Longsheng

By selecting suitable high-strength material and combining it with precision metallic stamp technology, the overall durability of stamped parts can be greatly improved and the industry's strict requirements for long-term reliability can be met. 

How to prevent rust treatment on stainless steel stamped parts?

1.Surface cleaning and removal of pollutants

Uses: Removing oil, cutting fluid, metal debris and other pollutants in stamping process to avoid oxide film damage.

JS measures:

• A combination of alkaline degreaser and ultrasonic cleaning process was used to achieve Sa2.5 level (ISO standard) cleanliness.
• Automated phosphating/passivation production line to form uniform protective layer on treated surface.

Main operations:

• Brush the surface oil stains with a clean cloth immediately after stamping.
• Chlorine-containing solvents such as hydrochloric acid are prohibited to prevent stress corrosion and cracking.

2.Chemical passivation treatment

Objective: To improve the density and corrosion resistance of stainless steel surface oxide film (CR₂O₃).

JS measures:

• Environmentally friendly passivation solution (free of hexavalent chromium) meets RoHS standards.
• Passivated salt spray test last more than 240 hours (304 stainless steel as standard).

Process parameters:

• Temperature: Normal ~50 °C (adjusted for material).
• Time: 15-30 minutes.

Post-treatment: Rinse + dry with pure water to ensure no residue.

3.Physical protection coating

Purpose: Physical isolation layer for special environment such as high humidity and chemical medium.

JS measures:

• Electrophoretic coating: Epoxy resin coating, salt-resistant spray time up to 500 hours.
• PVD vacuum coating: Deposition chromium nitride film, hardness HV 2000+, increase abrasion resistance.

4.Structural design and process optimization

Objective: To reduce stress concentration, surface damage and corrosion risk.

JS measures:

• Hard chromium (Ra ≤ 0.1μm) on die surface to avoid stamping scratches.
• Hydraulic forming is used instead of traditional stamping to reduce strain on the material.

Design highlights:

• Rounded transition: Avoid stress concentration caused by sharp angles.
• Exhaust design: Avoid liquid accumulation inside the stamped parts.

5.Environmental control and maintenance

Purpose: To block external corrosion sources and prolong rust prevention time.

JS measures:

• Storage environment: Constant temperature and humidity warehouse (moisture ≤60%).
• Transport protection: Wrapped in polyethylene film and filled with desiccant, moisture-proof and rust.
• Periodic maintenance: Check surface condition monthly, treat small rust spots with a professional stainless steel cleaning, and repair local passivation of welded areas.

What are the difficulties in designing stamping molds for irregular parts?

The dificulty of stamping die design for irregular parts involves many technical challenges and requires a combination of precisionmanufacturing experience and innovative solutions. Here are specific difficulties and how JS company's response strategies:

1.Design challenges posed by structural complexity

Difficulties:

• Split die design: Irregular parts usually require a multi-cavity die or slider structures with a high mold complexity (e.g. 7-8 slider linkage for car coverings).
• Core extractor: For deep stretching or lateral core extractor parts, precision core is needed, otherwise mold jamming or size deviation may occur.
• Mold strength: Complex structures are prone to stress concentration and topology optimization is required to improve stiffness.

Response strategies:

• Modular design and individual manufacturing of key components.
• The force distribution of die is optimized by FEA.

2.Material utilization and layout optimization

Difficulties:

• Irregular parts are prone to waste layout process, resulting in material utilization rate less than 60%.
• Complex contours require a balance between stamping sequence and deformation control.

Response strategies:

• Samples are automatically optimized and arranged using AI algorithms.
• The universal edge cutting technology reduces waste.

3.Accuracy control and dimensional stability

Difficulties:

• The tolerances for irregular parts (e.g. electronic components stand ±0.02mm) are strictly required.
• Stamping recoil results in size bias (stainless steel recoil rate can be 8%-12%).

Response strategies:

• Real-time on-line detection system (CCD+laser ranging).
• The surface of the die is modified by the rebound compensation algorithm algorithm.

4.Service life and abrasion resistance of mold

Difficulties:

• The stamping frequency of irregular parts is limited (500000 times the service life of ordinary moulds and more than 2 million times the service life of highly demanding parts).
• The welding process of hard alloy and mold steel is difficult.

Response strategies:

• Surface hardening (e.g. TD coating, PVD coating).
• The abrasion area was repaired by laser cladding.

