Introduction to Stamping 100

accuracy

The exactness of a produced part compared to the desired result. Accuracy is negatively affected on presses that have experienced deflection.

automation

The use of mechanical systems that operate with limited human interaction. Automation is an efficient means of performing manufacturing processes.

bed

The lower portion of a press frame that serves as its foundation. The bed absorbs the forces generated by the slide.

bending

A forming operation that shapes a workpiece by straining it around a desired angle. Bending often creates parts with simple shapes and minor contours.

blanking

A cutting operation that cuts a desired shape from the workpiece. Blanking removes a section of material from a workpiece to form the desired part.

bolster plate

A flat metal surface attached to the top of the press bed. The bolster plate supports the die during stamping operations.

capacity

The maximum amount of force that a press can generate without harming its structural integrity. The capacity of a press, also known as tonnage rating, varies depending on the drive system.

C-frame press

A common type of press that suspends the crown over the bed in a C-shaped frame. A C-frame press, also called a gap-frame press, has an open portion that allows for easy access to the die set.

changeover

The process of switching a machine from one part setup or process to another. Changeover in stamping includes removal of the old die set and installation of the new die set.

computer numerical control

CNC. A type of programmable automation that uses mathematical data to precisely direct machine tool movements. CNC is used in turret punch presses to complete strings of complex operations.

contours

A curved part of a workpiece. Simple contours can be made with forming operations while more complex contours require drawing operations.

crossbar transfer press

A type of transfer press whose automation includes wide bars equipped with suction cups that move the workpiece from one station to the next. Crossbar transfer presses are often used to move large parts such as automotive body panels.

crown

The upper portion of a press frame that contains the press's drive mechanism. The crown supports and guides the reciprocating motion of the slide.

cutting

Stamping operations that cut the workpiece by penetrating through it. Common cutting operations include blanking and punching.

deflection

The misalignment of press components caused by excessive force or vibration. Deflection can lead to the creation of inaccurate parts.

deformation

A change in the size or shape of a workpiece as a result of stress. Presses use deformation to form metal workpieces into desired shapes.

die

A tooling component of stamping presses that attaches to the slide and bolster plate. Dies perform various stamping operations including cutting and forming metal parts.

die set

A series of unique dies used to create a specific part. Die sets are used to create parts that require multiple stamping operations.

drawing

Stamping operations that shape parts by stretching metal around a punch and forcing it into the die cavity. Drawing operations are often used to create parts with complex contours such as automotive body panels.

drive system

A series of components that provide force to a press to move the slide. The press drive system is an important factor in determining how much force a press can generate.

forming

Stamping operations that shape sheet metal by exposing it to tension, compression, or both. Forming operations are used to create parts such as brackets and automotive frame components.

frame

The structural column that supports the press and absorbs the forces generated by the slide. The frame determines what size die can fit into the press and what operations a press can complete.

frame

The structural column that supports the press and absorbs the forces generated by the slide. The shape of the frame determines what size die designed for a part can fit into the press and what operations a press can complete.

gap-frame press

A common type of press that suspends the crown over the bed in a C-shaped frame. A gap-frame press, also called a C-frame press, has an open portion that allows for easy access to the die set.

handling tools

Devices that allow press operators to move objects within the die area without compromising the safety of their hands. Common handling tools in stamping include safety tongs, hand vacuums, and magnetic lifters.

hydraulic press

A press that uses pressurized liquids to power the slide. A hydraulic press can provide full capacity at any point in the stroke and is ideal for stamping complex parts.

Industrial Internet of Things

IIOT. A network of physical devices used in manufacturing that contain computing systems that allow them to send and receive data. The Industrial Internet of Things allows devices to exchange data and automate processes without any human intervention.

kilonewtons

kN. A metric system unit for force that is equal to 1,000 Newtons. Kilonewtons are used to describe how much force a press can generate.

lower die shoe

The die component that attaches the lower half of the die to the bolster plate. The lower die shoe ensures the lower die tooling stays securely in place during stamping operations.

mechanical press

A press that uses a rotary motor to transfer power to the slide. A mechanical press provides full capacity near the bottom of the stroke, and are faster and generally cost less than other press types.

metal forming

The plastic deformation of a metal to produce a useful shape. Metal forming on presses includes a variety of operations, such as drawing, bending, blanking, and piercing.

personal protective equipment

PPE. Any clothing or device used to minimize exposure to hazards and prevent injuries. Personal protective equipment for stamping operations includes gloves, eye protection, and ear protection.

