Key Considerations in Metal Stamping

Metal stamping is a versatile and efficient manufacturing process that involves shaping metal sheets or strips by pressing them into a specific shape or design. One of its advantages is that it allows for creating complex configurations with extreme precision and consistency. The process typically uses a set of dies, which are specialized tools designed to cut, shape, and form metal sheets or strips.

When considering metal stamping for a project, understanding the key considerations that go into the process is crucial. Factors such as material selection, tooling design, production volume, and quality control can influence the success of a stamping project. This article will explore some of the most important design guidelines and principles when using stamping for manufacturing components.

Metal Stamping Design Guidelines and Principles

Creating a successful stamping requires careful consideration of the part or component design. Here are several essential guidelines and principles that must be kept in mind during the designing phase of the project:

Material Selection

Metal stamping involves using various materials, such as aluminum, copper, brass, steel, and alloys. Choosing the appropriate material for the project depends on factors like ductility, formability, and thickness to prevent any damage to the metal. Particularly, material thickness impacts the manufacturing process. Thin materials are easier to form and stamp, while thicker ones are durable but require additional pressure and force.

Part Geometry and Complexity

Part complexity refers to the number of bends, curves, and angles in the design, while geometry is the overall size and shape. Generally, parts with straight edges and curves are easier to stamp than those with multiple angles, bends, and turns.

Part complexity also influences the design of the tooling required. For example, complex parts require specialized tooling to achieve the desired outcome.

Tolerance and Fit

The accuracy and precision of the dies and punches used in the process often determine the tolerance of the stamped parts. This tolerance ensures the pieces join properly with other components in the final product.

The fit of the stamped parts is also crucial, as it affects the product’s functionality. If the stamped parts do not fit well, it can lead to assembly issues, reduced product performance, and safety hazards.

Part Nesting

Part nesting is the arrangement of parts or components within a metal sheet to minimize material waste and reduce production costs. It involves carefully positioning the pieces on the metal sheet to ensure optimal material usage and reduce scrap. This aspect requires close attention to the part geometry, orientation, and placement to cut the parts from the sheet accurately and precisely.

Strip Layout

Strip layout is particularly important for high-volume production runs, as it affects the efficiency and speed of the stamping process.It refers to the placement of the stamped parts or components on the strip. A well-planned strip layout can minimize scrap and maximize production output, lowering production costs and higher quality products.

Additional Features

The following are features commonly incorporated into the stamped parts and components:

Holes

The hole diameter must be equal to or greater than 1.2 times the material thickness. However, the minimum diameter of the hole should be at least twice as wide as the thickness of metals with high tensile strength. This helps in avoiding material deformation or cracking.

Corners

A punch and die with a radius of at least four times the material thickness is required to achieve proper corner formation. If the material is 1.5 mm or less thick, it is advisable to use a punch and die with a larger radius.

Notches and Tabs

Punches exert significant force during stamping, and smaller formations cannot withstand this force. Instances like this can lead to cracking and deformation. Thus, the formation of notches and tabs should have a minimum size of 1.5 times the material thickness to prevent breakage.

Choose Principal Manufacturing for High-Quality Metal Stamping Services

Principal Manufacturing Corporation has over 80 years of rich history in the stamping industry! We have established ourselves as a trusted provider of precision-stamped products known for their exceptional quality. Moreover, our unwavering focus on quality and results-oriented approach ensures our clients receive 100% defect-free components. Our state-of-the-art manufacturing facility has multiple stamping presses, ranging from 45 to 700 tons, and bed sizes up to 10 ft.

At PMC we pride ourselves on adhering to the highest industry standards to ensure the quality of our products and sustainability of our operations. Our commitment is reflected in our globally recognized certifications, IATF 16949:2016 for automotive quality management and ISO 14001:2015 for environmental management. Additionally, we maintain strict compliance with the International Traffic In Arms Regulations (ITAR) showcasing our commitment to safeguarding sensitive information and technology.

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How To Choose the Right Plastic Injection Molding Partner

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Plastic injection molding is a versatile and cost-effective manufacturing process for producing various plastic parts, from small components to intricate structures. It is highly regarded as one of the most adaptable techniques for creating parts and components in large quantities. Its applications are also widespread, ranging from the automotive and aerospace industries to medical and electronic devices.

In the competitive market of product development, getting the injection molding process right is crucial. Therefore, choosing the right partner is paramount as it can significantly impact every aspect of the project, from quality to profitability.Moreover, working with unqualified contractors may lead to complications. These include extended delays, increased costs, and subpar quality.

