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Stamping Copper

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Stamping Copper

Stamping Copper

RustyH

(Mechanical)

(OP)

25 Jul 23 21:36

Good Evening,

I am looking to design and make a machining that can stamp out a 5mm hole in 3mm think copper.
I was wondering how I would go about calculating the force needed to do this.

Also, does anyone think that this would be possible pneumatically with an air piston running off an air compressor?

Many thanks
Rusty

Replies continue below

Recommended for you

RE: Stamping Copper

dvd

(Mechanical)

25 Jul 23 22:21

Please provide a sketch of the hoop

what quantities do you intend to produce?

RE: Stamping Copper

RustyH

(Mechanical)

(OP)

26 Jul 23 06:14

Sorry, that was a Typo, was meant to say "5mm Hole", so it's just a simple 5mm diameter hole to be punched out.

I would say around holes per week.

RE: Stamping Copper

MintJulep

(Mechanical)

26 Jul 23 06:30

https://www.machinemfg.com/punching-tonnage-calcul...

This is the second of 27 million hits from Google.

RE: Stamping Copper

RustyH

(Mechanical)

(OP)

26 Jul 23 06:49

Thanks for the link

So using that, I need less than a tonne.
Is that something that can be achieved pneumatically?

RE: Stamping Copper

ctopher

(Mechanical)

26 Jul 23 14:25
Copper is soft, doesn't take much force.

I don't know the details of the machine, but we have a pneumatic press for stamping beryllium copper (a little harder than copper).Copper is soft, doesn't take much force.

Chris, CSWP
SolidWorks
ctophers home

RE: Stamping Copper

RustyH

(Mechanical)

(OP)

26 Jul 23 15:05

Hi Chris,

Appreciate the reply. If you get chance to see the make and model of the machine please let me know

RE: Stamping Copper

dvd

(Mechanical)

26 Jul 23 15:32

You could also use a

It would be possible to punch these by hand with a Whitney punch You could also use a Unipunch setup in a press brake, or with a custom pneumatic arrangement. There is discussion of this on the Unipunch website.

RE: Stamping Copper

RustyH

(Mechanical)

(OP)

26 Jul 23 15:38

Thanks DVD

I would certainly like a press brake setup, but I don't have the facility to place such a large machine unfortunately, and I only have access to 240v

I would be punching in the region of holes per week

RE: Stamping Copper

SnTMan

(Mechanical)

26 Jul 23 16:26

Regards,

Mike

If I have done my F = P * A right, 100 psi shop air and a 5" cylinder would get you a ton ( lb).Regards,Mike

The problem with sloppy work is that the supply FAR EXCEEDS the demand

RE: Stamping Copper

EdStainless

(Materials)

26 Jul 23 18:47
If you look it up there will be a lot of info.
There is considerable clamping force applied and then the punch is driven quickly.
It results in very clean holes.
We had special toolset made for an electrical solenoid driven press.
We were putting coffin shaped holes about 3x5mm into 5mm thick high purity Cu.

small holes in thick material (especially when it is soft) are a job for 'fine blanking'.If you look it up there will be a lot of info.There is considerable clamping force applied and then the punch is driven quickly.It results in very clean holes.We had special toolset made for an electrical solenoid driven press.We were putting coffin shaped holes about 3x5mm into 5mm thick high purity Cu.

= = = = = = = = = = = = = = = = = = = =
P.E. Metallurgy, consulting work welcomed

RE: Stamping Copper

SnTMan

(Mechanical)

26 Jul 23 20:24

Can they be drilled?

The problem with sloppy work is that the supply FAR EXCEEDS the demand

RE: Stamping Copper

Artisi

(Mechanical)

27 Jul 23 00:27

any sheet metal shop with a small press could handle this without even thinking about it.

It is a capital mistake to theorise before one has data. Insensibly one begins to twist facts to suit theories, instead of theories to suit facts. (Sherlock Holmes - A Scandal in Bohemia.)

RE: Stamping Copper

EdStainless

(Materials)

27 Jul 23 00:41
It would be very difficult to get clean holes.
Stamping these is a lot harder than you think, holes that are as deep (or deeper) than the diameter pose very special problems.

They cannot be drilled because of the very soft Cu.It would be very difficult to get clean holes.Stamping these is a lot harder than you think, holes that are as deep (or deeper) than the diameter pose very special problems.

