Precision metal stamping is one of the most popular metalworking techniques to convert sheet metal into customized components. It is also known as shaping and forming a sheet metal workpiece between a punch and a die. This process is utilized in various sectors and applications, such as fasteners, lighting, ventilation, telecommunications, electronics and appliances, automotive, agriculture, and heavy truck or trailer.
There are several factors affecting the service life of metal stamping dies. This article will walk you through the key considerations to look for in tooling type.
How Does Die Metal Stamping Work?
Die metal stamping is a cold-forming method that utilizes a single or set of dies to cut and shape a metal strip (also known as a tool or blank steel) into the required shape or profile. Then, the force is applied to the blank steel to modify and alter its geometry, resulting in stress that renders the piece ideal for sculpting or forming into complex shapes.
Depending on the application, the manufactured parts may be either small or incredibly large.
Key Considerations To Look For in Metal Stamping Dies
A successful die metal stamping project has several factors to consider, especially regarding the finished product’s quality, reliability, and durability. The following are some things to keep in mind:
Types of Metals
In precise metal stampings, a range of metals can be utilized by manufacturers. Nevertheless, some metals perform more effectively in the precision metal stamping process or are better suited to a particular application.
Here are some of the most commonly used metals for die stamping:
Carbon tool steel
Low-alloy tool steel
Carbide and steel-cemented carbide
High carbon, high chromium tool steel
High carbon, medium chromium tool steel
Material Characteristics and Capabilities
The features and capabilities of the material can make or break a die metal stamping project. Therefore, it is necessary to understand the essential characteristics a material must contain to guarantee its quality and effectiveness. Among the most important factors are the following:
Forming takes place halfway between the material’s elastic limit and tensile strength. You can examine the material’s grain size, commonly used to determine its formability. Metals with uniform grain sizes are highly suitable for forming processes.
Machinability is the ease with which a material may be cut or molded. A metal conducive to machining can be cut with speed and precision, resulting in reduced costs.
Work Hardening Rate
The work hardening rate is the phase or level at which the material becomes tougher or more brittle as it is handled or stamped. Depending on the amount of effort applied to the metal and how much it must be deformed in a given process, it may require annealing to readjust its characteristics.
A material’s tensile strength is the force it can withstand before breaking. Some metals are stronger than others, and the strength of an alloy varies based on its subcomponents. Therefore, you must examine the metal’s mechanical properties to confirm whether it can resist the amount of force or not.
Types of Stamping Dies
For metal stamping, a wide variety of die types perform distinct processes. Here are some examples of stamping dies:
Blanking dies: a cutting die that cuts flat pieces of material in conjunction with a blanking punch
Compound dies: applicable in cases where several cutting operations must be completed in a single stroke and stage (one stroke creates a single component, resulting in a high production rate)
Forming dies: typically attached to presses to facilitate producing plastic and sheet metal
Progressive dies: can perform multiple cutting and forming tasks simultaneously and produce precise and consistent parts quickly
Coining dies: a closed die forging method in which pressure is applied to the forging’s surface to achieve tighter tolerances and smoother surfaces
Ohio Valley Manufacturing for Precision Tool and Die Design and Fabrication
At Ohio Valley Manufacturing, we work to establish ourselves as a major provider of first-operation blanking, stampings, secondary blank-fed transfer, and value-added products to our diversified client base. We also specialize in the production of precise tool and die designs.
From CAD modeling and design to prototypes on new programs, testing, and verification, we manage all phases of the production process for tools and dies! We also design dies and tools suitable for brackets, cross members, pans, blanks, and channels that adhere to various standards and criteria.
Contact us today to learn more about our services!
With over 40 years of experience, the reliable team at Ohio Valley Manufacturing has been working hard to become established as a superior provider of first operation industrial blanking, second-hand transfers, stampings, and value-added parts.
For decades, our company has had a solid reputation for supplying high-quality products to our customers in different industries, including automobile, trucking, recreation, and home improvement. Here is a closer look at our portfolio and case studies.
