Improving Progressive Die Stamping Operations: 8 Design Tips for Stamping Parts with Progressive Dies

Published on October 3, 2024

Design Tips for Stamping Parts with Progressive Dies

Progressive die stamping is a cornerstone in the metal stamping industry, known for its efficiency in high-volume production and the ability to produce intricate geometries with tight tolerances. In this article, we explore the progressive die stamping process and share essential design tips to optimize your stamping capabilities with progressive dies.

Are You Looking to Enhance Your Progressive Metal Stamping Operations?

Alpha Contract Manufacturing Group offers specialized industrial contract manufacturing services designed to optimize your production processes. With state-of-the-art equipment and expert knowledge, we provide comprehensive solutions from initial design to final production, ensuring precision and efficiency in every stamping project.

Whether you require advanced automation, precise metal processing, or specialized coatings like powder coating or e-coating, ACMG delivers turnkey services tailored to meet your specific needs. Contact us today to discover how we can elevate your progressive stamping operations with reliable, cost-effective solutions that enhance productivity and quality.

Turnkey Metal Processing Services

The Progressive Stamping Process

Progressive die stamping involves a series of stations, each performing a specific operation on the metal strip. This continuous process, known as the progressive stamping process, is designed to maximize production efficiency while minimizing material waste. The steps in this process include cutting, bending into shape, punching holes, and forming, all conducted simultaneously.

Designing for Progressive Die Stamping

Progressive die stamping for sheet metal fabrication is a sophisticated process requiring precise tooling design to achieve high-quality parts. Design factors are often interconnected, necessitating concurrent decision-making that might involve trade-offs. Typically, several prototype runs are essential to refine the design before moving to full-scale production.

Sequence Design and Strip Layout

The sequence design determines the order in which a part is formed, including the number of forming processes and their respective dies. This complex process benefits from the expertise of experienced progressive stamping designers.

  • The sequence should align with the part’s requirements, such as material thickness, properties, and desired surface finish.
  • Each step requires tooling specifications, including draw depth and blank holder force.
  • Empty stations can help prevent die weakening and allow for future operations.
  • Uneven force distribution across the strip can cause movement or tipping during press engagement, potentially damaging the dies and affecting part consistency and quality.
  • Orienting the part at an angle to the grain can prevent cracking and fatigue, though it can increase material waste.
  • To enhance feed efficiency, design for the shortest possible feed, especially when using heavy material with narrow strips.

Carriers, Webs, Strips, and Ties

The carrier, also known as webs, strips, or ties, transports parts through the progressive stamping dies, connecting them to each die station. Various carrier types facilitate different processes.

  • By designing the carrier within the part’s width, additional material needs are minimized.
  • The carrier width should be at least twice the material thickness.
  • Larger dies require wider carriers to push the strip through the die.
  • Carriers should be long enough to accommodate necessary stretch or bend during operations and designed with large radii for clearances.
  • Carriers should be attached at points that allow easy removal and management of resulting burrs.

Center Carriers

Center carriers are formed by a strip of metal near the part’s center. Employing narrow center carriers allows for forming around the entire part, while wide center carriers restrict forming to the part’s sides.

Inboard Carriers

Attached at two points, one near the center and one near the outside of the part. The carrier should not extend beyond the part’s width.

Lance Carriers

A lance is created instead of trimming material from the strip. It minimizes scrap but generates shavings.

Outside Carriers

They’re attached to the part’s exterior through trimming, lancing, or punching shapes for drawing. This allows forming near the strip’s center. Lifter rails are often used to feed and balance the strip.

One-Sided Carriers

Attached to only one side of the part. Features include:

  • Allows forming on three sides, maximizing access for forming
  • Can cause movement issues during strip lifting and feeding
  • Often requires center lifters to feed the strip through the dies
  • The lift can be challenging with several large downward flanges

Alignment issues can arise due to significant excess material trimming. Increasing the strip width can mitigate this by allowing trimming on the carrier side.

Feed Height and Strip Lifting

Feed height is the amount the strip must be lifted to progress to the next die. Even flat pieces need slight lifting to break the oil seal with the die. Strip lifters support strip progression from die to die.

