Progressive Die - The Advanced Level of Metal Stamping
What is a progressive die?
A progressive die is a complex, multi-station die used in progressive stamping. It is designed to process flat metal strip into complex parts. As the metal strip is fed into the press, it continuously passes through the various stations of the die. Typically, each station performs a different operation, such as blanking, chamfering, punching, bending, rounding, and even deep drawing. Multiple operations are performed simultaneously during each stamping stroke, making progressive dies extremely efficient. The process is similar to an assembly line, with each station focusing on a specific task but working in tandem to transform the metal strip into the finished product, thereby increasing overall efficiency.
What is the difference between progressive dies and other metal stamping dies?
A simple die has only one station and performs only one operation per stroke, such as cutting, bending, or piercing, making it a single-purpose tool.
It is suitable for parts with low complexity. While multiple simple dies can be used in succession to form a single part, using too many dies significantly reduces efficiency.
It is suitable for small-batch production, especially for simple designs. Compared to compound or multi-station dies, they are generally less expensive and simpler to manufacture.
A progressive die differs from a simple die in several key ways:
It contains multiple stations, each designed to perform a different operation. This setup allows for the production of more complex parts with high precision and efficiency. In contrast, a simple die performs only one operation per punch stroke. Progressive dies, with their advanced feeding systems, can perform multiple operations simultaneously during each punch stroke.
Progressive die stamping is particularly advantageous for projects involving complex designs that require high-volume or large-scale production.
Comparison Between Tooling Dies: Simple dies vs. Compound dies vs. Progressive dies vs. Transfer Dies
| Feature | Simple Die | Compound Die or Combination Die | Progressive Die | Transfer Die |
|---|---|---|---|---|
| Operations | Single operation | Multiple operations (single stroke). Very limited to design. | Multiple operations (sequence). Slightly limited to design. Some complex drawing operations would require a transfer die | Multiple operations (transfer between stations). Any operation process is possible. |
| Stations | One station | One station | Multiple stations | Multiple stations |
| Complexity | Low | Low to medium | High complexity | High complexity |
| Mold testing and set up | Easy | Difficult | Moderate. Modules reduce complexity and increase set up efficiency. | Usually easier than progressive, but requires transfer and lifting devices that are also complex to design. |
| Efficiency | Very low | Low | Very high | High. Slower than progressive given the required transfer operations. |
| Cost | Low tooling cost, high part unit cost | Medium tooling cost, medium part unit cost | High tooling cost, very low part unit cost | Normally higher tooling and unit cost than progressive |
| Production volume | Low volume | Medium to high volume | High volume (appropriate for mass production) | High volume, (appropriate for mass production) |
| Suitability | Simple parts | Simple parts | Complex parts | Larger and/or concave parts, complex parts |
| Material utilization rate | Moderate to high | Moderate to high | Moderate. The need for pilots and carriers can reduce material utilization. A good design can highly reduce the scrap produced. | Moderate to high |
| Blanking operation | 1 stroke | 1 stroke | The last operation | The first operation |
Not sure which stamping tool is right for your project?
Dongmo has a strong R&D team dedicated to providing you with the best manufacturing solutions. With over 20 years of experience in transfer mold design, we can help you determine the best transfer mold type for your project and expertly design and develop the tooling and equipment needed for efficient and precise manufacturing. We are a leading global OEM manufacturer specializing in metal stamping, ISO 9001 certified.
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