LS Manufacturing は、データ主導のエンドツーエンドの品質管理システムを構築し、精密スタンピング分野に深く携わっており、ステンレス鋼の成形原理を徹底的に理解しています。 当社は、ASTM A240/A240M-24 規格に厳密に従って、0.05 ～ 3.0 mm の範囲のシート厚さのオーダーメイドの専用プロセスを提供し、プロセス全体を通じて定量化された制御を実現します。
このようなプロセスにより、1 つの高強度図面を複数の軽量図面に分割することができ、材料の内部応力を徐々に解放し、過度の瞬間的な応力による亀裂を回避できます。 This method is most commonly used for the mass production of 316L precision stamping parts and can be tailored for various deep drawing needs for custom stainless steel stamping.
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With the help of 2-3 passes of staged stretching, gradual shaping is achieved thereby avoiding stress concentration from a single stretching.
1050℃-1100℃ solution annealing is used to clear work hardening completely and is interspersed with the stretched passes.
Directly after annealing is lead to rapid cooling which restores the original ductility of the raw material.
Precise Control of Die and Pressure
Die gap matching directly decides how uniform the wall thickness of deep drawn products will be. Ensuring consistent metal stamping batch positioning really helps with the uniformity of different batches. The group keenly controls the wall thickness reduction rate at 15% by highly accurate polishing of die radius corners and gap matching at a micron-level.
At the same time, changing the servo blank holder force dynamically, which is a response to the wrinkling and tearing problems caused by uneven blank holder pressure, guarantees stable production of high-quality metal stamping components for all sorts of high end deep drawing mass production scenarios.
Figure 3: Deep-drawn 316L stainless steel parts with smooth, metallic finishes and intricate shapes.
What Strict Inspection Criteria Validate Medical Grade 316L Precision Stamping Parts?
Medical-grade 316L precision stamping inspection relies on CMM dimensional verification, NDT non-destructive testing, and passivation residual oil detection to reach zero defects in parts. It is compatible with high-end international medical standards and responds to the core requirements for compliant mass production of medical components.
Dimensional and Defect Detection System
Full dimension rechecking makes it possible to achieve 100% full quality assurance of mass-produced parts. A comprehensive metal stamping malfunction detection system greatly lowers the defect rate. It acts as the base service standard for high-end stainless steel stamping services, ensuring the factory quality of lots of precision metal stamping components in a comprehensive manner.
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Employs CMM (Coordinate Measuring Machine) equipment for whole-dimensional validation, checking that all tolerances are in the approved range.
Performs NDT (Non-Destructive Testing) method to locate tiny cracks and internal defects in the materials.
Has AOI (Automated Optical Inspection) machines on hand for batch-sorting of parts that have surface scratches and other defects.
Corrosion Resistance and Compliance Testing Standards
Corrosion resistance check assures the components are compatible with sterile medical environment.Standard metal stamping edge finishing allows better assembly fit.All final products are tested per the ASTM B117 salt spray standard and show a rust-free operation time of 96-240 hours. Formal testing of passivation and residual oil, together with a 100% Material Quality Assurance (MTR) traceability system, are key quality control steps to a genuine 304/316L stamping manufacturing.
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Send your specifications to get a compliance report for specialized medical grade testing services, to acquire the entire, detailed quality control procedure, please see the Medical Industry Testing Standards Handbook, it's free.
Figure 4: Stainless steel tweezers and medical supplies arranged on a green sterile cloth or tray.
Why Choose Progressive Dies Over Transfer Tools For High Volume Stainless Stamping?
Progressive stamping dies are capable of performing multi-station continuous processing on a single press, and they can reach a mass production efficiency of 60-120 strokes/min. This not only ensures that different batches are dimensionally consistent, but also cuts down the labor cost. Then again, they are well suited for mass production of high-volume stainless stamping and retain all the advantages of traditional dies and more.
High-Precision Positioning Mass Production Advantages
Accurate pitch positioning is the fundamental condition for dimensional consistency in batch manufacturing. It is possible for metal stamping batch productionwith a high level of precision to have micron-level batch replication. Progressive dies have precision guide pins, which provide a pitch positioning of 0.005mm, removing dimensional deviations in mass production, and producing a high level of uniformity in precision for tens of thousands of precision metal stamping parts. This represents a major hardware edge of professional precision metal stamping areas.
Loss and Safety Management Advantages
Automatic error detection cuts down losses and safety risks tremendously in mass production. Plus that, smart metal stamping process monitoring gives you the opportunity to have control over mass production at any time. Copper foils mass production of 304 316L stamping manufacturing are safeguarded, leading to a highly efficient reduction of the defect rate of customized stamping mass production.
The machine is able to detect misfeed and material overlap through sensors to prevent production accidents in real time.
The combination of different materials in a single handling process leads to a drastic reduction of material waste and better use of material.