Here is a five-step process to follow when selecting a plastic injection molding partner:

Step 1: Strategize and Prepare for the Product

The product’s specifications must be carefully outlined, which may include its size, weight, color, and other attributes. Identifying the intended market and understanding the customer’s needs is also essential to ensure the product meets their requirements.

Second, the product’s concept is transformed into a tangible and functional model during design. This may involve 3D modeling, prototyping, and simulation testing to verify the product’s integrity and functionality. Lastly, end-use applications must be determined to select the appropriate materials and production processes.

Step 2: Assess Potential Partners’ Resources and Material Availability

During the evaluation process, the availability of materials is a significant factor to consider. The chosen company should have an adequate supply of essential materials to ensure the project is completed within the specified timeframe.

Additional questions to ask include the following:

• What facilities do they have? Are they adequate for the project’s requirements?
• Do they have a stable supply chain for the necessary raw materials? Arethey readily available?
• What is their production capacity? Can they meet the required production volumes and timelines?
• Do they have the equipment and expertise to handle the project’s requirements, such as multi-cavity molds or insert molding?

Step 3: Inquire About Relevant Certifications

Certifications held by a potential partner can gauge the company’s quality standards, safety dedication, and adherence to the best practices. For example, ISO standards are widely recognized and provide a common language and framework for companies and businesses. These aim to promote consistency and reliability in processes, products, and services.

Here are other relevant certifications that a potential partner may hold, depending on the industry and type of product:

• GMP (Good Manufacturing Practice)
• FDA (Food and Drug Administration)
• CE Marking
• RoHS (Restriction of Hazardous Substances)
• REACH (Registration, Evaluation, Authorization, and Restriction of Chemicals)
• IATF (International Automotive Task Force)
• CQI-23 (Molding System Assessment)

Step 4: Ask About Their Experience

Experienced injection molding service providers can identify potential issues and suggest solutions, optimize the manufacturing process, and even assist in the design stage. Companies with proven track records can also provide references and case studies to demonstrate their capabilities and quality standards.

Step 5: Determine the Type of Partnership To Establish

A short-term, transactional relationship may be the most suitable option for a project with a fixed deadline and a restricted budget. However, establishing a long-term partnership benefits businesses with frequent projects that need injection molding services. Continuous communication can also lead to advantages such as streamlined production processes, cost-effectiveness, and better quality control.

Partner With PMC for the Best Plastic Injection Molding Services

Principal Manufacturing Corporation is a globally recognized leader in providing engineered solutions for the automotive, industrial, and OEM sectors! We are a highly skilled and experienced injection molding service provider, utilizing cutting-edge equipment and high-end engineering-grade resins to manufacture quality parts. We pride ourselves on being a full-service supplier of ready-to-use parts and offer assistance to reduce costs and speed up time to market.

At PMC we pride ourselves on adhering to the highest industry standards to ensure the quality of our products and sustainability of our operations. Our commitment is reflected in our globally recognized certifications, IATF16949:2016 for automotive quality management and ISO14001:2015 for environmental management. Additionally, we maintain strict compliance with the International Traffic In Arms Regulations (ITAR) showcasing our commitment to safeguarding sensitive information and technology.

Contact us today for additional information, and we will promptly respond to your inquiry!

Fineblanking Services to Automotive, Industrial, and EOM Companies

Fineblanking is a metal forming technique that produces precise and complex parts for various industries, including automotive, industrial, and original equipment manufacturers (OEMs). These services offer a cost-effective solution to manufacturing superior-quality components with tight tolerances and intricate designs.

This process also offers several advantages over other metalworking methods, such as stamping, laser cutting, and water jet cutting. This leads to less material waste and produces less scrap than other methods.

This article will discuss the process of fineblanking and its applications in automotive, industrial, and OEM companies.

The Fineblanking Process

Heres the step-by-step process for fineblanking:

Step 1: Material Preparation

The material used for fineblanking is typically a sheet metal coil cut to the desired width and length. The thickness of it can range from 0.5 mm to 12 mm, depending on the application. Afterward, the material is fed through a straightener to remove any distortions or deformations that may have occurred during the coil-making process.

Step 2: Blanking

Blanking is cutting the material to the desired shape and size. The blanking process uses a fineblanking press with three main components: the punch, the die, and the stripper.

Step 3: Piercing

Piercing uses a punch and a die, similar to the blanking process. However, the punch is typically smaller than the blanking punch and is used to create the desired holes or shapes in the component.

