Stamping parts processing technology: Stamping forming, a solid pillar of the forging manufacturing industry

　　In the huge system of modern manufacturing, stamping parts processing technology has become an indispensable key link in industrial production with its high efficiency, precision and economy. From automobile parts manufacturing to electronic equipment shell processing, from home appliance production to aerospace precision parts manufacturing, stamping parts processing technology, with its unique process advantages, provides high-quality and standardized parts for various industries, and promotes the development of manufacturing industry towards scale and intelligence.

　　1. Technical principle: exquisite transformation of force and shape

　　Stamping parts processing technology is a processing method that uses the strong pressure generated by stamping equipment (such as presses) to make metal sheets or other materials plastically deform or separate through molds to obtain parts of the required shape and size. Its core principle is based on the plastic deformation characteristics of the material. Under the action of pressure, the internal crystal structure of the material slips and reorganizes to achieve shape changes. This process involves multidisciplinary knowledge such as mechanics and materials science. By accurately controlling parameters such as pressure, mold shape, and stamping speed, the accuracy and consistency of part forming are ensured. For example, in the stamping production of automobile covers, large presses are used to apply hundreds of tons or even thousands of tons of pressure, and high-precision molds are used to quickly stamp flat metal sheets into complex body shell shapes, demonstrating the powerful forming capabilities of stamping technology.

　　II. Core technology: diverse processes work together

　　(I) Punching process: precise separation of materials

　　Punching is one of the most basic processes in stamping processing, which is mainly used to separate sheets into blanks or parts of the required shape. It includes two forms: blanking and punching. Blanking is to punch parts off the sheet, while punching is to punch the required holes on the sheet. In the punching process, the edge design of the mold is crucial. A sharp and high-precision edge can ensure a smooth cut and small burrs. For example, in the production of heat sinks for electronic equipment, heat dissipation holes are accurately punched out through the punching process, which not only improves the heat dissipation efficiency, but also ensures the structural strength and aesthetics of the heat sink.

　　(II) Bending process: shaping complex shapes

　　The bending process is a method of making the sheet material produce plastic deformation along the bending line to obtain parts with certain angles and shapes. During the bending process, the rebound phenomenon of the material needs to be considered, that is, the angle and shape changes caused by the elastic recovery of the material after the bending deformation. By optimizing the mold design and adjusting the stamping parameters (such as bending radius, bending angle), the rebound can be effectively controlled to ensure that the parts meet the design requirements. The bending process is widely used in parts such as car seat frames and the frames of home appliance shells to shape complex shapes to meet the product function and appearance requirements.

　　(III) Drawing process: achieving three-dimensional forming

　　The drawing process is a processing method that makes a flat blank into an open hollow part, or further changes the shape and size of a hollow part. It stretches the sheet material through a mold and presses it into a concave mold, so that it gradually forms into the desired three-dimensional shape. During the drawing process, the material will experience a complex stress-strain state, and it is easy to have defects such as wrinkling and cracking. Therefore, it is necessary to reasonably design the mold parameters such as the fillet radius and the blank holding force, and select a suitable lubricant to improve the drawing quality. Common products such as cans and stainless steel tableware are typical application results of the deep drawing process.

　　(IV) Forming process: meeting special needs

　　In addition to the above basic processes, stamping processing also includes a variety of forming processes such as flanging, bulging, and hole expansion to meet the special structural and functional requirements of different parts. For example, the flanging process can form a flange on the edge of the part to enhance the strength and rigidity of the part; the bulging process can make the local surface of the hollow part expand outward to form a specific shape, such as the forming of the automobile muffler.