Big Bed Progressive Stampings
Recently, a client from the trucking industry reached out to us to conduct a series of big bed, progressive stamping services. Our facility is fully equipped with presses that feature large bed sizes between 250 and 4,000 tons, giving us the capability to produce this client’s custom parts.
We constructed these stampings using grade 80 carbon steel with mild to high strength. We met ISO 9001:2015 during this project, and the part dimensions measured up to 100’’ in length, up to 72’’ in width, and up to 8’’ in height. They also featured a gauge size larger than .150, a 90-degree bend angle, and one cavity. After project completion, we stacked, banded, and delivered the products. With our advanced technology and expert team, we were able to successfully manufacture these stampings all while meeting the customer’s project requirements.
Thin to Heavy Gauge Blanking Services
Ohio Valley Manufacturing was asked to complete a series of thin to heavy gauge blanking operations for the heavy truck, automotive, and material handling industry. Our advanced large-ton presses gave us the capabilities to manufacture products with gauge sizes between .020 and .625 with dimensions measuring up to 100’’ in length and 72’’ in width.
To meet this project’s needs, we constructed the products using grade 80 carbon steel with mild to high strength. While some final products featured multiple cavities, others only contained one. Additionally, we conducted secondary hand transfer forming and welding processes to complete the project.
Custom Manufactured Steel Circle Blanks
Our team of experts was asked to conduct circle blanking services to produce packaged circles of various thicknesses and sizes. These products are ideal for a range of industries, including tank heads, lawn & garden, material handling equipment, automotive, heavy truck, trailer, and transportation.
To complete this circle blanking order, we created our own specialty tooling. We were able to machine a line of grade 80 carbon steel circles, ranging from mild strength to high strength. The finished products had thicknesses between .020’’ and .625’’ with varying widths up to 72’’ and lengths up to 100’’. We also have the option for multiple cavity blanking.
Multi-Cavity Tooling & Production
A client recently placed an order requiring multiple part stampings, with strict budgetary limitations that needed to be considered. Our advanced equipment and expertise enabled us to complete this project while meeting all requirements. Our multi-cavity tooling and production process nests different parts into a single multi-cavity tool. This allows various stamping operations to take place at higher efficiency, resulting in increased savings that we pass on to our customers.
We can work with all types of carbon steel, including mild and high-strength variations. Because of this, we were fully prepared to meet this client’s requirements as well as a wide range of other projects. To finish this project, we performed in-house welding and forming processes.
Partner With The Experts At Ohio Valley Manufacturing
Ohio Valley Manufacturing understands that each customer is unique, and our capabilities allow us to meet each client’s need with optimal efficiency. Through our impressive capacity, Ohio Valley Manufacturing stamps out the competition, providing quality heavy gauge stamping and precision blanking services for a range of industries. For more information about our services, contact us today.
Posted by sachin on | Comments Off on Benefits of Stainless Steel Blanking
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The process of steel blanking has gained popularity mainly because of its ability to manufacture quality parts while reducing waste and cutting costs. Simply put, stainless steel blanking involves feeding a coil sheet of metal into a press and die to create a flat, geometric shape known as a blank. The blanking punch is positioned on top of the metal coil and is then pressed down into the die opening, removing the desired shape from the stainless steel sheet.
Stainless steel is a popular material option for the blanking process due to its many benefits, including strength and durability, corrosion resistance, low maintenance, and more.
Strength and Durability
Stainless steel is a tough and highly durable material that maintains its strength even if it’s exposed to extreme weather or high and low temperatures. The durability of stainless steel also allows it to withstand all kinds of impacts. These properties mean that stainless steel blanks will last longer than those made with other types of metal.
One of the best and most popular stainless steel features is its corrosion resistance. The higher the chromium content, the more excellent the corrosion resistance is in stainless steel. This metal is especially ideal for applications exposed to alkaline or acid solutions.
Its strong resistance to corrosion, rust, water, stains, etc., makes it the perfect metal for any place where there might be weather extremes or exposure to chemicals. When the metal is manufactured, chromium is added, which fuses with oxygen to create a protective film over the steel. This film’s purpose is to repair itself when damaged, making it the best metal choice for corrosive environments.
