Guide of Metal Stamping Dies: How Does Metal Stamping Work?

Metal stamping is the practice of cutting and forming metal sheet into a required contour with the help of tool known as a stamping tool.

 

Metal stamping is the practice of cutting and forming metal sheet into a required contour with the help of tool known as a stamping tool. Sheet metal components are used universally, from the regular clips to complex computer hard drive components, all are manufactured by a precision sheet metal stamping process. Stamping die design is the preliminary phase in stamping tool and dies making and is carried out as soon as the component design is finished. The stamping die drawing stage is extremely critical as a good quality stamping die blueprint can generate accurate stamped components which can run for an extended time with less maintenance.

 

Stamping tool design calls for selecting the required metal stamping operations, basic strip layout, manufacturing processes, type of stamping presses to be used and so on. It is necessary for a tool designer to have thorough knowledge of these elements to construct a fine die design. Computer aided design techniques have progressively developed in the last decade to assist die designers.

 

There are various procedures involved in metal stamping tooling designs which are necessary for accurate tool production. The very first stage in die design is the process of evaluating the metallic part to be made, its properties, dimension and complexity of the contour. Next the designer will proceed with the strip layout design and then he will determine the cutting force and the die-set to be used and then begins making the assembly sketch. Once the assembly sketch is completed, part details, drawing of die parts, and the final step of preparation of the bill of materials can be undertaken.

 

How Does Metal Stamping Work?

Metal Stamping includes many different types of sheet-metal forming manufacturing processes. Key parts of the process include punching (using a machine or stamping press), blanking, coining, embossing, and bending. Stamping is primarily carried out on sheet metal, but can also be used on other materials, such as aluminum, steel, plastic and foil.

 

  • Bending

Process that result in a V, U, or channel shape in any bendable material (most often sheet metal) without fracturing. An example would be the bottom of drinks can.

 

  • Blanking

A shearing operation uses a punch to create a blank from the sheet metal or a plate.

 

  • Progressive Die

Metal Stamping die that pushes a sheet of metal through a series of operations until a finished part is made. An example would be the lid of a soda can (separate operations for the lid and pull tab).

 

  • Compound Die

Metal Stamping Die performs more than one operation in a single press.

 

  • Deep Draw

Process of a drawing press is used to form sheet metal through the mechanical action of a punch. An example would be a kitchen sink.

 

  • Tapping

Process of cutting is the threads in a hole. An example of this would be a nut, where a bolt screws into.

 

  • Coining

A precision metal stamping form used most often where high relief or very fine features are needed. An example would be money (quarter, nickel, dime), badges, and medals.

 

  • Embossing

Metalworking process of soft malleable metals are shaped and designed by hammering on the reverse side.

 

  • Blanking

Metal stamping operation by the sheet metal is punched to get the required outer profile of the sheet metal component. During the blanking process the blanking punch penetrates into the sheet metal and forces the material into the blanking die. The portion of the sheet Metal which comes out through the blanking die opening is the component with the required profile. Hence it is important that the dimension of the blanking die profile is equal to the dimension of the component profile. In blanking tools, the cutting clearance is given on the blanking punch.

 

If you have requirement of metal stamping dies, I recommend you to visit Coolmosa Technology Co., Ltd. – they are the professional manufacturer of specializing in metal stampings. Now, check out their website and feel free to contact with Coolmosa for more details!

 

Article Source: https://www.totalmateria.com/page.aspx?ID=CheckArticle&site=kts&NM=301

The Best Casting Process for Your Needs

In the field of metal work, various methods of casting are used to turn molten metals into specific shapes for use in commercial and industrial products. Within each casting process, a cavity is formed in which molten metal is poured either with gravity or high pressure. After a number of seconds have passed, the metal solidifies and the newly hardened casting is released from the mold or form.

 

Casting is most often employed to make intricate metal objects that would otherwise be complicated and much costlier to produce with different methods.

 

The process of casting has existed since ancient times. Some of the earliest examples of metal casting exist today in the form of jewelry, tools and sculptures that have been retrieved from archeological sites and put on display in museums around the world. Early methods of casting included plaster mold casting and lost wax casting.

