The manufacture of stamped handwheels usually involves a metal stamping process. Metal stamping is a manufacturing process in which metal is formed into a specific shape through the application of high pressure and tension. In a stamping operation, metal (usually in the form of sheet, strip, or coil) is formed into a specific shape between dies by shearing, pressing, and stretching at room temperature. This process may require a single-station linear mold or a 40-station progressive mold. This is undoubtedly the most important step in determining the success of your stamping operation.
A stamping die is typically a one-of-a-kind, custom-designed tool. Unlike store-bought items, there are no instructions for assembly, operation, and maintenance. If any of these factors are not performed correctly, it can result in catastrophic tooling and stamping failure.
Before you begin the process of designing and building a mold, you must determine whether the part in question can be manufactured using metal stamping. Many parts have dimensional and tolerance characteristics that cannot be manufactured using traditional stamping processes and must be manufactured using alternative methods, such as casting followed by machining to specified tolerances1. Being able to look at a part and determine if it can be stamped takes years of experience. And, just because a part can be made with stamping, doesn't mean it should be. Metal stamping dies are often used to produce very large part quantities1. For low part counts, sometimes it makes more sense to use lower-cost methods to produce parts, such as press bending, welding, and machining.
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