Progressive die manufacturing uses a single die that performs a series of metal stamping operations ranging from cutting and forming operations. As the metal sheet goes through these operations, it transforms into the desired shape and size.
Since it allows more than one metal stamping operation in one go, manufacturers prefer progressive die manufacturing to create complex parts of small and medium sizes at large scales. It is also known for creating custom metal parts for critical applications like the medical and oil and gas industry.
However, like any other metal part manufacturing process, the output quality from progressive die stamping services depends significantly on its die design.
Therefore, in this article, you will get some tips to create a pitch-perfect progressive die, and the advantages of using high-quality progressive die design for manufacturing complex and simple metal parts for various industries.
Tips for a pitch-perfect progressive die design
As already mentioned, progressive die design holds a critical role in the success of the progressive die stamping process. It ensures maximum throughput and minimal waste.
Here are some tips that ensure pitch-perfect progressive die design
- Optimize the Metal Sheet Design
The first step is to understand the metal part features, and the bend and folding capabilities of the metal sheet. Using this knowledge, manufacturers decide how to design associative intermediate metal stamping operations.
- .Create a strip layout
Next, an optimized workflow with a proper strip layout where the designers clearly define the progression of each design stage.
- Take care while choosing the carrier type and width
A carrier carries the metal part and hence it must be appropriately placed to minimize the need for the additional metal sheet to complete the progressive die stamping process. The ideal carrier width is around twice the thickness of the worksheet.
The common carrier types are center carriers, one-sided carriers, and outside carriers. Selection of the carrier type depends on the geometry and size of your metal part.
- Consider appropriate feed height.
A good feed height ensures the perfect orientation of the metal strip, as there is enough room to lift the metal pieces during the progressive die-stamping process.
- Avoid sagging between lifters.
Sagging is one of the reasons why metal parts fail to match the design guidelines. Therefore, metal lifts between each station in progressive dies should not have sags between the lifters.
- Choose the right number of pilots
The number of pilots plays a crucial role in producing accurate end-products as it in a depends on the carrier and work material.
Advantages of Progressive Die Design for Manufacturing
A good progressive die design includes the right sequence from start to finish of the metal stamping. It could either be the multi-project or multi-die in the same die. Whatever the arrangement may be, the right design turns progressive die highly beneficial for manufacturing in the following ways:
- Adjustable Production Speed
The production speed of progressive die is quite high. It can go as high as 1000/min. When compared to other die-stamping methods, it has a high production speed. This speed is adjustable to suit the number of parts required.
- Ease in managing projects
An efficient progressive die design translates seemingly complex metal part production projects into a simple system by arranging the operations at a different workstation. It keeps the fagile part of the die from being a disruptor in adding life to the machines.
- Fewer scrap
Progressive die processing produces much fewer straps than other of its contemporary metal stamping techniques. With an ideal step pitch of around 0.8mm, it can save material and increase the utilization of resources to produce top-notch metal parts that adhere to the design.
Progressive die stamping has become automatic in more than one way. It has eliminated the need for manual processing operation, which has reduced the human contact and improved the safety of the process.
- Ability to create complex geometries:
As mentioned earlier in the article, progressive dies are a preferred metal fabrication technique, especially for those with complex structures. With technological advancements, it can design progressive dies in a way that matches the part’s geometry.
- Faster setup:
Automation dominates most of the progressive stamping process. Automated progressive dies takes much less time to set up and produce results. Comparing progressive die stamoing to the conventional stamping methods, it is clear that the former is highly popular metal fabrication technqiue for complex parts at a better speed.
Progressive die stamping allows simultaneous multiple cutting and forming operations, which makes it an ideal choice to create metal parts for various industries like Automotive, Electronics, Aerospace, Agriculture, Oil and Gas, Medical, and many more. With the right design, progressive dies offer benefits that are listed in the article.