 

Today, the methods of casting fall into the non-expendable and expendable categories. Other variants of the two categories include the methods used to fill cavities — including pressure and gravity — and the material used to form a particular mold.

 

First, there’s the non-expendable type of casting, which would account for any method in which the mold can be used again. Examples of non-expendable casting include permanent mold and die casting methods, in which the molding cavities are made of metal. Non-expendable casting is often favored for its ability to produce uniform parts at high volumes.

 

Expendable casting accounts for any method in which the mold is discarded after a single use. Examples in this category include sand and plaster casting, in which molten metal is poured into a cavity that is then broken away to reveal a finished casting. A further example of expendable casting is investment casting, a modern version of lost wax casting, in which molds are formed around wax patterns, which are then melted away to reveal hard ceramic cavities for subsequent metal molding.

 

Aluminum Die Casting

With aluminum die casting, a process takes place where molten metal is forced into a cavity in which a mold is formed. The process is achieved with a pair of steel dies that have been machined into particular shapes, which form the molding cavity when joined together. A similar process can also be applied with castings made of copper, magnesium and other metals.

 

The aluminum die casting process is divided into four stages: preparation, fill, ejection and trim off the gate.

 

First, a lubricant or die release agent is applied to each half of the cavity in preparation for the injection of the metal to be cast. Next, the dies are brought together and the cavity — in some cases one, in some cases two or more — is filled with molten metal under high pressure, which is maintained until the casting hardens.

 

A waiting period follows, after which the metal will have hardened into its final shape. With that step completed, the dies are separated and the castings are pushed out of the mold with ejector pins. Afterward, the parts that comprise the scrap — runners, sprues, overflows etc. — are trimmed away. In some cases, the finished shape will then receive sanding or polishing along the surfaces.

 

The high pressure at which the cavity is filled is crucial to the process because this prevents any part of the casting from hardening prematurely. This also ensures that the entire cavity is filled with no discontinuity, which could otherwise occur in die castings with complex shape formations. High pressure also eliminates the possibility of air bubbles, while the entrapment of air is further avoided with vents along the dies surfaces.

 

Aluminum die castings can also be produced with secondary features on molds, such as holes and grooves. Aluminum die casting is used to create everything from marine and sporting components to oil pumps, engine cradles, transmission transfer cases, heatsinks, enclosures, and brake components. The process is generally reserved for high-volume industrial productions.

 

Sand Casting

In the process known as sand casting, hardened casts of sand are used within a gating system to mold metals and other materials into shape. The sand is formed around patterns, which form cavities within the sand that are subsequently filled with molten metal. Due to sand’s heat-resistant quality, sand casting accounts for the vast majority of metal mold production.

 

To make the sand castings, sand is mixed with clay, water and sometimes other substances. The process here is a lot different than die casting because the hard sand that forms the mold is broken away and dispensed with afterward. Nonetheless, sand castings are often used to produce complex molds that are harder to make with die castings.

 

The process of sand casting is divided into several steps. First, a pattern is placed into the sand, where a cavity is then formed within the sand through the application of gating, after which the pattern is removed. In some cases, the cavity will be rather complex, with multiple grooves and several turns, twists and corridors.

 

Next, the cavity within the sand is filled at high pressure with molten metal. Once the metal has cooled into a hardened shape, the sand cast is broken away and the mold is removed. The finished mold might then be modified in whichever way is necessary, whether it needs to be trimmed or buffered to a smooth shine.

 

Sand casting molds are commonly used to make complex metal objects, such as one-piece equipment parts with various contours that would be hard to produce through other casting methods. Examples include the trap pipes used in household plumbing systems and metal doorknobs and lampshades.

 

Sand casting is also used for artistic items such as living room fixtures and metal sculptures. Sand casts are even used in jewelry production for items such as rings and metal bracelets. Whether the finished product is complex or simple, sand casting is a reliable method that allows manufacturers to form exact shapes with the utmost precision and detail.

