Aluminum stamping is a key process to reduce the weight of vehicles. It improves fuel efficiency while reducing carbon emissions. Therefore, people are manufacturing lighter parts by replacing steel with aluminum alloys. The weight reduction does not affect the safety of the body-in-white (BiW) structure.
JWB utilizes advanced software and an extensive database of aluminum alloys. Therefore, the latest tools and techniques enable the production of quality aluminum stampings. Stamped aluminum parts are more prone to springback than stamped steel parts. JWB uses advanced software to get the proper springback compensation. In addition to quality, they also ensure that the parts must meet certain production tolerances on the production line. Some of the common products manufactured include body side openings, outer panels, and closures, which are well suited for aluminum alloys. These products also involve structural components of the vehicle.
Metal stamping refers to several forming processes that are often used to transform standard aluminum products into smaller components. The different techniques involved in the aluminum metal stamping process are given by the following formula:
· Blanking： The blanking process forms a die that is used to cut the workpiece from the aluminum sheet metal. This process produces a clean blank that can then be processed using a punch press or other equipment.
· Punching: Punching uses a punch and die to cut small slots, notches or holes in a part. Punching provides a smaller clearance size and therefore produces a cleaner edge than drilling. Punching is generally considered more efficient than laser cutting.
· Deep Drawing: The deep drawing process uses tensile force to give a part the desired shape and thickness. The deep drawing process changes the shape of the blank by gradually stretching it over a die. Deep drawing is commonly used in the manufacture of various electronic devices.
· Forming： Forming is a general term covering the techniques and processes used to shape or form the blank.
Stamping is a broad term. There are a variety of manufacturing methods. These techniques allow you to form aluminum sheets into any desired shape
Blanking Aluminum
In the blanking process, a punching tool is used to remove certain parts of the aluminum sheet. Usually, a die is usually used to remove the desired design from the workpiece. Punching only removes the unwanted parts. Blanking removes the desired parts of the aluminum sheet
Perforated Aluminum
Punching is a process of making holes or slots on aluminum plates using a punch and a die. It can accurately shape the desired shape on the blank aluminum plate with high dimensional accuracy.
Stamped Aluminum
Coining is another aluminum bending process where the metal sheet is placed between a punch and a die. The aluminum can be pressed into an L, V, or U shape. Coining methods are also categorized as aluminum stamping methods.
Aluminum deep drawing
Deep drawing is a process that applies tension to create deep indentations in the surface of aluminum. The method presses the aluminum into a cavity to create a deeper shape. While drawing can be a challenging process, expertise is required to minimize deformation.
Embossed Aluminum
In the embossing process you can create high or low profiles on aluminum. The tooling system stamps the desired design into the metal. Embossing provides a high level of detail in the pattern/design creation
Flanged aluminum
Flanging involves using a tool to place a flange or flare on an aluminum surface. This process is used to develop structural elements in stamped parts and/or to form undercuts
There are four key aluminum stamping operations to consider:
1. Aluminum Progressive Stamping Dies
Progressive stamping dies use a set of dies to accomplish certain operations. As the metal, or more precisely aluminum, passes through the machine, the copper goes through several processes in sequence. In each die station, there is a specific job to do in order to be able to run efficiently. The final die is used to separate the final part from the scrap metal. Aluminum progressive stamping dies can be used well for large production runs. In addition, they are used to transfer dies from one location to another.
2. Aluminum Transfer Die Riveting
Transfer die stamping is a process that uses mechanical means to move parts from one location to another. After the first stamping process, the cross-sectional areas of a specific shape are separated from the main plate. They are then transferred to other stamping stations. This technique is best used for large aluminum parts that may require further processing.
3. Aluminum Four-Slide Stamping
Four-slide stamping uses multiple sliding tools to produce complex shapes on the workpiece. The process is ideal for designs with high complexity because it allows for multiple deformations to be made at one time. Moreover, aluminum metal stamping costs are cheaper and suitable for mass production as the production time is minimal. The four-slide stamping design is flexible, making it easier for manufacturers to produce large quantities of aluminum parts.
4. Aluminum Fine Blanking
Fine blanking forms aluminum parts with precise dimensions. It does not produce burrs on the edge of the part. Moreover, blanking reduces the formation of burrs, thereby providing the tight tolerances required for high-quality applications. It is mainly suitable for high-dimensional applications in aerospace and automotive. Therefore, fine blanking provides the best solution for complex aluminum parts.
Stamped aluminum parts have a good surface finish and are suitable for additional operations such as painting and powder coating. Aluminum is often used in the manufacture of aerospace hardware due to its excellent strength-to-weight ratio.
Due to its extremely high thermal conductivity, it is considered a perfect stamping material for making cookware and radiators. In addition, aluminum has good electrical conductivity. In addition, it has stable performance characteristics at low temperatures, maintaining high strength and ductility. Aluminum oxide (Al2O3) coating on aluminum provides excellent corrosion protection against harsh environments.
