Aluminum coil strip is a versatile raw material, widely used in a variety of molding operations. These include stamping, drawing, rolling forming, extrusion, etc. Due to its light weight, thermal conductivity, corrosion resistance, recyclability and processability, aluminum is the material of choice for many manufacturers. Let's take a look at some of the more common aluminum molding methods:

stamping

Stamping of aluminum billets is one of the most common manufacturing processes. This process uses a press and die to form an aluminum strip. There are many stamping methods on the market now. They can be classified by the type of press, tool and process used for stamping parts.

Four-slide stamping - A four-slide stamping press is a simultaneous use of four tools to form and bend aluminum in multiple ways and directions, all in one step.

Fine stamping - is a special type of stamping used when producing parts that require very good flatness and fully cut edges.

Progressive die stamping - This type of stamping feeds the strip through a variety of different sequential "stations", each of which performs a different part of the strip required to form. When the part is moved between stations and subsequently formed, the part remains attached to the original strip until it reaches the final station where the part is finished.

Transfer die stamping - similar to progressive stamping, but the transfer stamping press does not leave the part attached to the strip. They can be one or more continuous molds, with parts moved in steps by a delivery system.

draw

In the simplest terms, drawing refers to the use of a press to force metal through a mold or die to displace, forming a stretched shape. Forcing the flat metal to form a mold shape causes cold working to occur. This allows the shape to remain when removed from the mold. Keeping shape is crucial. If the amount of deformation in one step is too large, the aluminum will split or shear. For deeper or more complex shapes, use small stretches in multiple stages to gradually produce the complete shape.

Tensile aluminum parts are deeply drawn

In general, any metal shaped finished part whose height exceeds its width can be considered deep drawing. "Deep drawing" is achieved by re-stretching the shape with a series of gradually deepening molds. Successful deep drawing requires extreme precision and a careful balance of forming load, bending force, punching radius, wall thickness, lubrication, and many other variables.

Roll forming

Roll forming is an operation in which an aluminum strip is continuously bent through a long series of rollers to further the strip into the final desired shape. The rollers are precisely positioned so they can remain bent and form bands a little further away, making only a small change from the shape of the previous roll set. Rolled parts are usually "long and thin".

Aluminium extrusion

Extrusion is the process of using a strong impact pressure to force the mass of an aluminum alloy through a mold of a specific shape. This causes the metal to form a mold shape and be pushed out in a long form running table.

cast

This process is somewhat different from what we have already discussed. By casting, molten aluminum is poured into a mold or cast to make components. Similar to stamping, casting can be further classified into:

Sand casting - Here, the mold is created from a sand mixture. It is ideal for prototypes and short runs.

Aluminum auto parts casting die casting - This method is similar to injection molding, but uses molten aluminum instead of plastic or rubber. It is a high-pressure process that is ideal for high precision, or shorter runs on complex or detailed parts.

Permanent die casting (aka gravity die casting)- This process uses reusable metal molds into which molten aluminum is poured. The parts it produces have strong mechanical properties and can be used for middle and long distance running.

Investment casting (aka wax casting)- The use of wax models to coat ceramics. The wax is then melted, leaving a cavity for the molten aluminum to infuse.

As you can see, aluminum strips are very versatile and used in a wide range of manufacturing processes. The exact method and choice will depend on the geometry of the part, the complexity, the size of the run and other factors. Similarly, the type of aluminum or aluminum alloy used will depend on the desired properties of the part, including strength, weight, finish, etc.