 

V-Casting

An alternate form of sand casting is known as vacuum molding, or V-casting, which involves the use of unbonded sand. V-casting is often employed in the production of ferrous and non-ferrous metal molds.

 

The process makes it possible to form molds without the use of pressurized compaction methods, such as squeezing and blowing. Instead, clean molds are achieved with dry sand and vacuum pressure. V-casting allows manufacturers to do away with sand mixers and other equipment required for hardened sand.

 

V-casting can be carried out with a simple arsenal that consists of a vacuum system, a pattern, a film heater, a flask and a vibration surface. The process is generally clean and free of fumes or odors. Once finished, the dry sand is simply recycled for the next application. As such, V-casting is one of the most waste-free methods by which molds are cast for metal products.

 

In V-casting, patterns are placed onto boards with vacuum chamber vents. Heat-softened sheets of plastic are then placed over the pattern and the vacuums are activated. This causes the plastic to wrap tightly to the details of the pattern. Once hardened, the pattern is removed from the mold. Then, a vacuum process is utilized to pull molten aluminum through the cavities.

 

V-casting is often favored due to its ability to produce fine finishes with precise dimensions. A multitude of shapes can be achieved with the method, whether the mold is lightweight or heavy. The process allows you to reuse patterns multiple times and leaves little scrap excess material upon completion.

 

Investment Casting

Investment casting is a modern-day method of lost wax casting, which has been used for thousands of years in the creation of art fixtures, figures and masks. Archeological finds throughout Eurasia have included plates, vases and furnishings made with earlier forms of the wax casting method.

 

Investment casting is favored in a variety of industrial productions because of its versatility and accuracy of detail. Numerous mechanical pieces, such as valves and turbines, are made from the process of investment casting.

 

First, a master pattern is made from wax, or sometimes from wax replicas of a preexisting non-wax pattern. Next, a mold is created, which is also referred to as the “master die.” Several different wax patterns can be combined into a bigger pattern for a single molding. For industrial applications, the wax patterns are applied to a sprue that connects to a mechanical arm.

 

Next, the wax molds are dipped in ceramic with factory machinery. Then, the mold is heated and the wax melts out from the surrounding ceramic mold. With the ceramic molds now empty, molten metals are poured into the cavities formed by the ceramic.

 

Once the metal inside the ceramic molds have hardened, the ceramic forms are broken away. Afterward, excess parts are removed from the metal shapes, which are then readied for their ultimate use.

 

Where to Find Die Casting Manufacturer?

Champion H&C Inc. is a professional manufacturer of specializing in kinds of die casting processes and CNC machined products. Such as aluminum die casting parts, zinc alloy die casting parts, CNC lathe machining parts, CNC turning parts, and much more products that you all can find on Champion H&C website. If you need more information about die casting process, please do not hesitate to send inquiry to contact with Champion H&C Inc. immediately.

 

 

Article Source: https://diecasting.com/blog/2017/07/31/best-casting-process-for-your-needs/

The Utilization of Vertical Injection Molding Machines

When it comes to making items that combine light weight, durability, and pleasing shape, look and feel, there’s nothing that quite matches modern plastics. And this is especially true of hand-held items, such as small electronic appliances, where providing ergonomic shape and a grippy, easy-to-hold surface are particularly important.

 

Whether they’re GPS receivers, medical devices, toys, or even kitchen utensils, the best way to produce such items is through the process of over molding. It involves the molding of two different plastics, one on top of, or around, the other, so as to produce what amounts to a single, unified structure that’s strong on the inside yet flexible, colorful, and easy to hold on the outside.

 

Benefits of over molded plastics devices include:

 

  • More Resistant To Shock
  • More Resistant To Water
  • More Resistant To Dust And Vapor
  • More Resistant To Vibration
  • Make Devices More Comfortable To Use
  • Make Devices Just Plain Prettier

 

By now, over molding is a standard process in the injection molding industry, but some methods of executing the process is superior to others. The challenge is to make sure the two pieces, rigid substrate and outer elastomer, to fit together just so, with no gaps, no slack, no possibility of slippage and with no chance of one part pulling on and distorting the shape or integrity of the other. Getting these two molded parts to match up just right takes a good deal of skill and experience. No adhesives can be used, and there should be no manual assembly steps involved, either – it’s mainly a matter of making molds that create a perfect fit and then performing the actual molding process with extreme precision.

