Progressive die stamping is a metal stamping process that facilitates the production of stamping parts at high speeds. In progressive metal stamping, the metal blank moves at a high speed while presssing down against an anvil die that impacts the blank between two or more dies. During each particular die, an impression is made on the material. After the completion of all die impressions, the completed part is ejected from the machine with a high speed. Progessive metal stampings differ from other forms of stamping processes in terms of their unique manufacturing process and cost effectiveness.
During the metal stamping services, there are different techniques that manufacturers and metal stamping companies may use to speed up the process. These techniques ensure that the metal stamping parts manufactured have a greater level of accuracy than the metal stamping parts manufactured using conventional stamping. Let’s take a look at some of these techniques in detail.
Have you ever wondered how the popular domed shape on coins and medals is made? A progressive die stamping press is the machine that makes these shapes. This is a tutorial illustrating how this process works. The standard dies with the coin motifs are usually created in an offset printing shop using steel dies. The offset printing plates are expensive and time consuming to create, so it is much more cost effective to have a steel die made from the plate used for printing. This can then be used to make cheaper and faster die stamping plates for stamping coins and medals.
The following metals are frequently used in progressive die stamping
- Stainless steel
Metal formation techniques
The progressive die stamping method frequently incorporates various metal modification techniques, such as: Non-traditional clamping treatments (Including no clamps at all!) Force-fit banding & various assembly methods. Precision Die & Stamping Die grinding (Remove burrs for precise machined fit) Bead blast or heavy grit sanding for grit contacts to create a “tighter” fit or dialed in radiuses.
Bending is a forming method for metal parts:
Bending involves pulling a blank into the desired shape by deflecting it with a punch or blow to the work surface. The blow may be delivered mechanically or with a hammer. Bending is commonly used to make metal parts that are subject to bolt or weld attachment requirements or that must be used in multi-part assemblies.
Flanging can be performed on almost any type of metalwork.
Flanging is the process of creating a tubular flange or an edge flange onto a workpiece. These flanges are then used in a manufacturing process to enhance the quality of the end product. Flanging can be done manually, semi-automatically, and fully automatically using special tools and machinery. A piece of sheet metal that has been formed into a tube forms a flange when the other end of the sheet is joined to it. The edges of this sheet serve as the base to form an edge or surface flange.
Punching is a metal formation technique used by manufacturing industries.
The punching method of forming is a type of blanking process. A punch, in this case, refers to the cutting tool that cuts material by removing mass (created by the die) from the workpiece. The punch has a slightly tapered shape on one end which fits into a matching shaped cavity in one end of a die. This die shape determines the final hole for the shape of the workpiece being formed and is always symmetrical about the center plane of symmetry.
Coining is a metal forming method involving the use of a die
It’s a technique that’s been used by smiths for ages; The term itself can be traced back to the 17th century. The technique is quite versatile, allowing the artist to create a variety of patterns depending on how much force is applied and how long the squeeze is held for.
Material choice, part design, and tooling selection are among the considerations essential to achieving the best results with a high-volume progressive stamping process. When pressure-forming metal sheets into parts, progressive dies perform multiple operations in one die, often in a single press (or punching) pass. This eliminates or significantly reduces secondary operations as well as avoids secondary equipment setups. The result is reduced labor, increased capacity, and improved cycle time.