Progressive die stamping is a metal forming process widely used to produce parts for various industries, such as automotive, electronics and appliances. Progressive die stamping consists of several individual work stations, each of which performs one or more different operations on the part.

1. Design of Stage
Progressive Die for a
Sheet Metal Component
AMIT SAHNI

2. CONTENTS
 Introduction
 Tool design procedure
 Elements of press tool
 Principle of metal cutting
 Press tool design considerations
 Methodology
 Die clearance
 Calculation was calculated by using formula
 Defects and remedies
 Metal stamping methodology offers several benefits
 Advantages and disadvantages

3. Introduction
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Progressive die stamping is a metal forming process widely used to produce parts for
various industries, such as automotive, electronics and appliances. Progressive die
stamping consists of several individual work stations, each of which performs one or
more different operations on the part. The part is carried from station to station by the
stock strip and is cut out of the strip in the final operation.

5. Introduction (CONTD.)
• The Progressive die or transfer die is dependent on size, complexity and volume
of production. Progressive die stamping is used to produce a large number of
parts and keep the costs as low as possible. The highest demands in precision
and durability must be met
Some of the metal-shaping techniques commonly used in progressive metal
stamping are:
•Coining – application of high force or pressure to create a shape by displacing
metal
•Bending – an operation commonly used to achieve and maintain right (or 90o)
angles
•Punching – producing holes in a metal using a punch press and counter-
supportive die
•Wire forming – the process of bending/shaping a component from a roll of
gauged wire
•Fine Blanking – to achieve features often not possible via conventional
cutting/punching
•Deep Drawing – transforming metal into shapes in which depth is greater than
diameter

6. TOOL DESIGN PROCEDURE
STUDY OF COMPONENT
The first step in the design procedure is to define the problem in a clear and simple
statement of the functional needs. The tool design will receive the part print,
information on which tool is needed, what the capabilities of the tool must be, the
type of the press on which tool is used, the number of parts to be produced and
pertinent information concerning the part.
CONCEPT DESIGN
The research and sketches should be combined to one or two attentive design
solution, which may consist of rough working showing the side and top view if
needed. The best selected and reworked and the final design decided upon.
DESIGN CONSIDERATION
Before start in any design some major considerations are required to be made
which can solve majority of the problems while designing the press tool, moulds,
jigs and fixtures.

7. PROCESS
In any design, manufacturing process should be easy, simplified and majority
of the operations should be carried out in house. By considering this point we
made our tool as simple as possible for manufacturing.
MAINTENANCE
Last but never the least is very much necessary to think about the maintenance,
if due to any reason some parts break down, it should be easily manufactured
in short time so that ideal times is reduced and that care to be taken during
designing.
TOOL DESIGN PROCEDURE (CONTD.)

8. ELEMENTS OF PRESS TOOL

9. ELEMENTS OF PRESS TOOL (CONTD.)
TOP PLATE
It is the top portion of the complete tool, which holds the top assembly or
complete tool through the punch holder.
Material: C45 or CI.
BOTTOM PLATE
It is also called as die shoe or bolster plate, its main function is to provide a
rigid foundation and base to the assembly. It assembles the fixed half of the
tool.
Material: C45 or CI.
STRIPPER PLATE
This plate is also called as guide plate. This plate helps in stripping operation. It
not only strips the strip from the punch but the main function of this plate is to
guide the punch accurately which maintains the alignment between punch and
die. Hence the plate is made with same care as die plate.It is made out of mild
steel. In some cases this guide plate is also made of tool steel. A channel is
milled in the plate which will guide the stock strip.

10. ELEMENTS OF PRESS TOOL (CONTD.)
GUIDE PILLAR
These are cylindrical pins known as guide pins or guide pillars. These provide
accurate alignment to the die set. One end of the pillar is given press fit in the base
plate with H7/p6 tolerance. The other portion, which is sufficiently long, provides
guide for top plate for easy sliding.
Material: EN-36 HRc: 54-56
GUIDE BUSH
These are mounted to the top plate, which provide smooth sliding contact between
pillars and top plate.
Material: EN-36 HRc: 60-62.
BALL CAUGES
In progressive press tools the punch and die should align very accurately to provide
equal clearance on all sides of the die. In such causes ball cages are used. Ball cages
contain ball bearings inserted within them, which provide the sliding movement.
Material: Aluminum or Brass