 

And it’s here that the right machinery also helps a great deal. Indeed, the best way to produce over-molded parts is with a vertical injection molding machine. It relies on the gentle force of gravity to clamp the inner and outer parts together.

 

That’s different from a horizontal injection molding machine, which relies on mechanical clamping, a method that requires more time and effort and raises the risk of improper fit: Gravity’s pull is always there, always trying to dislocate parts in a horizontal mold. The vertical mold simply takes advantage of gravity instead of trying to fight it.

 

Vertical injection molding equipment is designed with open clamps and rotary tables, which gives them the advantage of being able to work with multiple molds and simultaneous operations such as pre-molding, injection-, and post-molding. The result: less need for manual intervention, greater efficiency, greater productivity, and less cost. What’s more, vertical molding machines often save significant space on the factory floor.

 

In short, vertical injection molding is the method of choice when it comes to producing high-strength, high-touch parts for the electronics, medical, military, and similarly demanding industries.

 

More information about vertical injection molding machine, try to visit the website of Multiplas Enginery Co., Ltd... Multiplas is a leading industrial solutions provider that offers versatile moulding solutions, innovative design and manufactures for the production systems, and provides comprehensive technical support services to the customers committed in 3C electronics, electrical, automotive, medical / optical, and other technical moulding sectors. If you have any interest, please feel free to send inquiry or contact them directly.

 

 

Article Source: http://info.crescentind.com/blog/bid/40004/Over-molding-and-the-utilization-of-vertical-vertical-injection-molding-machines

Plastic Injection Molding and Its Advantages

Product identification plays an extremely important role in communicating a product’s position and brand in the marketplace. Plastic nameplates can convey messages, brand, classifications, description, schematics, warnings, instructions and many other types of product information.

 

Plastic injection molded nameplates help to identify your products and help them stand out in the crowd. Before we go further, let’s take a quick look at the plastic injection molding process.

 

The Plastic Injection Molding Process

 

The plastic injection molding process is not a complicated one. Molding processes of this sort involving metals go back many years, and basic principles have not changed, just the methods and materials.

 

Of course, you have seen what the finished product looks are. You’ve seen them more times than you may be aware of. You’ve seen them as car emblems, appliance and industrial nameplates, custom plastic nameplates, recreational product nameplates, point-of-purchase, plaques and signs. They fill the world around you, but do you know how are they made?

 

The process begins with a plastic pellet made of a composite of organic and inorganic polymers, plus additives to aid in the melting process. This small pellet is tossed into a hopper with thousands of other pellets. This begins the journey from pellet to product. The next step is preparing the plastic.

 

The pellets are released onto the threads of a giant rotating screw. As the pellets travel along, they are heated to melting temperatures, somewhere around 400 degrees Fahrenheit. Of course, the higher quality the plastic is the higher temperature it takes to melt it. The pellets are rolled along the screw because the process also requires friction and force. The screw provides both as the pellets roll along its surface and crash into each other.

 

Now that all three requirements are met, friction, force and heat, the pellets begin to liquefy and the next step of filling begins. The screw continues to guide the liquid plastic along its threads to a valve. Under high pressure the valve forces the plastic into a custom designed mold – made of heat resistant metals – until every cavity is filled. Once this is achieved the mold goes into the holding phase. The filling and holding phases are crucial steps in the plastic injection molding process. Their execution will determine the quality of the finished product. The metals we use for the mold insure that the last piece made carries the same qualities as the first.

 

The Next Step

 

The pressure on the mold is maintained while the molten plastic cools to a solid state. This stage could take a few minutes as the mold absorbs the heat from the melted plastic, and in turn is cooled by coolant that encircles it. While the part is cooling, the screw returns to its original position, collecting more pellets from the hopper. The product is then ejected from the mold and moves to its secondary processes such as decoration, sub assembly, or shipment. The mold closes, and the process begins all over again.