Compared to other materials, products made from stainless steel are highly functional, yet they are easy to clean and very low maintenance. Most stainless steel components can be cleaned with a mild soap or detergent and warm water. Stainless steel is generally used in industrial and commercial kitchens and other industries where tidiness and maintenance are crucial factors.
Stainless Steel Blanking from Ohio Valley Manufacturing
The many benefits of stainless steel make it a very popular material choice for the blanking process. If you require quality components that offer ease of maintenance, corrosion resistance, and durability, look no further than stainless steel blanking.
At Ohio Valley, we offer various blanking production methods and have the necessary experience and equipment to deliver quality stainless steel blanks in small and large production runs. Whether you require initial prototyping prior to long term/high volume production, intricate designs, bulk orders, contract manufacturing, production, custom blanks, or more, we have the skills to meet your unique needs. We can produce circular blanks up to 72’’ in diameter and configured blanks up to 72’’ wide and 100’’ long. We also offer a range of secondary services such as deburring, trimming, stress relieving, assembly, and more.
To learn more about the benefits of stainless steel blanking, or to get started on your custom solution, contact the experts at Ohio Valley Manufacturing.
Posted by Armani Goens on | Comments Off on An Introduction to Robotic TIG Welding
An Introduction to Robotic Welding
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Robotic welding is a manufacturing process that utilizes robotic technology to automate the formation of welds on assemblies. Compared to traditional welding methods, it requires little to no human involvement during actual welding operations. As a result, it offers increased weld accuracy, precision, speed, and safety, all of which can help shorten project timelines and reduce project costs.
Robotic welding machines have an articulating robot arm that holds, positions, and moves the welding torch as needed to create the welds. The arm needs to pre-programmed certified operator before the start of the welding operation. Its operational parameters should be based on the part and production specifications of the particular project.
Introduced in the 1960s, robotic welding has since been adopted by many industries for various welding assembly line purposes due to its effectiveness and efficiency. This blog post focuses on robotic TIG welding, including what it entails, what materials it accommodates, and how it differs from robotic MIG welding.
Robotic TIG Welding
Tungsten inert gas (TIG) welding—also referred to as gas tungsten arc welding (GTAW)— is an arc welding process that utilizes a non-consumable electrode to produce the weld. During TIG welding operations, electrical current is applied, resulting in the formation of a small, high-intensity arc between the electrode and the workpiece. This arc heats and melts the workpiece. Filler can be added separately to the weld pool to strengthen the final weld.
Materials for Robotic TIG Welding
The robotic TIG welding process can accommodate a wide range of materials, including, but not limited to, the following:
Robotic TIG vs. MIG Welding
TIG welding is one of the most commonly utilized welding processes. Another is metal inert gas (MIG) welding or gas metal arc welding (GMAW). While the two processes rely on the same basic principles, they have distinct characteristics that make them suitable for different applications. Key differences include:
TIG welding uses a non-consumable electrode, while MIG welding uses a consumable electrode.
TIG welding may or may not use a filler, while MIG welding always uses a filler since the electrode serves as one.
TIG welding is best suited for joining small and thin materials, while MIG welding is best suited for large and thick materials.
TIG welding offers better welding control, stronger welds, and broader material suitability, while MIG welding offers faster welding speeds, easier training requirements, and lower error rates.
Robotic TIG Welding at Ohio Valley Manufacturing
Robotic TIG welding is a suitable joining solution for many metal components and assemblies. It produces strong and clean welds on tighter timelines at lower costs than traditional welding methods. If you’re considered robotic TIG welding for your next manufacturing project, the experts at Ohio Valley Manufacturing are here to help.
At Ohio Valley Manufacturing, we an ISO 9001:2015 certified manufacturer offering a range of precision metalworking services. We provide a variety of robotic welding capabilities, including robotic TIG welding, to suit different customer needs. To learn more about our robotic welding capabilities or discuss your welding requirements with one of our team members, contact us today.