In addition, aluminum is a non-toxic, inorganic, highly reflective and relatively easy to form material. Despite this, it is generally more expensive than steel. The welding process of aluminum is a challenge and may require additional pre-treatment. However, some specific types of aluminum alloys cannot withstand heat treatment, which limits the ways in which they can be used.
The grades of aluminum commonly used in the aluminum stamping process are as follows;
1100 aluminum alloy
Features: 1100 alloy is easy to form, has excellent flexibility and excellent corrosion resistance. Made of 99% pure aluminum.
Applications: Used in decorative items and food packaging.
3003 aluminum alloy
Features: Has excellent mechanical properties, including high corrosion resistance, stronger than alloy 1100, but easy to form.
Applications: Commonly used in chemical equipment and kitchen equipment. Also used in general sheet metal projects.
5052 aluminum alloy
Features: 5052 alloy protects against salt water corrosion. Has high endurance strength in applications that are difficult to withstand pressure.
Applications: Due to its strength, titanium is suitable for marine applications, automotive parts, and as part of aircraft fuel tanks.
6061 aluminum alloy
Features: Al 6061 is valued for its adaptability, heat treatment qualities, weldability, and low corrosion resistance. After anodizing, it can produce a good surface finish.
Applications: Commonly found in buildings, automobiles, aircraft, spacecraft, and shipbuilding.
Here are some common challenges encountered during aluminum stamping:
Stitching
Stitching is a common problem in aluminum stamping. Stitching is when the aluminum sticks to the stamping tool, causing defects on the part surface. Therefore, it is important to use the right grease and contamination-free tools. Other coatings such as titanium nitride can also be used on the tool to minimize the adhesion of aluminum to the surface.
Springback
Aluminum also has a higher springback rate than other metals when bending forces are applied to it. The part fails to retain the intended shape. To avoid this, you need a lot of control during the stamping process. It is also possible to modify the tool design and use software simulation to estimate and compensate for springback.
Wrinkles
Wrinkling is a major problem in the stamping process, especially during deep stamping. Wrinkling occurs due to compressive stress acting on the aluminum sheet. Wrinkling can be reduced by controlling the blank holder pressure and optimizing the die design. In addition, wrinkling can be prevented by ensuring that the material is evenly distributed during the stamping process.
Tearing
Tearing is a splitting problem. It usually happens with aluminum sheets when the material is overstressed during the stamping process. To prevent this, the rate at which the material deforms must be well controlled. It is also important to choose an aluminum grade with good elongation. You can also try to optimize the tool design to minimize tearing.
Tool wear
Aluminum is a hard material that easily wears the tools used for processing. It shortens the life of the stamping tool. Using high-quality tool materials and applying a protective coating on the tool can avoid tool wear. Protection also minimizes failures and helps to extend the life of the tool and improve the quality of the part.
Custom metal stamping is widely used in aerospace, automotive, construction and medical fields.
Aerospace
Aluminum stampings are ideal when weight is not an issue. It is easy to handle, lightweight and has high mechanical strength, making it ideal for aircraft parts. Aluminum stampings are used to manufacture fuselages and wings as well as internal mechanisms. It helps reduce the overall weight of the aircraft, thereby improving aircraft and fuel efficiency.
Medical Devices
Aluminum stamping is a particularly important process for providing precise, precision medical parts. Aluminum alloys are often used in surgical instruments, diagnostic equipment, and patient transfer equipment. These parts help ensure cleanliness and reliability, which is very important in the healthcare field.
Building and Construction
Aluminum stampings are suitable for frames, panels, and structural members of building structures. These properties make them suitable for contemporary architectural designs in many buildings.
Food and Beverage Industry
Aluminum is non-toxic and does not corrode easily, so it is often used to manufacture food and beverage containers. In addition, aluminum is used in equipment in the food processing and storage industry that requires strict heat supply.
Automotive Industry
In the automotive industry, efficiency and safety are always key. Aluminum stampings are used for automotive frames, panels, and engine components. They provide support without adding weight to the car, thus improving fuel consumption and vehicle toxic emissions.
Electronics Industry
Aluminum is an excellent conductor of electricity and heat, a property that is essential in the production of electronic devices. It can be found in electronic device housings and computer heat sinks. Aluminum stamping provides both form and strength in the electronics industry.
JWB is your trusted provider of custom aluminum metal stamping services. Our professionals have years of experience and knowledge in aluminum stamping and are ready to meet all your metal stamping needs.
If you need precise tolerances, in-house tooling design, prototype forming, or high-volume production, you can count on JWB for quality results.
Over time, JWB has mastered a variety of metal stamping methods, surface treatment processes, and rigorous and comprehensive quality inspections. We are committed to providing quality aluminum parts within a limited budget.
Aluminum stamping is a flexible metal manufacturing process with a variety of available technologies. JWB guarantees that all stamped aluminum parts are produced with the highest precision and quality. Please feel free to contact us with any questions on how we can meet your production requirements.