11. ELEMENTS OF PRESS TOOL (CONTD.)
PUNCH
This is most important element of the tool. It is the cutting element of the tool.
Punch gives the whole size and the shape on the component. This is made out of
high carbon high chromium steel material (D3). [T215 CR12 W90]. Punches are
hardened and tempered to 58-60 HRC.
Material: HCHCR, OHNS HRC: 60-62
PUNCH HOLDER
This plate is also called as punch plate all the punches are accurately held in this
plate. This plate should be thick enough to accommodate punch shoulder and keep
the punches perpendicular. It is made out of HCHCR (D2).
Hardness: 56-58HRC.
DIE PLATE
In this plate all die inserts held accurately. This plate thickness as same as die
inserts thickness .This plate made out of HCHCr (D2).
Hardness: 56-58hrc

12. STRIP GUIDE
In progressive press tool there becomes a requirement of feeding the stock strip
along a particular path for each operation to take place. Thus strip guides are used
to guide the long stock strip in the required path for each operation can be carried
out properly. The strip guide combines of two material strips or parallel blocks,
which are screwed and doweled on the die surface in alignment with the die
parameters. It is one of the important elements of the progressive tools with
fixed as well as floating stripper.
Material:D2 HRC: 56-58
STOPPERS
Stoppers are installed on the dies to arrest the feedings movement of the strip,
to the requirement.
Material: D2 HRC: 52-56
ELEMENTS OF PRESS TOOL (CONTD.)

13. LIFTERS
Lifters are assembled in die plate with a close running fit. These are spring
actuated to hold and lift the strip.
Material: D2 HRC: 52-56
DOWELS
Dowels hold the parts in perfect related alignment by absorbing side
pressure and lateral thrust.
Dowels always should have case hardening.
SCREWS
In assembly process the parts of tool are held together rigidly by socket
head cap screws. Also screws fastened the assembly. Screws are available
in standard size.
ELEMENTS OF PRESS TOOL (CONTD.)

14. PRINCIPLE OF METAL CUTTING
STAGE I: Plastic Deformation
The stock material has been placed on the die and the punch is driven
towards the die. The punch contacts the stock material and exerts
pressure upon it. When the elastic limit of the stock material is
exceeded, plastic deformation takes place.
STAGE II: Penetration
As the driving force of the ram continues, the punch is forced to
penetrate the stock material and the blank or slug is displaced into the
die opening a corresponding amount. This is true shearing part in of the
cutting cycle, from which the term “shearing action” is derived.

15. PRINCIPLE OF METAL CUTTING
STAGE III Fracture
Further continuation of the punching pressure that causes fractures to start at the
cutting edges of the punch and the die. Under proper cutting conditions, the
fractures extended toward each other and meet. When this occurs, the fracture is
complete and the blank or slug is separated from the original stock material. The
punch then enters the die opening, pushing the blank or slug slightly below the
die cutting edge.
STAGE IV:
As the punch completes the down stroke up to the lower point, the component of
slug is pushed through the die opening. Strictly speaking this action is a
consequence of the dynamic fracture at the stage III and only in certain case the
push through takes place where the punch takes place where the punch travels
beyond the land of the die. This is the simplest approach on the shearing action.
Before dealing with the details of the phenomenon, the attention is drawn on the
same other allied factors which calls for deeper deliberations on the shearing
process.

16. Press Tool Design Considerations
Several points have to be taken into considerations during press tool
design process.
 All the parts are designed should have the capability to bear the forces.
 Sufficient space should be provided to load the stock.
 Die set should be made of proper material.

17. METHODOLOGY
1. Project product
The product chosen for the project is a Multi-purpose bottle opener. The
multi-purpose bottle opener is made up of aluminum that have thickness of
2mm. The product has several function and features, the purpose is bottle
opener, letter opener, nut screw opener with specified size and can opener.

18. 2. Redesign strip layout comparison
1. The first station usually is stating with notching and piercing process.
2. At the second stage, process that been operated is punching and
piloting.
3. The third stage process that had been performing is punching and
shaving.
4. The fourth stage, notching and bending were performed. Notch the
profile for the shape and bend the center of the feature for the can
opener .
5. The fifth stage, embossing and punching for the text and the nut
shape.
6. The final process is cut-off process to separate the finished product
from the strip layout or sheet metal.