Posted by Armani Goens on | Comments Off on An Introduction to Robotic MIG Welding
Robotic MIG Welding
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Robotic welding is an accurate and highly efficient welding process. This automated welding method requires little human intervention and delivers precise metal bonding under the supervision of an operator. Generally speaking, robotic welding offers better consistency and fewer errors than traditional welding practices. Robotic welders can handle numerous types of welding, including MIG welding, TIG welding, and spot welding. Implementing robotic welding into production can reduce overhead by reducing labor costs while increasing speed and weld quality.
A robotic welding machine consists of an automated arm with three-dimensional articulation. A torch is mounted to the arm along with a wire feeder and wire cleaner, when necessary. The arm delivers precise and replicable welding under the supervision of an operator. This operator uses a programmable teach pendant to enter parameters for the robot to follow.
Robotic welding was introduced in the 1960s and quickly adopted by the automotive industry to provide cost-effective assembly line spot welding. Robotic MIG welding delivers repeatable, high-quality welding results for numerous industries. This blog will discuss robotic MIG welding and its applications in more detail.
Robotic MIG Welding
Metal inert gas (MIG) welding uses a consumable electrode to fill the weld pool with a metallic material. It is a quick and effective welding method that works on metals with a high melting temperature, given that the torch can reach temperatures of up to 3,000°F. The additional filler metal from the consumable wire further reinforces the final bond.
Robotic MIG welding reduces splatter compared to traditional MIG welding. Since the machinery automates the process of feeding the consumable wire electrode into the welding torch, it guarantees a sturdy and consistent bead. The inert gas produces a shield around the weld pool to protect the area from contamination. An automated welding robot operates the welding torch to deliver high-precision results. The welding robot’s arm can move in multiple directions around the workpiece and perfectly replicates each weld on each workpiece across the production order.
Materials for Robotic MIG Welding
Robotic MIG welding is ideal for a wide range of materials. At Ohio Valley Manufacturing, we frequently use robotic MIG welding with the following metals:
Robotic MIG vs. TIG Welding
While robotic MIG welding is a popular choice, it has distinct differences to robotic tungsten inert gas (TIG) welding. Like their manual counterparts, robotic MIG welding and robotic TIG welding have various advantages and disadvantages that make them preferable for different applications.
MIG welding uses a filler that can be ideal for metals with extremely high melting points, but TIG welding requires no filler material.
MIG welding will deliver fast and easy welding on many types of metals, whereas TIG welding takes more time.
TIG welding offers cleaner and more aesthetically pleasing welds, making it better for applications where appearance matters.
MIG welding can handle thicker metal sheets, whereas TIG welding can not adequately heat thicker sheets to join them together.
TIG welding has no weld pool, and thus no splatter. TIG also will not produce sparks.
Traditional MIG welding offers more flexibility in terms of correcting errors than TIG welding. However, employing precise and automated robotic welding results in fewer mistakes than traditional welding with either method.
Robotic MIG Welding at Ohio Valley Manufacturing
Robotic MIG welding is an ideal method for joining components made from a variety of metals. It creates durable and effective welds and can reduce production costs through less labor, fewer mistakes, and shorter lead times.
Ohio Valley Manufacturing is an ISO 9001:2015-certified manufacturer offering a full portfolio of robotic welding services to meet your needs. To learn more about our robotic welding capabilities, contact us today.
Posted by Armani Goens on | Comments Off on A Guide to Blanking in Contract Manufacturing
A Guide to Blanking in Contract Manufacturing
Many startups and small product manufacturing businesses do not have the capital needed to construct and operate a production facility. In these situations, they often turn to contract manufacturers to make their products so they do not need to invest in their own factory. Below, we provide an overview of contract manufacturing, discussing what it is, what types are available, what to look for in a good partner, and what role blanking can play in the process.
What Is Contract Manufacturing?
Contract manufacturing is a business relationship in which one company (the contracting company) outsources some or all of its manufacturing operations to another company (the contracted company). The contracted company produces parts and products to the specifications given to it by the contracting company.
There are many advantages to forming a partnership with a contract manufacturer. For example, the contracting company does not need to worry about making their products, so they can focus their resources and efforts on other parts of the business, such as sales and marketing. Additionally, contract manufacturers may offer other services that can further streamline the product development process for the customer, such as design assistance, assembly, and distribution.
What Are the Different Forms of Contract Manufacturing?
