Progressive Die Design Requirements

1. Purpose

To standardize the design requirements for progressive dies and ensure high precision, high stability, high production efficiency, and long tooling life during mass production of metal stamping parts. These requirements are widely applied in the automotive, electronics, home appliance, and new energy industries.

2. Scope of Application

Applicable to:

• Precision Metal Stamping Parts

• Stainless Steel Stamping Parts

• Electronic Terminals

• Automotive Metal Components

• Deep Drawn Parts

• Bending Parts

• Multi-Station Progressive Stamping Dies

3. Basic Requirements for Progressive Die Design

3.1 Product Analysis Requirements

A comprehensive product analysis must be completed before die design.

Analysis Content

• Product Structure

• Material Properties

• Material Thickness

• Tolerance Requirements

• Surface Finish Requirements

• Forming Process

• Production Capacity

Key Evaluation Points

4. Material and Feeding Design Requirements

4.1 Material Requirements

The following information must be clearly defined:

• Material Grade

• Material Thickness

• Hardness

• Surface Condition

• Coil Width

4.2 Strip Layout Design Requirements

Basic Principles

• Improve Material Utilization

• Ensure Stable Feeding

• Reduce Deformation

• Prevent Scrap Jamming

Material Utilization Rate

Recommended values:

4.3 Carrier Strip Requirements

Minimum Carrier Width

(t = material thickness)

4.4 Pitch Design

Requirements:

• Stable Pitch

• Feeding Accuracy Compliance

• Prevention of Accumulated Errors

Pitch tolerance:

• ±0.02mm to ±0.05mm

5. Station Design Requirements

5.1 Station Arrangement Principles

The process sequence should be logically arranged:

1. Punching

2. Trimming

3. Forming

4. Bending

5. Restraining / Reshaping

6. Cut-Off

5.2 Number of Stations

The following factors must be considered comprehensively:

• Product Complexity

• Press Capacity

• Forming Difficulty

• Tooling Life

Avoid:

• Excessive Number of Stations

• Unbalanced Punching Force

5.3 Idle Stations

Idle stations may be added when necessary to:

• Release Stress

• Prevent Deformation

• Stabilize Material Feeding

6. Blanking Design Requirements

6.1 Blanking Clearance

Recommended clearances:

6.2 Cutting Edge Design

Requirements:

• Sharp Cutting Edge

• Easy Regrinding

• Sufficient Strength

Minimum Punch Hole Size

Recommended:

• ≥1.0t

6.3 Punch Pin Design

Requirements:

• Fracture Prevention

• Easy Replacement

• Guided Protection

Long and slender punches should include:

• Protective Sleeves

• High-Speed Steel or Tungsten Carbide Materials

7. Forming Design Requirements

7.1 Bending Design

Recommended Bending Radius

7.2 Springback Control

Recommended methods:

• Over-Bending Design

• Restraining Stations

• Pressure Control

7.3 Deep Drawing Design

Requirements:

• Prevent Cracking

• Prevent Wrinkling

• Ensure Adequate Lubrication

Drawing Ratio

Must comply with material standards.

8. Guiding and Positioning Design Requirements

8.1 Material Guiding System

Requirements:

• Stable Guiding

• Anti-Deviation Design

• Easy Adjustment

8.2 Positioning System

Common methods:

• Pilot Pins

• Positioning Blocks

• Stop Pins

Accuracy Requirements

Positioning accuracy:

• ±0.01mm to ±0.02mm

9. Stripping and Ejection Design Requirements

9.1 Stripping Methods

Common methods:

• Spring Stripping

• Fixed Stripping

• Pneumatic Stripping

9.2 Part Ejection Design

Requirements:

• Smooth Ejection

• No Product Damage

• No Impact on Production Cycle

10. Die Set Design Requirements

10.1 Die Set Materials

Common materials:

• S50C

• 45# Steel

• SKD11

10.2 Die Set Accuracy

Requirements:

• Parallelism

• Perpendicularity

• Concentricity

10.3 Guide Posts and Bushings

Requirements:

• High Wear Resistance

• High Precision

• Good Lubrication

11. Tooling Life Requirements

Standard Tooling Life

12. Safety Design Requirements

The die must include:

• Foolproof Design

• Reverse Feeding Prevention

• Misfeeding Prevention

• Safety Protection Devices

13. Automation Design Requirements

Applicable to high-speed progressive stamping production.

The following should be considered:

• Automatic Feeding

• CCD Inspection

• Robotic Pick-and-Place

• Online Inspection

14. Tooling Maintenance Requirements

14.1 Standardization of Wear Parts

Requirements:

• Easy Replacement

• Easy Maintenance

• Preference for Standard Components

14.2 Maintenance Schedule

Recommended schedule:

15. Common Materials Used in Progressive Dies

16. Progressive Die Design Acceptance Standards

Acceptance criteria include:

• Stable Dimensions

• Stable Continuous Production

• No Material Jamming

• No Scrap Jumping

• Qualified Product Yield

• Tooling Life Compliance

17. Required Progressive Die Design Deliverables

The following documents must be provided:

1. 2D Die Drawings

2. 3D Die Drawings

3. Strip Layout Drawings

4. BOM List

5. Wear Parts List

6. Tooling Manual

7. Trial Run Report

8. Maintenance Instruction Manual

18. Common International Standards for Progressive Die Design