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Diameter 3/8“, 2 sec. cycle time, flattening at 360,000 lbs, left and right version, series runs from 20,000 parts, finished part falling out, power requirement approx. 30 kW

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Flattening and punching

While manufacturing metal parts, several forming processes are required to achieve the desired results. This becomes especially relevant if we consider the simple shape and profiles of raw materials such as sheet metal and metal wires. For example, if you need a part with a round profile but also with a flat section, the best course of action often would be to get a metal wire and flatten the section you want to be flat.

What is flattening?

As the name suggests, it is the process of taking something with a round profile, like a metal wire, and making it flat. This can be done manually by hammering the wire, but a better result is usually achieved by means of a press in a cold forming process.

The application of this process is to allow for a change of profile in a given section of the part, moving from a round profile to a flat one for example.

What is punching?

Punching is a manufacturing process which is used to remove a part of the material with a specific shape and specific dimensions by means of a punch press. The shape and dimensions are defined by the tool used, which is called the punch. It is usually performed on sheet metal or metal strips, but it can be performed on any part with a flat section like the ones mentioned before. It is commonly used to create holes with specific diameters for assembly purposes.

Flattening and punching with Schmale machines

Traditionally, each process is performed independently, and they require specific tooling and operators for each of them. Of course, these requirements result in higher costs and reduced efficiency, which in turn means less productivity, a longer time to market and lower profitability.

To avoid the negative aspects of the activities described before, Schmale machines provide automated solutions that integrate flattening and punching with other required processes such as marking, bending, swaging and threading into the same production cycle.

Schmale automated solutions can flatten wire with a diameter of up to 1″ and then punch the flat section in the same production cycle. The entire cycle takes only a few seconds, and the wire automatically moves through the different processes to generate the expected results.

Series runs begin at 20,000 parts, which clearly represents an enormous increase in efficiency and productivity and a significant reduction in the time to market, meaning that the profitability of your business will be higher.

To have a better view of the process please refer to the pictures and videos.

If you are looking for flattening and punching solutions integrated in a fully automated production process, or you have any further questions, please do not hesitate to contact us and we will gladly help you.