Optimizing Progressive Stamping for Efficiency and Cost Reduction

Metal stamping creates simple or intricate metal forms out of sheet metal using pressure and well-crafted dies. Numerous different goods and components can be produced using this manufacturing technique. 

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A specialized area of industrial engineering called progressive stamping die design is concerned with creating tooling systems that can accurately and quickly produce complex metal components. 

Numerous industries have their roots in this methodology. Progressive stamping efficiency guarantees accuracy and effectiveness in every item created. Here mentioned are the optimizing progressive stamping for efficiency and cost reduction:

Make use of the tooling phase:

Since it lays the groundwork for all subsequent phases in your project, the tooling stage is among the most crucial. An experienced team will choose the optimal tooling design during this procedure to satisfy your requirements and guarantee improved output. 

By designing your product with secondary services and precision metal stamping in mind, you may avoid problems that cost you more money. Having the proper team on your side will reduce the likelihood of preventable errors and keep your expenses down while assisting you in optimizing your tools to sign and guarantee that your final product will meet the standards of your ultimate application.

Select the appropriate metal substances:

Many materials can be stamped with precision metal. However, some are more costly. When choosing the appropriate material for your project, you need to think about your budget and the specifications of the end use for your metal-stamped component.

Certain metal alloys are more resistant to the impacts of the environment than others, and certain selections could provide a degree of stiffness. Choose the material that will work best for your metal stamped part&#;s performance and usefulness while staying within your budget by consulting with your metal stamper. 

Speed and efficiency:

One of its most notable features is progressive stamping efficiency and exceptional speed at producing components. Several components are created with every press cycle because the process is continuous feed. 

This means that, depending on the design&#;s complexity, a stamping machine can produce thousands of components in an hour after it is set up. Moreover, the efficiency of the procedure is greater than the speed. 

Because many stamping stations operate simultaneously, tasks requiring multiple steps in other methods can be completed in a single pass. The entire production process is streamlined by this convergence of operations, which shortens the time it takes to go from raw materials to completed goods.

Stamping optimization techniques:

Enhancing quality and efficiency in the stamping process requires optimization, which may be achieved by combining creative thinking with meticulous implementation.  Progressive die stamping is one of these techniques and it simplifies the production of intricate parts by carrying out several processes in a single run. 

This guarantees accuracy and homogeneity in every component while accelerating the manufacturing process. Furthermore, fine blanking is a method that produces incredibly accurate and smooth cuts, making it perfect for high-precision parts. 

Stamping has joined the digital revolution by utilizing today&#;s automation and robotics technology. Modern techniques incorporate advanced machinery that increases manufacturing speed, decreases errors, and enhances precision.

Quality control:

For stamped components to remain functional and intact, quality control is not just a step in the manufacturing process but an integral component. Once more, businesses are investing significantly in cutting-edge equipment that uses laser technology to verify every component for compliance and safety automatically. 

These systems are exacting and resilient, identifying even the smallest deviations from specifications. These advanced technologies ensure that every tool and die set can reliably produce parts with the precise tolerances needed to meet the demands of the modern high-tech industry. 

Accuracy and uniformity:

Progressive stamping efficiency is a lifesaver for businesses where a few millimetre deviations can lead to catastrophic product failures. The specially made dies maintain strict adherence to design standards, guaranteeing that each part produced is identical to the last. 

Furthermore, because the process is automated, there is less opportunity for human mistakes associated with manual handling, which lowers the risk of error. Whether the first part or the ten thousandth, this automation ensures the quality doesn&#;t change.

The future of stamping:

The industry is becoming very exciting as it changes to accommodate new technology and evolving consumer wants. Future developments in stamping technology suggest that automation will rise, artificial intelligence (AI) will be incorporated for more intelligent production procedures, and sustainability will be given more attention. 

It is amazing how quickly the world of technology is changing such a conventional industrial method for the better.

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Eigen has the newest equipment to provide top-notch products. We offer the best quality progressive stamping die design at a reasonable cost. Our success lies in providing our clients with the utmost satisfaction. We operate under a few fundamental principles to provide our customers with the best possible service.

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1. What is the Stamping Die?
2. Types and Applications of Stamping Die
3. Single Die vs Progressive Die vs Compound Die
4. The Structure and Function of Stamping Die
5. The Materials of Stamping Die
6. The Design Processes of Stamping Die
7. The Processing Methods of Stamping Die

What is the Stamping Die?

Stamping die is a common type of die, in which metal or non-metal sheets are put into the die at room temperature and pressed by a press machine to separate or deform the sheet and eventually make the required parts.

