The decision to produce a part progressively is usually determined by two factors: the volume of production and the complexity of the part. These two factors are instrumental in the design and construction of the tooling. It is important to address all factors that will contribute to the desired level of part quality, tool maintenance, and tooling life. Trade-offs will be necessary to reach most decisions, and all will affect tooling costs.
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The process begins with determining how the part will be run through the die. This is governed by the features of the part and the locations of the datums and critical tolerances. Then, the trade-offs begin.
Optimizing material usage may require rotating the part in the strip, which changes the grain direction of the steel in the part and thus can affect the strength of any forms in the part. Forming with the grain can cause cracking and fatiguing of the metal and make holding consistent form angles more difficult. Therefore, the form will be far more susceptible to problems associated with the chemical makeup of each coil that is run.
For example, Figure 1 shows a part for the computer industry that was rotated in the strip to guard against inconsistent form angles that could be caused by differences between coils. The part contained critical dimensions with 0.025-millimeter tolerances dependent on the forms. Rotating the strip to ensure more consistent forms was not the most efficient use of material. In this case, however, part tolerances won out over optimizing material usage.
Part configuration could provide a second motivation for rotating a part in the strip. If cam forming or piercing is required to make the part progressively, rotating the part may be the best, and sometimes only, option because the cam and driver can take up a significant amount of room. The part typically is rotated so that the cams' functions are perpendicular to the coil. This provides the easiest and most accessible condition for the cams.
Often, a compromise between rotating a part to optimize material usage and angling the cams to keep them outside of the coil is the final result. This could increase piece part and tooling costs. To produce the part progressively, however, such a compromise may be necessary.
A third consideration that may require rotating the part in the strip is the amount of lift that is needed to carry the strip through the die. Lift can sometimes be reduced significantly or eliminated by properly rotating a part.
If all forms in a part are in the same direction, lift can be eliminated by forming upward. This usually adds to the cost of the die. When the part has forms in opposite directions, compromises must be made among excessive lift, poor material use, and the complexity and cost of the tooling.
One such compromise is shown in Figure 2. The part is carried through with a ladder-style carrier, which adds material to the coil width because only two small areas are available for carrying the part. Also, because of the shape and length of the forms, a significant amount of lift is needed. External stock lifters carrying the ladder strip work well in high-lift situations.
One final consideration for part orientation within the strip is that a part should be rotated so that the feed is as short as possible. This is especially true for heavier materials and narrow coils. The slitting process can cause camber in coils that can make feeding difficult. A shorter progression feed runs faster and has less chance to cause feed problems. When a substantial difference between the length and width of the part exists, it is usually more cost-effective to build the tooling with the shorter lead.
Figure 3:How parts are carried in the strip affects how well the die feeds, the ability to lift the strip for feeding, and the ability to produce consistent-quality parts.
Three basic options are available for carrying a part, although many variations of each also can be used. In the most straightforward approach, parts are carried by the scrap between them. Excess material equal to one to two material thicknesses per side is required for trimming. This method typically produces minimal scrap.
Certain part configurations are needed to use this method. When rotated and laid out end to end, the parts must have enough usable area on both the leading and trailing edges of the progression (see Figure 3).
Figure 4:The second basic strip option, in which a part is carried on one side of the strip, is shown in Figure 4. This style is suitable for parts that require a great deal of forming on as many as three sides. It also improves accessibility if cam piercing or forming is required.
Lifting the strip through the die can become more difficult when this carrier option is used. A stock lifter on the edge of the strip is not sufficient&#;lifters are needed in the center of the strip for balancing, or feeding the strip through the die can become a problem. If large or numerous flanges are to be formed down, achieving the proper lift can be difficult.
This type of carrier can cause another feeding problem. Trimming a large quantity of material from one side of the coil can cause camber in the strip as stresses are released from the steel. The more progressions in a die, the greater is the risk of feed and pilot alignment problems caused by camber.
Part configuration, stock material thickness, and how narrow the carrier must be are all factors that influence whether camber becomes a problem. To prevent camber, the coil width should be increased so that the carrier side of the coil also can be trimmed. The additional trim releases stresses from the opposite side of the coil and balances the strip. Even with the additional trim, carrying the part on one side of the strip can be the most effective method to run a part from a material usage standpoint.
The third carrier option is the ladder style. Some of the advantages of the ladder carrier were discussed earlier. These carriers work well with complex parts and with those requiring significant amounts of lift. Because this method allows a strip to feed easily, it also is often used in applications in which higher feed rates are needed.
The ladder carrier uses more material per part. Often, however, a part cannot be produced progressively any other way. If production volumes are borderline to begin with in terms of justifying progressive tooling, the added costs of the more complex progressive die and additional material waste may make producing the part through multiple operations a better option.