  • Designing for a minimal lift helps reduce manufacturing time. However, lift height must provide the necessary clearance to prevent catching on the next die.
  • Higher lift height increases the risk of orientation issues from vibration or bounce.
  • Sagging between strip lifters can cause carrier buckling. Bar lifters running between parts can provide better support for thin materials, preventing sagging.
  • Rotating the part on the strip to an angle to the grain can reduce the required lift.

Pilots

Pilots align and fix the strip in the correct position as it progresses through the machining. Their number and location impact the material and carrier type used. Holes in parts can serve as pilots if they’re large enough. However, using holes designed for tight tolerances as pilots can cause elongation and imperfections.

Exiting the Die

Designing the final die to finish a part involves considerations like strip orientation, carrier type, and overall die sequence.

  • Ladder strips ease part removal and do not always require a cut die.
  • Shedder pins can move the part off the last die.
  • Heavier parts might be slightly off balance on the final die, causing them to fall off.

Metal Processing Services

Streamlining Progressive Die Stamping Operations: 8 Design Tips for an Effective Metal Stamping Design Process

These design tips help producing high-quality, intricate metal components efficiently, meeting the demands of various high-volume production industries.

1. Material Selection

Selecting the right material is crucial for achieving consistent part quality. Common materials used in progressive stamping include stainless steel alloys, advanced high-strength steels, and other metal materials like aluminum and copper. Each material type has unique properties such as tensile strength, material thickness, and electrical conductivity, impacting the stamping process and the final product.

Key Factors to Consider to Choose a Material for Sheet Metal Parts

2. Tooling Design

The tooling design is integral to the success of progressive stamping. Utilizing hardened steel and advanced materials for tooling ensures longevity and precision. Considerations such as hole diameter, bend radius, and the arrangement of stations are critical for maintaining dimensional accuracy and meeting design requirements. Progressive tooling must also account for adjustment mechanisms to handle deviations from target specifications and ensure consistent part quality.

3. Managing Material Waste

Efficient material usage is a priority in the metal stamping process. Design strategies should aim to reduce scrap material and excess material. By optimizing the carrier type, such as ladder carriers or one-sided carriers, and minimizing material feed rates, manufacturers can significantly decrease material waste. Additionally, the proper progression of stations ensures minimal material thickness variations and reduces unnecessary waste.

4. Achieving Complex Progressive Die Design Shapes

Creating intricate geometries and complex shapes requires a detailed progressive die design. The die must be capable of handling tight tolerances and intricate designs without compromising on quality. Implementing features like beads to carriers, bend relief notches, and lifter rails helps in achieving precise control over the metal strip during stamping.

5. Enhancing Production Efficiency

Production efficiency in progressive stamping is achieved through a combination of high-speed operations and real-time monitoring. Advanced monitoring systems and control systems allow for immediate tool adjustments, ensuring accurate part dimensions and consistent product quality. Automated production processes further enhance speed and reduce human error, meeting the high-volume production demands of various industries, including the automotive and aerospace sectors.

6. Addressing Common Defects

Common defects in metal stamping, such as edge burrs, hole deformation, and insufficient hole spacing, can be mitigated through meticulous design and process control. Ensuring proper hole spacing, controlling burr direction, and addressing additional heat distortion are essential steps to maintain the integrity of the finished products.

7. Custom Metal Stamping Capabilities

For bespoke metal stamping capabilities, manufacturers often utilize advanced techniques such as four-slide stamping and transfer die stamping. These methods allow for greater flexibility in design and can accommodate unique customer requirements, ensuring that even the most complex metal components meet exact specifications.

8. Continuous Improvement in Metal Stamping

Continuous improvement is vital in the metal stamping industry. By regularly reviewing and refining the stamping type, adjusting lift amounts, and implementing advanced process monitoring, manufacturers can stay ahead in the industry and produce high-quality metal stampings. This commitment to improvement ensures that all design tips and processes remain at the forefront of the industry.

Industrial Manufacturing Services

Alpha Contract Manufacturing Group is your trusted partner for industrial contract manufacturing services, offering a diverse range of solutions to enhance your production efficiency and reduce costs. With expertise spanning construction, transportation, and logistics, our services include:

Contact us today for a free quote and experience the benefits of outsourcing with the leading contract manufacturing company.

Request a quote

Share your feedback with us.

Share on : 

Receive our latest news

Other articles that might interest you