Progressive stamping is a metalworking method that can encompass punching, coining, bending and several other ways of modifying metal raw material, combined with an automatic feeding system.
The feeding system pushes a strip of metal (as it unrolls from a coil) through all of the stations of a progressive stamping die. Each station performs one or more operations until a finished part is made. The final station is a cutoff operation, which separates the finished part from the carrying web. The carrying web, along with metal that is punched away in previous operations, is treated as scrap metal.
The progressive stamping die is placed into a reciprocating stamping press. As the press moves up, the top die moves with it, which allows the material to feed. When the press moves down, the die closes and performs the stamping operation. With each stroke of the press, a completed part is removed from the die.
Since additional work is done in each “station” of the die, it is important that the strip be advanced very precisely so that it aligns within a few thousandths of an inch as it moves from station to station. Bullet shaped or conical “pilots” enter previously pierced round holes in the strip to assure this alignment since the feeding mechanism usually cannot provide the necessary precision in feed length.
The dies are usually made of tool steel to withstand the high shock loading involved, retain the necessary sharp cutting edge, and resist the abrasive forces involved.
The cost is determined by the amount of features, which determine what tooling will need to be used. It is advised to keep the features as simple as possible to keep the cost of tooling to a minimum. Features that are close together produce a problem because it may not provide enough clearance for the punch, which could result in another station. It can also be problematic to have narrow cuts and protrusions.
Increased Speed:
Progressive die design process utilizes continuous feed of material through different die stations. When compared with traditional machining, this allows you to create more parts in a shorter time period. For high volume parts, you get the lowest cycle time per part with this stamping process.
Progressive die metal stamping involves various forming processes like punching, coining, bending, etc. for producing the end part. As a vast amount of material is used, the volume of scrap produced is very less. This makes it the most cost-effective material for part manufacturers.
The building nature of the die stations in a progressive stamping tool allows you to create more complex geometrics. Also, all the required geometrics of a part can be achieved in a single operation of the progressive die.
Progressive stamping process takes much less time compared to the conventional stamping methods. To produce complex parts, multiple setups, tool changes and die changes are required in traditional stamping, whereas the same can be achieved in one single progressive die operation.
All the above factors contribute to reducing the cost per part manufactured in progressive die stamping.
As multiple cutting and forming operations can be performed simultaneously, progressive die metal stamping is the right choice for a variety of industries for producing multiple small parts quickly.
Progressive Die Stamping is a metal stamping process used to cut and form raw sheets of metal using a stamping die. It comprises several individual workstations which perform one or more operations on that part. The progressive die can perform various actions like cutting, coining, punching, bending, lancing, shaving, extruding, drawing and embossing, etc.
As the name suggests, progressive die stamping encompasses many progressive steps where the raw material is pressed simultaneously and sequentially in an automatic feeding system. Each step is built on the previous step until the desired shape is achieved. All these steps have the same basic setup with some possible variations.
Progressive Die Stamping vs Transfer Die Stamping
Progressive die stamping is similar to transfer die stamping with some differences in the working nature. In case of transfer die stamping, the part is transferred from one station to another by a mechanical transport system. It is typically used for producing large parts like tube applications, frames, shells, and structural components. Whereas, progressive die metal stamping is ideal for larger volume production of smaller parts.
Working Process
At first, the die is fitted into the stamping press by a trained employee. Once the proper adjustment is done, the technician triggers the machine. As the press moves up, the top die moves along and allows the material to feed. The die closes as the press moves down, it presses the strip and starts performing the stamping process. This process is repeated numerous times depending upon the part being manufactured.
Progressive die stamping uses a type of tooling called a progressive die, which contains multiple stamping stations to carry out simultaneous operations on a sheet metal strip. By combining all the necessary tools into one die set, progressive die stamping is a great solution for high-volume production runs.
To begin the process, the die is placed into the stamping press. our straight side progressive presses feature a 60 to 500 ton capacity. The die opens as the stamping press moves up and closes as the stamping press moves down. While the die is open, the metal moves through the die, being precisely fed into the die with each press stroke.
When the die closes, it performs its work on the metal, which can include coining, bending, cutting, embossing, and more. Once the metal has moved through each station, the finished part is ejected from the die.
When to Use Progressive Die Stamping vs. Traditional Metal Stamping
When choosing between progressive die stamping and traditional metal stamping methods such as stage tooling and transfer press tooling, it’s important to consider factors such as cost, production volume, and lead time.
CostCost
When considering cost, it’s important to think about tooling setup costs as well as per-piece cost. Stage tooling boasts lower setup costs but has the highest per-piece cost. Progressive die and transfer press tooling have higher setup costs compared to stage tooling but offer lower per piece costs.
Production Volume
Progressive die stamping is specifically designed for high volume production, typically exceeding 50,000 pieces per year. While transfer press tooling is also good for high volume production, it differs in that the part is separated from the metal strip during the first operation. Stage tooling, on the other hand, is ideal for small, low-volume production runs of less than 50,000 pieces per year.
Lead TimeLead Time
When considering the needs of your project, it’s important to think of project timelines to determine which method is best. While stage tooling features a relatively slow fabrication speed, progressive die and transfer press tooling offer medium to fast production speeds.