Metal stamping is a fast, cost-effective type of metal forming for creating precise parts from metal materials such as sheets and coils. Keats Manufacturing Co. is a leading provider of comprehensive and accurate metal stamping, finishing, and value-added services. We can guide you through the metal stamping process to help confirm what procedures and finishes are necessary for your product, and we have the expertise to avoid the pitfalls of metal forming by using industry best practices in your product design.
Special Features for Metal Stamping
When choosing an electrical terminal for a wiring application, it is important to be mindful of both the connection requirements and environmental conditions of your application. Understanding the various types of terminals available and their ideal uses is critical for making the proper selection. The most common terminal designs include:
Threading processes displace metal to create raised edges, like the roll-formed threads and cut threads around a screw.
Countersinking processes create a cavity for the head of the screw that matches the size and orientation of a screw that will eventually need to be installed in the part.
Manufacturers can add raised or sunken numbers and characters to a metal form based on the unified numbering system (UNS) to distinguish a component’s metal or alloy composition.
Manufacturers can add raised and sunken graphics, like logos, onto metal parts as well.
Keats Manufacturing offers custom packaging, cell packaging, and continuously wound reel assembly services to minimize complications and streamline our customers’ supply chain needs.
In staking processes, a thin extrusion feeds through a hole of a matching piece and then deforms so the electrical contacts, crimp notes, bolts, and fasteners lock together.
Joining processes like welding utilize high temperatures to permanently merge or attach components of a configuration together.
Metal Stamping Design Considerations
Sheet metal and coiled metal wire are the most common materials used in metal stamping processes. To create well-formed, accurate, and virtually identical products, it’s important to consider these elements when creating metal stamping designs:
The material must generally bend in a single orientation, and the inside bend radius should equal the sheet thickness at a minimum.
Grooves, holes, and slots
Keeping the diameter of grooves, holes, and slots equal to or larger than sheet thickness results in better form with fewer burrs and bulges. Keeping the holes apart at a distance of at least twice the thickness of the material can also reduce bulging and deformation.
Material needs and characteristics
Different metals and alloys have different attributes, including different degrees of resistance to bending, strength, formability, and weight. Some metals will respond better to design specifications than others; conversely, designers will need to take the advantages and limitations of their chosen metal into consideration.
Determine the acceptable tolerance levels for your project. Achievable tolerances will vary based on the metal type, the design demands, and the machining tools used.
Consistent wall thickness throughout a product is typically ideal. If a part has walls with different thicknesses, then it will be subject to different bending effects, resulting in deformation or falling outside of your project’s tolerances.
Possible Defects and How to Avoid Them
Some of the most common defects in metal stamped products are:
Parts with dramatic bends are particularly vulnerable to cracks, especially if they’re made from stiff metals with little plasticity. If the bend is parallel to the grain direction of the metal, it could form long cracks along the bend.
Three-dimensional metal parts with holes often go through hole punching first and bending into shape second. If the holes are too close to the bent edge, they can stretch or deform.
Insufficient hole spacing
If a hole isn’t a proper distance from the edge of a piece, which is a minimum of twice the part’s thickness, then the strip of material between the hole and the edge will bulge outward.
Stamped edge burrs
Cutting and stamping tools can shear metal edges, causing sharp burrs along the bottom of the edge. This can make the piece sharp to the touch, lead to a blemished finish, or even negatively impact the dimensionality of the finished product.
These defects are often the result of poor stamping processes and deviation from best practices.
Choose Precision Metal Stamping Services From Keats Manufacturing
Keats Manufacturing is a custom metal stamping supplier specializing in high-quality metal stamping, wire form, and assembly services. Our engineering and production teams have the experience and skill to tackle your project, no matter how complex, all at an affordable cost.