What are the common problems and advantages and disadvantages of sheet metal processing stamping and forming lines?

What are the common problems and advantages and disadvantages of sheet metal processing stamping and forming lines?

The sheet metal stamping process converts hot rolled or cold rolled steel sheets by stamping them into the shape needed to manufacture your part. This technique allows a large number of parts to be produced simultaneously, but it can also result in about 15% of the raw material becoming scrap. The equipment used in this method requires less space than other methods, so if you have limited space, this type of manufacturing may be best for your business. When using sheet metal stamping, three main types of tooling are used – cutting, punching and bending.

Cutting involves cutting a part out of a sheet of metal. This is accomplished by impacting the sheet metal with a punch, which shears the sheet metal into the desired shape. The edges of the punched part will have burrs and therefore need to be filed or machined before use.

Punching is done by placing the sheet metal between two punches and forcing them together to make a hole in the sheet metal.
Bending is the deformation of metal by using pressure from a die. This type of punching is often used to make parts with curves.

Some common problems.

Burr: Punching or cutting edge corner process does not completely leave a residual material, the lower part of the steel plate truncated surface produces burr, with the truncated surface as the benchmark, when the burr height is 0.2mm or more, the occurrence of iron powder will damage the mold and produce convexity.

Convexity and concavity: abnormal convexity or concavity on the material surface is caused by foreign matter (iron chips, dust) mixed in the uncoiling line.
Roller print: caused by foreign matter attached to the cleaning rollers or feeding rollers (occurring at a fixed pitch), which can generally be removed by removing the foreign matter from the roller print on the sheet material.

Sliding print: caused by the roller sliding, occurring when suddenly stopped or accelerated.

Coil crushing, edge wrinkling: the guide roller of the uncoiling line or the guide roller gap on the mold when the wrinkling scenario, due to the unbalanced feeding of the coil material caused.

Scratching: the main reason for producing parts with scratches on them, sharp scars on the mold or metal dust chips falling into the mold, prevention measures for repairing the scars on the mold and removing metal dust chips.
Bottom cracking: the main reason for the cracking of the bottom of the part is the poor plasticity of the material or the pressure of the mold crimp ring is too tight, to prevent measures to replace the plasticity of better materials or crimp ring to relax some.

Side wall wrinkles: the main reason for the side wall wrinkles of the parts is the thickness of the material is not enough or the deviation of the upper and lower mold installation, resulting in a large gap on one side and a small gap on the other side, to prevent measures for timely replacement of materials and readjustment of the mold.

Sheet metal processing stamping parts advantages and disadvantages.

Advantages

Low Cost

Sheet metal stamping is a low-cost manufacturing technique. It is typically less expensive than other methods, making it ideal for small businesses with limited budgets. Since this method does not require tooling or dies to create parts or components, many believe it is also less expensive. However, the tool-less aspect of sheet metal stamping can sometimes make it more expensive because you need to pay for someone’s layout and design work rather than using standardized tooling.

High Volume Production

Sheet metal stamping can produce thousands of identical parts at a time, so this type of manufacturing allows you to efficiently make a large number of products while maintaining quality standards. This benefit is primarily for parts that are simple in shape and do not require extensive customization.

Ease of use

Shears, punches and bending dies make up the bulk of the tooling for sheet metal stamping, so this type of manufacturing is relatively easy to learn. If you have employees who are already familiar with basic machine operation, they will probably know how to stamp sheet metal without too much trouble.

Versatile

Sheet metal stamping is a very versatile manufacturing technology, capable of creating parts of various shapes and sizes. This makes it a good choice for companies that require high volume production. In addition, this type of stamping allows for the creation of both simple and complex parts.

Disadvantages

Scrap Rate

Sheet metal stamping has an inherently high scrap rate. In order to work properly, stamping dies need a flat, smooth sheet metal surface. If the sheet is not flat, the results are poor and the metal must be scrapped. Because this manufacturing process requires a large area of sheet metal, you risk wasting many small pieces that do not meet quality standards. Obviously, high volume production will increase the amount of scrap you have.

Not easily customizable

Machine parts that are straightforward and require little customization work best with sheet metal stamping technology. The simple shapes and curves make manufacturing easy and inexpensive. However, you may have to pay more when using this technique on custom projects or highly detailed parts due to design fees and the cost of the additional labor required to complete the project.

Limited design and sizing options

Sheet metal stamping is the best option for making simple parts, but if you need a more complex or detailed part, this may not be the best manufacturing option. The stampings used in sheet metal stamping cannot easily create tight curves or intricate details, so if you have a complex part design, you may have to look for other methods.

Slow Production

Sheet metal stamping is labor intensive and usually slower than other manufacturing techniques. This can be a significant drawback if you need a large number of products manufactured quickly.
If you need many parts quickly and at low cost, then sheet metal stamping is the better choice.