Contract manufacturing can be classified into several categories depending on what the contracted company provides to the contracting company. Four of the most common are:
Producing complete goods. This type of manufacturing relationship is also referred to as private label manufacturing. In this situation, the contracted company produces complete products for the contracting company. In addition to making all of the parts and components that go into the product, they assemble them together.
Producing parts or components. In this situation, the contracted company produces parts or components for the contracting company. The contracting company then uses these pieces in their own assembly operations to create finished products.
Supplying a service or labor. In this situation, the contracted company provides services to the contracting company, such as design, manufacturing, and distribution. The contracting company uses these services as part of their product development process. The contracted company may also supply a labor force if the contracting company does not have the manpower to carry out production.
Providing manufacturing equipment or facilities. In this situation, the contracted company allows the contracting company to use their equipment or facility to make the desired products.
7 Qualities to Look for in a Contract Manufacturer
Given the key role a contract manufacturer has in the production of a product, companies must choose who they partner with carefully. Otherwise, they risk subpar products, unmet production orders, and more.
The seven top qualities to look for in a good contract manufacturing partner are:
Good Reputation in Market
Good Financial Situation
Good Management at the Facility
Flexible to Market
Can Meet Product Demand
How Does Precision Blanking Fit in With Contract Manufacturing?
Contract manufacturing can encompass a wide range of manufacturing processes, including precision blanking. Precision blanking is a fabrication process that uses a punch and die to remove a piece—i.e., a blank—from a sheet or strip of material. Both the punch and die are in the shape of the desired component, ensuring the piece removed has the proper form.
Ohio Valley Manufacturing: Your Blanking Expert
Looking for a contract manufacturer with blanking capabilities? Ohio Valley Manufacturing is here to help you!
At Ohio Valley Manufacturing, we are an ISO 9001:2015 certified manufacturer offering blanking, stamping, and other precision metalworking services. We can produce circular blanks up to 72 inches in diameter and configured blanks up to 72 inches wide by 100 inches long from carbon steel, aluminum, and stainless steel. Equipped with extensive industry experience and quality presses, we’ve developed a reputation as one of the top Tier 2 suppliers in the United States.
To learn more about our precision blanking or other contract manufacturing capabilities and how they can benefit you and your company, contact us today.
Posted by Armani Goens on | Comments Off on Benefits of Robotic Welding
Benefits of Robotic Welding
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The welding process fuses two or more separate workpieces into a single piece using heat and pressure to create a strong joint as the weld cools and hardens. At Ohio Valley Manufacturing, we specialize in robotic welding, an automated process that produces reliable and repeatable welds. Typically faster and more accurate than manual welding, robotic welding offers a safe and effective means to handle complex and high-volume welding projects.
Robotic Welding vs. Manual Welding
Manual welding requires a skilled welder to operate the welding equipment and manipulate the workpieces by hand. While more manufacturers have turned to robotic welding, manual welding still plays an essential role in lower-volume production, prototyping, one-off projects, and more. Manual welding offers superior flexibility because human operators have better awareness and decision-making capabilities than automated equipment.
Robotic welding processes use welding tools and robotic arms to handle welding tasks. The two different types of robotic welding used in manufacturing include:
Fully automated welding: Robotic arms guide the separate pieces into position and hold them, while a robotically controlled welding tool uses heat and pressure to connect them.
Semi-automated welding: Autonomous tools handle the actual welding process per a design plan or instructions. A human employee loads the unwelded pieces and then moves the welded workpiece to the next step of the manufacturing process after welding is complete.
Benefits of Robotic Welding
Both fully automated and semi-automated welding processes offer distinct advantages over manual welding, especially in today’s manufacturing environment. Some of the advantages provided by robotic welding include:
High-Quality Welds: Automated robotic systems follow programmed instructions to create welds within very tight tolerances. Each weld will be nearly seamless, with no gaps, weak points, or blemishes. This precision also reduces the labor required for potential cleanup and finishing processes.
Consistent Welds: Not only will each weld be relatively free of imperfections, but robotic welding tools can also create identical welds for dozens, hundreds, or even thousands of parts — a crucial capability for mass production.
