Deep Draw Stamping
Deep-draw stamping is a high-speed, high-value shape transformation process in which sheet metal is drawn into a forming die to produce round, square or irregularly shaped parts.
Deep-draw stamping is typically done using a transfer press. This process starts with a blank trimmed from the strip of steel which is then transferred station-to-station via a mechanical transfer system, steadily forming the steel into a finished part. Transfer press technology provides an opportunity to stamp extra content into the part due to the part being free from the strip of metal during forming.
This picture illustrates the process, starting with the flat blank on the left and culminating after 13 forming stations with the finished part on the right.
Progressive Die Stamping
In progressive die stamping, an automatic feeding system pushes the strip of metal through all of the stations of the stamping die, while the part is maintained within the strip of metal. Each station performs one or more operations such as bending, forming and piercing until a finished part is made. One of the final stations of the tool is then used to trim the finished part from the metal strip.
The progressive die process typically uses more raw material than the transfer process, but prog-dies are quick to set-up and provide the opportunity for making two or more parts at the same time.
Although it’s a highly capable process, progressive die stamping is not always the most optimal solution for a part that requires extensive deep-drawing to reach its finished shape.
The picture illustrates how a part is “carried” within the strip of steel as it is progressively formed through the die.
The assembly process brings together design, manufacturing and logistics to create a multi-piece product with a value that is higher than its individual components. This way, complex components can be created by joining lower-cost individual pieces.
JMS is a proven supplier of build-to-print assemblies. Depending on the scope and complexity of the project, we will either design and tool up the equipment in-house, or we will partner with one of our specialized machine integrators to build the assembly process.
Regardless of which direction we take, we work closely with our customers to incorporate Design For Manufacturability principles and develop robust PFMEAs. Close collaboration with both our supply chain and demand chain allows us to provide cost-competitive assemblies that are delivered on time and that meet all specifications.
Our assemblies typically combine stampings with cold formed parts, machined parts, rubber parts or other stampings. Common joining processes we utilize include welding, clinching, pressing, bending and dimpling.
Simulation and Product Engineering
The JMS Engineering team utilizes DEFORM® simulation software to analyze the performance of tool designs well before tool steels are cut. Simulation runs in tandem with our engineers’ design work: one process informs the other until an optimized step-by-step forming process is achieved.
Some of our stamping tools include up to 24 working stations, so effective use of simulation ensures that earlier forming steps do not lead to problems further down the station lineup. This way, a quality, robust tool is built from the start, which aids and supports efficient product launches.
While we use our software in its 2D mode for traditional stampings, we often utilize its powerful 3D environment for alternative metal-forming processes, such as extruding and bulk forming (forging). DEFORM® also has the ability to detect tooling “hot spots” and deflection points, as well as identifying potential damage to the workpiece itself.
Our utilization of DEFORM® helps provide superior lead-times for tool development and PPAP, while also contributing to lower overall tooling costs. Last but not least, this technology allows us to routinely assist our customers in the early stages of their stamped product design, ensuring part quality and manufacturing efficiency.