In the metal stamping process, progressive die stamping completes many steps sequentially through a number of stations, such as punching, blanking, bending, trimming, drawing, and so forth. Progressive die stamping has various advantages over similar methods, including quick setup times, high production rates, and part position control during the stamping process.
Progressive die stamping creates distinct features with each punch to produce the final product by constantly feeding the web through a press into several die stations.
1. Scroll for Materials
To feed the material into the machine, load the corresponding roll onto the reel. To engage the coil, the spool enlarges on the inside diameter. After unrolling the material, the reels revolve to feed it into a press, followed by a straightener. This feed design allows for “lights-out” manufacturing by producing high-volume parts over an extended period of time.
2. Area of preparation
The material can rest in the preparation section for a short while before being fed into the straightener. The thickness of the material and the press feed rate determine the preparation area’s dimensions.
3. Straightening and leveling
A leveler flattens and stretches the material into straight strips on the reel in preparation for stamping items. In order to manufacture the desired part that complies with the mold design, the material must go through this procedure in order to correct various residual deformations caused by the winding configuration.
4. Constant nourishment
The material’s height, spacing, and path through the mold station and into the press are all regulated by the continuous feed system. In order for the press to arrive at the mold station when the material is in the proper position, this crucial step in the process needs to be precisely timed.
5. Station for molding
In order to make it easier to create the finished item, each mold station is inserted into a press in the proper order. When material is fed into the press, it simultaneously affects every mold station, giving the material properties. The material is fed forward as the press raises for the subsequent hit, allowing the component to constantly travel to the following mold station and be prepared for the press’s subsequent impact to develop features.As the material moves through the die station, progressive die stamping adds features to the component using several dies. New features are trimmed, chopped, punched, kerfed, bent, grooved, or sheared into the part each time the press arrives at the mold station. To enable the part to move continuously during the progressive die stamping process and achieve the final desired configuration, a strip of metal is left along the center or edge of the part. The true key to progressive die stamping is designing these dies to add features in the right order. Based on their years of experience and engineering knowledge, toolmakers design and create tool molds.
6. Finished components
The components are forced out of the mold and into ready-made bins via a chute. The part is now finished and in its final configuration. After a quality check, the components are ready for further processing including deburring, electroplating, processing, cleaning, etc., and are then packaged for delivery. Complex features and geometries can be produced in large quantities with this technology.
7. Scrap There is scrap from every mold station. To cut the total cost of parts, design engineers and toolmakers work to minimize scrap. They accomplish this by figuring out how to best arrange components on roll strips and by planning and setting up mold stations to minimize material loss during production. The waste produced is gathered in containers beneath the mold stations or via a conveyor belt system, where it is emptied into collection containers and sold to scrap recycling companies.
Post time: Mar-24-2024