Introduction to Stamping Presses
Stamping presses have played a big role in manufacturing operations for decades. Some also refer to these machines as power presses or punch presses. From automotive components to intricate electronic parts, stamping presses have long been and still are vital to the productivity and efficiency of manufacturing operations across numerous industries. Whether you currently own and operate stamping presses or are new to metal stamping, this article will provide a basic overview to help you gain a better understanding of the machines responsible for producing the many parts that make up the world around us.
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The History of The Stamping Press
Most people point to the 19th century when discussing the origins of the metal stamping press. Before this time, most stamping and metal forming were performed by hand-operated mechanisms, but as populations grew and demand increased, so did the complexity and capabilities of these machines. In the late s, presses powered by steam were developed. These early developments dramatically improved manufacturing operations' productivity, precision, and efficiency.
The 20th century introduced even greater machine capabilities when flywheels and electric motors were incorporated into stamping presses, allowing for dramatically faster production of metal components. Over the years as enhancements and innovations improved, the modern mechanical and hydraulic presses that we know of and use today were developed. These newer machine iterations offer greatly enhanced precision, productivity, control, and efficiency. Early into the 21st century, the servo press was introduced to the manufacturing world drastically furthering what could be accomplished in stamping.
The stamping press's evolution has helped manufacturers keep up with the needs of the modern highly demanding and technological society. Today, stamping presses are more versatile and efficient than ever, thanks to the ongoing improvements that accommodate various materials and complex geometries. The evolution of the stamping press has helped them remain as a key component in modern manufacturing environments by empowering industries with greater production capabilities and finer control over quality.
How Stamping Presses Work
A stamping press functions by converting rotational motion into linear motion, using force to form or cut sheet metal into desired shapes. The press uses a die'a specially designed tool'to shape, cut, or punch materials, such as steel or aluminum, to create specific components. The combination of speed, force, and precision allows stamping presses to produce large quantities of identical parts rapidly and efficiently.
The stamping process involves three key stages: feeding the material, forming the material, and removing the finished product. Raw metal is fed into the press, where the machine's ram moves down with force, shaping or cutting the metal through the die. Depending on the type of stamping process'such as blanking, coining, or drawing'the press can create different parts with high repeatability and accuracy.
Anatomy of a Stamping Press
Becoming familiar with their main components is important to better understand stamping presses.
Frame
This is the main structural body that holds all other components in place. The frame must be robust enough to withstand the dynamic forces produced during stamping.
Press Drive Mechanism
The Drive mechanism of a press powers the movement of the ram. Based on the type of press, it can be mechanical, hydraulic, or servo-driven. From there the classifications are then broken down even further based on the type of connection between the drive and the ram, which we plan to discuss in a future article.
Ram
The moving part that applies force to the die and forms, cuts, or punches the material into the desired shape. It is powered by a drive system, which as mentioned above depending on the type of press machine can be mechanical, servo, or hydraulic.
Press Controls
The PLC (Programmable Logic Controller) allows the operator to program and monitor the operation of the press. Today state-of-the-art presses come with digital controls that have provisions and functions to make stamping more accurate and consistent, while also keeping operators informed about the status of the machine.
Die Set
The tool that gives the desired shape to the workpiece. Dies are typically comprised of an upper and lower portion with the upper portion mounted to the ram and the lower portion mounted to the press work table or bolster plate. Stamping dies can be custom-made for each specific part to be manufactured.
Work Table/Bolster Plate
The fixed lower part of the press, where the lower half of the die is mounted and withstands the working force. For some stamping operations, the scrap or complete parts fall through an opening in the bolster, which can be customized based on the needs of the user.
This is not an exhaustive list of press components and parts, as many other elements of a press are crucial to their operation, but this serves as a good starting point for those who are new to this type of machinery.
Types Of Stamping Presses
Though the mechanisms, controls, and applications may differ, the core principle remains the same for the different types of presses, and that is they generate a great deal of force to be used in forming, cutting, or drawing metal into a desired shape. Another way in which stamping presses are categorized is according to the different types available for use in different applications, all with their own set of advantages. The main classifications are mechanical, hydraulic, and servo presses.
