Sheet Metal Stamping Dies: The Basics

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What is a Stamping Die?

Without reference to any official definition (in our own words!) a stamping die is a hard tool, usually as a male/female pair, that is used to cut, bend, shape or form a sheet of metal into a desired shape. A stamping die is also commonly referred to as a 'stamping tool' and often just as 'tooling'. Stamping dies are often described as 'tooling' because nearly always, more than one stamping die is required to manufacture the required shape, using multiple process steps.

Where are stamping dies commonly used?

The most common application of sheet metal stamping dies, is in the automotive industry. Any automotive component made from sheet metal is generally made in a metal stamping die. Perhaps the second largest application is in house hold consumer goods, such as dish-washers and clothes washing machines. Another industry that commonly use stamping dies is the building industry, although for only a select few sheet metal components, as well as the medical industry. There are many other applications for sheet metal stamping dies but by far when stamping dies are mentioned, automotive is at the forefront of this technology.

What are the disadvantages and advantages of metal stamping dies?

Sheet metal stamping dies are most appropriate when high volumes of parts are required eg: >50,000 parts per year. Correctly designed stamping dies can manufacture sheet metal parts at the rate of 60+ parts per minute, but more commonly at around 20 parts per minute. The disadvantage is that to produce parts at this rate, a large capital investment is required in 'tooling', and cost of such tooling can be in the order of USD $100,000 to $500,000 typically. In addition, this assumes that a line of presses (press machines) is available to run the tooling.

What are the types of stamping dies?

The types of stamping dies are usually categorized by the rate at which parts can be manufactured. For example 'pick and place' tooling is a set of stamping dies that require manual labour (by hand) to move the part from tool to tool. Where as 'transfer' tooling, usually means the set of stamping dies are linked via a mechanical (or robotic) system which automatically transfers parts from tool to tool, and from press to press in a line of press machines. The highest volume tooling (the stamping dies capable of producing 60+ parts per minute) are known as a 'progression' tool. They are named as such because many smaller tools are joined together and a sheet metal strip 'progresses' thru each tool, using the sheet metal as a carrier to progress the blank from stage to stage at a very rapid rate.

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How a stamping simulation can be used to improve quality?

Because of the significant capital investment required to create a stamping die or a set of sheet metal tools, any method which can reduce the risk of malfunction or an un-expected problem, is used as early as possible in the design stage. Sheet metal stamping simulation is used to validate and verify a tool design before any tooling is made, to ensure no unexpected problems are encountered and to ensure the time and money invested produces a successful outcome.

Other Helpful Reading:

Achieve Metal Stamping Success Through Smart Planning and Production
Understanding The Effects Of Oil Canning in Stamping Simulations

Sheet metal stamping is one of the most cost-effective ways to produce a high volume of identical parts at a rapid rate. While using a combination of dies and stamping presses, sheet metal can be pressed or transformed into the desired shape by feeding the raw material between die sections and applying pressure to the material. The flexibility and durability of sheet metal allows for this transformation to take place into the desired shape; however, this transformation must occur under tons of pressure using a specialized machine to apply this pressure.

What machine do you use to stamp the sheet metal?

To effectively transform the sheet metal, thousands of pounds of pressure are required. This can be done using different types of presses such as servo-drive, crank-drive, and hydraulic-drive presses.

With an automated blanking punch press system such as the 440-ton blanking line above, an uncoiler holds the raw material until it is ready to be used. Once production is ready to begin, a straightener pulls the coil material from the uncoiler into the ultrasonic loop control (gives direction to the straightener using ultrasound) and a servo-feeder motor then pulls the material from the loop and into the punch press (tool).  The servo-feeder is fully programable and allows for control of the feed length and pilot release.
During the press brake operation, other specific metal forming processes can occur at the same time. These specific processes can include:

• Blanking
• Punching
• Coining
• Bending
• Embossing
• Flanging

Advantages and Disadvantages of Stamping

While stamping can be a cost-effective production process for both low and high-volume parts, it has its own set of advantages and disadvantages depending on the application.

Some advantages to using a punch press system include:

• Lower piece price
• Faster blanking and forming run rate
• More consistent quality due to a repeatable production process
• A Progressive Die ensures all forms/features are 'Tool Controlled' ' No missing features or formed backwards parts, etc.

Some disadvantages include:

• Initial NRE (Tooling Cost) can be higher than other fabrication methods
• Longer lead time to initial shipment (tooling lead time)
• Typically, more difficult to integrate revision and/or part design changes

Being an important production process that reaches a variety of industries, sheet metal stamping is an essential production operation that touches our daily lives in some way. From stamped parts inside the vehicle you drive, to the oven you cook your food with, you are encountering stamped metal parts. Have a project you would like our engineers to evaluate for a cost-effective production solution? Reach out to us today at with any questions.

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