 

Advantages of the Plastic Injection Molding

 

There are several important advantages of utilizing injection-molded plastic:

 

  1. The plastic injection molding allows complex and intricate shapes to be manufactured. Shapes that would be too difficult or costly to manufacture with different processes.
  2. The plastic injection molding allows for a high volume of plastic nameplates and custom plastic signs to be manufactured at the same time with the same mold and quality.
  3. The metal molds have a long life. When you come back for a future order, the mold will be ready and your next order will be identical to your first. In addition, their initial cost is low too.
  4. The plastic nameplates can be decorated in a variety of ways such as textures in the mold, metallic foil, ink, UV protection, and more.

 

Other Advantages

 

Plastic Injection Molding allows manufacturers to produce custom plastic nameplates and components that would be too costly to make as intricately as required, by utilizing traditional machining methods. Injection-molded plastics also saves you time and money by allowing high numbers of pieces of the component to be made at the same time, with each copy identical to the one before it. This process also reduces labor costs by minimizing the need for manual labor from employees. Finally, there is virtually no wasted material. Any unused or left over plastic can be re-cycled to be reused in the process

 

Shin Fang Plastic Industrial Co., Ltd. was founded in 1974, mainly produced handbag hardware accessories in the early stages. In 1994, the company increased plastic material injection production line. Since it offers stable quality, complete patterns, it obtains great approval from the industry. We offer the customized OEM/ODM service and material selection to satisfy the best quality, minimum cost, and quick response requirement.

 

Our product line includes cart system, side wheel, side release buckle, hook, loop, ring, ladder lock, cam buckle, slide, cord lock, stud, washer, eyelet, shoulder pad, foot stand, pad, strip, handle, bottom case, two colors molding product, diving case, utility box, and tackle box whose are made of a wide plastic material of POM, NYLON, PP, ABS, PVC, HYTREAL, TPR, and others. If you need more details about Shin Fang’s plastic injection molding or plastic injection products, welcome to contact us for more information!

 

 

Article Source: http://EzineArticles.com/8316494

 

Experienced and skilled Mold design & Mold maker – Spro Tech

Introduction of Spro Tech

Spro Tech is a leading mold manufacturer whose business is based in two distinguished divisions – single shot plastic injection moulding and plastic parts, double shot injection molding and plastic parts , it is a unique model of success in the China/Taiwan industry for automotive components.Since 1994, with the foundation of Spro Tech has had an exponential growth; firstly on the mould manufacturing for the injection of thermoplastics and afterwards by creating their own industrial units for the injection of thermoplastics, as well as on the development of competences and technical and technological capacity for the pursuit of high level projects of investigation and development.

As a professional plastic mold manufacturer, we have skilled technicians and fine machineries, including CNC Milling Machines and NC Electric Discharging Machines. Our rich experience can provide you with molding suggestions that are fully cost-effective and efficiency-concerned, manufacturing high quality molds that are precisely to the design requirements. Customized modification is provided to meet the production requirement for high quality and efficiency products.

Spro Tech is a famous plastic injection mold manufacturer and designer. Spro Tech’s plastic injection molding products are with very competitive price and best quality to their customer. Spro Tech’s aim is to develop plastic injection mold products that offer a core advantage over that of traditional molding products for their customers and strategic partners. Right injection mold making at competitive prices backed by prompt customer services, is why so many customers choose Spro Tech.

Spro Tech has systematically established the comprehensive mold component database to accelerate the design process, and utilized proper design software on 2D and 3D designs. Spro Tech can load the file through a complex transformation process even with abnormality on the geographical figures, and quickly design mold cavity, core and sliding block cutting. Spro Tech can establish design modules which make the manufacturing process easier. Spro Tech also can perform input/output proficiently on almost every CAD application software.

 

==Molding For Auto Part==
Water Tank - BS4 Housing
Auto Manifold
Water Tank - W408 Cover

==Molding For Electronic & Computer==
Computer Panel
Computer Series
Panel R/L

==Molding For Consumer Electronic==
Electronic Parts
Consumer Parts
Consumer Parts