Mechanical Stamping Presses
Mechanical presses achieve their stamping action through energy stored and released from a large flywheel. The mechanical press's ability to produce parts at high speeds enables them to be better suited for higher-volume production environments.
Advantages:
High speed
Production capability with consistency
High-volume manufacturing feasible
Hydraulic Stamping Presses
Hydraulic presses use a hydraulic cylinder to develop force, which provides more control over the press operation. Hydraulic presses are capable of high tonnage that can be applied at any point in the stroke, which makes them suitable for work involving deep drawing, complex forming, and advanced high-strength materials.
Advantages:
High tonnage capacity
Precise control over force and speed
Well-suited for deep drawing applications or large workpieces
Servo Stamping Presses
Servo presses, as evidenced by the name, utilize servo motors to drive the press ram. Servo presses possess the ability to program the stroke motion profile. This enhances their precision, flexibility, and efficiency. Such presses are ideal for applications involving the stamping of complex parts. The servo motor provides very accurate control over the press stroke, speed, and position; hence it is a great solution in high-precision manufacturing.
Advantages:
High-precision and flexibility
Efficiency
Complex stamping tasks
In this article, you can see how servo presses match up to their mechanical counterparts.
Common Press Frame Configurations
Stamping presses are available in different frame configurations, all of which are designed for specific applications, with various advantages for each.
C Frame Presses
The open frame design of the C frame press allows easy access to the worktable, the die, and the workpiece. C Frame presses are also commonly referred to as gap frame presses or OBI presses (open-back inclinable). These presses are compact and versatile, making them suitable for smaller stamping dies, or environments where floor space is limited.
Advantages:
Compact
Versatile design
Easy access to die and workpiece
Learn more about our range of high-quality C Frame stamping presses.
Straight Side Presses
A straight-side press has a rigid frame structure that offers high precision, stability, and oftentimes additional working space. Therefore, it is used for heavy-duty stamping operations, large workpieces, and for progressive or transfer stamping applications. The straight-side design provides minimum deflection equating to higher accuracy and consistency in more demanding stamping applications. These presses also commonly have higher tonnage capabilities making them ideal in industries such as automotive or appliance manufacturing.
Advantages:
High precision and stability
Suitable for heavy-duty operations
Minimal deflection
Larger workspace
View our range of straight-side stamping presses.
Applications of Stamping Presses
Stamping Presses are utilized in nearly every industry at various points in the manufacturing process. Odds are a majority of the items you interact with on a day-to-day basis have some sort of stamped components. Some of the most significant uses are in the following industries:
Automotive Manufacturing
Stamping presses in the automotive industry are used as standard equipment for making body panels, mounting brackets, engine parts, and other common components of vehicles. In this case, the accuracy and efficiency of stamping presses guarantee the quality and quantities of the parts because they have to meet the rigid requirements demanded by the automobile industry.
Aerospace Manufacturing
The aerospace industry also resorts to using stamping presses to produce high-precision and high-volume components.
Electronics Manufacturing
The stamping press enables the production of small, intricate parts to be used in electronics and for electric connectors. In some high-volume electronic manufacturing operations high-speed stamping presses are utilized to produce as many of these small intricate parts as possible. Such parts find their application in consumer electronics, telecommunication devices, and other applications.
Appliance Manufacturing
Stamping presses are used to manufacture a variety of appliance components including structural elements, panels, and intricate fittings. Working with several different materials and producing products with uniform quality has made the stamping press an integral part of the appliance manufacturing industry.
Medical Component Manufacturing
Medical devices and their components demand a very high level of precision and reliability making stamping presses an ideal production solution for some areas of this industry.
The industries listed above are only a few of the more common areas where a stamping press may be used, but they also play a big role in other areas like consumer product manufacturing.
Advantages of Using Stamping Presses
Precision and Accuracy
Stamping presses allow for high productivity, precision, and repeatability in manufacturing components to meet exact quantities, specifications, and tolerances.