Step 4: Coining

This step is done using a punch and a die designed to apply high pressure to the components surface. The coining process improves the flatness and surface finish of the component.

Step 5: Finishing

Finishing involves removing any burrs or sharp edges that may have been left on the component during the blanking, piercing, or coining process. This step uses various finishing techniques, such as deburring, grinding, or polishing.

Automotive Industry

Fineblanking can produce high volumes of parts quickly and efficiently, making it a cost-saving option for automotive manufacturers. Engine components such as connecting rods, rocker arms, valve lifters, and timing gears are some critical parts produced using fineblanking. It is also ideal for creating gears, brakes, and fuel system components. These parts require high accuracy and precision to perform optimally in the engine.

Industrial Solutions

Fineblanking is widely used in industrial applications such as construction equipment, power tools, and appliances. One of its advantages is that it can produce parts with minimal distortion. Fineblanking can also have features with a smooth finish, which is important for some applications requiring a polished appearance.

The precision and repeatability of the process also reduce the need for secondary operations, further reducing production costs. These benefits make fineblanking an attractive option for industrial companies looking to produce high-quality parts at an affordable price.

OEM Sector

OEMs in various industries — such as aerospace, defense, and medical — rely on fineblanking to produce top-quality parts. These parts are often required to perform optimally in demanding environments. This process can also produce parts with minimal burrs. This makes it suitable for applications where precision and surface quality are crucial.

Some of the applications of fineblanking in the OEM sector include making components for hydraulic systems, surgical instruments, and firearm parts.

Exceptional Fine Blanking Solutions at PMC

Choose Principal Manufacturing Corporation for fineblanking services that exceed your expectations! Our fine blanking presses range from 100 to 700tons and feature three high-pressure pads that ensure exceptional dimensional control and consistent repeatability. This allows us to produce precisely finished components with outstanding flatness and inner and outer forms cleanly sheared over the total material thickness.

With systems in place to ensure industry compliance and continuous improvement, we have the resources to become your supply chain’s most vital and responsive link! At PMC we pride ourselves on adhering to the highest industry standards to ensure the quality of our products and sustainability of our operations. Our commitment is reflected in our globally recognized certifications, IATF16949:2016 for automotive quality management and ISO14001:2015 for environmental management. Additionally, we maintain strict compliance with the International Traffic In Arms Regulations (ITAR) showcasing our commitment to safeguarding sensitive information and technology.

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When To Choose Fineblanking vs. Stamping

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Fineblanking is a specialized manufacturing process that combines cutting, extrusion, and shearing. It involves using a punch and die set to cut a metal strip and applying high pressure to produce a precisely finished part.

Conversely, stamping is a metalworking process that uses a press machine to shape flat metal sheets into desired forms. It involves bending, stretching, or compressing the material to create the desired shape.

Fineblanking and stamping are both commonly used techniques in manufacturing precision metal parts. This article will explore the key factors differentiating fineblanking from stamping and help you decide based on your specific requirements.

Differences Between Fineblanking vs. Stamping

Fineblanking and stamping are two distinct techniques used in metalworking with key differences:

Material Requirements

Fineblanking is suitable for high-tensile materials like stainless steel and hardened alloys. On the other hand, stamping is versatile and can handle various materials, including aluminum, copper, and steel alloys.

Precision and Accuracy

While stamping can also achieve good precision, additional operations may be required for more intricate details. In contrast, fineblanking is renowned for high precision and accuracy, delivering parts with tighter dimensional tolerances and cleaner edges.

Cost-Effectiveness

The cost-effectiveness of the chosen technique depends on factors such as part complexity, production volume, and tooling requirements. For example, fineblanking is often more cost-effective for complex parts and high-volume production. Meanwhile, stamping may be more economical for simpler details or lower production volumes.

Factors To Consider When Choosing Fineblanking vs. Stamping

Here are the key considerations when deciding which technique to use for your project:

Part Complexity

Carefully assess the complexity of your part to determine which technique suits your specific requirements. If your project requires high precision and accurate tolerances, fineblanking might be the more suitable choice.

Production Volume

Fineblanking proves highly efficient for large production volumes due to its continuous strip processing capability. Stamping may also be used for high-volume production, although there are potential limitations regarding strip width and cycle times.

Material Type

Since stamping is more versatile regarding material compatibility, it is your go-to technique if your application involves various materials. However, if your project is focused on high-tensile materials like stainless steel and hardened alloys, fineblanking is an ideal and reliable method.

