Characteristics of multi-station progressive die
As a highly efficient and precise stamping equipment, multi-station progressive die occupies a core position in modern manufacturing. Its most notable feature is process integration. A set of molds can integrate multiple processes such as punching, bending, drawing, flanging, etc., realizing one-stop processing of parts from raw materials to finished products, eliminating the multiple clamping and transfer links of single-process molds. For example, the production of mobile phone connectors requires 8-12 processes such as punching, bending, and shaping. The use of progressive dies can complete these processes in one go during continuous feeding, increasing production efficiency by 5-10 times compared to single-process dies. It is particularly suitable for mass production (parts with an annual output of over 1 million pieces). This integrated feature not only shortens the production cycle, but also reduces positioning errors caused by multiple clamping, keeping part size consistency within ±0.02mm.
High precision and stability are another core feature of multi-station progressive dies, and precision control is implemented throughout the entire die design, manufacturing, and operation process. Rolling guide pins and bushings are often used for die guidance, with a clearance of ≤0.01mm, ensuring precise alignment of the punch and die during high-speed stamping (300-1000 times/min). The positioning system typically utilizes a combination of side cutting edges, guide pins, and servo feeders, achieving a step accuracy of ±0.005mm, meeting the precision requirements of industries such as electronics and medical devices. Stability is achieved through a modular structure, with standardized designs for consumable parts (such as punches and stripper plates), reducing replacement time to less than 30 minutes. The die is made of Cr12MoV or high-speed steel, achieving a hardness of HRC60-62 after cryogenic treatment, resulting in a service life exceeding one million cycles, far exceeding the 300,000-500,000 cycles of a single-process die.
Strong automation adaptability is a key advantage of multi-station progressive dies in adapting to modern intelligent manufacturing. The mold can be combined with an automatic feeder, a waste handling system, and online inspection equipment to form a fully automated production line, enabling unmanned production. The feeding process is driven by a servo motor with a response speed of ≤0.1 second, capable of real-time compensation for elastic deformation of the strip. Sensors are integrated with the unloading and ejection devices to ensure that parts land precisely on the conveyor belt. The visual inspection system completes a dimensional scan every 0.5 seconds to eliminate defective products. This automated integration not only reduces labor costs (a single production line can eliminate 5-8 operators) but also avoids quality fluctuations caused by human intervention, increasing the product qualification rate to over 99.5%.
High material utilization is a significant economic advantage of multi-station progressive dies. By optimizing the layout design, the material utilization rate can be increased by 10%-30% compared with single-process dies. For example, the stator and rotor silicon steel sheets of the motor are arranged in staggered patterns, which increases the material utilization rate from 65% to 82%; small stamping parts achieve zero material waste through overlap-free patterning technology combined with precise positioning. In addition, progressive dies can reduce waste generation by merging processes, such as integrating blanking and drawing processes to avoid scrap generated by separate blanking. This advantage is particularly prominent for high-value materials (such as copper alloys and titanium alloys), saving hundreds of thousands of yuan in raw material costs each year.
A high degree of flexibility is an important feature of multi-station progressive dies for coping with small-batch production of multiple varieties. Modern progressive dies mostly adopt a modular structure, which enables the production of multiple parts on the same die by replacing the punch assembly, adjusting the gasket thickness, etc. For example, the progressive die for terminal blocks in the home appliance industry can produce 8-12 different models of products by replacing punches of different specifications, and the die change time is ≤2 hours. At the same time, the mold design reserves space for process expansion, and product upgrades can be achieved by adding workstations in the future, thereby extending the service life of the mold. This flexible feature enables progressive dies to meet the needs of mass production while adapting to the market characteristics of rapid product iteration, significantly improving the competitiveness of manufacturing companies.
