Progressive dies are required to produce large quantities of sheet metal parts cost-effectively. We at Precision Forming in Amtzell offer our customers the complete range of progressive dies.
The advantages and disadvantages of a progressive die:
Advantages
- High stroke rate and therefore high output (ideal for large series of small parts)
- Simple material feed, i.e., no transfer bar is necessary because the part hangs on the strip
- Compact tool design
Disadvantages
- More complicated for deep forming
- Not suitable for large parts
The starting product for parts manufactured using a progressive die is usually a sheet metal in the form of a coil. The sheet metal is straightened and then moved through the press from station (die stage) to station in time with the press cycle. At each stage, the sheet metal is punched, stamped, formed, rolled, bent, etc. until it has the desired shape. The finished part is then separated from the sheet metal strip, preferably at the end of the process. The sheet metal strip connects the parts, which, in contrast to transfer tools, allows for easy material feed.
In general, a progressive die project with us begins with the strip pattern and ends with the tool tryout. If desired, we are also happy to provide support during part development or later during part production (pre-series/series).
Project process for progressive dies
Step 1: Strip pattern and forming simulation
First, the strip pattern (the method) is developed. This involves determining which processing steps are to be carried out in each individual stage until the final shape of the sheet metal part is achieved. The strip pattern shows the state of the part “hanging” on the sheet metal strip after each step. It is not uncommon for the process to involve more than ten processing steps (also known as operations).
For sheet metal parts that are produced in very large quantities, it has proven effective to manufacture two (or four) parts per cycle. The strip that “connects” the parts until the end is then centered, making the strip pattern symmetrical. This cancels out all the forces in the press that act outward.
In the accompanying forming simulation, the individual steps of sheet metal forming are simulated digitally in order to identify methodological errors and optimize the tool. We use Simufact Forming as our simulation tool. We also have the option of analyzing and improving the strip pattern or method using Autoform.
Step 2: Tool design
Based on the strip pattern and the simulation, the tool is then designed using CAD. Our experienced designers use the CAE programs CATIA or Inventor for this purpose. The virtual tool is then created in close consultation with the production department and the customer.
Step 3: Tool production and tryout
Once the design has been approved, the manufacturing process begins. Standard parts and production parts are sourced externally or manufactured at our plant in Amtzell. Thanks to our wide range of machine tools, we are generally able to produce many of the production parts in-house. Modern machining centers, grinding machines, wire EDM machines, and 3D metal printers are available.
Once all relevant parts of the tool are in-house, they are assembled and then tested. We have various presses and systems available for the so-called tryout. Thanks to our machine park, we are independent of suppliers when it comes to necessary optimization grinding and can quickly implement improvements.
If the part to be manufactured ultimately meets the specified and agreed requirements, the tool is approved and delivered.
Do you have any questions about progressive tools or would you like to start working with us?
Then don't hesitate to contact us – we are looking forward to hearing from you!
