Progressive Die Design 3z111t
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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
Die
Product
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 . Tool Maker
Manufacturing
Production
Progressive Die life cycle Quotation
Preliminary design
Quotation:
Strip Design
Tool Design
Documentation
Tool
Tool
Manufacturing
Maintenance
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
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Tool Design
Documentation
Quotation: Part formability – sharp edges Press requirements , Available presses Transfer specifications Feed method Production Volume Material savings Part rotation Multi station , single station
Tool
Tool
Manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Tool Design
Preliminary design ????? Geometry modification : Stiffening , Dimpling Notches, flanges
Springback compensation, forcing Material , press
Documentation
Tool
Tool
Manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Tool Design
Documentation
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
Tool
Tool
Manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Strip design : Intermediary Blank calculation Square blank Semi developed Blank
Tool Design
Documentation
Tool
Tool
Manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Strip design: design Analysis Blank shape Springback Safety margins Thinning analysis Punch force Safety zone Forming zone Wrinkle
Tool Design
Documentation
Tool
Tool
manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Tool Design
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
Documentation
Tool
Tool
manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Strip design :Nesting
Tool Design
Documentation
Tool
Tool
manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Carrier Strip balance Strip motion Material usage Part shape Connection area
Tool Design
Documentation
Tool
Tool
manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Pilot : centering pins
Tool Design
Documentation
Tool
Tool
manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Tool Design
Web : Remaining frame after product cuts Supply stiffness to the strip Allow smooth pulling where needed
Documentation
Tool
Tool
manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Tool Design
Web : Remaining frame after product cuts
Documentation
Tool
Tool
manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Tool design : Die Die size ,tolerance required Die material Draft angles Relief Radius , sharp edges
Ejection - Springs calculation Scrap removal
Tool Design
Documentation
Tool
Tool
manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Tool design : Stamp Die size – location Define bending – springback Punch structure Add Radius Avoid sharp edges Smoothness
Tool Design
Documentation
Tool
Tool
manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Tool Design
Documentation
Tool design : assembly Die set - standard components (Springs , gas pistons ) Tool material - Steel , stainless steel ,carbide Assembling to the press
Tool
Tool
manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Tool Design
Tool design : assembly Static side Balance - rails , pilots , spacers Guide unit – Bearing sleeves
Documentation
Tool
Tool
manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Tool design : assembly Sliding side striper plate , Springs
Tool Design
Documentation
Tool
Tool
manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Tool Design
Documentation
Tool design : Elements to be addressed product ejection Scrap handling Strip entrance, feed smoothness Lifters Die Lubrication
Tool
Tool
manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary Design
Strip Design
Tool Design
Documentation
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
Tool
Tool
Manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Tool Design
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
Documentation
Tool
Tool
manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Manufacturing Wire EDM cut Drill Milling Grinding
Tool Design
Documentation
Tool
Tool
Manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Maintenance Ironing Removal Grinding Milling Heat treatment Springs replacement Lubrication
Tool Design
Documentation
Tool
Tool
Manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Maintenance Heat treatment Inserts
Tool Design
Documentation
Tool
Tool
Manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Tool Design
Documentation
ECO Intermediary shapes updates Strip modifications Tool modifications
ECO
Tool
Tool
Manufacturing
Maintenance
End of part 2
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
Die
Product
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 . Tool Maker
Manufacturing
Production
Progressive Die life cycle Quotation
Preliminary design
Quotation:
Strip Design
Tool Design
Documentation
Tool
Tool
Manufacturing
Maintenance
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
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Tool Design
Documentation
Quotation: Part formability – sharp edges Press requirements , Available presses Transfer specifications Feed method Production Volume Material savings Part rotation Multi station , single station
Tool
Tool
Manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Tool Design
Preliminary design ????? Geometry modification : Stiffening , Dimpling Notches, flanges
Springback compensation, forcing Material , press
Documentation
Tool
Tool
Manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Tool Design
Documentation
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
Tool
Tool
Manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Strip design : Intermediary Blank calculation Square blank Semi developed Blank
Tool Design
Documentation
Tool
Tool
Manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Strip design: design Analysis Blank shape Springback Safety margins Thinning analysis Punch force Safety zone Forming zone Wrinkle
Tool Design
Documentation
Tool
Tool
manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Tool Design
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
Documentation
Tool
Tool
manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Strip design :Nesting
Tool Design
Documentation
Tool
Tool
manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Carrier Strip balance Strip motion Material usage Part shape Connection area
Tool Design
Documentation
Tool
Tool
manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Pilot : centering pins
Tool Design
Documentation
Tool
Tool
manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Tool Design
Web : Remaining frame after product cuts Supply stiffness to the strip Allow smooth pulling where needed
Documentation
Tool
Tool
manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Tool Design
Web : Remaining frame after product cuts
Documentation
Tool
Tool
manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Tool design : Die Die size ,tolerance required Die material Draft angles Relief Radius , sharp edges
Ejection - Springs calculation Scrap removal
Tool Design
Documentation
Tool
Tool
manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Tool design : Stamp Die size – location Define bending – springback Punch structure Add Radius Avoid sharp edges Smoothness
Tool Design
Documentation
Tool
Tool
manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Tool Design
Documentation
Tool design : assembly Die set - standard components (Springs , gas pistons ) Tool material - Steel , stainless steel ,carbide Assembling to the press
Tool
Tool
manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Tool Design
Tool design : assembly Static side Balance - rails , pilots , spacers Guide unit – Bearing sleeves
Documentation
Tool
Tool
manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Tool design : assembly Sliding side striper plate , Springs
Tool Design
Documentation
Tool
Tool
manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Tool Design
Documentation
Tool design : Elements to be addressed product ejection Scrap handling Strip entrance, feed smoothness Lifters Die Lubrication
Tool
Tool
manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary Design
Strip Design
Tool Design
Documentation
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
Tool
Tool
Manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Tool Design
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
Documentation
Tool
Tool
manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Manufacturing Wire EDM cut Drill Milling Grinding
Tool Design
Documentation
Tool
Tool
Manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Maintenance Ironing Removal Grinding Milling Heat treatment Springs replacement Lubrication
Tool Design
Documentation
Tool
Tool
Manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Maintenance Heat treatment Inserts
Tool Design
Documentation
Tool
Tool
Manufacturing
Maintenance
Progressive Die life cycle Quotation
Preliminary design
Strip Design
Tool Design
Documentation
ECO Intermediary shapes updates Strip modifications Tool modifications
ECO
Tool
Tool
Manufacturing
Maintenance
End of part 2
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