Safety: Robotic tools handle each step of moving, holding, and welding potentially sharp or heavy metal pieces, especially during fully automated processes. Robotic handling mitigates the risk of injury for technicians involved in the project.
Speed: Robotic systems work faster and perform longer than manual welders, ultimately shortening lead times on large-volume welding projects.
Material Efficiency: Robotic welding processes are less likely to make errors or waste welding materials. A lower error rate results in reduced scrap metal, making the process more efficient, greener, and more cost-effective per weld.
Long-Term Affordability: Robotic welding has high initial expenses, but the process gains economies of scale over large orders, eventually lowering the cost per unit over manual welding. The reduced material waste and lower labor requirements also contribute to the affordability of robotic welding over time.
Common Applications for Robotic Welding
Robotic welding creates and repairs parts across an expansive range of industries. Markets that increasingly rely on robotic welding include:
Agriculture (heavy equipment components, trailer parts, outdoor power equipment)
Automotive (on- and off-highway vehicle and truck parts)
General industry (material handling components and equipment
Petrochemical (chemical processing systems)
Standard Materials for Robotic Welding
At Ohio Valley Manufacturing, we work with numerous metals and alloys, including:
Ohio Valley Manufacturing Is Your Robotic Welding Manufacturer
Ohio Valley Manufacturing is committed to quality. Our company is ISO 9001:2015-certified, and we maintain extensive quality management and quality control processes for every service we offer. We serve an array of industries with precision robotic welding services to create fast and reliable welded parts.
Posted by Armani Goens on | Comments Off on How Does Progressive Die Stamping Compare to the Competition?
Progressive Die Stamping vs. Other Common Metal Stamping Methods
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Progressive die stamping, compound die stamping, and transfer die stamping are the three most common metal stamping methods. With varying tolerance requirements, design elements, and production sizes required by each application, it is often the case that one of these metal stamping processes offers a superior solution for a particular project.
At Ohio Valley Manufacturing, our team has extensive experience in metal stamping, and we can guide you to the best stamping process to best fit your needs. Let’s take a closer look at when to use progressive stamping, compound stamping, or transfer stamping.
Progressive Die Stamping
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Progressive die stamping is ideal for long production runs because of its ability to achieve high repeatability. This metal stamping process uses one machine with multiple die stations. A metal strip of stock material automatically moves through each station where a stamping operation is applied. The last step cuts the completed part free from the strip.
Progressive stamping has a lower setup time. Setting up the metal strip requires careful attention to ensure the accuracy of the finished products. Progressive die stamping automatically and continuously feeds material into the machine, allowing for longer production runs, as well as the production of more parts in less time. Therefore, progressive die stamping is ideal for the fast and affordable production of complex components with high part-to-part repeatability.
Benefits of Progressive Die Stamping
Faster production time
Low setup time
Lower labor costs
Compound Die Stamping
Compound die stamping is ideal for medium- and high-volume production of flat parts. The compound stamping process feeds a metal strip through a compound die that performs all cutting, bending, and punching operations in a single stroke. The one-stroke process is good for flat metal parts, like wheel blanks and 1st operation blanks for any application. The production time of this stamping process varies, as it is dependent on the size of the component being produced. Smaller and less complicated parts will finish more quickly than larger parts and parts with more complex design elements.
Benefits of Compound Die Stamping
Ensures high repeatability in single-die cases
Quick and accurate production of simple parts
Transfer Die Stamping
Unlike progressive die stamping, the first step of transfer die stamping is to separate the workpiece from the metal strip. Transfer die stamping is typically used for large parts that can’t easily move through die stamping stations. The workpiece is transferred automatically between multiple stations, with automation effectively handling the required alignment between processes.
Transfer stamping is best when working with complex design elements. This metal stamping process requires precise execution and high die durability for successful completion.
Benefits of Transfer Die Stamping
Well-suited for producing complex parts
Good for large parts
Ohio Valley Manufacturing: Your Stamping Professionals
Ohio Valley Manufacturing has extensive experience in stamping thin, standard, and heavy-gauge metal parts. We specialize in progressive and compound die stamping. We can handle production sizes ranging from prototypes to high-volume runs. We work closely with a variety of major OEMs and Tier 1 suppliers, and we’ve earned a reputation as one of the top Tier 2 metal stamping suppliers in the United States.
