A Guide to Progressive Die Stamping

Progressive die stamping, also known as prog die stamping, is a versatile process that allows for efficient, cost-effective manufacturing of numerous parts and products. Capable of producing metal components of varying shapes and sizes, it leads to lower production costs and shorter lead times.

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During the progressive die stamping process, a stock strip moves the part through a series of individual work stations, each of which performs its own task on the workpiece, such as bending, punching, and coining. As the part moves through each station, it progressively takes on the desired size and shape. Once completed, the part is cut from the stock strip to reveal the final product.

Progressive die stamping is often preferred over other stamping methods due to the many benefits it provides in terms of lead times, production time, and overall cost.

Compound Metal Stamping
During the compound metal stamping process, a metal strip is fed through a compound die, which performs all stamping operations in one stroke. This process is most suitable for projects requiring medium and high-volume production of flat parts. While progressive die stamping offers fast production times regardless of part complexity, compound die stamping can be slower for larger parts with more intricate design elements.

Transfer Die Stamping
One of the main differences between transfer die stamping and progressive die stamping is that the workpiece is separated from the metal strip in the first step. The workpiece is then transferred between several workstations to complete the part. This process is ideal when working with complex designs and larger parts that can&#;t easily move through die stamping stations.

Traditional Metal Stamping
Traditional metal stamping often utilizes stage tooling for stamping operations. While stage tooling offers lower setup costs, it results in the highest price per piece. With progressive die tooling, you have higher initial costs, but lower costs per piece. In terms of speed and production volume, stage tooling is slower and more ideal for small, low-volume production runs, whereas progressive die stamping is fast and suitable for large production runs.

As a premier provider of progressive die stamping, Aranda Tooling offers cost-effective solutions for a broad range of applications. Our state-of-the-art facilities and extensive industry experience allow us to manufacture high-quality components that meet precise design implementations.

Specializing in high-volume progressive die stamping runs, we manufacture up to a half million parts daily on a daily basis and can work with the following materials:

• Aluminum
• Titanium
• Brass
• Bronze
• Copper
• Stainless Steel
• Low and High Carbon Steel
• Inconel®
• Nickel Alloys

We can handle virtually any size progressive die stamping project, using an 18&#; maximum hydraulic press stroke and 31&#; maximum mechanical press stroke. For more information about our progressive die stamping capabilities, contact us today. You can also request a quote to get started.

Progressive die stamping for sheet metal fabrication is a complex process.  For that reason, you want to design the tooling accurately in order to achieve the quality part you want.

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We&#;ve included several design tips in this chapter to help you along the process.

Many of these factors are interconnected so decisions about each should be made concurrently, which can sometimes lead to trade-offs in your design and outcomes.

Several prototype runs are usually necessary to perfect the design before production.

Your design will determining the sequence in which the part will be formed, including the number of forming processes and their corresponding dies.

This is a complex process and can present significant challenges so working with a designer who has experience in progressive stamping is an advantage.

• The strip layout can impact your costs, accuracy, and quality
• The sequence should be appropriate for the part and material thickness, the material properties, the desired surface finish, and other variables such as inconsistent source material thickness and work hardening
• Each step in the sequence requires specifications for the tooling, draw depth, or blank holder force
• Tooling should be designed to minimize weakening and to facilitate maintenance
• Empty stations can help minimize die weakening and to compensate for concerns about the drawing or movement of the strip
• Empty stations initially allow for the addition of operations at a later time
• When force across the strip is not distributed evenly, movement or tipping can occur when the press is engaged, causing damage to the dies which can impact consistency and quality across parts. Your sequence design should consider this factor.
• The part may need to be oriented on the strip at an angle to the grain in order to avoid cracking and fatiguing that sometimes occurs when forming with the grain. This is especially important if tight tolerances are necessary. There is more material waste in this case.
• Orient the part on the strip to have the shortest feed possible, especially when using heavy material with narrow strips. This helps the feed run easier and faster.

The material that carries the parts through the progressive stamping dies is sometimes call the carrier, or webs, strips or ties.

It connects and transports the part to each die station. There are several different types of carriers that allow for different processes on the part.

• Designing the carrier within the width of the part minimizes the need for additional material to be included in the process
• Carrier width should be at least 2 times the material thickness
• Larger dies may require larger carrier widths to facilitate pushing the strip through the die
• If more than one carrier is used, try to design with consistent lengths to prevent twisting of the strip
• Design carriers long enough to accommodate any stretch or bend necessary during any of the press operations. These loops should be designed with as large a radius as possible but still allows for any necessary clearances
• Try to attach the carrier at a point that will allow it to be removed easily and any burrs that result can be addressed
• Use stiffening beads to carriers or lance form the edge when large parts are being fabricated from thin materials

The feed height is defined as the amount the strip must be lifted to progress to the next die.

Even for flat pieces, slight lift is required to break the oil seal with the die.

Strip lifters are used to support the progression of the strip from die to die.

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• Design with the minimal lift possible as lifting adds to the time required for part manufacturing
• The amount of lift should consider necessary clearance to prevent catching on the next die. Bending processes for example require the part to be lifted high enough to clear the die that created the bend
• The higher the lift height, the higher the chance it can impact the orientation of the strip from vibration or bounce
• Sagging between strip lifters can cause buckling to the carriers
• Spool lifters that are spaced too far apart can cause thin materials to not remain flat, affectingpilot positioning
• Bar lifters can run the distance between two parts, providing better support to thin materials and help prevent sagging
• Rotating the part on the strip so it&#;s at an angle to the grain can help reduce the lift required. If all the forms are in the same direction, the form can be made upward instead. This may have more costs for the die and materials.