piercing

A cutting operation that creates an open hole in a workpiece by separating an interior section. Piercing, also known as punching, removes a section of material from a workpiece that becomes discarded scrap.

press

A machine with a stationary base and an upper slide that repeatedly moves up and down. A press shapes or cuts metal to create useful parts for a range of industries.

press brake

A type of press with an open frame and wide, narrow bed. A press brake is often used for high-capacity bending operations.

preventative maintenance

PM. A type of maintenance performed while a component is in working order to keep it from breaking down. Preventive maintenance may include lubricating, tightening, and replacing worn parts.

production line management

Systems and methods that allow manufacturers to efficiently complete manufacturing operations. Production line management enables manufacturers to minimize inefficiencies and waste.

production rates

The speed at which a manufacturing operation produces products. Production rates can be more easily tracked and adjusted with the integration of smart technology.

progressive die press

A single press containing stations that perform a series of stamping operations. A progressive die press gradually forms a complex part as it moves through the die.

punch

A tooling component that pushes into or penetrates the workpiece. The punch is a component of the upper half of the die that is used in drawing and punching operations.

punching

A cutting operation that creates an open hole in a workpiece by separating an interior section. Punching, also known as piercing, removes a section of material from a workpiece that becomes discarded scrap.

ram

The upper portion of a stamping press that moves up and down within the press frame during operation. The ram, sometimes called a slide, provides the required force to complete stamping operations.

real time

The near-instantaneous interval of time that computers require to process data. Real time is virtually the same as actual time because computers process data almost immediately.

repeatability

The ability of a machine or process to continually deliver consistent and uniform results. Repeatability is crucial for efficiently producing quality, identical parts.

rigidity

The stiffness or inflexibility of a machine. Rigidity in a press reduces deflection and increases the accuracy of produced parts.

safeguarding devices

Devices or machine components used to prevent operators from contacting hazards. Common safeguarding devices in stamping include barrier guards, light curtains, and dual palm buttons.

scrap

Unusable material produced during a manufacturing process. Scrap from stamping operations is often caught or removed through components in the press's bed.

sensors

Devices that detect, measure, and record changes in physical stimuli. Sensors may be connected to a machine or system to collect operational data and enhance safety.

servomotor

A type of motor used in applications that require precise positioning. Servomotors enable fine control of the part's positioning in automated stamping operations.

sheet metal

Flat metal stock. The sheet metal used in stamping operations is commonly steel with thicknesses ranging from 0.001 inches (0.0254 mm) to 0.625 inches (15.875 mm).

slide

The upper portion of a stamping press that moves up and down within the press frame during operation. The slide, sometimes called a ram, provides the required force to complete stamping operations.

smart manufacturing

An information-driven, event-driven, collaborative orchestration of business and factories across the value chain. Smart manufacturing uses sensors, data, and analytical models to automate and prescribe action for various processes and situations

stamping

A metal forming operation that uses dies to shape or cut sheet metal into parts. Stamping can be performed on a press.

straight-side press

A common type of press that suspends the crown over the bed with supporting columns in each corner of the frame. A straight-side press offers high rigidity and reduced deflection.

stroke

The reciprocating motion of the slide. One stroke entails the complete cycle of the slide's up-and-down motion.

tonnage

The amount of force that a press must generate to complete a given stamping operation. Tonnage must be applied correctly to accurately create parts that meet specifications.

tonnage monitor

A sensor that measures the amount of force a press applies in real time. Tonnage monitors allow manufacturers to make adjustments to the press and die to ensure the press applies accurate tonnage to create a part.

tonnage rating

The maximum amount of force that a press can generate without harming its structural integrity. The tonnage rating of a press, also known as capacity, varies depending on the drive system.

tons

tn. An English System unit for force that is equal to 2,000 pounds. Tons are used to describe how much force a press can generate.

tooling

Assorted tools used in various manufacturing processes. Tooling used in stamping includes dies.

transfer press

A press that includes multiple die stations to perform a sequence of stamping operations. In a transfer press, the part is transferred from one station to the next via automation.

tri-axis transfer press

A type of transfer press that uses moving grippers to transfer the part from one station to the next. Tri-axis transfer presses are often used to move medium-sized parts, such as components for automotive fenders.

turret punch press

A press with an open frame and a turret containing multiple punches. A turret punch press uses CNC technology to complete a variety of punching and cutting operations.

upper die shoe

The die component that attaches the upper half of the die to the slide. The upper die shoe ensures the upper half of the die stays securely in place during stamping operations.

workpiece

A part that is being worked on during manufacturing. The workpiece in stamping is often a sheet or coil of thin metal.