= = = = = = = = = = = = = = = = = = = =
P.E. Metallurgy, consulting work welcomed

RE: Stamping Copper

mfgenggear

(Aerospace)

27 Jul 23 01:24

I agree with Ed
I would suggest testing

RE: Stamping Copper

SnTMan

(Mechanical)

27 Jul 23 01:32

Well, TBH, we have no idea what the OP is doing, really.

The problem with sloppy work is that the supply FAR EXCEEDS the demand

RE: Stamping Copper

dvd

(Mechanical)

27 Jul 23 03:30
Hole dia. 5mm

(see attached Dayton Rogers Redbook for more info)



from -

• https://files.engineering.com/getfile.aspx?folder=bbe--4d06-b77b-c

Mat'l thickness 3mmHole dia. 5mm(see attached Dayton Rogers Redbook for more info)from - https://alloys.copper.org/alloy/C

RE: Stamping Copper

tygerdawg

(Mechanical)

27 Jul 23 13:39
If you don't have Shear Stress values, an alternative formula is F = (0.7)*T*L*(UTS) where UTS is Ultimate Tensile Strength (T = thickness, L = perimeter length of shear line). Mind your units in the calculations.

The critical issue for quality holes is clearance values between the punch and die. In none of your descriptions did I see any mention of the process quality requirements.

A websearch using the terms arbor press, ironworker, stamping press, hydraulic press, air-over-oil press, etc. should lead you to various types of equipment that could do this. 5mm hole punch and die sets are readily available on the market. Knowing that there will be substantial support structure design requirements, I wouldn't waste my time designing anything. I'd just purchase a suitable unit from somewhere.

holes per week:
For a 40-hour week and 100% efficiency, that will be a continuous production rate of 72 seconds per hole at one hole per stroke. At a more realistic 70% efficiency, it will be ~102 seconds/hole. It is unlikely you will be able to maintain that rate for 40 hours.

Most textbooks in Manufacturing Processes will give the equation provided in the link above.If you don't have Shear Stress values, an alternative formula is F = (0.7)*T*L*(UTS) where UTS is Ultimate Tensile Strength (T = thickness, L = perimeter length of shear line). Mind your units in the calculations.The critical issue for quality holes is clearance values between the punch and die. In none of your descriptions did I see any mention of the process quality requirements.A websearch using the terms arbor press, ironworker, stamping press, hydraulic press, air-over-oil press, etc. should lead you to various types of equipment that could do this. 5mm hole punch and die sets are readily available on the market. Knowing that there will be substantial support structure design requirements, I wouldn't waste my time designing anything. I'd just purchase a suitable unit from somewhere. holes per week:For a 40-hour week and 100% efficiency, that will be a continuous production rate of 72 seconds per hole at one hole per stroke. At a more realistic 70% efficiency, it will be ~102 seconds/hole. It is unlikely you will be able to maintain that rate for 40 hours.

TygerDawg
Blue Technik LLC
Manufacturing Engineering Consulting
www.bluetechnik.com

RE: Stamping Copper

SnTMan

(Mechanical)

27 Jul 23 13:43

One hole in pieces of metal? holes in one piece of metal? Something in between? Who knows?

The problem with sloppy work is that the supply FAR EXCEEDS the demand

RE: Stamping Copper

RustyH

(Mechanical)

(OP)

27 Jul 23 14:15

Thank you for all the replies, much appreciated.

It will be approx HOLES per week

I do drill them at the moment, but drilling leaves a large burr on the drill out side, which them involves a separate process to deburr.

In terms of quality, pretty low quality in all honesty, a shear burr from punching out would be ok, as it would form flat with a fastener anyway (The burr from drilling is pretty excessive, but I dont have coolant setup so that may play a part)

I think you right in finding a compact machine that is capable of doing this with out designing and making one. Every time I search, it either throws up the huge 55 tone presses or the manual pump hydraulic type ones. Some new terms thrown out in the thread though that I will google now

RE: Stamping Copper

EdStainless

(Materials)

27 Jul 23 14:56
https://www.kencopress.com/

Be willing to pay good money for the toolset.
A cheep one will only cause pain and frustration.

Try thisBe willing to pay good money for the toolset.A cheep one will only cause pain and frustration.

