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About Progressive Die Stampings
Progressive die stampings are produced from flat strips
of metal that have been put through a series of stamping stations within
one machine. Each die station changes the metal configuration left on
the metal by the previous station. In a progressive die, the components,
which are unique for every part, are located and guided in precision cut
openings in plates. The plates are located and guided by pins. A mechanical
press actuates the entire die, moving it up and down. The press also feeds
the material through the die, moving it forward with every stroke. Punches
perform actions such as cutting, forming and drawing.
Progressive die stamping performs multiple cutting and/or forming operations
simultaneously. The ability to combine forming operations saves time and
money, as there is no setting up of and moving to machines that perform
secondary operations. This stamping process can produce small workpieces
at a rapid rate. Close tolerances are maintained, as both punched and
formed dimensions are tool controlled. It is necessary to invest in expensive
die sets up front, but tools typically last the life of the project. As
a result, unit cost is exceptionally low.
The process of progressive die stamping is generally limited to shallow
draw stamping. Products that require deeper drawing are put through a
related process, deep draw stamping (http://deepdrawn.metalstamper.net).
Aluminum, brass, cold rolled commercial steel, cold rolled draw steel
and cold rolled stainless steel are materials that are typically progressively
drawn. Progressive die stamping remains useful in a number of industries
including the automotive, packaging, apparel and fashion, communications
and medical industries. Fasteners, washers and connective mechanisms represent
a few examples of the production capabilities achieved with progressive
die stamping.
Featured
Articles
http://archive.metalformingmagazine.com/1999/02/progdie/progd.htm
http://www2.thefabricator.com/Articles/Stamping_Exclusive.cfm?ID=556
Types
- (http://deepdrawn.metalstamper.net)
converts flat sheet metal into three-dimensional shapes—including
cylindrical, shell-like, cup-like, rectangular and square shapes—whose
lengths (depths) exceed the radius of the part. As the flat metal moves
over the die, the metal blank is restrained on either side of the die
opening by a blankholder; the punch then pushes the secured blank into
the die cavity, creating the desired shape.
- (http://electronic.metalstamper.net)
are metal stamped electronic components.
- (http://fourslide.metalstamper.net)
is a specialized metal stamping process that allows fourslides to produce
complex stamped parts from strips and wires with multiple bends and
twists,
as well as parts requiring bends greater than 90°. During fourslide
forming, sliding tools, regulated by cams, glide into the metal blank
from four directions at right angles to one another, bending the metal
around a vertical mandrel.
- (http://medical.metalstamper.net)
are metal stamped parts created specifically for use in the medical
industry.
- (http://shortrun.metalstamper.net)
produces between five and ten thousand pieces, and the cost of the
dies themselves
is greater than the cost of the parts produced. Labor costs
are higher
per piece, materials are more costly, setup time is greater and
other cost factors are higher in short run stamping than conventional
stamping,
because of the greater number of operations involved.
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