Metal stamping processes facilitate the creation of a variety of customized components from metal sheets or bars. Machinery-driven dies cut and press materials into the desired shape quickly and efficiently, making the process ideal for high volume production runs. With the proper setup, multiple steps can be performed on each component. With metal stamping machinery, materials can be pressed, punched, coined, embossed, bent, blanked, pierced, and notched to meet a broad range of design specifications.
A variety of metals work well in stamping processes. Stainless steel, aluminum, and hot-rolled carbon steel are all commonly used to produce stamped components.
Carbon Steel Stamping
Carbon steel is a highly malleable alloy revered for its strength. Typically, carbon steel contains between 0.8% and 2.11% carbon content. Higher carbon contents create a harder final alloy. However, these harder materials are more brittle and easily break under the repetitive stress of metal stamping and other machining processes. The average carbon steel used in metal stamping contains roughly 1.5% carbon composition. Some alloys may also include trace amounts of chromium, cobalt, nickel, and other metals to customize the metal for a particular purpose.
There are a number of advantages to using carbon steel for metal stamping:
Carbon is a cost-effective option for hardening steel.
High-carbon steel is an excellent option for manufacturing efficient and reliable cutting tools.
Manufacturing tools made with high-carbon steel ease the mechanical manipulation of other production materials.
These metals are frequently used to produce drill bits, woodcutting tools, masonry nails, saws, and other sharp-ended tools in high volumes.
Aluminum is one of the most abundant naturally occurring metals on the planet. Using aluminum in low-volume metal stamping offers some important advantages for many manufacturers:
Lightweight aluminum alloys support the production of high-speed aircraft, trains, and passenger vehicles.
Aluminum materials support sustainability efforts by lowering the amount of energy needed to produce and transport parts.
Due to its versatility, popularity, and abundance, aluminum is readily available in any amount.
Aluminum stamping also works well in high-volume metal stamping production for items such as beverage cans, hand tools, and flatware.
Metal Stamping at Ohio Valley Manufacturing
Ohio Valley Manufacturing provides metal stamping for businesses in a diverse range of industries, such as military/defense, agriculture, and automotive. Our 4000-ton presses deliver up to 24 inches of maximum stroke, and beds measuring 312-by-72 inches accommodate materials between 0.02-0.625 inches in thickness, which means we possess the capability to fabricate an expansive variety of parts and components. Our other capabilities include:
Thin and heavy gauge materials
Alongside our metal stamping capabilities, our other services allow us to customize metal products for both aesthetic appeal and functionality. We offer:
In our work with businesses in the construction, equipment, and material handling industries, we have successfully produced parts such as:
We also assist our clients with planning and designing to ensure they reach their goals in an efficient manner. In our production process, we use continuous strip stamping and progressive dies. This lets us perform two or more stamping processes on each die, enabling faster production without sacrificing quality.
Partner with Ohio Valley Manufacturing on your metal stamping production project for a fast, efficient, and reliable experience. Pleasecontact us for more information.
Manufacturers use blanking to punch pieces in specific shapes from sheets or strips of raw material. The punched-out piece is called the “blank,” hence the term “blanking.” Blanking is most often performed with tools made from hardened steel or carbide, which work on metals like aluminum, carbon steel, stainless steel, and even plastic.
Blanking has many benefits, but manufacturers must take some considerations into account before embarking on a full course of metal blanking. Although this process is a quick and cost-effective way to produce a large number of identical pieces, these punched-out pieces may have burrs or cracks on the edges. However, these drawbacks can be avoided by using high-quality tools, and they can be corrected by post-processing the blanks.
Although blanking sounds simple, this basic option can accommodate many variations. A full overview continues below.
Benefits of Blanking
Machinery used for blanking ranges from simple punches and dies to sophisticated CNC machinery. Blanking equipment can quickly be configured to end product specifications, and the process itself takes little time per part as it involves simply feeding the primary metal stock continuously into the blanking machine.
