Process of designing a progressive die:
The process of designing a progressive die stamping begins with the decision of making sure that the part is run efficiently throughout on the press till it reaches the final station. Also, it is determined by the production volume, the complexity, the size and the intricate design and construction of the part. Other factors that require attention is the quality of the part, the life and maintenance of the part which plays a major role in the designing process. The designer then follows a definite outline or specification while deciding on the construction of different progressive die components, like the shape and the size of the part. This stage of planning is very important because if the design is haphazard then the entire operation will go for a waste which will result not only in time loss but will effect the cost too.
Progressive Die Stamping:
Progressive die stamping is a process in which a metal sheet or strip unrolls itself automatically from a coil and is fed through a feeder. This feeding system feeds the material or the metal strip through progressions, which means that the metal strip unrolls itself and moves forward to different stations to complete the given task. The progression includes various stations which meets the requirement of the part of production and it also has a fixed given distance between each stations, all the way through till the end of the finished part. In progressive die the part that is designed moves gradually from station to station and at the end of the finished product, the part is cut off from the metal strip to its final completion.
Progressive die Components:
In progressive die as the feeding system moves the metal strips towards the final station there are many various methods of stamping techniques used like trimming, bending, forming and coining. During this process all kinds of different stamping operations take place while the press moves up and down in a systematic manner. At the end station the final finished part is then cut and removed from the die and the metal strip is then placed in scrap bins which can be recycled for later use.
Metal used for Progressive die:
Progressive die is made from tool steel as it is the best for making any kinds of tools. The amazing feature of this metal is that due to its distinctive hardness this metal can withstand high shocks, resist the abrasion and distortion of the metal. It can also very beautifully hold on to the sharp cutting edges even at intense temperatures. Hence, tool steel perfectly suits progressive die stamping as it can be easily used for shaping, cutting, coining and pressing metals.
Benefits of progressive die stamping:
- High volume production: Progressive die is often utilized for the production of high volumes. Since there is a continuous feed of the metal strip on the press it enables to produce the parts more quickly and reduces the time spent in manufacturing each part.
- Fast Operation: With progressive die the operation can be performed in just one setup which reduces the overall cost of the part. Also, as it functions at a higher speed rate it helps in reducing the setup time.
- Low wastage: Progressive die is a metal stamping method which uses various kinds of stamping techniques like punching, trimming, bending and so a major part of the metal strip is used for achieving the final part. Hence, there is a very low wastage.
- High Quality: In producing the parts, progressive die maintains high quality standards which means there are very few parts that actually gets deformed or damaged.
Progressive die stamping can at times be more expensive to manufacture because it depends on the complexity and intricate designing of the parts. So, the more complex the design of the part is the more precise and accurate the manufacturing methods has to be, which adds to the overall cost. Hence, it can be concluded that progressive die is versatile and can