Types of Stamping Die

According to the classification of process combination degree, a stamping die can be divided into four categories: single tool, compound tool, progressive tool andtransfer tool.

Applications of Stamping Die

Custom metal die stamp is the basic process equipment for industrial production. In electronics, automobiles, motors, electrical appliances, instruments, meters, household appliances and communications products, 60% to 80% of mirco metal parts are formed by high precision stamping dies.

Single Tool vs Progressive Tool vs Compound Tool

Single Stamping Die

Definition: A tool that can only complete one stamping process in one stroke of a press, such as punching, blanking, bending, deep drawing, etc.

Features: Simple structure, low cost, suitable for small or large batch production of automobile panels.

Progressive Tool

Definition: A tool that completes several stamping processes simultaneously at different positions of the die in one stroke of the press. The different die stamping process of the same part completed by the continuous tool is arranged in a certain order in the feeding direction of the die at certain step distance, and one or several stamped sheet parts are obtained in one stroke of the press.

Features: Multi-process die; It can include multiple proces

ses such as punching, bending, forming ,etc in a die with higher production efficiency than composite die.

Compound Tool

Definition: A tool with two or more stations in the feed direction of the blank that complete several die stamping processes at the same position in one stroke of the press.

Features:

• High precision of punching parts and the relative position of the inner and outer shape are consistent;
• Can make full use of short materials and leftover materials.

According to the classification of process properties, it is divided into blanking die, bending die, drawing die, forming die, riveting die.

• Blanking Die: It is a die that separate the materials along aclosed or open contour. Such as blanking die, punching die, cutting die, incision die, trimming dies,
• Bending Die: It is a die that bends and deforms sheet blanks or other blank along a straight line (bending line) to obtain a workpieces with a certain angle and shap
• Deep Drawing Die: It is a die that make the blank of the sheet into an open hollow part, or further change the shape and size of hollow parts.
• Forming Die: It isa die that directly copies and forms the blank or semi-finished workpiece according to the shape of the convex and concave die, and the material itself only produce local plastic deformation. Such as bulging die, shrinkage die, flaring die, undulating forming die, flanging die, plastic die and so on.
• Riveting Die: It is a die that useexternal forces to connect or overlapthe participating parts in a certain order and way to form a whole.

The Materials of Stamping Dies

The selection of precison stamping die material should consider the batch production of stamping parts. If the batch is not large, there is no need to choose a die material with a long life; Thus, We should consider the material of stamping parts. Different materials are suitable for different mould materials.

At present, most of the materials for manufacturing stamping die are mainly steel. The kinds of materials commonly used for working parts of the die are:

• Carbon tool steel
• Low alloy tool steel
• High carbon high chromium or medium chromium tool steel
• Medium carbon alloy steel
• High speed steel
• The matrix steel
• Carbide
• Steel bonded carbide and so on.

The Design Process of Stamping Dies

Specifically, We can divided into four main stages: process design, layout, outline design, structure design and parts design.

• Process Design: It is to analyze the forming processes of the product parts one by one to determine the processing technology scheme of the product parts.
• The layout and outlinedesign are based onthe premise that the process design is feasible,specifically determine the process plan and basic structure of the mold when processing parts.
• Structural design and parts design are specifically designed for the formal production of the progressive mold.

The Methods of Stamping Dies Processing

• Turning processing: Used for processing rotating parts, such as guide posts, guide sleeve, brace head, flange, thread and so on.
• Drilling processing: Used for processing threaded bottom holes, positioning pin holes, thimble holes, etc.
• Milling processing: It is mainly use a milling cutter to milling the plane.
• Grinding: It is mainly use grinding wheel to grind the surface of the workpiece.
• Planing processing: It is mainly planing the surface of the workpiece with a planing knife.
• Special processing: It is use of electrical energy, chemical energy and other mold processing methods directly.
• CNC processing: Control the machine tool through digital information to, so that the relative movement between the machined parts and tool meets the requirements.

Conclusion

There are still many problems in stamping dies. In actual project, we have to choose different stamping die according to the actual needs of the product. Such as part size, dimensional accuracy requirements, parts complexity, actual demand, etc. The production process of die is complex.

The Best Precision Metal Stamping Manufacturer in China

With 30 years of experience in the precision metal stamping industry, Heju Stamping has helped many industries to solve stamping problems around the world. Therefore, If you have a project under development or production problems, please contact us. We will use years of stamping experience and the most advanced stamping die technology for your service.

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