Because of this, blanking can perform long production runs that require little or no changes to the machinery or base material. The straightforward process also allows you to construct materials to strict tolerances with little part-to-part variation, and technology has become so sophisticated that it can build multiple geometries using a single process.
Furthermore, because the primary metal stock can be reused, blanking can help manufacturing firms reduce their material waste. Due to these benefits, blanking is commonly used to mass produce components for industries such as aerospace and automobile manufacturing. It’s also used for high-volume fabrication of parts for common household appliances.
Differences Between Punching and Blanking
Punching and blanking are often confused with each other since both processes remove pieces from a base sheet of material. Adding to the confusion is the fact that the same terms, punch and die, are used in both operations.
A simple way to remember the difference between the two processes is to note that an alternate term for punching is piercing. Manufacturers sometimes refer to this process as piercing because the desired end product is the pierced sheet of metal, not the metal that’s been punched out of it.
As discussed above, the punched-out slugs created by are the end products of the process, and unused sheet metal is discarded or reused after the slugs have been obtained.
There are many other operations that follow, but differ from, the basic process. Some of these include:
No matter the type of hole-punching process used, it will result in quality parts at tight tolerances.
Different Types of Blanking Methods
While the fundamentals of the blanking process are simple, they have many variations, which we describe below:
Compound Die Stamping
This type of blanking is used to precisely manufacture complex steel parts. In this process, workers or automated equipment feed a steel strip through the stamping machine, which punches out a blank every three seconds. This simple, precise, and fast technique enables firms to produce steel components in bulk.
Continuous Strip Blanking
As implied by the name, continuous strip blanking continuously feeds metal substrates through a machine. This allows punching machines to produce uniform end products around the clock, with each product having the same characteristics of those before and after it. This process is a great way to develop coins, bottle caps, and medallions.
Progressive Die Stamping
Progressive die stamping uses coiled strips of thin flat metal as its base material. In this process, progressive die machines sequentially stamp, trim, and bend workpieces to make the finished parts, which exit the machine in conjoined strips. After performing this task, the machine separates individual parts from the strip, which results in the creation of several identical parts.
Square Sheared Blanking
Square sheared blanking is a fine process that uses specialized clamping tools to produce square-edged and contoured blanks. This process is a great way to create panels, casings, and any other component that requires a uniform square shape.
This process combines metal cutting and metal blanking procedures to create highly specialized blanks. When cutoff blanking, manufacturers blank metal sheets and then cut the metal at the sheets, allowing the production of long, flat pieces.
Metalworkers use carbon steel to make industrial equipment and household tools like knives because of this material’s exceptional strength and hardness. Carbon steel’s hardness varies depending on the amount of carbon present within it, and the higher the carbon content, the harder the alloy is.
Carbon content in carbon steel ranges from 0.8% to 2.11%, and the typical value is about 1.5%. Carbon steel is more cost effective than other materials of comparable hardness, thus making it a popular raw material to use as a substrate.
Stainless steel has low carbon content but a large amount of chromium, which ranges from 10% to 30% of the final material. This chromium content makes stainless steel highly resistant to corrosion and heat.
Stainless steel may also incorporate other metals like aluminum, copper, and titanium to enhance various attributes, and even nonmetals like phosphorous and sulfur can be used to improve resistance to certain types of corrosive substances. Stainless steel is thus a versatile alloy that can take on a variety of uses depending on its composition.
Aluminum’s softness and flexibility make it very suitable. In fact, aluminum is the most common metal used to create industrial and household products because of this material’s low cost, ease of extraction, and properties like lightness, durability, and recycling potential.
For these reasons, many applications in the automotive, aerospace, energy, and packaging industries use aluminum in large quantities. Aluminum is a very cost-effective way to produce high volumes of components.
Quality Metal Blanking from Ohio Valley Manufacturing
Ohio Valley Manufacturing offers precision blanking services for clients from all industries. We accommodate all types of orders, from prototyping to low- and high-volume production runs. We’ve been in business for over 20 years and are adept at meeting the unique needs of our customers.
Contact us today for all your custom blanking requirements.