Efficiency and Speed
Modern stamping presses, like mechanical and servo presses, offer highly efficient production capabilities. Mechanical presses offer higher speeds and more simplicity, which raises efficiency, shortens production time, and enables the production of parts in very large quantities. Servo presses, while typically slower than mechanical presses, have the unique capability to program the stroke as needed.
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Versatility
They can process various materials and make components that differ in size, shape, and functionality.
Cost-Effectiveness
Stamping presses can require a hefty up-front investment, but in the long run, they can bring dramatic cost savings and, if maintained properly, remain in operation for decades. The precision and efficiency of these machines ensure minimized material waste and greatly reduced potential errors in production.
Stampings Press Safety Considerations
Stamping presses generate high forces and have many moving parts, which, if not managed properly, can be seriously dangerous. This makes safety the number one priority above all else. Most modern presses incorporate several safety features to prevent operator injuries.
Guarding
Guards prevent access to the point of operation and other hazardous areas of the press. Common forms of guarding are physical barriers, light curtains, and interlocking safeguards.
Emergency Stop
An emergency stop button allows an operator to stop the press immediately in case of an emergency. This is an important feature to prevent injuries, accidents, and serious damage to the machine.
Training
Proper training is essential for an operator to be capable of running the press safely and efficiently. Training programs should include machine operation, safe working procedures, and emergency response in the event of an accident.
Visit the Precision Metalforming Association's website to learn more about their operator training resources.
Maintenance of the Stamping Press
Regular maintenance is required to maintain the longevity of the press and better performance. This involves lubricating, inspecting, and replacing worn parts.
Lubrication
Proper lubrication minimizes friction and thus reduces wear on moving parts. This extends the life of the press while also aiding in maintaining the overall performance. Operators must check the press manual or with the manufacturer to determine what types of lubrication are suitable for their particular press.
Inspection
Inspecting the ram, die, and drive mechanism components regularly ensures the press runs trouble-free. Regular preventative maintenance inspections can help technicians spot issues before they turn into major repairs.
Replacement of Worn Components
The common wear components need to be replaced to prevent damage to the press and sustain precision and performance. One way to ensure minimal downtime is to keep an inventory of the common wear items to avoid lead times or delays when parts are needed.
Future Trends in Metal Stamping Press Technology
Stamping press technology and processes are only evolving further with new technological advancements and manufacturing requirements changing continuously.
Automation and Robotics
Stamping processes are increasingly being integrated with automation and robotics. Automation enhances efficiency, decreases labor costs, and improves safety by performing any type of repetitive or dangerous tasks. In recent years manufacturing operations have sought out automation and robotics as a means of combatting the ongoing labor shortages.
Smart Manufacturing
The adoption of smart manufacturing technologies is shifting the stamping industry. Those technologies provide real-time monitoring and insights into the optimization and status of stamping processes.
Sustainable Practices
There is an increasing trend in manufacturing regarding sustainability. Modern metal stamping presses and processes are designed to reduce energy use, cut down on waste, and ensure the use of more eco-friendly materials.
The awareness of different stamping presses and their applications can make a huge difference in manufacturing efficiency and product quality. Whether you need a high-speed stamping press or a precision servo press, possessing the proper knowledge and equipment means everything.
Want more in-depth information on each type of press, and how it can help your operations? Check out our other in-depth guides.
Have questions, or need some help choosing the right equipment for your stamping operations? Someone from our team would be happy to help you, so contact our team today to find the best metal stamping press to fit your needs
Employee shortages and high turnover have made training important so that new employees'or those filling in for others'can adapt quickly to the challenges at hand ' not to mention, the task flexibility required by supply chain disruptions. At the same time, press lines and tooling have become more automated with multiple interfaces that result in more complicated operations.
Press controls have been upgraded frequently to modernize an older press system. Now they have evolved to help stamping manufacturers grapple with today's personnel and automation challenges.
