Deep drawn components are products made using the deep drawing process. When sheet metal is pulled or stretched into a die to create a desired shape, we need to have a very profound understanding of its properties and behavior to predict the outcome accurately. Basically JCL has two parts of analysis which are materials and shapes, materials thinking will help us evaluate the feasibility in the first step and shapes thinking is more likely to justify the design and forming process.
JCL has an extensive material database that records the characteristics and specifications of different metal materials. By understanding this data, we can conduct early cost assessments, feasibility analyses, tool designs, and equipment selection. Additionally, during production, we leverage our knowledge of these metal processing techniques to minimize defects, control production costs, and enhance efficiency. Material selection is crucial in the project, influencing its success or failure.
Sheet Metal is the most commonly used raw material form at JCL, with common thickness ranging from 0.5 millimeters to 6 millimeters. Anything thinner than 0.5 millimeters is called metal foil, and anything thicker than 6 millimeters is called metal plate. These distinctions cater to different industry needs; for example, the electronics industry often prefers sheet metal below 3 millimeters, while the automotive and aerospace industries commonly use sheet metal above 4 millimeters. The choice of thickness depends on practical considerations like strength, structure, weight, and cost.
When evaluating sheet metal thickness, we introduce a measurement standard known as gauge thickness system. This standard defines the thickness of metal sheets, and you can convert it to obtain the weight per unit area. Gauge thickness predates the commonly known metric and imperial measurement systems. Different countries have their own systems with varying data, but we can convert between these systems. Here are the corresponding data for gauge thickness in inches and millimeters for some common materials.
Gauge | Carbon Steel | Aluminum | Stainless Steel | Brass | Copper | |||||
in | mm | in | mm | in | mm | in | mm | in | mm | |
7 | 0.1793 | 4.554 | 0.1443 | 3.665 | 0.1875 | 4.763 | 0.1443 | 3.665 | 0.18 | 4.572 |
8 | 0.1644 | 4.176 | 0.1285 | 3.264 | 0.1719 | 4.366 | 0.1285 | 3.264 | 0.165 | 4.191 |
10 | 0.1345 | 3.416 | 0.1019 | 2.588 | 0.1406 | 3.571 | 0.1019 | 2.588 | 0.134 | 3.404 |
12 | 0.1046 | 2.657 | 0.0808 | 2.052 | 0.1094 | 2.779 | 0.08081 | 2.053 | 0.109 | 2.769 |
14 | 0.0747 | 1.897 | 0.0641 | 1.628 | 0.0781 | 1.984 | 0.06408 | 1.628 | 0.083 | 2.108 |
18 | 0.0478 | 1.214 | 0.0403 | 1.024 | 0.05 | 1.27 | 0.0403 | 1.024 | 0.049 | 1.245 |
20 | 0.0359 | 0.912 | 0.032 | 0.813 | 0.0375 | 0.953 | 0.03196 | 0.812 | 0.035 | 0.889 |
22 | 0.0299 | 0.759 | 0.0253 | 0.643 | 0.0312 | 0.792 | 0.02535 | 0.644 | 0.028 | 0.711 |
24 | 0.0239 | 0.607 | 0.0201 | 0.511 | 0.025 | 0.635 | 0.0201 | 0.511 | 0.022 | 0.559 |
28 | 0.0149 | 0.378 | 0.0126 | 0.32 | 0.0156 | 0.396 | 0.01264 | 0.321 | 0.014 | 0.356 |
30 | 0.012 | 0.305 | 0.01 | 0.254 | 0.0125 | 0.318 | 0.01003 | 0.255 | 0.012 | 0.305 |
In addition to sheet metal, there's another common material form known as metal strip. Metal strip width is determined to be narrower than 24 inches (around 610 mm). Unlike metal sheets with relatively fixed length and width, the length of metal coils is much greater than the width. Metal coils are more suitable for continuous feed production methods like progressive die stamping. This method offers much higher production efficiency compared to the single station stamping associated with metal sheets. When considering the dimensions of raw materials, you need to look at it from the perspective of machine capacity and material utilization. Too small raw material dimensions can lead to product defects, while excessive dimensions result in significant waste. Striking a proper balance is a necessary measure.