PilotingDecisions on part rotation and carrier type must be made concurrently with a third consideration, piloting. The type, locations, and number of pilots all affect the progression, coil, and carrier type.
Choosing pilots begins with examining the part configuration and tolerance requirements. Is piloting off of holes within the part possible or even acceptable? If a part contains holes, they must be large enough if they are to be used as pilots. Holes should be spaced as far apart as possible to help increase accuracy, and they must be in the proper locations if they are used to stabilize a strip and help with the forming taking place in the die.
The tolerances of the proposed pilot holes in the part should be considered. If the hole diameter tolerance is very tight, even slight elongations caused during forming may produce scrap parts. Elongation could be caused by something as simple as an old feeder or one that is slightly out of adjustment. If a pilot is located in the scrap or the carrier, slight elongation is acceptable, as long as the piece part dimensions remain within tolerance.
At times, two different sets of pilots may be required. In these applications, both sets of pilots should be pierced at the same time to provide an accurate transition from the first set of pilots to the second. When a significant amount of stripper travel is involved, problems can occur. The pilots will contact the material as they line up the strip. If considerable stripper travel is involved, the pilots will rub on the pilot hole for the complete distance, which can cause a burr on the hole and lead to galling of the pilots. The best solution is to guide the stripper and place the pilots in the stripper.
Determining how a part exits from a die is often overlooked until the end of the design. It is at times, however, the pivotal factor in determining how a die is designed. Removing the part from the die may require rotating the part, using a different type of carrier, or changing the sequence of operations within the die.
The locations of the forms in the part and their relationship to where the part is carried directly bear on how or whether the part comes out of the die. A ladder strip provides the easiest method for removing a part from the die. Usually, a part can be cut and blanked through the die.
When a die is designed so that parts are cut and allowed to fall off the end, several factors must be considered. For instance, the part weight must be sufficiently off-balance to allow it to fall off the die block. A shedder pin can be added to the top stripper to ensure that the part exits the die.
If form tabs or flanges are formed down on the part, clearances must be added. If that is not possible, it may be necessary to redesign the die to ensure that the part exits. If flanges are formed up, the advancement of the strip sometimes will kick the part out of the die.
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Once the basic design is determined, the exact number of stations needed can be assessed. It is important to keep die construction in mind when finalizing strip layout. Often, empty stations should be included to prevent weakening a die if further modifications become necessary. In addition, the ease of maintaining the tool should be kept in mind.
As the complexity of a tool increases, the degree of confidence in the design also plays a role in deciding how many stations should be included. If questions arise as to whether the part will draw properly or the form will come out as desired, one or more empty stations should be added&#;the more uncertainties, the higher the number of empties that should be added.
If a die is built without empty stations and additional operations must be added later, options are few. In almost all such cases, the integrity of the die must be compromised to accommodate the modification. Oftentimes, very undesirable maintenance conditions must be built into the die. Either situation could result in producing a die that breaks repeatedly and is costly to maintain.
Getting the fundamentals right is the key to producing a quality, cost-effective die and piece part. The more complex the die, the more important are the decisions on the fundamentals. With proper evaluation and the proper compromises, the best option can be determined. This will give a strong, good-feeding die that is easily maintainable. The die will produce consistent, quality parts to print. The proper decision should provide the best value for a company's tooling dollars.
Progressive stamping, also known as progressive die stamping, is a metalworking process that involves feeding a strip of metal through a series of dies to create a finished part. The strip of metal is fed through the dies in a continuous motion, with each die performing a specific operation on the metal until the final part is produced.
The process is highly automated and can produce high volumes of complex parts quickly and efficiently. Progressive stamping is commonly used in the automotive, aerospace, and electronics industries, among others.
Progressive stamping offers several benefits over other metalworking processes, including:
Progressive stamping requires specialized equipment to perform the various operations on the metal strip. The main components of a progressive stamping machine include:
The feeder is responsible for feeding the metal strip into the machine and ensuring that it is properly aligned for the next operation. The feeder can be either pneumatic or mechanical, depending on the type of machine.
The die set is a series of dies that are used to perform the various operations on the metal strip. Each die is responsible for a specific operation, such as cutting, bending, or forming.
The press is the main component of the progressive stamping machine. It provides the force needed to perform the operations on the metal strip. The press can be either mechanical or hydraulic.
The stripper is responsible for removing the finished part from the metal strip after each operation. It ensures that the part is released cleanly and without any damage.
Other components of a progressive stamping machine may include sensors, lubrication systems, and safety features to help streamline the stamping process.
The first step in the progressive stamping process is the design and engineering phase. This involves creating a design for the part and determining the best way to produce it using progressive stamping. This step may also involve creating prototypes to test the design and make any necessary adjustments.
