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Processing Steel in the U.S. – Metal Forming 101

jane2024-03-13T17:10:30+00:00March 8th, 2024|News Blog|

Metal forming is a process vital in the US steel processing industry. Renowned for its capacity to mold complex shapes and structures, it’s a process embraced by steel processors throughout North America for its capability to generate a wide array of essential products, from precision automotive parts to critical aerospace components.

Metal forming requires skilled professionals and advanced machinery, which is where steel service centers come in. These centers are the go-to source for metal processing, forming, and distribution, providing essential services that help transform raw materials into finished products.

What is Metal Forming?

Have you ever wondered how metals manufacturers create various shapes and sizes of metal parts? It’s thanks to the fascinating process of metal forming: the art of shaping a piece of metal into any desired shape. Various methods are involved in this process, from roll forming and bending to extrusion and forging.

The best part about metal forming is its efficiency and accuracy. With this technique, manufacturers can create large, sturdy metal parts with high precision. And that’s why it has become an indispensable part of the manufacturing industry today. Next time you observe a metal part, remember it was made using a specific process.

Metal Forming Process: The Basics

Metal forming is a captivating process that encompasses a diverse array of production techniques. From forging and casting to rolling and bending, there are countless ways to transform raw metal stock into a finished item. Regardless of the technique, manufacturers aim to create high-quality products that meet customers’ needs. So, whether you’re a metalworking expert or just curious about the industry, metal forming is worth learning more about!

Cold Working Process

In the cold working process, one applies force to reshape metal, changing its shape without adding or removing any material. This process can achieve the desired shape of the metal at room temperature.

Heat Treated Process

Metals can be changed in many ways to make them more robust, flexible, and wear-resistant. One way to do this is by heat treatment, a process of altering the physical or chemical properties of a metal through the use of heating or chilling, normally with extreme temperatures, to achieve the desired result or appearance. Heat treatment is a common method used by manufacturers to give metals intricate shapes that are impossible to achieve through simple bending. It can also make steel more flexible and last longer.

Five distinct metal-forming processes:

1. Roll Forming

Roll forming is a key manufacturing process that involves bending a long strip of metal, typically coiled steel, by passing it through consecutive sets of rolls. Each pair of rolls performs a part of the bend until the metal achieves the intended cross-sectional profile. This method is versatile, allowing for the creation of various shapes and sizes at room temperature.

The process allows for manipulation of metals to enhance their physical or mechanical properties, achieving […]

Metal Stamping 101: Understanding the Metal Stamping Process

maria2023-08-08T22:11:07+00:00August 8th, 2023|News Blog|

National Material Company is regarded as a global leader in servicing the needs of the steel industry and leading industrial and consumer product manufacturers. With over 50 years of expertise in metals processing and supply chain management, NMC offers metal stamping services as a part of a wide array of steel processing capabilities. Read on to learn more about metal stamping:

Metal Stamping Process

Metal stamping is an incredibly versatile and efficient manufacturing process that takes flat metal sheets or coils and transforms them into precisely shaped and intricate parts. By utilizing force, pressure, and specialized tooling, components with diverse forms — including bends, curves, cutouts, and embossing, are possible. This process offers low costs and higher lead times — both for short and long production runs while keeping consistent quality, dimensional accuracy, and repeatability of the manufactured parts.

How It Works

At the core of metal stamping lies the stamp press, a component responsible for applying the necessary force and pressure to mold the metal sheets or coils into the desired shape or profiles. This powerful machine incorporates specialized tooling known as dies, which performs a variety of stamping operations on the metal. By carefully controlling the movement of the press and the interaction between the dies and the metal in the production line, the stamping process brings forth remarkable transformations in the shape and structure of the material.

Now, let’s dive deeper into the fascinating world of metal stamping and explore its different stages and intricacies.

Design and Tooling Preparation

Experts begin the process with meticulous design and engineering, where the desired part geometry is carefully planned. Stamping professionals consider multiple factors such as material properties, die design, and tooling requirements. Once the design is finalized, it is plotted using CAD (computer-aided design) or CAM (computer-aided manufacturing) software to ensure accuracy. After the tool design is completed, the specialized tooling (such as blanking dies, forming dies, and piercing dies), is fabricated using a variety of machining tools and technology. The tool and die design must ensure proper material flow, adequate clearance for the metal sheet, and appropriate support for the part during stamping.

Material Preparation

Based on the requirements of the part, specialists select metal sheets or coils. Considerations include mechanical properties such as strength and ductility, as well as other factors like corrosion resistance, conductivity, and cost. The selected material should be compatible with the stamping process and the desired part’s functionality.

Feeding

The selected materials undergo preparation processes like cutting, slitting, and leveling to obtain the proper dimensions and flatness necessary for stamping. The prepared metal sheets or coils are then fed into the stamping press, where an automated feeding mechanism ensures precise positioning for accurate stamping.

Stamping Operations

As the stamp press initiates its action, the dies close together, subjecting the metal to high force and pressure. This pressure deforms the material, shaping it according to the contours of the dies. There are also a variety of […]