Resources
METALFORMING TIPS BLOG
Practical Tolerances for Short Run Metal Stampings
Practical tolerances for our Short Run Metal Stampings vary according to the design of the part. Generally, all dimensional tolerances compared to costs can be illustrated by the following diagram “A”. Reading from right to left, we illustrate that within the more generous limitations, the cost increases slowly—but, as the
Dimensioning Practices for Press Brake
Practical experience has proven that dimensioning and measuring practices must both be understood and agreed on by all parties to achieve a workable, mutual standard. Formed sheet metal parts present a unique problem in that angular tolerances as well as the flatness conditions interact with single plane dimensions because of
![How to Calculate Tonnage [FREE FORMULA]](https://daytonrogers.com/wp-content/uploads/2021/12/Worker-at-manufacture-workshop-operating-cidan-folding-machine-300x150.jpeg)
How to Calculate Tonnage [FREE FORMULA]
The Tonnage Formula is the pressure required in tons to cut a blank or contour using a flat faced punch with no shear. Tonnages can be calculated for forming, bending, cutting, drawing, and blanking operations. Having the ability to calculate the tonnages for a sheet metal project is vital for
The Minimum Bend Radius for Aluminum
When working with aluminum over sheet metal, several variables need to be considered. Aluminum is typically thicker and stronger, and requires more force to bend as well as consideration of edge conditions and punch nose radii. This free chart outlines what bend radii is required for the approximate thickness of aluminum. We recommend printing
How to Position the Metal Form
The position of the metal form is vital for the success of your project. Diagram “A” illustrates a design that is not desirable for quality or economy. When the form is inside the blank profile, as shown, the material must be torn through the stock thickness and the bend radius.
3 Ways to Improve Edge Conditions
During shearing and punching, there are a number of factors to keep in mind to improve edge conditions. On ferrous materials, the clearance between punch and die should be about 8% to 10% of the material thickness, which may vary due to hardness and thickness. The punch and die clearance
How to Pierce Round Holes in Metal Stampings
Many metal stampings require holes, but there are several considerations when choosing where to place a hole and how to pierce the hole. To pierce holes with economical tools and operations, the hole diameter must not be less than the stock thickness. If the hole diameter is less than the
How to Prevent Fractures in Metalforming
Distortions are sometimes unavoidable while metalforming, but if youre you are encountering fractures in your metalforming pieces, there are a few steps you can take to prevent them. The illustration below shows a fracture condition that occurs when the burr side of the blank is on the outside of the
Dayton Rogers Turns 90!
This year, Dayton Rogers turns 90! In 1929, Dayton A. Rogers founded a new manufacturing company and altered the business of metal manufacturing forever. 90 years later, his legacy continues as Dayton Rogers impacts the world of manufacturing with its innovations now and into the future. Our Timeline 1923: Dayton
FAQ's
Resources/Blog
Yes. Our CEO, Stephanie Lowry, recently joined the Destiny of Manufacturing podcast to discuss “The Road to 2030.” We provide insights on how Artificial Intelligence (AI) and preventative maintenance technologies are transforming the metal forming industry, helping you understand how to leverage these advancements for more reliable supply chains.
You can request a physical or digital copy of our industry-standard design guides by completing the online request form on our website or by emailing us directly at info@daytonrogers.com. These books provide essential formulas, tolerance charts, and “Do’s and Don’ts” for engineers designing stamped and fabricated metal parts.
We offer detailed technical articles explaining the trade-offs. Generally, Short-Run Stamping is best for prototypes and low volumes (minimizing tooling costs), while Progressive Die Stamping is ideal for high-volume production (lowering piece-part price). Our blog breaks down the break-even points and tooling implications for each.
Yes. Our resources include guides on rapid prototyping strategies, helping you move swiftly from concept to reality. We explain how to use laser cutting and soft tooling to validate designs quickly before investing in hard production tooling, ensuring your product is market-ready faster.
Our blog features technical deep-dives into Deep Draw Stamping , covering critical design considerations like draw ratios, corner radii, and material selection. These articles help engineers understand the unique capabilities and constraints of creating seamless, 3D metal shapes.
