Stamping Steel: The Art Of Steel Pan Making

Stamping a steel pan is a process that involves transforming a flat metal sheet into a specific shape. This is done through permanent deformation by cold forming to produce complex three-dimensional shapes. The process is carried out by tensile forces with a high ratio of surface area to thickness. Steel hand stamps are commonly used in this process, as they are versatile, long-lasting, and made from a special grade of tool steel to resist spalling and mushrooming. The stamping process typically begins by supporting the metal from underneath with a steel block or sandbag, marking the desired positions, and then using a hammer to strike the stamp and create the desired shape.

Stamping equipment

The basic equipment required for metal stamping includes:

• Metal stamps: letter stamps, number stamps, or design stamps.
• A stamping hammer: used to create the desired impression with the appropriate force.
• A stamping block or flat plate: provides a stable and sturdy surface for stamping.
• Metal blanks: different sizes of metal sheets to work on.
• Stamping tape: holds the metal blanks in place during stamping.
• Marker pen: used to mark the desired impression and enhance the final design.
• Polishing cloth: removes excess marker pen ink and highlights the impressions.

For industrial stamping, the process involves the use of dies to manufacture stamped parts. These dies consist of male and female parts that work in opposition, with the flat sheet metal placed between them. The hydraulic or mechanical press is then activated to deform the metal into the desired shape.

Additionally, for more intricate designs, 3D modelling software is used to create positive and negative dies. This ensures that the sheet metal fits perfectly during the stamping process.

Preparing the steel

Once you have selected the suitable steel for your pan, it is crucial to design and create a die. The die is a specialised tool that will shape and cut the steel into the desired form. You can use computer-aided design (CAD) software to create a 3D model of the die, ensuring that it is designed with your specific tooling in mind. This step involves determining the offset, which is the gap between the two halves of the die that allows the steel to fit during the stamping process. Incorporating the offset into your design ensures that the die forms the steel to the desired shape without cutting through it.

After designing the die, it's time to move on to the next step: Computer-Aided Manufacturing (CAM). Using CAM software, you can create tool paths based on your 3D model to guide the manufacturing process. This step involves determining the cutting strategy, including the type of end mill and the stepdown or stepover value, which will influence the smoothness and efficiency of the cutting process.

With the CAM programme set up, you can now start preparing the steel blanks. These blanks will be placed in the stamping press and transformed into the final product. It is important to ensure that the blanks are securely clamped or fixed in the press to prevent movement during the stamping process. Additionally, you may need to apply a thin coating of lubrication to the blanks to facilitate the forming process and improve the final outcome.

Before initiating the stamping process, ensure that your stamping press is properly set up and adjusted according to the requirements of your project. The press should be linked to an automatic feeder that moves the steel blanks through the press. Depending on the complexity of your design, you may need to use a mechanical, hydraulic, or mechanical servo press. Each type of press has different capabilities and advantages, so choosing the right one is crucial for achieving the desired outcome.

Stamping techniques

Stamping is a process used to transform flat metal sheets into specific shapes. It is based on permanent deformation by cold forming to produce complex three-dimensional shapes. There are two types of sheet metal stamping presses: hydraulic and mechanical. Both use "dies" to manufacture stamped parts. The "dies" consist of male and female parts that work in opposition.

• Ensure you have a sturdy and stable surface to work on. Use a stamping block or a flat plate to provide a secure and level base.
• Prepare your metal sheet by placing it on a steel block or a sandbag. Tape it down, securing the bottom without covering too much of the metal.
• Use a ruler and a marker pen to mark the desired positions of your impressions. This will guide your stamping and ensure accurate placement.
• Choose the appropriate hammer size based on the material and the number of characters you plan to stamp. For marking a single 1/4" tall character into mild steel, you'll need approximately 2.1 tons of pressure, which equates to a 3/4 to 1-1/4 lb hammer.
• Hold the stamp at a 90-degree angle on the metal sheet. Ensure that any logos or specific designs on the stamp are facing the correct direction.
• When striking the stamp with the hammer, apply medium force and strike only once. The speed and accuracy of the hammer blow are crucial.
• To enhance your design, you can use a marker pen or enamel ink to fill in the indentations and make the impressions stand out.
• For more complex designs, consider using a hand stamp holder for better control and safety.
• Always wear safety goggles or eye protection when using a hammer and marking with hand stamps.
• For more intricate designs or when working with harder metals, you may need to apply more force or use a harder strike.
• To create letters, patterns, or textures on pendants or earrings, you can use letter stamps, number stamps, or design stamps.
• To ensure even spacing and alignment, use a stamp guide. Write your desired message on the guide and use the guidelines to space out the letters or designs.
• Secure the metal sheet to the stamping block using tape or a stamp guide to prevent it from moving during the stamping process.
• If you are stamping multiple characters, the amount of striking force required will increase significantly.

By following these techniques, you can effectively stamp steel pans or create intricate designs on jewellery pieces.

Safety precautions

Stamping a steel pan can be a dangerous process if the correct safety precautions are not taken. Here are some essential safety measures to follow when stamping a steel pan:

Understand the Machine and its Operation:

Familiarize yourself with the sheet metal bending machine and its functions before using it. Read the instruction manual to gain a comprehensive understanding of the machine's operation, eliminating any potential accidents or mishaps. Consider seeking training from experienced individuals if you are a first-time user.

Warm up the Machine:

In cold weather, it is recommended to warm up the machine before use. Set the machine in motion and let it operate for a few minutes. This helps to achieve optimal results and prevents the machine from getting stressed.

Sheet Placement and Angle:

Always hold the sheet metal parallel to the bender before starting the bending process. Improper placement may cause the sheet to hit your body and result in injury. Ensure your hands are in a safe position and pay close attention to avoid severe accidents or permanent injuries.

Wear Protective Gear:

When working with sheet metal, always wear safety gloves to protect your hands from sharp edges. Wear safety goggles to shield your eyes from fine particles that may fly during the bending process. Additionally, wear work boots to prevent any scrap or pointed material from injuring your feet.

Handle Wet Metal Sheets with Care:

Wet metal sheets can be slippery due to the presence of moisture, dirt, and oil. Always handle them with caution to maintain a secure grip and prevent accidents.

Keep the Work Area Clean and Organized:

Maintain a tidy work surface by clearing away any scrap metal. A cluttered workspace increases the risk of injury, as sharp edges and debris can cause cuts or other hazards.

Avoid Running Your Hands Over Sharp Edges:

Even when wearing gloves, avoid running your hands over sharp edges or cut metal. This precaution helps prevent injuries, even with protective gear in place.

By following these safety precautions, you can help ensure a safe working environment when stamping a steel pan using a sheet metal bending machine.

Finishing touches

Once you have stamped your design, there are a few additional steps you can take to enhance the final product. Firstly, you can use a marker pen to rub over the indentations, which will help highlight the impressions and make them stand out more. A stamping enamel marker pen is ideal for this purpose. If you use a marker pen, you will then need to use a polishing cloth to buff away any remnants of the pen and create a clean finish.

If you are stamping multiple characters, it is important to note that the amount of striking force required will increase. Therefore, you may need to adjust the force of your hammer strikes or the type of hammer used. Additionally, always ensure that you only strike the stamp once and then pull the hammer away to avoid creating double or triple impressions.

Finally, remember to wear safety goggles or eye protection whenever using a hammer and marking with hand stamps to ensure your safety during the metal stamping process.

Frequently asked questions