3.11.

2020 Custom Three Post Progressive Stamping Die Design with Feeder Coiler

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Custom Three Post Progressive Metal

Stamping Die Design
There are special requests toward the progressive stamping die that
must be included in a tool and die design that ensures trouble free
long service as well as following guidelines set by the client.
 
Stamped part must be flat 
High volume production 
High speed punch press is available for the tool 
Coil will be used. No room for the exiting coil. Coil must be cut to
small pieces 
Progression is controlled by a feeder. Manual operation may be
required 
Stamping die must be easily accessible for in-tool adjustment,
maintenance

Stamped Part Must Be Flat 

When the stamped parts must stay flat, pressure plates must be
used both from the top and from the bottom as well. Without the use
of pressure plates, the stamped parts will be slightly bowed. As the
punch forces the part to cut out from the stock it applies a lot of
force and stress to the steel. The die plate supports the cut part on
its outer perimeter with no support within.
As a result, the stamped part will try to bulge downward from the
blanking pressure before the stock or sheet metal yields and
separates from the rest of the strip. This minor deformation remains
in the part. Sometimes the flatness of the part is important, and this
minor distortion is not acceptable. To overcome this problem and
ensure that the part remains flat, the blanked part must be
supported well while separated or blanked from the stock. A lower
pressure plate with the same profile must be under the part,
preventing it from bulging. The top face is supported by the cutting
face of the punch, while an upper pressure plate holds the strip
down, preventing from bulging upward around the cut edges. The
force behind the pressure plate  must be greater than the force that
could result deformation. Standard die springs are generally not
powerful enough to produce so much pressure, especially when the
blanked parts are small. For smaller parts smaller sprigs are used
due to space limitations.
Since the part is trapped between the lower pressure plate and the
punch, it can not exit the tool with the same stroke. The cut part is
pushed back into the strip by the lower pressure plate (usually
partially). It then carried forward with the progression and then
knocked down in an empty station, separating it from the strip. 
 
The use of nitrogen filled gas springs can do the job well, while
lasting much longer than conventional springs. E.g. a 1 inch
diameter 2.5 inch long extra heavy duty spring (strongest available)
can produce around 340 lbs at 15% compression or 0.375
compressed distance. At 0.200 compression the force is less than
120 lbs.
A nitrogen filled gas spring, also 1 inch in diameter can produce
between 955 – 1,700 lbs.
No pre-load is necessary, so a lot of force can go against the blanked
part, preventing it from deformation. As an upside, it saves the
thread of the shoulder bolts and its retainer. Since no pre-load
required, the shoulder bolts could have e.g. 0.005 slack of free
movement with no stress on them whatsoever. 

High Volume Metal Stamping Part High Speed Punch Press 

Production  There are different punch presses with different speed. The stroke
per minute (SPM) ranges from 30 and up. Average high-speed
When the amount of parts to be produced are high, you want the tool presses run around 200 spm. Some can get much higher.
last long, without down time, without sharpening. Generally used

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3.11.2020 Custom Three Post Progressive Stamping Die Design with Feeder Coiler
tool steel for punches and dies are suitable for most applications. This speed means more friction and more heat. Not only the tool
When the stamped part is harder, and the amount is high, you want steel should be chosen accordingly, but the die set that will slide up
to use a suitable tool steel for the cutting components. At this design and down, while precision guiding the components. The die set
CPM10V tool steel was used.  should not overheat and jam. Most presses run at 30 – 80 spm can
use standard guided die sets that require regular lubrication, grease

Coil will be Used 

 
When coil is used to stamp the parts from you need to consider what
to do with the coil as it exits the die. Either it should be wind back
again and dispose the used or stamped coil when run out, or cut the
stock at each stroke, so only small bits are exiting the tool as scrap,
that is easy to collect and dispose. For this reason, a scrap cutter is
designed to separate the exiting portion from the coil.  between the bushing and the pin when fully engaged. This guide
while in production. If the same die set with standard guide pins and
bushing would be used running at 200 - 400 spm, it would not take
long before the sliding components would swell from heat
expansion and would seize.
There is a solution for that. Ball bearing guided units are available.
There is a called ball cage, a bushing and a die pin. The ball cage
retains the hundreds of ball bearing balls. The balls are tightly roll
system is designed for high speed production. For ball bearing guide
components grease is not recommended. They work better dry. This
special three post design allowed to use a smaller footprint die set
while giving plenty of room for the stock pusher, and more room for
in tool adjustment or maintenance 

Progression of Metal Stamping

Die Controlled Feeder
Manual operation may be required 
 
When coil is used to produce the parts from, it is necessary to use a
feeder that can be set for the proper progression. The feeder
advances the stock forward by the amount of the progression it was
set to. To control the progression as precisely as possible, internal,
mechanical components are used in conjunction with a feeder.
These are e.g. French stop, also called side trim or side notch. Pilot
punches are also used for precision positioning. The pilots are about
0.002 smaller than the hole diameter that they go into and were
pierced usually at the 1st or 2nd progression. Progressive metal
stamping dies can have easily over 10 progressions before the
finished part is complete. From this point a complete part is made at
every stroke. As part of the of the proper progression and its
To prevent such events and when the feeder is in use, a misfeed
effectiveness, stock pushers should be used to keep the coil or strip
sensor can be used. In this design instead of using a French stop
coaxial with the feed direction and at a relative position, e.g. datum
based pivoting electro- mechanical misfeed sensor, a different one
face, in this case the rear edge of the coil.
was designed. It eliminates moving components as well as gives
more free space at the front. The sensor was placed above the strip.
French stops are the first line in progression control. Its distance is
When the coil is passing through it makes the sensor give out
set by the design and manufactured accuracy. IT does not change
signals, either when it detects metal under or does not detect
from time to time. The feeder could slightly over feed while allow
slipping to prevent strip buckling. If used properly the progression anything because there is a hole. When the proper progression is
amount always equals the dimension of the French stop which has reached, the sensor can give signal to the PLC and then to the feeder
the dimension for the progression. Many feeders have options for and to the press to go ahead and make the next stroke. When the
pilot release. This is to temporarily release the grip the holds the coil strip is e.g. jammed for any reason and could not fully reach the set
to be advanced. At that moment, the pilots can freely position the progression, the sensor will not give out the signal to proceed,
strip for the optimum position before the next hit. Feeders without a therefore both the feeder and press is stopped until corrections
pilot release can fight the pilots, easily under or over feed, that can were made and cleared the jam.
cause error and crashes. Another advantage of the use of French
stops is that the tool or rather the strip advance can be done Such event should not happen ever but if it does, it means tool crash
with considerable down time, repair costs and possible injuries.
manually in case the feeder is out of commission.

The French stop or side trim cuts a portion off the edge of the strip
with the length of the progression. You advance the strip until it can
not go any further. The back end of the notch reaches a stationary
stop block. The block is made thicker than the stock thickness to
prevent the strip going over the stop. It is not possible to over feed
or make the progression more than the cut notch length. However, it
can be under fed, when the back end of the notch does not reach the
stationary stop.

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Custom Three Post Progressive Stamping Die Design with Feeder Coiler
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