Once the design is finalized, the next step is to create the tooling. This involves creating the dies that will be used to perform the various operations on the metal strip. The tooling is typically made from hardened steel to withstand the high forces and pressures involved in the stamping process.
Once the tooling is complete, it is installed in the progressive stamping machine. The machine is then set up to ensure that the metal strip is fed through the dies correctly and that the operations are performed accurately.
With the machine set up, production can begin. The metal strip is fed through the machine, and each die performs its operation on the strip until the final part is produced. The finished parts are then removed from the strip and inspected for quality.
Progressive stamping can be used with a variety of materials, including steel, aluminum, and copper. These metals are commonly used in progressive stamping due to their versatility and ability to withstand the high forces and pressures involved in the stamping process. The choice of metal depends on the specific requirements of the part being produced and the desired characteristics of the finished product.
Steel is a versatile material that can be easily formed and shaped during the progressive stamping process. It can be used to create parts with various geometries, including intricate designs and complex features. This versatility allows for the production of a wide range of parts for different industries and applications. Steel is known for its high strength-to-weight ratio, making it suitable for applications that require strong and sturdy parts. Progressive stamping can produce complex parts with tight tolerances, and steel&#;s strength ensures that the parts can withstand the forces and pressures involved in the stamping process. Progressive stamped parts made from steel are less likely to deform or break under stress, ensuring their longevity and reliability. Steel is readily available and relatively inexpensive compared to other metals, which makes it a cost-effective material for progressive stamping.
Aluminum is highly formable, allowing for the creation of complex shapes and designs during the progressive stamping process. It can be easily bent, formed, and shaped without sacrificing its structural integrity. This versatility makes aluminum a popular choice for parts with intricate geometries and tight tolerances. Aluminum is also known for its low density, making it significantly lighter than steel. This makes it an ideal choice for applications where weight reduction is important, such as in the automotive and aerospace industries. Aluminum is an excellent conductor of electricity, making it a preferred choice for electrical and electronic applications. Progressive stamping can be used to create intricate designs and features in aluminum parts, allowing for efficient electrical conductivity and connectivity. Aluminum has high thermal conductivity as well. This makes it suitable for applications where heat dissipation is important, such as in heat sinks or cooling systems.
Copper and copper alloys can be a good material choice for parts made with progressive stamping in cases where excellent electrical conductivity is required. Copper is known for its high electrical conductivity, making it ideal for applications in the electrical and electronics industries. Progressive stamping can be used to create intricate designs and features in copper parts, allowing for efficient electrical conductivity and connectivity. Copper alloys, which are mixtures of copper with other metals, can also offer improved strength, corrosion resistance, and other desirable properties while still maintaining good electrical conductivity.
&#;Exotic metals&#; is an umbrella term that is used to describe a group of high strength alloys whose unique properties come from the addition of a less common material. These alloys can be based in steel, aluminum, copper, titanium, magnesium, and more. Exotic metals can be used for progressive stamping, especially when the parts being formed call for a very specific set of properties that cannot be achieved with more common alloys alone. Exotic metals are typically used to make parts for the aerospace, electronics, and medical industries.
Dayton Rogers is a leading provider of progressive stamping services, with over 80 years of experience in the industry. We offer a wide range of capabilities, including in-house tooling, design, and engineering services. We also have a variety of presses capable of exerting forces up to 300 tons to accommodate different part sizes and production volumes.
One of our company&#;s greatest accolades is the creation of the Metalforming Design Handbook- commonly referred to as The Red Book- and the accompanying illustrated guide Example of Design Principles- also called The Black Book. The Metalforming Design Handbook provides comprehensive information on the design principles and best practices for metal stamping. It covers topics such as material selection, die design, tooling considerations, and troubleshooting common issues. The handbook serves as a valuable resource for engineers and designers involved in progressive stamping, helping them optimize the design of parts for manufacturability and efficiency. The Example of Design Principles, or The Black Book, serves as an illustrated guide that showcases real-life examples of successful progressive stamping designs. It provides practical insights into the application of design principles and demonstrates how to overcome common challenges in the stamping process. This guide is a valuable tool for designers looking for inspiration and guidance in creating progressive stamping parts. Despite first being published decades ago, our reference materials are widely used across the manufacturing industry even today.
Our extensive experience, combined with these reference materials, makes us a trusted authority in the field of progressive stamping design. By leveraging our expertise and the knowledge shared in The Red Book and The Black Book, Dayton Rogers can provide high-quality progressive stamping services and ensure that your part designs are optimized for manufacturability.
Progressive stamping is a highly efficient and cost-effective metalworking process that is used to produce high volumes of complex parts. Using the right equipment and decades of metal stamping expertise, like Dayton Rogers can provide high-quality progressive stamping services for a variety of industries. By understanding the process and the benefits it offers, you can make informed decisions about whether progressive stamping is the right choice for your manufacturing needs.
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