When the workstation is completely automated, the probability of errors and the expenses resulting from manual intervention are lowered.
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If you want to find out if your mass production molds are fit for use, you may get a mass production process planning solution free of charge, for the calculation of the overall cost of your mass production, please get in touch with our engineers for an accurate quote.
How To Eliminate Edge Burrs During The Custom Stainless Steel Stamping Shearing Process?
Caring exact control of the shearing gap on both sides of the mold within 6%-10% of the plate thickness, and use of sharp cutting edges and accurately after-processing, can thoroughly eliminate the problem of edge burrs in custom stainless steel stamping, this way preventing safety hazards such as assembly scratches and equipment short circuits.
Accurate Shearing Gap Calibration
Shear gap measurement is a big part that decides the likelihood of burr formation, accurate tuning of the metal stamping gap can effectively eliminate the production of defects at their roots. The company uses high-precision wire EDM (WEDM) made molds to guarantee consistent and stable blanking clearances on both sides, strictly following the sheet thickness ratio.
This reduces the chances of burr formation at its origin, preventing the shear fracture zones. This technique is ideal for 304 stamping service and various precision processing stainless steel situations, and it is capable of making the finished products comply with the high-end precision metal stamping component standards.
Integrated Deburring Post-Processing
Integration of surface finishing ensures that parts have zero-burr edges. Metal stamping post processing at a refined level will greatly improve the overall product quality. As a post-processing step, it is a must-have for stainless steel stamping at a very high-end level, which can especially increase the assembly compatibility of the products that are mass-produced.
Primary Operating Conditions: Fine edge burrs can be quickly removed with vibratory grinding.
Highly-Precise Operating Conditions: Electrochemical deburring is implemented, where the part remains undamaged by contact, so preserving its precision.
Ultrasonic precision cleaning will finally and thoroughly eliminate residual debris even from edges and corners.
LS Manufacturing Custom 316L Precision Stamping for Medical Endoscope Components: A Success Story
This medical real-world mass production example is a proof of the power of top-level 316L precision stamping and also gives a great solution to the industry's unsolved problems like thin-wall hardening, too much springback tolerance, and the emergence of micro-cracks. So, it is a demonstration of our custom stainless steel stamping mass production capabilities.
Client Challenges
The client is a German medical device manufacturer ranked among the top five worldwide. Their main R&D product, stainless steel 316L precision housing for endoscopes, is of only 0.4mm wall thickness and has been suffering from quality issues of their original European and American suppliers.
Secondly, due to the very strong work hardening nature of 316L material, micro-tears often occur when the parts are stretched and formed, and with springback tolerances going beyond 0.07mm, far exceeding the client's drawing requirement of 0.015mm. The consequences of this problem are that the customer's overall assembly defect rate has reached 12.5%, which has severely impacted the launch of new products and the company suffered quite a few losses also due to the downtime and rework.
LS Manufacturing Solution:
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As soon as they came into contact with the problem, LS Manufacturing technical team rolled out a series of DFM design optimization measures at a rapid pace. We gave up the use of old-fashioned general-purpose molds and instead created a very precise and 14-station completely servo progressive die.
The die is mainly made of imported DC53 steel, to which is added a special CVD-CrN ultra-pure coating, thereby surface roughening and adhesion problems on thin walled precision metal stamping components are completely eliminated.
Our staff performed FEA rheological stress simulations three times, deciding at last on a specialized 3.8 bending relief angle that would accurately counteract springback deformation of the material.
In the meantime, an ultra high pressure closed-loop extreme pressure lubrication system was installed so that the forming needs of thin walled parts could be satisfied. Besides forming, the next stage in the process is a fully automated ultrasonic citric acid passivation production line and 100% optical intelligent self-inspection that altogether allow complete quality control from the beginning to the end.
結果と値
Subsequent to checking 50,000 production runs, the solution has invariably controlled the partspringback tolerance within 0.01mm, thinning rate has been lowered to 11%, cracks and burrs have been completely eradicated, and only assembly defect rates have been eliminated. Overall project cost has been reduced by 22%, delivery time has been greatly shortened, and at the same time, it fully meets the high volume stainless stamping mass production standards.
The project successfully implemented continuous cooperation with the long-term client who highly appreciates our manufacturing technology of professional 304 316L stamping manufacturing and capability of mass production delivery.
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To replicate the same medical-grade precision stamping solution, you can submit part drawings to customize your exclusive process, to learn more about high-end mass production cases, you can view the complete case library for free.
よくある質問
Q1: What lead time can one expect for custom stainless steel stamping toolings at LS Manufacturing?
The normal lead time for manufacturing an engineering die is 3-4 weeks, while multi-station progressive dies of a higher complexity level may take 5-6 weeks. The overall procedure comprises DFM optimization, FEA simulation, and several prototyping testing sessions, which together guarantee the die mass production stability and the finished product yield.
