Metal Stamping is the process that uses dies to transform metal sheets into shapes of intricate designs. With the automobile industry flourishing, the need for such metal parts has increased manifold. Therefore, manufacturing companies are now leveraging cutting-edge tools and techniques to create a cost-efficient and productive process.
One such technique is the use of tools such as progressive dies. These dies are a wise choice if the output is mass production of metal shapes of complex geometry that fits perfectly as an automobile component.
What Is Progressive Tool?
A progressive die is a metal stamping tool that enables the completion of the entire metal stamping process in a single press stroke. These perform metal stamping processes like forming, bending, cutting, embossing, coining, etc. simultaneously depending on the desired shape
The progressive tools have become an integral part of the automobile industry today. As the industry is now focussing on building eco-friendly transport solutions, the need for processed, lightweight metal parts has increased abundantly.
Every automobile model requires a set of unique parts and spare parts. It itself poses a challenge for the automobile part manufacturers. The skills and expertise of automobile engineers are used to create designs that add efficiency to the me.
Design considerations While using progressive tools
The automobile industry requires metal parts of high complexity and demands a bulk production of the same. Therefore, these are usually produced using progressive tools.
However, there are a few design considerations while manufacturing automobile parts using this technique. These are crucial in determining the final layout of the progressive strip.
How will the part run through the progressive die?
The answer lies in the geometries of the parts and their critical tolerances. Rotating the metal sheets to optimize the metal sheets may be required. It may lead to deterioration of the strength of the material, as it may affect the grain direction depending on the malleability and tolerance of the material. The grains can make the material easily fragile and have lesser consistent angles.
In a trade-off between the material optimization and angling tools, the overall tooling costs may shoot up. The rotation sometimes requires lifting the metal sheet to carry the strip to the die.
How to carry parts in the strip?
When this is clear, you know the ability of dies to feed and lift the feed for striping. There are few options available for carrying a part. Choosing the right one depends on the part configurations. For example, if the part is laid out end to end or rotated, the scraps are filled inside the parts to carry them to the strip. It ensures minimal scrap.
If the parts require heavy-duty forming, then they can be carried on one side of the strip. However, the downside to this approach is that it may require lifters at the center of the metal strip to maintain the balance. While this may not pose a problem for small or medium-sized parts, heavy parts may be subjected to misfit, which ultimately compromises the accuracy of the output.
What is the number of pivots required?
The number of pivots and the technique of piloting depend on the part configuration and tolerance requirements. You need to ensure the material can tolerate pivoting off of holes. The holes must be big enough and adequately spaced to facilitate pivoting action. Proper placing of pilot holes is a must stabilize the strip and facilitate the proper forming process.
While designing hole tolerances must be considered. If tight, it can cause scrap parts with the slightest elongation of the material during the metal forming process. This elongation can be due to an old feeder or due to misalignment of part in the striper.
How will the metal strip exit the die?
It is one of the most crucial aspects of designing the progressive tool. The removal of metal strips from the die involves either rotation of the metal part, or changing the alignment of the part within the die, or simply cutting and dropping the metal strip.
Conclusion
The progressive tools are a legitimate means to manufacture automobile components in bulk amounts. As it uses intricate technology, where over one stamping operation occurs, designing the progressive dies perfectly is of utmost importance.