Wintriss Controls Group Product Manager Jim Finnerty, and Bosch Rexroth Control System Application & Engineering Manager Ken Rayden weigh in on trends in press control technology affecting stamping manufacturing.
Stamping Journal: What challenges are stampers currently faced with related to press controls?
Finnerty: A lot of employee turnover has occurred the last few years, and it has been difficult for stampers to fill skilled positions with qualified people, so training has become more important than ever.
In addition, press lines and tooling have become more automated with multiple interfaces, which results in more complicated operations, exacerbating the training issue.
Also, supply chain interruptions have forced manufacturers to become more adaptable. Instead of sticking to a 'normal' schedule, shops are scheduling jobs when raw material and parts become available. This results in more frequent tool changes at the presses. Reducing set up time has become a constant challenge.
Rayden: The trend in automobile bodies is towards larger panels with deeper draws. This necessitates the use of more complex presses, including servo-hydraulic cushion systems.'
At the same time, stamping manufacturers continue to face the erosion of skilled maintenance technicians and engineers who are capable of providing robust and timely troubleshooting and repair services for this equipment, including hydraulics.
SJ: How are press controls evolving to help meet these challenges?
Rayden: In all markets using advanced hydraulic machinery, there is a need to include troubleshooting assistance within the control system to bridge the gap between skilled labor and complex machinery. More and more control systems include some form of graphical representation of the status of the electric, pneumatic, and hydraulic press systems to aid troubleshooting. However, much more can and needs to be done on this front.
Finnerty: Multiple automated systems on the press can result in multiple user interfaces that require programming and adjustment each time a job is changed. The challenge for control manufacturers is to find a way to unify these systems and reduce the number of screens on the machine, while keeping the interface as simple and user-friendly as possible. This is no small task.
SJ: What have you done with press controls to address these challenges?
Finnerty: We have adopted a 'one press, one screen' philosophy. We've collaborated with suppliers of servo feeds, lube systems, PLCs, and other devices to enable our controls to act as the main user interface for their equipment. Now, when the job changes at the press, operators need to learn how to use only one controller and access only one screen instead of many. This alleviates the training burden and reduces set up time.
As part of our interoperability mandate, we've expanded the remote access features of our controllers. Now, subject matter experts can quickly access and program our controllers remotely from a computer or mobile device whenever application problems arise or when programming help is needed.
Also, Wintriss is including training specialists and user experience experts on our control design teams. This helps to ensure that our systems continue to be intuitive and user friendly. We've added features such as unique, context-sensitive help screens written in simplified language for every programming screen on the control. We've created the ability for press operators to configure custom dashboards for the controls that put the features they want at their fingertips for quick access.
To meet the challenges raised by advanced tooling and automation, Wintriss has greatly expanded our controllers' sensor monitoring and programmable limit switch capabilities.
We've added dozens of new features to provide next-generation flexibility to our die protection systems. We've also included functions to make the system more forgiving and to reduce nuisance stops. Complex automation can require complex timing and control logic. In the past, this was often accomplished by adding a separate PLC to our integrated systems. We have recently reduced the need for these additional controllers by releasing a sweeping upgrade of our programmable limit switch capabilities. Users can now control automated tooling, complex operations, and external ancillary equipment without the need for a custom control.
Rayden: We have developed an advanced diagnostics system to assist stampers with rapid troubleshooting, repair, and part procurement for our hydraulic systems. The Bosch Rexroth advanced diagnostics package is a PLC-, HMI-, and sensor-based system. It brings together a number of features, hosted through the machine HMI. Its sole purpose is to provide real-time, embedded system component testing; system documentation; and system visualization into one central location.
A key feature of the diagnostics is the inclusion of expert hydraulic troubleshooting for each system component. This exists even for those without a direct electrical interface, such as check valves, relief valves, and throttles. Think of it as an 'engineer in a box.'
The user simply launches the troubleshooting portion of the package. A series of predetermined tests are executed, systematically testing each component and reporting the findings to users. The report offers either a specific action item or a short list of possible solutions. The operator makes the recommended checks or corrections and then reruns the test to verify that the correction was successful.
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