19. 3. Progressive die component redesign
The progressive die is divided into three sections, which is upper die, middle
die and lower die.
Upper Die – upper die component it consists of a top plate punch holder and
backup pressure plate.
Middle Die – For middle die component it consists of stripper plate and thrust
plate.
Lower Die – consists of a ground block, cutting plate, guide fence, sub-block
and lower clamping plate

20. 4. Assembly cross section & bill of material
5. Stamping calculation
Stock material preservation is a decisive factor in means should be
tried to attain this without sacrificing the piece part.
The economic factor is also known as material utilization. The
economy of any strip layout in percentage is found out by the
following formula factors .
1. Die Clearance
2. Strip Layout
3. Shear Force (Blanking)
4. Shear Force (Piercing)
5. Stripping Force
6. Cutting Force.

21. Die Clearance
Die clearance is depend on the part material property. If the material is ductile
in nature then the clearance is small and for brittle material it is large clearance.
If the clearance is given in reverse then there for ductile material it pass
through die means here it draw from die instead of cutting. And in ductile
material it damages the cutting edges of punch and die. The die clearance for
mild steel is 2.5% or 5% of thickness per side.
C = 2.5 % of thickness
= (2.5/100) x 6
= 0.15 mm
Or
C = 5% of thickness
= (5/100) x 6
= 0.3 mm
Large clearance increases the tool life. So here take 5% of
thickness per side.

22. Calculation was calculated by using formula;
Material Utilization,
Economic Factor = 𝐴 𝑥 𝑅 / 𝐵 𝑥 𝑉 100% (1)
A =Blank area (mm2)
R =Number of rows per strip
B =Width of strip
V =Pitch of strip
Cutting Force, F=L x T x (2)
Where:
F =Cutting force
L =Total length of the cutting edge (perimeter punch)
T =Material thickness
𝜎𝑠 =Shear strength
Total Force = Cutting Force + Bending Force (3)
Stripping Force = 10% x Total Force (4)

23. DEFECTS AND REMEDIES
SL. NO DEFECTS CAUSES REMEDIES
1 Burr
collection at
draw die
Thickness of the
component
Polish the draw dies and draw
punch,
Use good lubricants,
For every 3 stroke remove the burrs
on draw die
2 Thinning Clearance is insufficient
improper radius on punch
& die, Drawing speed is
more
Appropriated clearance is given on
each draw in punch & die check the
radius on draw die & punch and
reduce the drawing
3 Cracking Insufficient clearance,
lubrication problems.
Insufficient draw radius
on punch & die Drawing
speed is more.
Appropriated clearance is to be
given
on each draw, used good lubricants,
Check the radius on punch & die
reduce the drawing speed & check
the reduction ratio.

24. SL.
NO
DEFECTS CAUSES REMEDIES
4 Ejection
problems
Insufficient draft on
punch & die,
Lubricants problems,
Ejection force is low
Sufficient draft to punch &
die,
Effective lubricants are use
and
polish to the draw punch &
die.
Sufficient ejection force or
press
force.
5 Burrs on
blank or
pierced part
Excessive cutting
clearance between punch
and die.
Proper cutting clearance
maintain in
die.
6 Tight strip
movement
Clearance in strip guide
not correct
Clearance provided as per
requirement.
7 Dent mark
on blanked
component
Burr on lower surface of
the floating stripper plate
Spotting is done throughout
the
floating stripper plate (Blue
matching)
DEFECTS AND REMEDIES

25. This Metal Stamping Methodology Offers Several Benefits in the
precision manufacturing of parts or products; the most salient of these
advantages would consist of:
•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

26. • Progressive die advantages are:
1.They can produce a great volume of parts very quickly.
2.They often can run unattended.
3.They require only one press.
• Progressive die disadvantages are:
1.They usually cost more than line or transfer dies.
2.They often require precision alignment and setup procedures.
3.They require a coil feeder system.
4.They require an open-ended press to allow for the metal to feed into the die.
5.Damage to a single station requires removing the entire die set.
6.They often are much heavier than single-station line dies.
ADVENTAGES AND DISADVANTAGES

27. THANK YOU
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