= = = = = = = = = = = = = = = = = = = =
P.E. Metallurgy, consulting work welcomed

RE: Stamping Copper

IRstuff

(Aerospace)

27 Jul 23 15:10
> Pilot hole first, then drill from side 1 partially, and then from side 2 to finish
> clamp between sacrificial plates or templates
> changing drill speed/rate
> manually apply oil

Some possible alternative approaches to drill out burrs> Pilot hole first, then drill from side 1 partially, and then from side 2 to finish> clamp between sacrificial plates or templates> changing drill speed/rate> manually apply oil

TTFN (ta ta for now)
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RE: Stamping Copper

Brian Malone

(Industrial)

27 Jul 23 15:45

If your processing time can allow for slightly slower throughput, consider using a center-cutting end mill rather than a twist drill. The finished hole size will be very clean and end mills produce very little backside burr if the cutter is sharp and the proper spindle speed and feed rate are used. For cutting copper no coolant/oil is needed.

RE: Stamping Copper

mfgenggear

(Aerospace)

27 Jul 23 16:57

I agree with brian malone,
using a punch may not produce round or undamaged holes, and expect tool wear of the punch. half of the hole will not have a smooth surface due to it will break and not shear

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News

Mechanical Stamping: Ultimate Guide to FAQ

Updated on Mar,28

Want more information on stamping press for complex parts? Feel free to contact us.

The market for mechanical stamping is still very promising, and investing in mechanical stamping is a very worthy option to consider. This guide will provide detailed answers to the knowledge and questions about Mechanical stamping and will hopefully help you in your choice.

 

 

 

Mechanical stamping is a metal stamping and forming machine that uses preformed dies and pressure to form sheet metal blanks into products and parts. The manufacturer uses an automatic or manual feeder to insert the sheet metal into the stamping press between the tool and the die surface. The press descends onto the sheet metal and uses compressive forces to press the material into the die to form the desired shape.

 

Metal can be shaped or cut precisely to your specifications. The process involves forming, stretching, trimming, punching and/or perforating the metal with a die. Typically, the process is available in sheet metal and coil form.

The press consists of a pad and a plunger. The stamping process works by forming the metal between the two halves of the stamping tool. The top part is attached to the slide of the press, while the bottom part is attached to a fixed pad (or bed). Some large presses also have a die pad integrated into the pad plate that helps apply the crimping force

 

Mechanical stamping press is generally distinguished by the body structure type and application characteristics.

According to the body structure type: there are open and closed two types.

• Open type press

  Open type presses are mostly vertical. The body is C-shaped, the front, left and right side open, simple structure, easy to operate, The body is C-shaped, the front, left and right side open, simple structure, easy to operate, the body can be tilted to a certain angle, so that the workpiece slides down into the hopper, easy to achieve automation, But the open body rigidity is poor, affecting the accuracy of the parts and die life, only for 40 ~ kN of small and medium-sized presses.

• Closed type press

  The body is H-shaped, the front and rear of the body open, good rigidity, high precision, the size of the table is larger, suitable for pressing large parts, The body is H-shaped, the front and rear of the body open, good rigidity, high precision, the size of the table is larger, suitable for pressing large parts, nominal working force of ~ kN. cold extrusion, hot die forging and double-action deep drawing and other heavy presses use closed body.

  According to the application characteristics: there are double-action deep drawing press, multi-station automatic press, rotary head press, hot die forging press and cold extrusion press.

 

Mechanical stamping offers high production speeds and allows for mass production. On Mechanical stamping, only a few standard parameters can be set, so the machine is not as flexible or versatile as a hydraulic press. Mechanical stamping usually requires an operator to manage the operations associated with the strikes. Therefore, it is necessary to equip such machines with suitable safety devices, such as foot switches, grills, etc.

MachineMechanical stamping are usually high precision machines and can guarantee repeated strikes over time. On the other hand, they run only on a given course. Therefore, it is important to check that the opening distances are appropriate for the part size before and after manufacturing.

MachineMechanical stamping makes forming metal materials easier and more efficient. Understanding the different types and how they work will allow you to choose the one that best suits your business.

 

Mechanical stamping machines can stamp and form a variety of metals, including ferrous and non-ferrous metals. Typically the type of metal chosen for a metal stamping part depends greatly on its intended application as well as the size, shape and design of the product.

• Ferrous Metals

  Ferrous metals containing iron are usually magnetic and tend to be strong and durable. Steel is a well known ferrous metal with a wide range of uses. Ferrous metals are valued for their high strength, but their iron content makes them more susceptible to rust and corrosion than non-ferrous metals. Carbon steel is the most commonly used ferrous metal in metal stamping applications because of its extremely high tensile strength. 

