How to Achieve High Consistency and Burr-Free Edges in Metal Special Plate Stamping of Hardware Parts?
Publish Time: 2025-12-04
In high-end manufacturing fields such as electronic devices, consumer electronics, communication modules, and medical instruments, metal special plates made of stainless steel, copper alloys, titanium alloys, and nickel-based alloys are commonly used as raw materials for stamping of hardware parts. While these materials possess excellent conductivity, corrosion resistance, and biocompatibility, their high strength, high elastic modulus, and work hardening characteristics also pose significant challenges to stamping—especially in mass production. Achieving both high dimensional consistency and burr-free edges simultaneously has become a core indicator of process quality. This not only affects product assembly accuracy but also directly impacts electrical performance, sealing, and user experience.1. Material Properties and Process Matching: Source Control is KeyThe material condition of the metal special plate directly affects stamping performance. For example, if ultra-thin stainless steel strips have excessively high hardness, they are prone to producing high tear bands and burrs during shearing; while if the oxygen content of copper alloys is not properly controlled, micro-cracks may form at the stamping edges. Therefore, it is necessary to strictly select material grades, thickness tolerances, and mechanical properties according to the functional requirements of the parts, and to perform necessary leveling or stress-relieving annealing treatments before stamping to reduce the risk of springback and cracking, laying the foundation for subsequent high-consistency forming.2. Precision Die Design: Micron-Level Clearance Determines Edge QualityThe blanking clearance is the decisive factor affecting burr height. For special metal sheets, the ideal clearance is usually 3%–8% of the material thickness, and specific optimization needs to be achieved through experimentation. Too large a clearance will lead to an expansion of the tensile tear band, forming high burrs; too small a clearance will exacerbate die wear and may even cause "secondary shearing," resulting in double-layer burrs. High-end stamping dies generally adopt high-precision slow wire EDM machining, with an edge roughness of Ra 0.2μm or less, supplemented by a nano-coating to improve wear resistance and demolding performance. Furthermore, using stepped blanking, oblique blanking, or silent blanking structures can effectively disperse impact force, reduce vibration, and further suppress burr formation.3. Precise Control of Stamping Parameters: Synergistic Optimization of Speed, Pressure, and LubricationExcessive stamping speed can lead to excessively high local strain rates in the material, causing brittle fracture; excessively slow speeds prolong plastic deformation time, increasing the risk of mold sticking. For special metals, servo presses are often used instead of traditional mechanical stamping presses, enabling flexible programming of the slide movement curve—low-speed, high-precision operation during the shearing stage and high-speed reset during the return stage, balancing quality and efficiency. Simultaneously, the use of specialized micro-lubricants or dry lubrication films reduces the coefficient of friction, prevents material adhesion to the mold, and avoids oil contamination of medical or electronic components requiring high cleanliness.4. Process Monitoring and Automated Inspection: Ensuring Batch ConsistencyHigh consistency relies not only on the quality of a single stamping operation but also on stable control throughout the entire process. Modern stamping production lines generally integrate online vision inspection systems to scan each product in real time for key parameters such as edge burr height, hole offset, and flatness. If any parameters exceed a set threshold, the product is automatically rejected and an alarm is triggered. Meanwhile, through mold temperature monitoring, stamping pressure feedback, and automatic compensation mechanisms, process parameters are dynamically adjusted to offset deviations caused by material batch fluctuations or mold wear, ensuring the consistency of tens of thousands or even millions of products.5. Post-processing Assistance: The Last Line of Quality DefenseAlthough process optimization can significantly reduce burrs, for ultra-high-requirement scenarios, lightweight post-processing is still necessary. Non-contact technologies such as centrifugal grinding, magnetic polishing, or plasma deburring can thoroughly remove micro-burrs without altering part dimensions, while simultaneously improving surface finish and fatigue resistance.The high consistency and burr-free edges of stamped hardware parts on metal special plates are not the result of a single step, but rather a manifestation of the deep integration of materials science, mold engineering, equipment control, and intelligent detection. Only by pursuing excellence in every micrometer, every millisecond, and every stroke can these "invisible parts" silently support a reliable, safe, and precise future in high-end equipment.