　　III. Wide application scenarios: covering multiple industries

　　(I) Automobile manufacturing field

　　Automobile manufacturing is an important application field of stamping parts processing technology, and stamping parts on a car account for as much as 70% - 80%. From body panels (such as doors, hoods, and roofs) to frame structural parts (such as longitudinal beams and cross beams), to interior parts (such as instrument panel brackets and seat slides), they all rely on stamping technology for production. The application of stamping technology not only improves the production efficiency and quality stability of automotive parts, but also reduces costs through large-scale production, promoting the vigorous development of the automotive industry. For example, the integrated body structure of Tesla cars uses large-scale stamping equipment and advanced molds to integrate multiple parts into a whole, simplifying the production process and improving the performance and safety of the vehicle.

　　(II) Electronic equipment manufacturing field

　　In the manufacturing of electronic equipment, stamping parts are widely used in the production of shells, internal brackets, connectors and other parts of mobile phones, computers, tablets and other products. Electronic equipment has extremely high requirements for the precision, lightness and appearance quality of parts. Stamping technology can meet these requirements with high-precision molds and precision stamping equipment. For example, the metal shell of a smartphone is formed by a stamping process, and then undergoes precision machining and surface treatment to present a delicate appearance and good feel; the connector stamping parts on the computer motherboard, with its tiny size and high-precision manufacturing, ensure the stability and efficiency of signal transmission.

　　(III) Home appliance manufacturing field

　　The shells and internal structural parts of home appliances such as refrigerators, washing machines, air conditioners, etc. are mostly stamped. The stamping process has standardized and scaled the production of home appliances, reduced production costs, and improved production efficiency. At the same time, through the diversified design of molds, it can meet the appearance requirements of home appliances of different brands and models, and enhance the market competitiveness of products. For example, after the outer shell of the refrigerator is formed by the stamping process, it is sprayed, printed and other surface treatments to create a rich and diverse appearance style to meet the personalized needs of consumers.

　　(IV) Aerospace field

　　The aerospace field has extremely strict requirements on the quality and performance of parts. Stamping parts processing technology plays an important role in this field with its high precision and high strength. The key parts of the aircraft, such as the wing skin, fuselage frame, and engine blades, are all manufactured by stamping. By using high-strength aviation aluminum alloys, titanium alloys and other materials, combined with advanced stamping processes and mold technologies, the stamping parts produced have the advantages of light weight, high strength, and strong reliability, which provides a guarantee for the flight safety and performance improvement of the aircraft.

　　4. Technical advantages: highlighting the charm of industrial manufacturing

　　(I) Efficient production and cost reduction

　　Stamping has extremely high production efficiency. Under the continuous stamping of the press, dozens or even hundreds of parts can be produced per minute. At the same time, the service life of the stamping die is long, and a large number of parts can be produced with one mold investment, reducing the mold sharing cost of a single product. In addition, the material utilization rate is high during the stamping process. Through reasonable layout design, waste generation can be reduced, further reducing production costs. Large-scale automated stamping production lines have raised production efficiency to a new level and met the needs of modern manufacturing for mass production.

　　(II) High precision and consistency

　　Stamping dies are precisely manufactured according to the designed size and shape of the parts. During the stamping process, as long as the mold is kept in good condition, parts with high dimensional accuracy and consistent shape can be produced. Modern stamping technology combines advanced technologies such as CNC machining and precision measurement to enable the dimensional accuracy of stamped parts to reach micron level, meeting the high-precision requirements of parts in high-end manufacturing fields such as electronics and aerospace. At the same time, the stable production process ensures the consistency of product quality, reduces assembly problems caused by part differences, and improves the overall reliability of the product.

　　(III) Complex shape processing capability

　　The stamping process can process metal sheets into parts of various complex shapes. Whether it is a simple plane shape or a three-dimensional shape with a spatial curved surface, it can be achieved through mold design and stamping process. Through the combination of multiple stamping processes, more complex structures and more complete functions can also be manufactured to meet the diverse needs of different products. For example, the complex internal structure of the cylinder block of an automobile engine is gradually processed through multiple stamping, stretching, forming and other processes.

