Progressive Dies

Progressive dies are used to prevent time losses that may occur during the movement of parts between stations and the multiple steps each part goes through in the process. These dies can be used for producing parts of various sizes. When the die needs to be compatible with presses in the production process, a progressive die is used. Additionally, it is used when there is a need for sufficient press tonnage capacity, consistent part quality, or fast die changes.

Progressive dies are long in design and feature numerous narrow stations. At each station, a different process is performed. Raw material is fed at the entry point of the die. Then, at each station, a new process is applied, different from the previous one. At the final stage, the part is formed into its final shape.

If you want to make mass production more efficient, you can always get help from Çelik Kalıp for your progressive die needs.

What is Progressive Die?

A progressive die is a method that allows multiple metal forming processes to be carried out in a single die. This die is also known as a staged die. The basic logic in this die is that raw material is fed at the entrance of the die, and multiple operations are carried out inside the die.

The raw material is subjected to multiple steps within the die, and the product reaches its final form at the end of the die.

Progressive dies are long in design and narrow in width. There are many stations on the die, and a process is performed at each station. The stations are designed to allow the raw material to pass through a different operation at each stage. After each station completes its task, the part progresses to the next one. Once all stations have completed their tasks, the part takes its final shape and is ready for use.

How is Progressive Die Designed?

The design process for progressive dies requires expertise and involves complex steps. When designing a progressive die, it is necessary to rely on experts in mechanical and manufacturing engineering fields.

The steps in designing a progressive die are as follows:

1.Determining the Part's Geometry: In the first step, the part's geometry is examined. Dimensions, surface quality, and tolerance analysis are performed. Then, the die material is determined, including the type of sheet metal, thickness, and expected mechanical properties of the material. The manufacturing steps such as cutting, punching, bending, and forming are listed in order. Production volume, die life, and costs are also considered to determine the manufacturing volume.

2.Designing the Production Line: In the second step, the production line design is made. The movement of the material in the die and its position at each station are considered. Then, the process sequence is determined according to the logical flow. The die's side punch size calculations are made to handle the movement of the material. Fine adjustments are made based on the parts tolerance.

3.Designing the Station Line: In the third step, the stations are designed. Detailed drawings for the production process at each station are created. The correct tools and equipment for each station are determined. The required force calculations for each operation are made, and the material's flow at each station is determined.

4.Assembly Process of the Die: In the fourth step, the die is assembled according to the determined station order. All stations are placed in the die according to the sequence. After the die assembly is complete, fine adjustments are made. A test is performed for production, and any necessary changes are made if errors are found.

5.Testing and Adjustment: After the die assembly, a simulation is performed with computer-aided software to analyze the die’s performance. At this stage, all details of the production process are examined. If there is an error, it is identified, and necessary adjustments are made in the design process.

Our team will provide support throughout the entire process to ensure that the progressive die design operates smoothly.

Where Are Progressive Dies Used?

The progressive die production process is used in many sectors with high-volume manufacturing needs. They are used in all industries where metal sheet processing takes place. These dies provide high precision and efficiency and also facilitate repetitive high-production processes.

The areas where progressive dies are used include:

• In the automotive industry, they are used to produce parts such as body components, chassis, engine parts, and suspension parts.
• In all white goods, they are used in the production of main bodies and internal parts.
• They can be used in the production of metal casings and parts of various electronic products such as computers, mobile phones, and household appliances.
• They can be used in the production of metal parts in airplanes, such as wings, bodies, and internal upholstery.
• In the construction industry, they are used in steel construction applications for producing profiles and connection elements.
• They can be used in the production of packaging materials such as metal and tin cans.
• They can be used in the production of surgical instruments and implants in the medical equipment and parts industry.
• They are useful for producing industrial parts quickly and efficiently.

Advantages of Progressive Dies

Progressive dies are used when high precision and efficiency are required in the metal sheet processing process. These dies provide significant advantages in the production process.

The advantages of progressive dies include:

• Multiple operations can be performed in a single die, which increases functionality and reduces production time.
• Human labor requirements during the production process are minimized because a significant portion of the process is automated, reducing error rates and labor costs.
• Parts produced have lower dimensional and shape tolerance, allowing for higher quality products.
• All parts produced in a single die are consistent with each other.
• Material waste in progressive dies is minimal, reducing production costs.
• Complex parts, which are typically hard and costly to produce, can be easily manufactured in a single die.
• They allow the shaping of thick sheets without any problems.
• With slight adjustments to the die design, different products can be produced, making it a versatile die.
• Progressive dies reduce production costs for businesses with high-volume production plans.
• Quality control is more efficient as error rates are minimal at each station.
• Automation systems make the production process much safer, minimizing accident risks.
• They are suitable for companies that want to adopt environmentally friendly manufacturing practices due to the very low material waste.

Businesses that want to take advantage of these benefits and make their production processes more functional can contact us.

Progressive Die Manufacturing

Progressive dies are particularly used in high-volume manufacturing facilities, especially to produce metal parts. Metal strips, in coil form, are fed at the start of the die, and pass through multiple operations without leaving the die. This allows the product to take its final form at the end of the die, even in complex production processes.

Since multiple operations are performed in a single die, production time is significantly reduced. Therefore, using a single die makes the production process faster.

Progressive dies provide parts with minimal dimensional and shape tolerance, which leads to the production of higher quality products. Since all stations in the die use automation systems, labor costs are also minimized. Even complex parts that cannot be produced in a single operation can be successfully manufactured in this die.

If you need progressive die manufacturing, contact us immediately. We will design a progressive die tailored to your production volume, sector, and needs.

Progressive Die Production

Progressive dies are used for shaping and manufacturing metal parts with high precision. Processes such as cutting, punching, bending, and forming can be performed in these dies.

Progressive dies have multiple stations, and each station is designed to perform a different operation. The material enters the first station, the operation is completed, and the material is then sent to the next station for the next operation.

Progressive dies make challenging manufacturing processes practical, error-free, and fast. For all your progressive die production needs, contact us. We produce high-quality progressive dies for the automotive and electrical industries.

If you need economical, reliable, and long-lasting production solutions, we can complete your projects with high-quality standards. For detailed information, project planning, and pricing, feel free to contact us.