Causes of Sheet Overlap in Stamping and How to Solve It

During stamping processes, sheet overlap (double-feed) can be a troublesome issue that affects production. Below we examine common causes and solutions.

Why does overlap occur?

1. Material issues: uneven surface roughness or inconsistent hardness can cause irregular deformation during stamping and lead to overlap.

2. Die design: improper die structure, incorrect die opening design, or excessive punch wear can prevent correct material guidance and cause overlap.

3. Press adjustment: incorrect press parameters or punch misalignment can produce overlap during stamping.

4. Operator errors: insufficient operator skill or non-standard operation may also contribute to overlap.

How to solve overlap?

1. Optimize material selection: choose stable-quality materials with uniform hardness and good surface finish.

2. Improve die design: optimize die structure and openings, and regularly inspect and maintain punches.

3. Adjust press parameters: set parameters correctly and ensure accurate punch positioning.

4. Strengthen operator training: raise operator skill levels and standardize procedures to reduce errors.

If the issue persists, use a sheet overlap detector (double-sheet detector). Install the detector at the robot feeding stage so sheets are checked before entering the die: single sheets proceed, while detected overlaps immediately send a signal to the controller for handling, preventing die damage and material waste.

Atonm specializes in research and manufacturing of metal sheet overlap detectors. With a mission to empower smart manufacturing through sensor technology, the company has a team of experienced engineers and holds over 20 patents. Atonm products and solutions are used across automotive parts, home appliances, lithium batteries, PCB, 3C, metal canning and packaging industries, serving 2000+ customers including BYD, CATL, Tesla and Midea.