Q2: What method does LS Manufacturing employ to effectively manage the severe springback effect during 316L precision stamping?
Through FEA simulation, the deformation features of 316L material can be accurately determined, this way allowing 3-5 overbending compensation to be set aside at the forming station. The combination of this with a multi-stage locking process utilizing a fully servo press means that the material springback deformation can be precisely counteracted, thereby securing a stable control of the part precision tolerances.
Q3: Does your stainless steel stamping capabilities include the making of extra-thin components with a thickness below 0.2mm?
We furnish stainless steel stamping of every specification from 0.05-3.0mm. When it comes to ultra-thin parts below 0.2mm, we rely on micron level wire cutting to control the die gap which in turn, helps to effectively avoid warping and deformation issues while ensuring forming accuracy and appearance quality.
Q4: What kinds of mold surface treatment are your company implementing to prevent your production components from galling?
For mass production, we generally adopt TD thermal diffusion hardening or CVD professional coating processes, resulting in a mold hardness of HV2500 or even higher. By doing so, we are able to completely solve high-frequency defects in stainless steel stamping, such as cold welding, nodules, and surface roughening, which are the production defects that happen during high-speed mass production. This, in turn, guarantees the quality of the product's appearance.
Q5: Can you please tell me how LS Manufacturing is able to guarantee 100% material traceability for 304 and 316L stamping manufacturing?
To implement batch traceability control of raw materials using barcodes, we rely on an ERP system. Every batch of finished goods is issued a full MTR material quality certificate. This certificate contains sub-details of material chemical composition and mechanical properties and is the evidence for verification of full traceability and compliance.
Q6: What is your MOQ for the production of custom precision metal stamping?
Generally, we set the MOQ for mass production of progressive dies as 10,000 pieces. But, our company is also capable of instantly making products for customers who need R&D prototyping and small-batch trial production, and the support for customized processing of hundreds of pieces is totally in line with the production needs of entire project development, trial production, and mass production stages.
Q7: How do you manage to meet the very high cleaning standards of medical or food grade 304 stainless steel components?
We have a state-of-the-art, fully automatic, closed-loop pure water ultrasonic cleaning production line. This, together with our standardized passivation processes, can completely remove surface contaminations and residual oils from the parts, thereby fully complying with the strict cleanliness production standards of medical and food industries.
Q8: Is it possible to upload our custom 3D STEP drawings to LS Manufacturing for a quick DFM evaluation?
We allow you to upload various 3D drawing formats like STEP, IGS, and DXF. So you can upload your drawings to get accurate quotations. Once the order is confirmed, our skilled stamping engineers will offer a complimentary professional DFM manufacturability analysis report within 24 hours, enabling clients to rapidly realize their projects.
概要
One cannot rely on experience alone when it comes to stamping 304/316L stainless steel. Simulation backed by data and a set of standards in the production can very effectively handle the typical problems of springback, roughening, and cracking in the stainless steel during stamping. Outsourcing professional stainless steel stamping can change the game in quality and more stable production and at the same time lead to cost reduction and higher efficiency of operation in the scenarios of high-end manufacturing while at the same time provide solutions to the core problems of the mass production process.
In case you face 304 and 316L stamping manufacturing process bottlenecks or need supplier replacement, we are also able to provide you with technical support to be exact tailored to your needs. Upload your CAD/3D drawings and get free DFM analysis and mass production price quotations within 24 hours, book a one-on-one technical consultation, and have your very own stamping solution tailored to your needs.
The contents of this page are for informational purposes only. LS Manufacturing services There are no representations or warranties, express or implied, as to the accuracy, completeness or validity of the information.サードパーティのサプライヤーまたはメーカーが、LS Manufacturing ネットワークを通じて性能パラメータ、幾何公差、特定の設計特性、材料の品質およびタイプまたは仕上がりを提供すると推測すべきではありません。 It's the buyer's responsibility. Require parts quotation Identify specific requirements for these sections.Please contact us for more information.
LS 製造チーム
LS Manufacturing は業界をリードする企業です。カスタム製造ソリューションに焦点を当てます。 We have over 20 years of experience with over 5,000 customers, and we focus on high precision CNC machining, Sheet metal manufacturing, 3D printing, Injection molding. Metal stamping,and other one-stop manufacturing services. Our factory is equipped with over 100 state-of-the-art 5-axis machining centers, ISO 9001:2015 certified.当社は、世界 150 か国以上のお客様に、迅速、効率的、高品質の製造ソリューションを提供しています。少量生産でも大規模なカスタマイズでも、24時間以内の最速納期でお客様のニーズにお応えします。 LSマニュファクチャリングを選択します。 This means selection efficiency, quality and professionalism. To learn more, visit our website:www.lsrpf.com
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