　　(IV) Strong material adaptability

　　Stamping processing is suitable for a variety of materials, including metal materials (such as steel plates, aluminum plates, copper plates, etc.) and non-metallic materials (such as plastic plates, rubber plates, etc.). Different materials have different performance characteristics. By selecting appropriate materials and stamping processes, the advantages of the materials can be fully utilized to meet the requirements of parts in terms of strength, hardness, conductivity, corrosion resistance, etc. For example, in the production of new energy vehicle battery shells, high-strength aluminum alloy materials are used, and battery shells with good protective performance and lightweight characteristics are manufactured through stamping processes, which improves the safety of batteries and the endurance of vehicles.

　　V. Development Trends: Towards a New Journey of Intelligent Manufacturing

　　(I) Automation and Intelligent Upgrade

　　With the development of industrial robots, automated production lines and artificial intelligence technology, stamping parts processing is gradually moving towards automation and intelligence. The automated stamping production line can realize the full process automation operation from sheet material loading, stamping processing to parts sorting, reducing manual intervention, improving production efficiency and product quality stability. At the same time, by introducing sensors, visual inspection systems and intelligent control systems, various parameters in the stamping process (such as pressure, temperature, displacement, etc.) can be monitored in real time, the production process can be intelligently controlled, problems in production can be discovered and solved in time, and intelligent production can be realized. For example, some advanced stamping workshops use unmanned stamping production lines, which automatically complete sheet handling, mold replacement and parts processing through robots, and the production efficiency has been increased by more than 30%, and the product defect rate has been reduced by 50%.

　　(II) Innovation of mold technology

　　Molds are the key elements of stamping processing, and the innovation of mold technology has an important impact on the processing quality and efficiency of stamping parts. In the future, molds will develop in the direction of high precision, long life, multi-function and intelligence. The use of advanced CNC processing technology, EDM technology and laser processing technology can produce molds with higher precision and better surface quality; the research and development and application of new mold materials, such as high-performance mold steel and cemented carbide, will improve the wear resistance and fatigue resistance of the mold and extend the service life of the mold; the design of multifunctional molds can realize multiple stamping processes on one mold, reducing the handling and positioning errors between processes and improving production efficiency; intelligent molds can monitor the working status and wear of molds in real time through built-in sensors and chips, provide data support for mold maintenance and replacement, and realize intelligent management of molds.

　　(III) Integration of green manufacturing concept

　　Today, with the increasing awareness of environmental protection, the concept of green manufacturing will penetrate into the field of stamping parts processing technology. On the one hand, by optimizing the stamping process and mold design, the material utilization rate can be improved and the waste generation can be reduced; on the other hand, environmentally friendly stamping oil, cleaning agent and other auxiliary materials can be used to reduce environmental pollution in the production process. In addition, the recycling and reuse of stamping waste will also become an important development direction. By establishing a complete waste recycling system, stamping waste can be processed into recycled materials to achieve the recycling of resources and promote the sustainable development of the stamping industry.

　　(IV) Coordinated development with new materials

　　With the continuous emergence of new materials, such as high-strength steel, aluminum alloy, magnesium alloy, composite materials, etc., stamping parts processing technology will be closely integrated with new materials to jointly promote the progress of the manufacturing industry. According to the characteristics of new materials, stamping processes and mold technologies that are suitable for them are developed to give full play to the performance advantages of new materials. For example, for the stamping processing of high-strength steel, it is necessary to develop special mold lubrication technology and stamping process parameters to solve the problems of easy cracking and large rebound during the stamping process of high-strength steel; for the stamping forming of composite materials, it is necessary to study its forming mechanism and process method to achieve efficient production of composite parts.

　　As one of the core technologies of modern manufacturing, stamping parts processing technology has made important contributions to the development of industrial production with its unique process advantages and wide application scenarios. In the future, with the continuous innovation and development of technology, stamping parts processing technology will continue to move towards automation, intelligence, and greening, and deeply integrate with new materials and new technologies, injecting new vitality into the transformation and upgrading of the manufacturing industry, playing a greater role in a broader field, and becoming a powerful driving force for industrial development.