custom metal stamping die
BALFORD is a company engaged in the custom processing of precision metal stamping parts, with more than 30 years of production and processing experience. Produce custom metal stampings to your specifications – that’s what we do!
Die development is the premise of our independent production, so how should the stamping die be designed? Next, let’s take a look at the design steps of the stamping die.
1. Generally, first trimming, punching, punching, pre-breaking, crimping, punching, tearing, (cutting, stretching), post-punching blanking, pressing burrs, forming, bending in two steps, first Form half, then form the other half.
2. When punching and blanking, generally punch the small round holes first, then punch the holes; first punch the waste near the forming, and then drop the leftovers at other positions: because if the punched small round holes are placed at the back, then When it is punching, there is likely to be a vacancy in the position carried by the matching material around the punch (the hole that has been punched in the front), so that the punch may cause uneven bearing force during the whole punching process, and the small round hole of the original is punched. The compressive strength is too weak, and the bearing force is not uniform, so it is easy to break. Naturally, this is only the case in most cases. Sometimes, according to the specific requirements, the small round hole punching can be ranked at the back, but there are still methods. If The thickness of the punch is really small and can be reinforced:
- A: Adopt the precision guide of stripping;
- B: The punch is produced and processed by PG.
3. Judging whether to use the blank holder: the blank holder is generally used on the continuous die and the blanking die, and its actual effect is rough positioning, which is conducive to feeding the test piece; some blank holder also has a punching design. The actual effect, if the mold is punched first to accurately locate the needle eye, then immediately guide the needle with the correct guide needle.
In today’s manufacturing, there are several methods used to shape metal parts. Of all these techniques, metal stamping is arguably the most cost-effective and popular metalworking method used by manufacturers.
Components fabricated using metal stamping have multiple operations as they pass through the various stations. These processes include punching, extrusion, blanking, beading and tongue cutting. Each process has a different foundation, allowing administrators to mix and match the sequences needed to produce the highest quality product at the lowest possible price.
Understanding each process and each step involved can help you:
- Avoid costly business mistakes
- Set appropriate expectations for budgets and delivery schedules
- Access to quality components that enable the product to operate with optimized functionality
- The volume of the required part
- the complexity of each part
- These factors are the basis for the construction and design of progressive dies (continuous dies). Every element that helps ensure product quality, tool life and tool maintenance must be carefully evaluated. At this stage you will face moments when you have certain tradeoffs to optimize output, spend and time.
5 tips for successful continuous die design:
#1 – Determine the direction of the product:
The design of continuous dies mainly depends on how the product or component passes through them. A challenging stage of progressive die (continuous die) design is rotating the part along the metal strip. In most cases, rotating components to optimize materials is often the only option. In other cases, you need to compromise between component rotation and cam angle. This directly impacts your continuous die and tooling costs and design.
Another factor that determines the orientation of the assembly is the lift required to transport the strip from one stage to another. However, you can design your continuous die and tooling so that the part rotates well so you don’t need to lift it. Alternatively, you can also eliminate the need for a lift when you form the tool upwards. If the part is formed in the opposite direction, you can make fine adjustments in material usage optimization, tool complexity, and overlift.
Another factor to consider when shortening the material feed is the rotation of the component. If the feed is shorter, it has fewer problems and runs faster. If your components have a large gap between the width and length, your design will be more efficient if your progressive die has shorter leads.
#2 – Determine how the part is fed:
How each component is handled will directly affect how you feel about the raw material, whether the strip is lifted during the feeding process, and the quality and consistency of the output. Carrying components requires specific configuration. Your other option is to place the part on one side of the strip. In this case, however, it is more difficult to lift the strip. You will need to use a lift in the center of the strip.
Another option is to use a ladder style to carry components. This is more efficient for complex assemblies or assemblies that require more lift. Engineers work on tool and die design and must ensure the proper carrier is used for this task.
#3 – Pilot:
To decide on a pilot in this step, the engineer and mold designer must consider the configuration and tolerance needs of the customer and the project.
#4 – Ensure Blanking Plan:
Blanking plans are an essential part of continuous die design. Several factors must be included, such as the weight of the assembly, dropout pins, and the type of carrier used. Therefore, manufacturers must develop a blanking strategy from the start to ensure that the continuous die design process is effective.
#5 – Determine the exact number of sites needed:
After completing the continuous die design, you should confirm the number of steps required for the project. If you don’t do this in the first place and the quantities don’t match, the final design can damage the mold you currently have. Complex progressive dies (continuous dies) automatically indicate that you need more steps. Likewise, if the design is simple, you can reduce the number of sites. If you need to add more workstations later, you may compromise the integrity of the progressive die (continuous die).
Producing high-quality and cost-effective molds requires an in-depth understanding of:
- Basic knowledge of sheet metal stamping dies
- Continuous Mode Basics
As molds become more complex, decisions that depend on the basis of mold design become more critical. When you evaluate and weigh strategically, you end up with the best output. Your result will be a powerful progressive die (continuous die) that you can maintain with ease. This results in consistently superior quality in every component.
Metal stamping parts
Metal stamping machines are used for mass production of stamped and formed metal parts. These presses operate custom dies used to produce custom metal stampings. With the metal stamping process, parts can be made from a variety of materials to close tolerances. Metal stamping is one of the inexpensive and versatile techniques for making large numbers of identical metal parts.
All custom metal stampings we produce for our customers have specifications for their specific application. If you have production drawings, we can convert them into actual products with your specified materials, dimensional tolerances and quality requirements. If your project is only in the concept or development stage, we can work with you to develop suitable custom metal stampings to suit your needs.
To get a quote for your next custom metal stamping project, request a quote