In sheet metal manufacturing, the feature-based design and analysis of progressive press tools are pivotal. Using progressive tools to work on sheet metal for producing specific metal components is a highly fine process. This industrial engineering feat depends on multiple features
These include sheet metal properties, the layout of the strip, equipment positioning, die shear, and the final component specifications. Progressive press dies are designed after myriad calculations, careful planning, and analysis. To prevent die failure or incorrect dimensions of the final part, quantifying all the possible features and parameters is necessary. It also ensures cost-effective manufacturing with quick turnovers.
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Making Design Calculation for Progressive Press Tools
To accurately plan and design progressive press tools, the following data points need to be calculate:-
- Component Data– Based on the type of metal being used, deduce the die shear stress, tensile strength, impact level, and dimensions. The accuracy of progressive press dies designing is directly proportional to the accuracy of your component data.
- Tool Specifications– These include the press type and capacity, conveyor belt width and clearance, feeding method, stroke type, and tool dimensions. Therefore the number of strikes and pitch specifications also need to be take into account.
Software for Real-time Visualization of Progressive Press Dies
Tedious manual calculations and drawings are no longer require.
With the advance progressive press tool designing software available nowadays, highly efficient results can be attain seamlessly. currently, Some metal stamping vendors still prefer the manual method over computer-aided ones.
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But a majority of metal stamping companies worldwide have embraced digital technology like 3D visual mapping and software-aided designs. There are several disadvantages of the manual method. Being time-consuming and prone to errors are obvious ones. The biggest con is in case of a trial run deficiency, one has to begin from scratch yet again. Software-aided designs and workflow models help you edit/modify the arrangements as per the trial run shortcomings if any.
Latest Insights on Progressive Press Tools
An increasing number of metal stamping vendors are depending on progressive press tools. As compared to the transfer press, these are much more efficient to produce large outcomes of metal parts with complex sizes.
Since multiple stamping operations are simultaneously imparting in a single stroke, it is a much faster process.
The need to develop automated arms as in the case of a transfer press is no longer require, hence this saves both manpower and money. The overall intricacy of the arrangement and space require for the stamping unit also gets minimize with progressive press dies.
Progressive Press Tool Designing: Best Practices for Scrap Minimization
The higher the efficiency of the progressive press dies, the lower is the volume of scrap/waste metal produce. After each metal stamping procedure, a certain part of the metal sheet gets discard as scrap.
A competent metal stamping team will always focus on designing progressive press tools with minimal wastage. This will lower the final pricing of the metal components and ensure the cost-effectiveness of the entire project. Before you charge any vendor with your metal component manufacturing requirements you should ask them about their best practices for scrap reduction. Here are some of the commonly adopt practices by top-notch sheet metal stamping experts:-
- Highly accurate, software-aided designing of press tools, along with extensive trial runs
- Precision-based placement of tools for a smooth press cycle
- Clubbing maximum number of metal stamping operations for longer operational runs
- Multiple checks on designing and alignment taking all possible factors into account
- Innovative methods to reuse metal scrap in subsidiary projects
Conclusion
There is no scope for error in progressive press tools design. Even a small miscalculation can wreak devastation in the operational sequence, affecting the speed, efficiency, scrap yield, and component quality. Only a well-experienced and certified team should be entrust with the design and analysis of progressive press dies. Well-versed press-setting and precision-based tool making are the keys to full sheet metal manufacturing facilities.
