How to Reduce Stamping Costs

In recent years, the cost of stamping has been rising, which is beyond all control; after all, the economic environment has changed. By choosing our company, we will be able to reduce the cost for you while ensuring quality and providing you with a one-stop solution.

Manual single-process stamping

A single process is executed by a single machine, with loading and unloading operations carried out by hand.

Features:

High flexibility, no automation-related factors to consider in the tool structure, and simple structure requiring low investment in tooling.

The investment in equipment is also very low, maintenance costs are low, and the single machine has a small footprint because there are no automated auxiliaries.

Separate shears or drop-in machines are required to pre-production the sheets, and the cost of one more sheet turnaround.

The sheet does not require complex positioning areas, the contour shape is less restricted, and the material utilization is higher.

Very high labour costs, operator to machine ratio at least 1:1, 1-2 persons each for loading and unloading larger parts.

Production efficiency is low, SPM: 5 to 10.

Knowledge: SPM is known as strokes per minute, i.e. the number of strokes per minute, which means the number of strokes per minute.

Because of the equipment and mould’s simplicity and the high level of manual involvement, production stability is poor, and quality costs are relatively high.

Application scenario:

The general life cycle usage is below 20w strokes, especially for products with less than 10w strokes. In this case, the savings in investment in tooling and automation are generally greater than the increase in production costs due to inefficient labour.

Automated single-process tandem stamping

The main differences between automated press production and manual press production are

The use of automated production system equipment, including in-line (or off-line) sheet feeding systems, automatic sheet cleaning and oiling systems, often also for large covered parts, automated loading systems, automated transfer systems for parts in the die process parts, as well as automated discharging and even parts collection systems.

To ensure the continuous movement of the production system, the moulds need to be equipped with a top feeder mechanism linked to the machine, a sensor system to detect the position of the product, to detect if the mould structure is in place or even if the mould is damaged, and auxiliary structures to assist in the automatic loading and unloading of the moulds.

The design of the moulds is complex, and the design costs, manufacturing costs and commissioning costs are much higher than for manual moulds.

Stable operation of equipment and moulds, less personnel involvement, high production stability and consistent quality.

A single process is carried out by a single machine, with a transfer beam or robot to transfer parts between different processes. Generally suitable for large parts, such as coverings for cars, larger structural parts for body-in-white chassis, etc., some small parts are also produced in automatic single moulds, such as seat slides, etc.

Features:

An automatic single die is still a pair of moulds on one machine, so there is more room for the mould structure to play, good process flexibility and the ability to process complex shapes.

Investment in additional automation equipment is required; the drop-in process is often separate, so additional drop-in moulds and process costs for the drop-in need to be considered, but material utilization is relatively high.

The ratio of operators to production units on the machine is usually 2:1 or more. Large stampings require at least two people for product collection and another for in-line visual inspection. In addition to the operators, additional sheet palletizers are required for loading.

The SPM is usually 12 to 20 due to the large transfer distance between processes and the lower production efficiency compared to other automated stamping production modes.

Applicable scenarios.

Large or medium-sized products with a life cycle of 20 watts or more, such as car coverings, body chassis parts, housings for large household appliances, etc.

Automatic transfer die stamping

All processes are completed on a single machine, and the parts are transferred between processes using a robot arm.

Features:

The robotic arm can be turned over, and the structure of the die is relatively flexible. However, due to the size of the press table, two machines may be required for in-line production if too many production processes are encountered.

Limited by the punching machine table size, it is not recommended to produce too large products.

Additional investment in robotic arms and a corresponding robotic hand for each pair of dies are required.

The machine can produce in-line dropouts in rolls or individually with a depalletizing mechanism, with a relatively high material utilization rate for individual dropouts.

The ratio of the operator to the machine is approximately 1:1 to 2:1. One person can watch more than one press. With stable production, only the operator is needed for loading and unloading the coil, sampling the product and collecting the product, or in the case of larger ones, two people are needed to collect the product.

SPM is usually 16~60. Body chassis parts such as front longitudinal beam, front subframe etc. SPM 16 or more.

Applicable scenarios.

Life cycle usage of 20w or more, medium or small to medium-sized products, e.g. A, B, C pillars, longitudinal beams, basin surfaces in seat skeletons, side panels, motor housings that require deep drawing, etc., for automotive body-in-white.

Automatic progressive die stamping

The strip consists of several processes (generally 10 to 25 for automotive stampings). The parts are formed in sequence by joining materials called carriers in each process, and the product is cut off and separated in the final process.

Features:

Due to the limitations of the carrier, it is difficult to reverse the product. Therefore, complex parts and parts that are too large are difficult to use with progressive dies, which are generally used with stamping equipment of fewer than 1000 tons.

Unwinding and unloading systems are required.

In-line uncoiling requires more material for the connection (carrier) of the parts and has a lower material utilization rate.

The operator-to-machine ratio is usually 1:3 to 1:1. One person can watch more than one press. With stable production, only the operator is needed to load and unload the rolled material, sample the product and collect the product.

SPM is usually 18~2000. 18~60 for general automotive structural parts; 100~200 for stator and rotor; 800~2000 for terminal connectors.

Applicable scenarios.

Life cycle usage of 20w or more, small and medium-sized or small products, such as small connection parts on car bodies, motor core laminations, terminal products, etc.

 

How to choose the right stamping

Stamping cost analysis is not just a narrowly defined analysis of the cost of a single stamped product but a broad consideration. We analyze the total costs incurred during the entire project cycle. In the case of stamping, the factors that influence the cost are the total project life cycle, the cost of the individual stamped product, the tooling cost of the project cycle, the tooling cost and the quality cost.

How to control the production costs of precision stamping

1.Reducing the cost of stamped parts in small-batch production

    The effective way to reduce costs in the trial production of stamping dies or the small batch production of stamping parts is to reduce the fixed costs, which can achieve better economic benefits.

2.Multi-piece simultaneous stamping

    When the output is larger, multiple pieces are pressed at the same time, i.e. multiple products are produced on one set of moulds, which can reduce the mould cost, product material cost (reduce material loss) and processing cost, and is also beneficial to the forming process in terms of material stress and strain symmetry and uniformity.

3. Rationalization of process

    Reasonable technology is a reliable guarantee to reduce stamping dies and product costs.

    In the case of mass production, the process should be concentrated as far as possible, using a composite or progressive die for stamping to increase productivity and achieve safe/safe production.

In the case of small batches, however, it is appropriate to adopt a single-process die and use a decentralized stamping process.

4.High-speed automation of the stamping process

     Automatic production is beneficial to safety and cost reduction.

5.Improved material utilization

     Reducing material costs requires serious consideration, especially when material prices are high.

6.Save tooling costs

     The cost of moulds occupies a considerable proportion of the manufacturing cost of stamped parts.

     The tooling cost should be reduced to reduce the cost of processing stamped parts in small quantities.

     In mass production, carbide dies with high/efficiency and long life should be used for progressive stamping.

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