• Non-Ferrous Metals

  Non-ferrous metals and alloys do not include iron and are therefore not magnetic. Non-ferrous metals are very popular in a variety of stamping products because of their high ductility and wide range of useful properties. The most common non-ferrous metals used in stamping applications include aluminum, tin, copper, brass, bronze, gold and silver. Aluminum is particularly popular in stamped parts and products due to its low cost, lightweight strength and corrosion resistance. 

  When selecting the right material for your metal stamping application, it is also important to consider the material composition of the tooling you will be using. While most dies consist of tool or hardened steel, different workpiece materials or processes may require alternative die materials, such as aluminum or mild steel. 

 

Many Chinese Mechanical stamping manufacturers combine American, European and domestic technologies with Chinese manufacturing advantages.

This alone gives Chinese companies the upper hand over all of their global competitors. As a result, most Chinese Mechanical stamping is cost competitive with American and European made machines.

You will find that most European and American companies have OEM partners in China. Nevertheless, using this business model, you will pay more for Mechanical stamping.

In short, it is cost effective to source Mechanical stamping from China. Always strive for the best deal.

 

• Know your needs

  Before you start browsing and selecting a Mechanical stamping machine, write down a general list of the jobs you regularly perform. Whether it's drop stock, stamping, punching, bending, deep drawing, metal forming or molding, know how you will use your new press.

  This will tell you which processes you need the machine Mechanical stamping to perform.

• Flexibility of choice

  Modern presses for mechanical stamping have a wide range of tonnage and many features. Many make it easy to control pressure and plunger speed. These presses are highly customizable and can easily handle a variety of jobs. Use a full-featured press that can handle many types of jobs from the master list of processes you often need to complete.

• Using advanced technology

  The latest mechanical presses can handle more complex jobs faster and more efficiently than previous presses. They are equipped with programmable electronic control panels. This means you can customize your press features to individual jobs and their specifications. You get a consistently high level of output excellence at a faster rate.

• Check accuracy and precision

  Most machine shops need to deliver high-end results for their customers. That's why it's critical to choose a machine press that offers precision and accuracy for every job. Choose a model with an adjustable power function and lateral movement slide control. This can prevent problems with unbalanced loads.

• Choose a versatile design

  Choose technology that allows your operators to take full advantage of the press, using its design and production techniques creatively. If you need low tonnage, use a larger press. Smaller bed presses can handle high tonnage and high quality finishes, using side action, under action and multi-action.

• Research cost effectiveness

  Modern machineMechanical stamping saves space and minimizes maintenance costs. They take up less than half the space of machineMechanical stamping. This means you can make efficient use of store space. Ensure that spare parts for the press you are working on are easy to find, thus limiting potential downtime.

 

It is important to know how the starting tonnage is calculated in order to choose the most suitable mechanical stamping press.

The calculation formula is as follows.

P= p/q= (64-73) F/q where P---- screw press tonnage (KN)

p - the deformation force required for die forging (KN)

F - forging together with the projected area of the flying edge (cm 2)

(64 to 73) - the coefficient is taken as 73 for complex forgings and 64 for simple parts.

q - is a deformation coefficient, which can be divided by stroke and deformation work in spiral press die forging.

Forgings require a larger deformation stroke, deformation and deformation work in die forging, q = 0.9 to 1.1.

When forgings need smaller deformation stroke and deformation work of die forging q=1.3.

When the forgings need only a small deformation stroke, but need a large deformation force for fine pressing q=1.6.

P=(17.5~28)KF total (KN) where the total projected area of forging together with flying edge (&#;2)

K - steel grade coefficient, refer to the third unit of the equipment tonnage calculation chapter; ((17.5-28) - coefficient 28 is used for difficult deformation (such as extrusion deformation, deformation with flying edges, etc.) and high productivity, and vice versa. The above formula applies to the calculation of the required equipment tonnage hammering 2-3 times.

If a single stamping is required, it should be doubled as calculated.

 

Mechanical stamping machines should be maintained in a standard way during daily use. There is no doubt that normal and reasonable maintenance can greatly save production costs for later maintenance and bring greater cost benefits.

 

• Before each shift, operate the brake shaft of the manipulator with full lubricating oil at each point, and lubricate the clutch part with oil pressure once a day. Clean the machine before stopping each shift.

