Progressive stamping is the ideal method to achieve the best efficiency. The process is becoming leaner, faster and more efficient than ever before, delivering superior value for money at lower cost through higher output.
Equipment for progressive stamping ranges from bare dies (dies) directly adapted to specific parts to complex multi-station presses (multi-tools) that produce multiple parts without changing tools or setup. When installed, it will be one of the most flexible components in an assembly line, rapidly producing finished components while maintaining accuracy and providing an excellent return on investment. The use of advanced technology in the manufacturing process provides a low-pressure way to meet delivery deadlines and reduce operator fatigue.
Progressive techniques are particularly successful in high-volume work, where costs are driven by setup time, tool rework, and scrap. The ability to quickly change molds without setting up or changing tools can save overall operation time and help increase production.
Benefits of progressive stamping
Mass stamping without increasing die cost
Progressive stamping provides many opportunities to control the cost of part production by achieving high production rates.
The progressive process starts with a die that performs molding operations several times in one stroke. The result is a combination of shear, stretch, closure, and ejection stages. When the workpiece contour changes from its initial flat state to the final part geometry, several metal deformation processes occur. This results in the reduction or elimination of secondary processing costs.
The progressive process is suitable for high-volume work where die wear and replacement costs quickly become very expensive.
Low rejection rate
In the past, progressive stamping and Progressive Die Stamping were considered cost-effective and could eliminate a lot of waste by increasing production rates without increasing tool expenditures.
Intelligence in stamping control allows optimization of the flow of parts through this section, greatly reducing secondary machining steps, especially when combined with good placement practices that take full advantage of the machine's ability to run multiple parts simultaneously.
Avoid costly secondary operations
Production methods have improved so much in recent years that secondary operations have become a thing of the past. Secondary PROCESSING COSTS CAN BE UP TO 75% HIGHER THAN PRIMARY PROCESSING, SO IT IS IN THE BEST INTEREST OF PART MANUFACTURERS TO ENSURE THAT THEIR STAMPING PRODUCTION TECHNIQUES ARE FULLY UTILIZED BY SWITCHING TO HIGH PRODUCTIVITY EQUIPMENT AND PROCESSES.
Reduce part size
Progressive processes do not involve sliding between tool stations as traditional transmission lines or turret presses do. Each stroke produces a parting line for part ejection, regardless of the stroke number. When combined with multi-tool techniques, this results in higher efficiency than other processes by avoiding the sliding speed transfer time loss problem.
An added benefit is reduced variation in specification requirements due to complete control over secondary machining.
Quick setting time
The gradual process from start to finish is flexible and can be set up quickly, with one operator setting it up in less than three hours.
The whole machine operates as one unit and tool changes are significantly reduced or eliminated. By eliminating molds, sliders, and other components that wear out during use on the assembly line, not only are initial capital expenditures significantly reduced, but running costs are also greatly reduced. There is no need for an experienced operator at each station, as all press controls are on the central control panel or PLC interface.
In addition, tools such as contact probes can easily automate precise chip positioning through the PC screen, eliminating costly errors. This ensures that the operator does not miss a beat because the entire system is fully automated, creating a refined production line ideal for high-volume stamping.
Intelligence in stamping control allows optimization of the flow of parts through the cell
The percentage of waste can be reduced by using a multi-tool press with multiple dies. For added value, if a combination of shear and molding dies can be used, the cost of the first operation is likely to be reduced because it eliminates secondary machining.
Low cost materials are allowed
In addition to improving throughput rates faster than traditional metal forming techniques such as deep drawing, progressive technology also enables you to produce parts with lower material thickness and cost. It allows the creation of elements with thinner walls that are stronger and lighter than conventionally grown elements.
Higher quality components
The consistency, precision and surface finish that can be achieved are significantly more advanced than turret or transmission line systems. Since the closed unit of each stroke is created in a single die, there are multiple sliding movements. This allows size control 3-5 times better than turret presses while stamping faster. You can also expect more freedom in choosing cheaper building materials.
The ability of advanced technology to create complex geometric shapes
While some advanced presses are designed to make simple shapes, others can make complex geometry. Although each progressive press has its limitations, many companies focus on custom tool designs for specific jobs. For example, sculpting tools can produce some amazing results for small batch production runs.
High capacity support
Each progressive unit has a maximum capacity determined by the length of the stroke and the number of tool stations, allowing thousands or tens of thousands of pounds per hour on some presses, if necessary. This is achieved by being able to run for hours at a time without the operator noticing.
Multiple progressive tools can be used to produce parts with internal and external configurations simultaneously, further improving productivity.
Most metal stamping processes have drawbacks, such as size limitations imposed by tool length. However, for small batches or large pieces of material, progressive printing systems are a viable option that can save you money while improving speed and quality.
Large parts that support thick walls where appropriate
Depending on the specific system, these tools can be adapted to part thicknesses up to 10 mm with stroke lengths between 8 and 40 mm. Parts can have complex shapes or different geometries on either side if desired.
Some companies offer "true double-sided" presses that allow full open or close motion during the stroke, combined with indexing motion in order to press both sides of the part simultaneously.
Higher quality to increase life cycle cost
Improved tolerances, dimensional accuracy and surface finish translate into better service performance of parts over the product life cycle, resulting in higher quality and lower cost products.
Progressive stamping also reduces the number and cost of secondary finishing operations and simplifies the assembly process. You can save another cost by combining stamping and forming functions to completely eliminate secondary machining.
Support for multiple materials
In terms of material selection, advanced technologies can be used in non-ferrous alloys such as aluminium alloys, copper and brass, carbon fibre composites and steel plates. All of these require a lot of force to complete the stamping process, so lightweight parts may prove difficult, such as delicate, fragile metal plates. However, the more stations the mold can have, the more flexible the material type.
Allows faster conversions
All presses are electro-pneumatic and hydraulically driven. They can be connected to the motor through simple electronic interfaces via plug and play wiring. Assuming you need to switch between different tool types or materials, this should not take long due to low maintenance requirements. In this case, no rework is required except to replace the tool. The same applies if you want to replace the punch line, for example, by moving from one workstation to another in the direction of the production line with minimal downtime.
Background information about progressive metal stamping technique, progressive metal stamping, or progressive die stamping is a process of progressively establishing the geometry of a part by adding another layer of material after each previous operation. This method allows more complex parts to be made from sheet metal than traditional tool and die techniques.
Use a machine to simplify operation
As you move along the production line, each progressive stamping station shares the same common control unit. This means companies can rely on a single machine to drive their operations, reducing capital expenditure and maintenance costs. Standardization also helps reduce die costs compared to traditional presses because only one set of dies per station is required to perform all the stamping operations that may be involved.
When your order size is too large for more traditional methods but too small for the economies of scale that make automated assembly worthwhile, stamping with progressive techniques is ideal for low to medium volume production. It is also ideal for short-term production runs, as it reduces the need to store a large number of finished parts. Progressive metal stamping offers manufacturers a range of benefits, including lower costs and greater flexibility.
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Progressive stamping is a cost-effective manufacturing technique that can manufacture a large number of parts from a variety of materials, making it ideal for complex multi-component assemblies. It has significant advantages over traditional metal forming methods, such as deep drawing, and can produce the same or better functional results with significantly fewer operations and cheaper tools.