3 Ways To Optimize Progressive Die Design For Material Use Efficiency

The stamping industry has come a long way since its inception. Various technologies and design methods are available nowadays, but earlier, the same process used to be done by the hammer only. The technological advancement in the stamping world has increased efficiency and production, plus it also reduces the production cost.

One such design which is gaining a lot of attraction is the progressive die design. It is the procedure that performs more than one operation in a single stroke. This die delivers the end product in a single stroke.

Let’s understand in detail all about the progressive die design and progressive die press.

A Brief Overview of Progressive Die Stamping

It is a metalworking process commonly used in industries including automotive, electronics, and appliances to make parts. Progressive die stamping comprises multiple working areas, each conducting one or more procedures on the component. The inventory strip transports the component from point to point, and the finished component is cut out of the strips in the end process.

Process of Starting a Progressive Die Design

The procedure for progressive die design typically goes like this: the first thing is when the users send the print of the part to the manufacturer. Various designing software generates the print. The die manufacturer starts by making a flattened blank from the component drawing or Cad data and orienting it to maximize material consumption while taking texture and cam access into account. It is essential to determine the kind and numbers of die terminals, attach the component carriers, and design the die architecture and features. Much of this labour is now automated thanks to modern die design tools.

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Role Of Progressive Die Press

In progressive die stamping, the machine uses an automatic calibration mechanism to transmit a metal strip throughout every stamping point. Every station operates more than one process for the component production process in the progressive die design. The last station then performs a cutoff procedure, separating the finished portion from the conveying web. The conveying web is scrapped, together with a metal cutaway in prior activities.

 

Ways to Optimize Progressive Die Design

To optimize the progressive die design, you should keep a few things in mind that will help alleviate all the issues that can affect it.

1.     Material

The very thing which can affect the progressive die design is the material.

Its construction depends significantly on the kind, quality, and width of the metal sheet. Manufacturers can deduce the type of material and thickness from the component design. They must comprehend how different material qualities affect die design. The material affects the results.

2.     Press

The second thing which affects the design is the lack of knowledge about progressive die presses. Die manufacturers must comprehend the difference between a centred ‘load’ and a centred ‘die.’ Loads dispersed irregularly over a press slide allow the slides to tip and travel laterally in the area of the highest force in a stamping die. A load that isn’t centred beneath the press ram can cause essential die tolerances to change. Tough wearing or injury can happen if this change happens while punches are involved with other die elements. Quick die wear raises die-maintenance expenses and jeopardizes stamped component structural accuracy.

3.     Methodology

Lastly, the methodology also plays a crucial role in progressive die design. The methodology’s primary goal is to ensure that the design was well-organized throughout its development to be successful. One wrong move can affect the whole procedure. That’s why designers must opt for the right technology and methods that can fasten up the product and reduce the efforts.

Various modern techniques are employed in sheet-metal forming procedures nowadays. The overall goal is to lower costs, the time it takes to produce, and the punch’s lifetime.

That’s it! Progressive die design is the fastest and widely known method for component manufacturing. This procedure can produce around 7- 8 parts every minute. That’s why it is best suited for bulk production. Not just this, it is one of the cost-effective methods that are suitable for a variety of applications because of their close tolerances.

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