products.
• Through statistical process control Analyze production data, dynamic adjustment of stamping parameters (pressure, speed, temperature) to prevent batch deviations.

2.Adjustment of material properties

Match the best material grade (e.g. Al6061) and thickness (0.1-5mm) to the application of metal punch (e.g. automotive sheet metal and electronic components) to avoid rebound or cracking due to insufficient material ductility.

Full-process quality management system

1.ISO 9001 and IATF 16949 certification

• Strictly in accordance with industry standards for auto parts, 100% of tests are performed from the time the raw materials are stored to the time the finished product is out of storage, with measurement accuracy of key dimensions reaching μ level (0.001mm).
• Provide production parts approval process documentation, including size reports, material certifications and performance testing data to ensure customer verification safety.

2.Reverse engineering and rapid feedback

For accuracy of customer feedback, the failure analysis is carried out using coordinate measuring machine, and the improvement scheme is provided within 48 hours to shorten the debugging cycle.

Summary

Metal stamping is the core technology of modern industry, which can effectively transform metal sheets into high-precision metallic stamps. Process flow includes design optimization, material adaptation, mold manufacturing, stamping production and reprocessing, each step requiring strict tolerance and deformation control. The hardness of the material directly influences the wear and tear of the die, the selection of process adjustment parameters and the quality of the finished product.

With ultra-precision its ultra precision stamping equipment mold technology full process quality management system JS Company ensures that metal stamping tolerance is controlled to ±0.005mm and material utilization is increased to over 92%. At the same time, it reduces energy consumption and waste through sustainable manufacturing practices. Providing efficient, reliable and cost-effective solutions for manufacturing highlights the irreplaceable role of metal stamping in precision manufacturing.

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jsは業界をリードする会社ですカスタム製造ソリューションに焦点を当てています。 5,000人以上の顧客にサービスを提供している20年以上の経験により、高精度 cnc machining 、 3d printing 、射出成形、私たちの工場には、100を超える最先端の5軸機械加工センターが装備されており、ISO 9001：2015の認定があります。世界中の150か国以上の顧客に、高速で効率的で高品質の製造ソリューションを提供しています。少量生産であろうと大量のカスタマイズであろうと、24時間以内に最速の配信でお客様のニーズを満たすことができます。 jsテクノロジーを選択してくださいそれは効率、品質、プロフェッショナリズムを選択することを意味します。 href = "https://jsrpm.com/"> jsrpm.com

FAQs

1.What tools are needed for metal stamping?

Includes high-precision die, press, tool, lubricant, clamping devices, quality inspection equipment, etc. Mould ensures accuracy of shape, press provides punch pressure, tool completes cutting, lubricant reduces friction, fixture fixed plate, test equipment ensures consistency of dimensions.

2.What materials are suitable for stamping?

Common materials include stainless steel, aluminum, copper, steel plates, etc. Thickness (0.1-5mm) and strength shall be selected according to the purpose of the product, taking into account ductility, corrosion resistance and cost requirements.

3.Do stamped parts need additional processing?

Stamped parts usually require burr removal, polishing, or surface treatment to improve appearance, rust resistance, or functional compatibility. Treatment depends on the product's purpose, for example, electronic components require high-precision polishing and automotive parts often require anticorrosive coatings.

4.What are the consequences of stamping metal too fast?

High speed stamping may cause material tearing or mold impact damage due to inertia. Normally, stainless steel stamping speed is controlled at 50-80 times perminute, while aluminum can be ramped up to 120 times perminute, depending on the malleability of the material.

Resources

Metalworking

Stamping press

Progressive stamping