Progressive dies are compounding tools utilized in a die press for carrying out multiple processes. It performs tasks like punching, coining, stamping, drawing, and bending. All these are carried out in a single motion or minimal successive processes.
How to create a progressive die design and its process?
A manufacturing unit using progressive die stamping is dependent on two prominent factors-
- Production volume of the part
- Complexity and operational processes
These factors determine whether you require a progressive die, ensuring desired quantity in the given time.
An optimal progressive die design ensures high-quality parts and longer tool life.
Prominent factors to consider before designing optimal progressive dies
One must consider the following four stages before designing a progressive die.
Part orientation
One has to arrange the part orientation by rotating it to make a better and more cost-effective strip design. The orientation of the part also determines the way it will pass from the die.
Similarly, the grain direction is also prominent, as it determines the part strength. It is advisable to arrange bending perpendicular to the direction of the grains. This way, the metal does not undergo fatigue or cracking.
Ways to carry the part
It is essential to carry the part in the strip for optimal die feeding. The process results in standard and high-quality end-products. The process involves three options.
Option 1: One can carry the part most easily by carrying parts with the scrap in between. In this way, one can make savings on the scrap material.
Option 2: The next option involves carrying the part on the strip side. It is a difficult process and one has to lift the strips from the center.
Option 3: The ladder option is another way to carry the part as it is suitable for complex parts or ones that require a high lift.
Piloting
It is another prominent factor in progressive die design. It ensures that parts get fed at a considerable rate. The pilot hole must have sufficient tolerance as a minor strip elongation can result in rejection of the part. The operation is performed on a part with holes in the cash, and piloting takes place on the scrap part.
Progression or stage numbers
After piloting, the next step is to determine the number of progressions that happen successively. It is essential to create the strip layout and define the station numbers. These stations define the part’s strength, and one must avoid idle stations.
Final thoughts
The above factors determine a good-quality die design. A progressive die design and accurate process are required to manufacture a high-quality and affordable die. To produce a complex design, one has to be more precise with these steps and follow the fundamentals. Accurate evaluation of these parameters results in an optimal and strong feed die one can easily maintain. The die results produce high-quality and consistent parts that meet customer requirements.
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