Tooling Considerations

Fineblanking requires specialized tooling that adheres to tight tolerances, which might involve a higher initial investment. Conversely, stamping provides a flexible range of tooling options and often has comparatively lower upfront costs.

Applications

Fineblanking is commonly used in the automotive, aerospace, electronics, and consumer goods industries for producing precision parts. Meanwhile, stamping finds applications in various industries including automotive, appliances, electronics, and construction for manufacturing components such as brackets, panels, hinges, and clips.

Discover the Power of Fineblanking With Principal Manufacturing

As a full-service supplier, we offer various capabilities to meet your diverse needs. We have an in-house, state-of-the-art tool room to build and service tools. Our services include fineblanking up to 700 tons, conventional stamping up to 400 tons, and plastic injection molding. Thus, we have the expertise and equipment to handle various manufacturing processes.

At Principal Manufacturing Corporation we pride ourselves on adhering to the highest industry standards to ensure the quality of our products and sustainability of our operations. Our commitment is reflected in our globally recognized certifications, IATF16949:2016 for automotive quality management and ISO14001:2015 for environmental management. Additionally, we maintain strict compliance with the International Traffic In Arms Regulations (ITAR) showcasing our commitment to safeguarding sensitive information and technology.

Contact us today to get started!

What To Look For in Your CNC Machining Partner

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Computer numerical control (CNC) machining is a complex process requiring deep technical knowledge and expertise. It offers numerous advantages, such as high accuracy, repeatability, and working with various materials. Also, it is utilized in automotive, aerospace, medical, construction, electronics, and various other industries.

Selecting the right CNC machining partner ensures your project’s success. A seasoned company can positively impact every aspect of the production process, from quality to timely delivery. In contrast, working with an inexperienced or unqualified machining contractor can result in complications and setbacks.

The following are some of the most important aspects and qualities to look for when choosing a CNC machining partner:

1. Capabilities

A reputable partner boasts a highly skilled team with top-notch machining processes and materials expertise. Ensure they have adequate experience in operating advanced machinery and managing varying part complexities effectively. Additionally, its important to verify their proficiency in working with the specific materials required for your project. This includes assessing their capability to select suitable machining tools and employ appropriate strategies to achieve optimal results.

2. Customer Service

A customer-oriented company will work closely with the client to offer valuable insights, discuss design improvements, and suggest cost-saving measures. The partners should serve as trusted advisors who could share their expertise to help achieve the best possible outcomes. They should also respond to inquiries, provide clear and timely updates, and address any concerns or questions. These attributes can be verified by seeking references or testimonials from other customers who have worked with the company.

3. Scalability

It is essential to work with a company that can accommodate future growth. As your business expands or the project requirements increase, a reliable partner can seamlessly handle larger production volumes and evolving demands. They can ramp up or down quantities as needed without compromising quality or delivery timelines. This flexibility ensures that the production needs can be met without delay or complications.

Scalable machining partners also understand the importance of investing in advanced technology. They continuously upgrade their equipment, software, and manufacturing processes to stay competitive and meet evolving industry demands. This can help clients benefit from the latest machining capabilities, improved efficiencies, and enhanced product quality.

4. Oversight

A reliable partner should have robust project management processes, including clear communication channels, well-defined project timelines, and proactive coordination with the client’s team. They should assign project managers who will serve as the main point of contact, ensuring that the project progresses smoothly.

The company must also have thorough project documentation and traceability. This encompasses detailed records of materials used, machining parameters, inspection reports, and any modifications or deviations from the initial plan. Comprehensive documentation also allows for transparency and efficient troubleshooting if needed.

5. Cost

While cost should not be the sole deciding factor, ensuring that the service provider offers competitive pricing for their work is essential. However, be cautious of significantly lower prices that may indicate potential compromises in quality or service. They must provide transparent and detailed quotes that outline the costs of materials, operations, tooling, and other services.

Trust Principal Manufacturing Corporation for High-Quality CNC Machining Services!

Principal Manufacturing Corporation is a reliable provider of machining services and precision manufacturing, catering to a wide range of industries! We also offer fineblanking, plastic injection molding, and conventional stamping.

At PMC we pride ourselves on adhering to the highest industry standards to ensure the quality of our products and sustainability of our operations. Our commitment is reflected in our globally recognized certifications, IATF16949:2016 for automotive quality management and ISO14001:2015 for environmental management. Additionally, we maintain strict compliance with the International Traffic In Arms Regulations (ITAR) showcasing our commitment to safeguarding sensitive information and technology.

Contact us today to discuss your project requirements!

