Sheet metal Stamping
Mufaddal Rasheed 
Explore the factors to be considered when designing for sheet metal stamping for design engineers
Sheet metal Stamping is a process in which a flat sheet of metal undergoes a series of deformation processes to achieve the desired shape and features.
A high-volume manufacturing process used to convert flat metal sheets into specific shapes through the application of a press and a die. This technique is fundamental in producing components with precise dimensions and intricate details, making it indispensable in industries such as automotive, aerospace, electronics, and appliances. Involves multiple operations like blanking, punching, embossing, and coining.
Designing for sheet metal stamping considerations :
- Selecting the right material apt for application: The material should have suitable properties such as ductility, strength, and corrosion resistance to withstand the stamping process and meet the functional requirements of the part.
- Importance of Bend radius in stamping : A general guideline is to use a minimum bend radius of at least one to two times the material thickness. Sharp corners should be avoided. In areas where there is complex geometry it is better to use larger radii to avoid thinning and cracking
- Placement of holes and other features : When designing holes and other features, consider their placement relative to bends and edges. Holes should be placed at least twp material thickness away from bends to prevent distortion. avoid placing features too close to the edges to reduce the risk of tearing or deformation during stamping.
- Tolerances : Tolerances should be defined keeping the capability of stamping process in mind. Depending on quality achievable by machine which will be used for producing the parts. Overly tight tolerances can increase production costs and may not be necessary for the function of the part.
- Spring back : Spring back is the tendency of bent or stamped metal to return to original shape .Evaluate the chances of spring back from material selection and geometry and incorporate considerations for spring back in design .
- Draft angles : Facilitates easy removal of the part from the die. Even a small draft angle can significantly reduce wear on the tooling and improve the lifespan of the dies
- Geometry simplification : Simplify the design where possible to facilitate stamping and reduce tooling complexity. Avoid intricate details that require multiple steps or specialized tooling. Use gradual transitions and smooth contours to enhance manufacturability.
- Ribs and embosses : Ribs and embosses add strength and rigidity to flat sections of the stamped part without significantly increasing weight or material usage. Incorporate them wherever possible and feasible.
- Tooling and fixturing considerations : Early collaboration with tooling engineers can help identify potential issues and optimize the design for efficient production. Providing tooling holes in design to make sure the holding of the sheet is rigid while stamping is taking place .
Stamped part- Vehicle chassis component
Stamping vs Bending
Bending is a specific sheet metal forming process where the metal is deformed along a straight axis to create an angular shape. typically involves simpler operations focused solely on changing the angle of the metal sheet.
Used to create straightforward geometric shapes like L, U, or V-bends.
Can produce highly complex shapes with multiple features in a single or a series of operations.
Bending utilizes simpler tooling, such as press brakes or roll benders, which are more versatile and easier to set up.
Stamping is Highly efficient for large-scale production, capable of producing large quantities of parts rapidly.
Bending is generally slower than stamping due to the sequential nature of bending operations. More flexible and quicker to set up for different shapes and sizes, suitable for customized and varied production runs.
Designing sheet metal stamping part – Outrigger in chassis :
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Categories: : Sheet metal