The cost of metal sheets can vary significantly based on several factors, including the type and grades of metal, thickness and size, and market conditions. Below are general factors that influence the cost of various metal sheets. Different metals have different costs. Common metals include:
Steel: Generally more affordable.
Stainless Steel: Higher cost due to corrosion resistance.
Aluminum: Moderate cost, lighter than steel.
Copper and Brass: Relatively higher cost, valued for aesthetics.
Titanium: Highest cost comparing materials above for availability and processing difficulty.
JCL has rich experience of making deep drawn parts in diverse shapes and structures. The basic shapes are fundamental of complexity, or in other words, complicated parts consist of duplication of simple shapes and features. We outlined some very basic shapes such as round, rectangular, cylindrical, tapered, reversed, miniature, they are very typical features you can find in deep drawn products, analyzing these shapes and understanding their forming principles enable your understanding of part feasibility, which will lead to a open and correct direction of your efforts. Here is some direct information about JCL common cases in terms of shapes and sizes.
Offered Shapes: Basic shapes in round, square, rectangular, cylindrical, tapered, reversed, miniature are available.
Size in Length & Width: Minimum 3mm to Max. 450mm in diameter and 500 mm in blank length; Length can reach 50m in metal coils feeding.
Sheet Thickness: Common materials specification is 0.01 mm to 5 mm; Super thin foil forming available to achieve thickness below 0.01mm.
Operative Precision: Our minimum blanking tolerances can reach 0.03mm without extra machining; Profile tolerances are measured to 0.015 mm on ultra punching headers; Blanking radius can be as small as 0.1mm. Deep drawn corner radii can be minimized to the lowest of 0.1 mm.
Production Volume: low volume prototype to over 1000000 parts in automotive business and 5000000 parts in consumer electronic business.
JCL is able to manufacture parts within these specifications, offering excellent quality and effective cost. We are driving deep drawing technology into a manufacturing method that allows for efficient production used in various industries.
Here are some typical dimensions to measure, common measurement instruments are optical measurement machines and coordinated measurement machines. OMM is a way of non-contact measurements that uses the projection to reflect the distance of the parts. CMM uses a probe attached that can be controlled along the X, Y, and Z in 3D. The probe is positioned at different points on the object and the coordinated distances of these points are recorded.
1. What are the common basic shapes that JCL specializes in for deep drawn parts?
JCL specializes in deep drawn parts with a range of basic shapes including round, square, rectangular, cylindrical, tapered, reversed, and miniature. These shapes cover a wide variety of applications and industries.
2. What is the maximum size in terms of diameter and blank length that JCL can handle?
JCL can handle deep drawn parts with diameters ranging from a minimum of 3mm to a maximum of 450mm. In terms of blank length, JCL can work with parts up to 500mm in length. For certain applications, JCL also has the capability to work with metal coils and feed lengths up to 50m.
3. What is the range of sheet thickness that JCL can work with for deep drawing?
JCL has the capability to work with sheet thicknesses ranging from 0.01mm to 5mm. Additionally, JCL is equipped to handle super thin foil forming, which allows for the production of parts with thicknesses below 0.01mm.
As you may find JCL expertise in material solutions and forming shapes evaluations. We are capable of dividing your requirements into these high technical areas and you will feel easily with our assistance and service. Cost and quality has a good balance under our evaluation and we are able to bring the analysis into your real outcome. Partner with JCL as your trusted metal stamping supplier in China, contact us and let’s start your sheet metal drawing project instantly with our delicate team.
We are excited to collaborate with you!
If you have any questions about our products or require custom machining services, please don’t hesitate to reach out to us. We are here to assist you and provide the solutions you need.
