Five Type Stamping Process To Introduce You: Milling, Machining, Die-Casting, Investment Casting, and Forging
Knowledge

Five Type Stamping Process To Introduce You: Milling, Machining, Die-Casting, Investment Casting, and Forging

Stamping is a process in which thin walled metal parts are shaped by punches and dies.
Published: May 28, 2020
Five Type Stamping Process To Introduce You: Milling, Machining, Die-Casting, Investment Casting, and Forging

Stamping operation

The punches and dies are mounted on mechanical or hydraulic presses and they perform two functions during the stamping process: shearing and bending. Mechanical presses utilize a flywheel to store the energy required for the stamping operation. The flywheel runs continuously and is engaged by a clutch only when a press stroke is needed. The drawback of mechanical presses is the driving force varies with the length of the stroke. Hydraulic presses use pressurized oil acting against one or more pistons to drive the punch and die on the press. It is capable of providing a full force of the hydraulically driven piston over the entire length of the stroke. However, hydraulic presses are slow compared to mechanical presses. Most stamping operations are carried out on high-speed mechanical presses even though they are more expensive than hydraulic presses.

The stamping operation can be done at either a single die station or multiple die stations using progressive dies. Progressive dies are often used when the part contains closely spaced features or if they have a bend angle greater than 90°. They can also reduce die wear and decrease the amount of spring back (thus improves geometric accuracy). The disadvantage of the progressive die is they require multiple stations, which requires more space to accommodate additional presses.

In order to minimize die cost, the following guideline should be followed while designing parts for stamping manufacturing process:

  • Minimize the number of distinct features in a part.
  • Avoid closely spaced feature.
  • Avoid the use of narrow cutouts and narrow projections.
  • Minimize the number of bend stages in a part.
  • Bend angles greater than 90° should be avoided if possible.
  • Avoid side action feature.

Processing technology introduction

Investment Casting

Investment casting is sometimes called lost wax process where a ceramic mold is used to form the desired part. In order to fabricate the ceramic mold, a metal mold is made by machining or casting. Wax is then injected into the mold and is removed after it cools. The wax, which resembles the desired part, is then coated with ceramic slurry in several layers. The completed ceramic slurry is placed in a furnace to harden and the wax removed by melting and evaporation. The desired part is made by filling the mold cavity with molten metal. After solidification, the mold is destroyed and the part removed. Investment casting is capable of surface finishes such that machining is not generally required.

Investment cast parts can be made of steel because the ceramic mold can withstand the high temperature of molten steel. It is used when low production volumes are expected.

Die-Casting

Similar to injection molding, die-casting injects a melt into a metal mold. The melt then allowed to cool and solidify in the mold. The cost of the mold increase as part geometry becomes more complex. The cycling time required increase as the wall thickness increase because more time is needed for solidification. Parts that contain undercuts are not generally die-cast because they are difficult to remove from the mold. Since the molds used in die-casting are made of steel, only metals with relatively low melting temperatures can be used. There are two types of die casting machines: a hot chamber machine and a cold chamber machine. A hot chamber machine has its injection mechanism submerged in the molten metal and it can be used for a part made with alloys with a lower melting temperature that does not chemically attack the submerged injection mechanism. Because the injection mechanism is constantly subjected to high temperatures, it tends to shorten the life of hot chamber machines. Cold chamber machine is sometimes used, especially when producing parts with higher melting temperatures. In a cold chamber machine, molten metal is stored in a separate furnace and the machine barrel is filled upon mold closure. The plunger in the barrel then forces the melt into the mold to form the part.

Forging

The forging process involves deforming a hot workpiece with dies attached to a mechanical or hydraulic press. Forging is used to produce some of the highly stressed parts in tools and aircraft because forged parts have high resistance to shock and fatigue. Since forged parts are plastically deformed, they are stronger and more ductile than parts produced with die-casting.

Machining

Machining is a part removal process in which small chips are removed from a solid workpiece to obtain the desire dimension and geometry. Machining is not an economical process because it is relatively slow when compared to other manufacturing processes such as forging. The process also creates a great deal of scrap material, which increases costs as more raw materials are needed. In most cases, machining is used to improve the tolerances or surface finish of part made by other processes. Some examples of machining methods are: Lathes: Lathes are used to produce cylindrical exterior or interior surfaces. The workpiece is mounted onto the spindle and rotates while the cutting tool is fed into the workpiece. Lathes can also be used to product screw threads (threading) with the appropriate cutting tool.

Milling

Milling machines can be used to form slots, angles, concave and convex contours on the surface of the workpiece. Unlike lathes, the cutting tool is rotated and the workpiece is fed into the tool in a milling machine.