• Inspect all aspects of the mechanical press. Check fasteners and make up missing external parts; check the clutch, springs and belts; check the lubrication device of the machine; check the damage and aging of the circuit and the normalcy of the motor and solenoid; check the accuracy and wear of the crankshaft guide; check the brake, clutch, slider, closing block and closing ring; check the electrical control part; check and adjust the body table connecting bolts.

• According to the different types of presses and processing requirements, develop targeted and practical safety operating procedures, and conduct the necessary job training and safety education. Using units and operators must strictly comply with the design and manufacturing units, provide safety instructions and operating procedures, and use and maintain them correctly.

• Pay attention to safety during maintenance to ensure that the locking and opening process is performed correctly to ensure the safety of maintenance personnel and that the sleeve is placed at the bottom of the stroke before performing maintenance work on the brake. If this is done, the sleeve does not need to be locked.

• Shop floor environmental controls. A clean press allows the operator or maintenance personnel to identify problems as soon as they occur. For example, if the press is clean, it is easy to identify the location of oil leaks, air leaks, breaks, etc.

• Make sure the mechanical press is in a balanced position. A precisely balanced press will work better, so it is best to check it once a year. Pneumatic systems that operate pneumatic braking and balancing systems need to be checked for air leaks, as improper air pressure can affect the performance of the braking and balancing systems and they control the stopping time of the press, which can put the operator and the equipment at risk if there is a problem. In addition, all pneumatic systems have regulators, lubricators and water reservoirs. Water that accumulates in the gas lines should be removed daily.

• Replace lubricants and screens regularly. Improper maintenance of the press lubrication system is also a major cause of press downtime. For a variety of reasons, many press operators operate screen-equipped circulating oil systems without changing screens regularly. Be sure to change the screen at the same time as the oil change and generally change it frequently.

 

Precautions to be observed before and after starting the Mechanical stamping machine

1. Check the safety conditions around, in front of, behind, and above and below the machine before starting.

2. Check whether the air, oil and electric circuits are normal.

3. Turn on the power to check whether the air supply, oil supply and hydraulic overload protection are normal, and check whether the pressure and electrical indicators of each pressure gauge are normal.

4. Start, while observing the start electrical status and machine tool mechanical status.

5. First place the machine in the micro position pointing point to start rotation, while observing whether the state of the machine is normal such as: transmission, slider, balance cylinder, oil supply, etc.

6. Machine start single, continuous action, check the mechanical transmission, sound, current is normal.

7. Commissioning, test the performance of each machine such as: adjust the closing height, cam control angle, flywheel brake, air cushion, precision, move the table, manual unloading, etc.

8. Continuous machine observation such as: whether the alarm, each drive and guide temperature change, air pressure, sound, oil supply, oil circuit, etc.

 

With the continuous development of stamping technology, the momentum of Mechanical stamping can be improved. High stamping accuracy, good surface quality and long die life.

The mechanical precision automatic presses manufactured by JDM have the following features.

1. The machine body is welded with high quality steel plate, which eliminates tension and improves the stability of machine accuracy.

2. To ensure the smooth operation of the machine, a symmetrical two-piece slide design with balancer is adopted.

3. The accuracy of mold adjustment can reach 0.1mm, which is safe, reliable and convenient.

4. The crank, gear and connecting rod are oxidation hardened and milled, which have super comprehensive mechanical properties and durable functions.

5. Reasonable structure design, easy for automatic production and assembly line production.

6. Adopt reliable high-strength clutch/brake, double solenoid valve and overload protection device to ensure safe production in all aspects.

7. Adopt high quality alloy steel, double crank, wide working center and connecting rod structure. Optimized design is suitable for pressing large size, large impact load dies and eccentric dies.

8. Adopt closed-loop circuit, compatible with any automatic equipment.

After purchasing our mechanical presses, we will provide you with long-term service. We will be happy to provide you with the necessary assistance during use. The maintenance effort during the use of the machine Mechanical stamping can be greatly reduced by routine maintenance and inspection. If problems arise, we will do our best to help you get back to production in no time. With our experienced technical team, we can provide you with sound advice on Mechanical stamping.

Read more:

Top 10 High Speed Press Manufacturers in China

Mechanical Presses: Buying Guide

If you are looking for more details, kindly visit stamping press maintenance practices.