Progressive stamping

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Progressive (punch and blanking) die with strip and punchings

Progressive Die is a

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.

scrap metal. Both are cut away, knocked down (or out of the dies) and then ejected from the die set, and in mass production are often transferred to scrap bins via underground scrap material conveyor belts
.

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.

Progressive stamping can also be produced on transfer presses. These are presses that transfer the components from one station to the next with the use of mechanical "fingers".

concentricity and ovality
issues and non uniform material thickness. Other disadvantages of progressive presses compared to transfer presses are: increased raw material input required to transfer parts, tools are much more expensive because they are made in blocks with very little independent regulation per station; impossibility to perform processes in the press that require the part leave the strip (example beading, necking, flange curling, thread rolling, rotary stamping etc.).[3]

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. [4]

The cost is determined by the number of features, which determine what tooling will need to be used. Engineers 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.

Applications

A representative example of the product of a progressive die is the lid of a

beverage can. The pull tab is made in one progressive stamping process and the lid & assembly is made in another, the pull tab simultaneously feeding at a right angle into the lid & assembly process. Also various car brake calipers have plates that are bent into shape, possibly cut too using these methods.[5]

See also

References

  1. ^ DOE Workshop on Research and Development Needs for Bipolar Plates for PEM Fuel Cell Technologies (14 February 2017). "Bipolar Plate Cost and Issues at High Production Rate" (PDF).
  2. ^ Occupational Safety and Health Administration (11 February 2022). "1910.217 - Mechanical power presses".
  3. ^ BlechMal GmbH (11 February 2022). "Bleche nach Mass" (in German).
  4. ^ Johnson, Carl-Johan (August 2021). "DESIGN KNOWLEDGE REUSE IN DESIGN OF PROGRESSIVE STAMPING TOOLS: A QUALITATIVE STUDY" (PDF). International Conference on Engineering Design, Iced21: 1053–1062. Retrieved 1 August 2023.
  5. ^ Thomas Engineering (17 November 2015). "Progressive Metal Stamping".
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