WHAT IS FINEBLANKING TECHNOLOGY?

If you are looking for a way to produce high-quality metal parts with smooth and even edges, Fineblanking might be the solution for you. Fineblanking is a specialized metal-forming process that combines cold extrusion and stamping technologies to produce parts that cannot be made by other stamping methods. In this blog post, we will explain what Fineblanking technology is, how it works, and what are its advantages and applications.

What is Fineblanking technology?

Originally developed for the Swiss watchmaking of precision gears, Fineblanking, also known as precision blanking, is a process that involves cutting a metal sheet with a punch and a die, while applying high pressure from both sides of the sheet and the part. This pressure prevents the metal from tearing or bending during the cutting process, and results in a clean and straight cut edge. Fineblanking can produce parts with very tight dimensional tolerances, excellent flatness, and intricate features such as forms, bends, coining, countersinks, counterbores, and more.

How does Fineblanking technology work?

Fineblanking technology uses a triple-action press that consists of three main components: a punch, a die, and an ejector. The punch is the tool that cuts the metal sheet into the desired shape. The die is the tool that supports the metal sheet and has a cavity that matches the shape of the punch. The ejector is the tool that applies counter pressure to the metal sheet from below and pushes the cut part out of the die.

The Fineblanking process involves four steps:

1. Clamping: The metal sheet is clamped between the punch and the die with a ring-shaped tool called a stinger. The stinger applies high pressure to the sheet and creates lateral pressure on the inner surface of the cut edge. This helps to prevent tearing and lateral flow of metal in the shear zone.
2. Counterforce: This applies opposing pressure to the part shape during the blanking process.
3. Blanking: The punch blanks the metal sheet into a part along the edge shape of the die. The ejector applies counter pressure to the sheet from below and compresses the material in the shear zone. This creates three-way compressive stress in the material and eliminates tensile stress that causes bending, stretching, and tearing. The result is a pure shear along the cut edge that produces a smooth and even surface. The clearance is typically 0.5% to 1% of the material thickness, which is much smaller than in conventional blanking. The small clearance reduces the stress concentration and improves the material’s plasticity in the shear zone. The punch starts to move downward and pierces the metal sheet with a small clearance between the punch and the die.
4. Ejection: The punch retracts and the ejector pushes the cut part out of the die. The stinger releases the clamped sheet and prepares for the next cycle.

What are the advantages of Fineblanking technology?

Fineblanking technology offers several advantages over conventional blanking or other metal-forming methods such as machining, forging, casting, or powder metallurgy. Some of these advantages are:

– High-quality edges: Fineblanked parts have cleanly sheared and straight-cut edges that can hold very tight dimensional tolerances throughout the thickness of the part. The straight-cut edges also provide excellent and functional bearing surfaces.

– High strength: Fineblanked parts are made with rolled stock, which makes them inherently stronger than powder metal components or cast components. Often this increased strength enables engineers to design smaller, lighter fineblanked components than would be designed for PM or casting.

– High precision: Fineblanked parts have excellent flatness as a result of the counter pressure applied throughout the blanking cycle. This often eliminates the need for secondary grinding or reduces the amount of stock that needs to be removed in grinding, saving time and cost.

– High flexibility: Fineblanked parts can have complex shapes and features that are difficult or impossible to produce by other methods. Multi-station progressive Fineblanking tooling can create parts with forms, bends, coining, countersinks, counterbores, and more in one operation.

– High accuracy: Fineblanked parts have high positional accuracy and repeatability as a result of the construction of fineblank tooling. True position tolerances can be held very closely throughout the life of a tool.

What are some applications of Fineblanking technology?

Fineblanking technology can be used to produce parts for various industries such as automobiles, motorcycles, electronics, medical devices, aerospace, defense, and more. Some examples of fineblanked parts are:

– Gears

– Levers

– Flanges

– Brackets

– Plates

– Housings

– Valves

– Connectors

– Washers

– Spacers

The benefit to Fineblanking is that it eliminates extra steps in the manufacturing process, saving costs. For example, casting, stampings and cold headings would require secondary machining/operations.

Fineblanking technology is a powerful metal-forming process that can help you achieve high-quality, high-precision, and high-strength parts for your applications at a lower cost. If you are interested in learning more about Fineblanking technology or want to get a quote for your project, contact us today. We are a leading Fineblanking company with state-of-the-art equipment, in-house finishing capabilities, and experienced engineers. We can help you design and produce fineblanked parts that meet your specifications and exceed your expectations.