How Much Does A Progressive Die Cost? Advantages Of Progressive Die Stamping vs. Transfer Die Stamping
The metal stamping industry is growing by leaps and bounds, with more manufacturers leveraging the cost-effective and fast technique. One of the most common metal stamping techniques involves progressive stamping due to its capability to produce small and medium metal parts of complex shapes in a stipulated time.
Even though it is one of the cost-effective processes, there are a few factors that decide the cost of progressive stamping. This article discusses how you can reduce operational and production costs of progressive stamping and discusses its advantages over transfer die stamping.
Best Practices To Reduce Progressive Stamping Costs
If you want to enjoy maximum benefits from progressive stamping, you must know the best practices that lead to maximum utilization of the metal sheet and minimum operational and production costs.
Here are some of the things you must consider during the design phase:
- The stock lace-up point must be able to lace up the metal sheet without creating half slugs. A misfit could lead to the metal sheets getting stuck in the die and create breakage.
- Minimize the Press stroke length as 200 strokes per minute with a 2-inch stroke is almost equivalent to 400 SPM with a 1-in. stroke.
- You need to carefully include slug controls like slug notches in the die sections, vacuums, punch rooftops, and slug dart in the design.
- Do not compromise with die features like using larger guide pins to prevent flexing or adding extra workstations. It adds to the robustness of the design and avoids restrike stations that ultimately add to the cost.
- Use sensors and stock support liners to prevent stock feeding issues.
- Create a checklist that outlines the must-haves to operate a successful progressive die design. A review discussion with your team can bring out the areas of improvement in the design.
Advantages of Progressive Die Stamping vs. Transfer Die Stamping
Progressive die stamping is often compared with transfer die stamping as both of them use multiple dies at multiple stations. The difference between them is that:
- In progressive die stamping metal coil or sheet is fed into a stamping press that simultaneously operates the designated stamping operations like punching, bending, cutting, etc. The workpiece never loses its touch with the base strip throughout the process.
- In transfer die stamping, the metal coil or sheet goes into the stamping press table. Here each workstation is considered as an individual unit. Every operation works in a sequence. The workpiece is detached from the base strip after every operation. It is transferred through the tool with fingers to different stations.
Progressive die stamping is often the preferred choice to manufacture complex geometries at high speed and has high repeatability rates. It uses metals such as steel, aluminum, copper, stainless steel, and brass and, in rare cases, also supports noble metals and titanium.
The progressive die stamping press tool must be made of steel. It increases the cost of investment, as it requires permanent steel tooling. The prominent advantages of using progressive die stamping are:
- It is capable to produce small and medium metal parts suitable for industrial applications with high tolerances
- The setup process is easy and takes less time.
- As more than one operation works simultaneously, it reduces human interference and hence the labor
- It has proven long run lengths
- With proper design, you can minimize the metal scrap.
The transfer dies stamping is ideal to create metal parts that need intricate design elements like knurls, ribs, and threading. It is, therefore, the most popular metal stamping technique to produce metal parts for tube applications. Since the metal strip gets detached at every station, you can use it for deep drawing.
The materials appropriate for this technique are similar to that for the progressive die stamping, such as aluminum, brass, copper, Inconel, stainless steel, and noble metals.
The progressive stamping tool design plays a crucial role in deciding the overall cost of the progressive die stamping technique. For applications where you need deep drawing and intricate designs, transfer dies are the best option. For metal parts with high tolerances, complex geometries, and moderate sizes, investing in a progressive tool component is a wise idea.