Lab Session 10

Objective
Design a progressive die for a 50 mm washer with 10 mm hole in the center. Thickness of the
washer is 0.8 mm and the material is stainless steel (Shear stress = 400 MPa, Ultimate tensile
strength = 580 MPa).

Theory
Progressive Die Stamping Process
Progressive Die Stamping is a cutting and forming process that utilizes a “Die” that contains a
series of stamping stations to perform simultaneous operations on sheet metal that has been
supplied on coiled strip. The final metal work piece is developed as the strip of metal is processed
through the stamping die. This transformation is performed incrementally, or progressively, by a
series of stations that cut and form the material into the desired shape. A Progressive Stamping
Die ("Die") is a metalworking device that is designed and built to convert a flat strip of metal raw
material into completed parts which conform to print specifications.
The Die is placed into a stamping press. As the stamping press moves up, the die opens. As the
stamping press moves down, the die closes. The metal moves through the die while the die is open,
being fed into the die a precise amount with each stroke of the press. The stamping die can modify
the raw material in several ways, such as cutting, bending, coining, shaving, burnishing, extruding,
lancing, embossing and drawing. When the die closes, the die performs its work on the metal and
one or more finished parts are ejected from the die. The finished parts may either be separate
(discrete) or connected to a carrier strip and supplied on disposable or returnable reels.
The linear travel of the strip stock at each press stroke is called the “feed progression” or “pitch”
and is equal to the distance between stations.
The unwanted parts of the strip are cut out as it advances through the die and one or more
ribbons or tabs (carrier strips) are left connected to each partially completed part to carry it
through the remaining stations of the die.
In a progressive die, the part remains connected to the stock strip which is fed through the die with
automatic feeds and positioned by pilots with speed and accuracy. Since additional work is done
in each "station" of the die, it is important that the strip be advanced very precisely so that it aligns
within thousandths of an inch as it moves from station to station. Bullet shaped or conical "pilots"
enter previously pierced round holes in the strip to assure this alignment since the feeding
mechanism usually cannot provide the necessary precision in feed length.

Progressive (punch and blanking) die with strip and punching

The components of the die that perform operations on the material are unique for every part. These
components are located and guided in precision cut openings in plates which are in turn located
and guided by pins.
The entire die is actuated by a mechanical press that moves the die up and down. A press feeding
mechanism is also responsible for feeding the material through the die, progressing it from one
station to the next with each stroke.
 Advantages
The benefits of utilizing the progressive die stamping process characteristically include:
• The ability to utilize of multiple cutting and/or forming operations simultaneously
• Excellent suitability to produce components at a rapid rate
• The ability to produce two or more parts per press stroke
• Quick set-up
• Ability to maintain control of part location throughout stamping process
• The capability to maintain consistently close tolerances
• High press tonnage
• Offering high: volume production capabilities
• Materials efficiency: less scrap/metal wastage
• Time efficiency: one set-up, multiple operations
• Production efficiency: faster cycle times per part
• Flexibility: multiple forms/lines/shapes with one operation
• Less downtime: fewer tooling changes, longer production runs
• Precision Stamping: enhanced repeatability, fewer failed parts/products
• Cost-effectiveness: lower cost per part, accelerated production, higher output

Demerits
• They usually cost more than line or transfer dies.
• They often require precision alignment and setup procedures.
• They require a coil feeder system.
• They require an open-ended press to allow for the metal to feed into the die.
• Damage to a single station requires removing the entire die set.
• They often are much heavier than single-station line dies.
Applications
Some of the metal-shaping techniques commonly used in progressive metal stamping are
coining, bending, punching, fine blanking and deep drawing (transforming metal into shapes
in which depth is greater than diameter).

Progressive die stamping parts depend on size, complexity, and production volume.
Progressive die stamping is used to produce a large number of parts, and maintain the lowest
cost as possible. It also need to meet the required precision and durability.
A good example of progressive die stamping parts is the cover of a beverage can. The cover
is pulled by progressive die stamping process and assembled at right angle to the can. A
variety of automotive calipers can be bent into plate by progressive die stamping process,
too.
Material
The progressive stamping process can be applied for a variety of metals, including:
• Aluminum
• Brass
• Copper
• Galvanized Steel
• Hot and Cold Rolled Steel
• Stainless Steel
• Titanium
• Zinc
Design Calculations
Punch and Die size Calculation

Value of allowance for different metals

Type Allowance

1100S and 5200S tempered aluminum alloys 0.045

2024ST and 6061ST, aluminum alloys, brass (all 0.06

tempered), rolled steel, soft cold rolled stainless steel

Cold rolled steel, half hard-stainless steel and full hard 0.075
Clearance
c=at
t=0.8mm
Value of allowance for stainless steel=a=0.075
c=0.075× 0.8
=0.06mm
Piercing
Punch and die sizes for round holes (piercing operation) can be found out by
following formulas;

Punch diameter= Dh =10mm

Die diameter = Dh +2c=10+2(0.06)

=10.12mm
Where Dh is the diameter that has to pierced, while c is the clearance.
Blanking
Punch and die sizes for blanking operation can be found out by following formulas;

Punch diameter= Db -2c=50-2(0.06)

=49.88mm
Die diameter = Db=50mm

Where Dh is the diameter that has to pierced, while c is the clearance.

Cutting Forces
Cutting forces are important as they determine the size of the press needed.
Fc = Cutting Force = StL
= (2π*5*0.8*400)
= 10053.1N
=1.02513 tonnes
Fb = Blanking Force = StL
= (2π*25*0.8*400)
= 50265.48246N
=5.1256 tonnes

TS is the ultimate tensile strength.

Angular Clearance
In order for the slug or the blank to drop through the die, the die opening
must have an angular clearance of 0.25o to 1.5o on each side.
Assembly of Progressive Die
Tool Steel is used to make the progressive die.