5.Trial Mode Cost and Efficiency

Difficulties:

• Irregular parts have long test die cycles and cost more than 10000 yuan per piece.
• Traditional methods of trial and error are difficult to locate the root cause of the problem quickly.

Response strategies:

• Digital twin technology simulates the stamping process.
• Rapid prototyping molds (3D printing) shorten the verification cycle.

How does JS company optimize the utilization rate of stamping materials?

1.Intelligent layout design

Technical means:

• Artificial intelligence algorithm is used to arrange stamp metal intelligently and calculate the most optimal nesting scheme automatically.
• Support for uploading STEP/IGES and other formatting files, the system automatically recognizes part contours and generates a layout.

Effect: Material utilization rate increased from 85% of the industry average to over 92% (especially irregular parts). Reduce waste and save approximately 15% to 20% on materials per order.

2.Residual material recycling and reuse system

Technical means:

• Fully automated waste sorting equipment is provided for the real-time classification of recyclable metal debris, such as stamping metal scraps.
• The remaining material is processed into small stamping parts by thermopressing process.

Effect: Meet the standard of sustainable production, a non-ferrous metal recovery rate up to 98%, reduce annual raw material procurement costs of more than 1 million.

3.Modular process, flexible production line

Technical means:

• The complex parts are broken down into standardized submodules (such as holes and bending areas) and batch processing using a uniform molds.
• Seamless switching of different stamp metal parts is achieved through the rapid die conversion system, and the changeover time is no more than 15 minutes.

Effect: 30% shorter lead time and 10% less material loss for multi-variety small order.

4.Material Characteristics and Process Matching Database

Technical means:

• There is a database of more than 50 metallic materials, including parameters such as thickness, ductility and resilience.
• Automatic stamping process parameters are generated to avoid waste due to improper material selection.

Effect: High strength steel (such as 430 stainless steel) stamping qualification rate increased to 99.5%, reducing rework waste.

5.Digital simulation and virtual debugging

Technical means:

• AutoForm software is used to simulate the stamping process of stamp metal and predict defects such as wrinklings and fractures.
• The mold surface is optimized by virtual debugging and the number of die physical tests is reduced.

Effect: 100% pass rate of mold initial inspection, 100% trial mold cycle.

要約

In the field of metal stamping, the choice of materials directly determines the performance and quality of metal stamped products. From aluminum alloy to stainless steel, each material meets the precision needs of different industries with its unique properties. JS company has advanced metal stamps technology and the flexibility to select more than 50 metal materials according to customer needs. The precision level of metal stamped is ±0.005mm by optimizing mold design and production process. Whether it's the impact resistance of car coverings or the corrosion resistance of medical devices, JS's professional team is able to create a fully functional and cost-effective metal stamping solution for customers.

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jsチーム

jsは業界をリードする会社ですカスタム製造ソリューションに焦点を当てています。 5,000人以上の顧客にサービスを提供している20年以上の経験により、高精度 cnc machining 、 3d printing 、射出成形、私たちの工場には、100を超える最先端の5軸機械加工センターが装備されており、ISO 9001：2015の認定があります。世界中の150か国以上の顧客に、高速で効率的で高品質の製造ソリューションを提供しています。少ない量の生産であろうと大量のカスタマイズであろうと、24時間以内に最速の配達でお客様のニーズを満たすことができます。 jsテクノロジーを選択してくださいそれは効率、品質、プロフェッショナリズムを選択することを意味します。 href = "https://jsrpm.com/"> jsrpm.com

FAQS

1.What are the advantages of stainless steel stamping parts? ​

Stainless steel stamping parts is corrosion resistant, abrasionresistant and high strength. It is suitable for long-term use in home appliances, medical devices and so on.

2.What are the materials with good ductility?

Including aluminum alloy, copper alloy, brass and pure metals such as gold, silver, aluminum, these materials are easy to shape, suitable for complex stamping parts processing.

3.How does the thickness of metal sheet affect the stamping effect? ​

Thin plate is easy to deform, but the strength is low. It is suitable for precision parts. Thick plates require greater punching force and are prone to burr, making them suitable for structural components. The die clearance and pressure parameters need to be adjusted according to the ductility of the material.

4.Is the dimensional accuracy of metal stamping parts related to the material? ​

Closely related to this, the ductility, bounce and uniformity of the material directly affect the stability of the molding and need to be controlled through mold design and process parameter optimization.

リソース

Stainless steel

Titanium alloys

Aluminium alloy