The automotive contains countless parts, large and small. How are these countless car parts created? This article briefly describes the characteristics of the automobile stamping process and the process flow.
The four major automobile manufacturing processes include stamping, welding, painting, and assembly. This article mainly talks about the automotive stamping process technology of automobiles.
Table of Contents
Auto stamping process
Stamping is a forming processing method that relies on presses and dies to apply external force to plates, strips, pipes, and profiles to produce plastic deformation or separation to obtain workpieces (stamping parts) of the required shape and size. Regarding stamping, it is necessary to talk about the main equipment used, such as presses and dies and other transport equipment.
These two pieces of equipment are the most valuable in a stamping plant, and it is now necessary to invest at least hundreds of millions of dollars in a stamping line. The flywheel drives the stamping machine through the electric motor, and through the clutch, the transmission gear drives the crank linkage mechanism to make the slider move up and down, driving the stretching die to form the steel plate.
The stamping machinery press is one of the most commonly used equipment in the stamping process among the four major automobile manufacturing processes. It mainly relies on the press’s press-down energy to work on the steel plate in the die to form it into the shell of the car body.
Auto stamping molds
In modern industrial production, molds are important process equipment for producing various industrial products, which shape raw materials in a certain way with their specific shapes. In the automobile industry, in various types of automobiles, an average model needs about 2000 sets of stamping dies, among which nearly 300 sets of large and medium-sized covering parts die.
Mold has become one of the important means of contemporary industrial production and process development direction. Modern industrial product variety development and production efficiency improvement, to a large extent, depends on the development of the mold and technology level. The mold has become an important symbol for measuring a country’s manufacturing level.
The sketch of the mold structure is used as a strong basis to draw the general assembly drawing. In the assembly drawing, the relationship between parts should be clear and distinct, relevant sections and projections should be presented, it should draw workpiece drawings, relevant requirements should be indicated, and should fill in parts details.
The working parts of the mold have certain standards in the production process, and they should follow the specifications in the calculation, positioning, pressing, and fastening. Suppose the wall thickness punch is small and long, and the concave die is thin. In that case, the calibration should be reinforced to determine the size and structure of the concave die, to carry out the design, following the selection of the perimeter die holder, to ensure that the closing height, size, and pressure of the die are adapted to the appropriate equipment, and to draw the relevant sketch of the die structure.
To meet the needs of automatic stamping production lines, well-known domestic press manufacturers have developed and produced high-performance single-machine in-line presses. They have developed stamping equipment with large tonnage, large stroke, large table surface, large tonnage air cushion, robotic, automatic loading and unloading system, automatic die change system, and functional touch screen monitoring system, producing fast speed and high precision.
The operation flow of the stamping workshop
Stamping is an important means to complete the plastic forming of metal, and it is one of the most basic, traditional, and important metal processing methods. Various cover parts, interior support parts, structural reinforcement parts, and many auto parts, such as engine exhaust elbow and muffler, hollow camshaft, oil pan, engine bracket, frame structure parts, cross, and longitudinal beams, etc., are all formed by stamping technology. It is developing in the direction of precise, multi-functional, energy-efficient, safe, and clean production. The manufacturing process level and quality of stamping workpieces impact the quality and cost of automobile manufacturing to a greater extent.
Stamping is a production technology that enables the sheet material to be directly deformed in the die by the power of conventional or special stamping equipment to obtain parts of a certain shape, size, and performance. The sheet, the die, and the equipment are the three elements of the stamping process. The dies used for stamping are called stamping dies or dies for short. A stamping die is a special tool for processing material (metal or non-metal) in bulk into the required stamped parts. Without a die that meets the requirements, it is difficult to carry out batch stamping production; we cannot achieve advanced stamping technology without a progressive die.
1. Basic stamping process. The processes of flanging, dropping, cutting, and punching are more common in the stamping process. Each process has its characteristics, and the differences are significant. The main processes for shaped holes in flat parts are shearing, dropping, and punching, while open barrel parts should include a deep drawing process. For specific parts, calculations and analysis are required to determine the nature of the process. For example, suppose the oil seal outer ring and inner ring stamping parts are different in terms of outer diameter and straight edge height after calculation and analysis. In that case, the outer ring stamping process is flanging, deep drawing, falling material, and punching, while the inner ring can eliminate the deep drawing process.
2. Determine the number of stamping. The number of stamping refers to the number of repetitions of the same process. For example, the deep drawing process can determine the number of times drawn by calculating the shape and characteristics of the material; the flanging process can determine the number of times processed by calculating the degree of deformation and size of the material. To appropriately reduce the number of processes and give full play to the plastic characteristics of the material, should arrange the process sequence s more reasonably based on the quality of the process.
3. Process combination. Stamping parts manufacturing can be derived from multiple processes, so the process plan should focus on the combination of processes, which can be a single process or multiple combinations. Stamped parts in terms of precision, size, production batch, and other factors related to the choice of tooling. If the product is of large volume nature, the stamping process should be combined and implemented. It should select a compound die or continuous die stamping, while it should select a simple process for small volume production. If the size of the stamped parts is too small, using a single process will reduce productivity and is not convenient, so should choose the stamping of compound die or continuous die.
4. Design of process scheme of each process. The design of the process scheme of the stamping process should be based on the overall part process scheme, determine the processing mode of a specific process, determine the process parameters in the process, and take the forming limit as the main basis in the stamping process, calculate the necessary process, such as the radius of the bent part, the height of the flanged edge, etc.; determine the shape and size of the blank and the suitable discharging method, calculate the material utilization rate, determine the process The forming force is determined, the time and material to be consumed in the process are determined within a certain range. The workpiece diagram of each process is drawn through relevant calculations.
Choose V1 Stamping Company for Your Automotive Metal Stamping
Precision metal stamping is a cost-effective, fast, and versatile manufacturing method. Automotive manufacturers can use metal stamping to create a range of metal parts while reducing material waste and costs.
If you’re an automotive manufacturer in need of precision metal stamping services, since 2004, we have created high-quality components to meet every customer’s needs. To learn more about our commitment to quality, contact us today, or request a quote for our precision metal stamping services.
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