Progressive Die Design

Progressive Die Design
Ronen Ben Arieh
Alpha Group
Die Design
Session plan
Environment
What are Dies?
Die technology
Progressive Die life-cycle
Progressive Die design step by step
Conclusions
Environment
Terminology
Die = press tool
Punch = male
Die = Matrix = Female
Blank = sheet format

Environment
Press
Common propulsion
Mechanical - simple force curve , cheap
Hydraulic - controlled force & motion curve.
Pneumatic - controlled force curve , expansive , use for small parts
Environment
Press
Features
Clamping Force
Stroke
Size
Open \ Close wall
Cycle rate
Environment
Die Product
Ability to Unfold
No sharp corners
Sharp corners >> Inner radius < sheet metal thickness
Environment
Die Product
Environment
Single axis part
At least one face keep its position along the operation
Multi axis part

Operations required part rotation
What are Dies ?
Die - transform a flat strip of metal into a part.
Coil Product
Die
Die Technology
Die production A combination of basic operations:
Material removing
Blanking (cutting)
Punching (cutting)
Plastic Forming
Bending
Forming
Stamping
Die Technology
Cutting Die
Die Technology
Cutting Die
Die Technology
Cutting
Die Technology
Fine Blanking
Die Technology
Cutting Die example
Compound Die Multi operations in one stroke
Die Technology
Stamping Die
Die Technology
Stamping Die
Die Technology
main Die types are:
Compound Die
Line Dies
Transfer Dies
Progressive Dies
Die technology
Line Dies
Die 1 Die 2 Die 3
Die technology
Line Dies
Each Operation required a separate press
Big parts
Run together in a common press
Cheap Die , Cheap Maintaining
Allow Multi axis rotation - complex geometries.
Smaller tools ,lighter die
Low production volume
Several presses required to manufacture a single part.

Require expensive robots or human resource.
Die technology
Transfer Dies
High Volume
Big and complex parts
How does it work
A piece is trimmed from the strip as the first Operation
Metal piece is transferred independently along the Die
Die technology
Transfer Dies
Mechanical feeders
Clamps transfer
Balance with/without pilots
Die technology
Transfer Dies
Die technology
Transfer Dies
Die technology
Transfer Dies
Die technology
Transfer Dies
Large parts
Stamped parts can be turned over or
rotated. (Multi axes parts)
Material savings - No strip
Expensive.
Require sophisticated equipment
Die Technology
Progressive Die
Combines a number of forming and trimming functions
performed continuously on a metal strip.
Die technology
Progressive Die
Great Production rate ~100 per min and Up
Steel is fed into the die, typically from a coil.
Each die cycles perform multi operations along the strip
Material progresses automatically along the die.
Completed parts is cut and ejected each cycle
Die technology
Progressive Die
Great volume production
They often can run unattended.
Require only one press.
expensive
Require precision alignment and setup procedures.
Require a coil feeder system.
Require an open-ended press.
Damage to a single station requires removing the entire die set.
Much heavier than single-station line dies.
Die technology
Progressive Die
Progressive Die life cycle
Quoting
Strip design
Tool design Maintenance
Tryouts
Documentation
Customer
E.C.O
Manufacturing Production
.
Tool Maker
Preliminary Tool Tool
Quotation Strip Design Tool Design Documentation
design Manufacturing Maintenance
Quotation: Die cost , Product cost
Approximate Die type and size

Blank shape & size.
Utilization
Quotation should be quick and supply accurate data (half day)
~2% of Quotation lead to die project

Quotation:
Part formability sharp edges

Press requirements , Available presses
Transfer specifications
Feed method
Production Volume
Material savings
Part rotation
Multi station , single station
Preliminary design ?????
Geometry modification :
Stiffening , Dimpling
Notches, flanges
Springback compensation, forcing
Material , press
Strip design : Intermediary shapes design

Basic operation required Trim , bend
Orientation ,operation Order , accuracy
Unfold , Blank calculation
Unfolding and blank calculation
Bending , unbending
Twisting
Die Stroke
Strip design : Intermediary
Blank calculation
Square blank
Semi developed Blank
design manufacturing Maintenance
Strip design:
design Analysis
Blank shape
Springback
Safety margins
Thinning analysis
Punch force
Safety zone
Forming zone
Wrinkle
Strip design :Nesting

Strip size
Number of parts (common 2)
Progression step
Number of progression
Nesting of blank on the strip

Balance of strip
Optimum position
Optimum material usage
optimal stiffness from the strip
Strip design :Nesting

Carrier
Strip balance
Strip motion
Material usage
Part shape
Connection area
Pilot : centering pins

Web : Remaining frame after product cuts
Supply stiffness to the strip

Allow smooth pulling where needed
Web : Remaining frame after product cuts

Tool design : Die

Die size ,tolerance required
Die material
Draft angles
Relief
Radius , sharp edges
Ejection - Springs calculation
Scrap removal
Tool design : Stamp
Die size location

Define bending springback
Punch structure
Add Radius
Avoid sharp edges
Smoothness
Tool design : assembly
Die set - standard components (Springs , gas pistons )

Tool material - Steel , stainless steel ,carbide
Assembling to the press
Static side
Balance - rails , pilots , spacers

Guide unit Bearing sleeves
Sliding side
striper plate , Springs
Tool design : Elements to be addressed
product ejection
Scrap handling
Strip entrance, feed smoothness
Lifters
Die Lubrication
Design Manufacturing Maintenance
Tryouts
Tryouts Goals
Product dimensions , accuracy ,quality

Die stability , Strip Feed , Strip balance
Die wear
Scrap removal
Production time
Die & Press fine tuning
Customer review & approval
Part drawing
Table of holes
Technology labels
Detailed part drawing for Punches include:
Name ,material , force , Operation
Assembly drawings
Ordinate dimension for Punch and Dies
BOM
Force subtotal force = Press force
BOM file
Manufacturing
Wire EDM cut
Drill
Milling
Grinding
Maintenance
Ironing Removal
Grinding
Milling
Heat treatment
Springs replacement
Lubrication
Maintenance
Heat treatment
Inserts
ECO
ECO
Intermediary shapes updates
Strip modifications
Tool modifications
End of part 2

Progressive Die Design

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Progressive Die Design

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Progressive Die Design

Ronen Ben Arieh

Die = press tool

Die = Matrix = Female

Blank = sheet format

Multi axis part

Several presses required to manufacture a single part.

Tool design Maintenance

Quotation: Die cost , Product cost

Approximate Die type and size

~2% of Quotation lead to die project

Part formability sharp edges

Preliminary design ?????

Strip design : Intermediary shapes design

Strip design : Intermediary

Strip design :Nesting

Nesting of blank on the strip

Strip design :Nesting

Pilot : centering pins

Web : Remaining frame after product cuts

Supply stiffness to the strip

Web : Remaining frame after product cuts

Tool design : Die

Tool design : Stamp

Die size location

Tool design : assembly

Die set - standard components (Springs , gas pistons )

Tool design : assembly

Balance - rails , pilots , spacers

Tool design : assembly

Tool design : Elements to be addressed

Product dimensions , accuracy ,quality

Wire EDM cut

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