Published by May 28, 2020 Source :engineering

Further reading

You might also be interested in ...

Headline
Knowledge
What Do You Know About Planetary Reducer?
Planetary reducer has been in existence for more than 30 years. During this long period of time, planetary reducer has gradually entered the field of automation from only appearing in high-end equipment in Europe and America, and has been widely used in machine tools, semiconductors, and packaging industries in recent years. The equipment in the medical food industry, aerospace and other fields will be used with planetary reducers. High, medium and low power servo motors with planetary reducers have become standard. What are the applications and advantages of planetary reducers? This article will let you know more about planetary reducers.
Headline
Knowledge
What are the Classifications of Packaging Equipment?
Packaging involves all walks of life. Manufacturers that produce physical products and need to enter the circulation field all need packaging processes, especially in light industry, and packaging equipment is indispensable. With the development of all walks of life, more and more industries use packaging equipment to reduce the labor intensity of the packaging process, improve product quality, reduce investment costs, and improve the labor environment. In the following, we are going to learn more about the common classifications of packaging equipment.
Headline
Knowledge
Safety and Use of Woodworking Machinery
Woodworking machine, as the name suggests, is the mechanical equipment used in wood processing. It is a variety of cutting and processing equipment used in the process of sawing logs and processing them into wood products, and furniture machinery is an important part of woodworking machinery. Woodworking machines are the same as machine tools, and can be divided into milling machines, lathes, planers, drilling, rotary cutting, sanding, etc. according to different processing methods. However, do you understand the safety and use of woodworking machinery? Check out the following.
Headline
Knowledge
What is the Importance of Lithography Technology and Mask Aligner in Chip Manufacturing?
Lithography is the most important processing technology of integrated circuits and the most critical technology for manufacturing chips. In the entire chip manufacturing process, the implementation of almost every process is inseparable from the technology of lithography.
Headline
Knowledge
What is A Switching Power Supply? Through Principal Analysis, Understand the Basics In 3 Minutes!
Many people do not know about switching power supply and have always thought that is similar to a linear power supply. Actually, there is difference. The following will explain the principles of basic regarding switching power supplies. Learn with us now!
Headline
Knowledge
Basics to An Electronic Connector
Electronic connectors are also often referred to as circuit connectors, electrical connectors, and conductor devices that bridge two conductors on a circuit so that current or signals can flow from one conductor to another. An electronic connector is a motor system that can provide a separable interface to connect two secondary electronic systems. Simply put, the components used to complete the electrical connection between circuits or electronic machines are called connector.
Headline
Knowledge
What is A KVM Switch?
KVM switches allow you to control multiple computers from a single keyboard, monitor and mouse, increasing productivity, saving space and money. This exclusive feature also provides IT administrators with multiple computers or servers, centralized real-time updates and maintenance.
Headline
Knowledge
Common Hand Tools in Our Daily life
Hand tools can be divided into wrenches, pliers, screwdrivers, etc. according to their uses, which are used to assist the assembly, maintenance, or tightening and loosening needs of machines or objects.
Headline
Knowledge
What is A Five-Axis Machine Tool?
Five-axis CNC machining means that there are at least five coordinate axes (three linear coordinates and two rotary coordinates) on a machine tool, and can be processed simultaneously with coordinated movements under the control of the computer numerical control system. The axis of the CNC machine tool means the motion axis, which is actually a coordinate axis in space, such as the XY axis of the coordinates. There is no motion axis with an independent controller and motor drive system.
Headline
Knowledge
What is the Lathe Manufacturing Process? Understand the Processing Methods and Components of Lathes
Lathe machines are used to remove excess material from a workpiece to give the workpiece the desired shape and size. Machining process designed for precision machining of relatively hard materials.
Headline
Knowledge
Forward-Looking Technology of End-to-End Encrypted Communication Protocol
When you chat with friends or family members using communication software, the information may be intercepted when transmitted on the Internet, thereby exposing the chat content. If the content contains confidential information, it may endanger privacy and security. End-to-end encryption (E2EE) is a method of protecting data that prevents potential eavesdroppers from monitoring data in transit.
Headline
Knowledge
Introduction to Types of Forklifts
The forklift is one of the most convenient tools and equipment for modern warehousing and logistics transportation. So, are you wondering what types of forklifts are there? What are the characteristics of various types of forklifts? Before purchasing a forklift, you must know the types of forklifts, and evaluate the use environment and usage before making a decision. This article will bring you an introduction to the types of forklifts, making it easier for you to choose one!
Agree