Classification of multi-station progressive dies
Multi-station progressive dies are efficient and precise stamping dies that can perform multiple processes, including blanking, bending, drawing, and forming, all within a single die. They can be categorized into various types based on their structural characteristics, process functions, and application areas. Appropriate classification helps select the appropriate die type based on production needs and optimize the stamping process. Multi-station progressive dies can be categorized by process characteristics, guidance method, feeding method, degree of automation, and application industry. Each classification reflects the die’s core characteristics and scope of application.
Based on the nature of the process, multi-station progressive dies can be categorized as blanking progressive dies, forming progressive dies, and compound progressive dies. Blanking progressive dies are the most common type, primarily performing punching, blanking, and trimming operations. They are suitable for the mass production of flat-plate parts, such as motor stator and rotor silicon steel sheets and gaskets. They are characterized by a relatively simple die structure, with both the punch and die being cutting edges, and part formation achieved through continuous multi-station blanking. Forming progressive dies, on the other hand, primarily utilize forming operations such as bending, drawing, and flanging, and are used to produce three-dimensional parts, such as small brackets and connector housings. These dies require specialized forming stations and a press device to ensure consistent forming quality. Compound progressive dies combine blanking and forming operations, enabling the complete processing of complex parts, such as flanged cylindrical parts and special-shaped curved parts, within a single die. Their complex structure and high precision requirements make them suitable for mass production of highly complex parts.
According to the guiding method, multi-station progressive dies can be divided into sliding guided progressive dies and rolling guided progressive dies. The sliding guide progressive die adopts the sliding fit guide of the guide pin and guide sleeve. The guide accuracy is generally 0.01-0.03mm. It is suitable for the production of medium-precision parts. The mold manufacturing cost is low and maintenance is easy. It is widely used in daily necessities, automotive parts and other fields. The rolling guide progressive die installs rolling elements (such as balls and needles) between the guide pins and guide sleeves. The guide accuracy can reach 0.005-0.01mm, which is suitable for stamping high-precision parts such as electronic connectors and precision instrument parts. Rolling guide can significantly reduce the friction coefficient of the guide pair, increase the service life of the die and the stamping speed, and is particularly suitable for high-speed stamping production lines (speed > 500 times/min).
Based on the feeding method, multi-station progressive dies can be divided into manual-fed progressive dies, automatic-fed progressive dies, and servo-fed progressive dies. Manual-fed progressive dies are suitable for small-batch production or the stamping of large parts. The feed of the strip is manually controlled, and auxiliary positioning devices such as locating pins and stop blocks are required on the die. Production efficiency is relatively low, but the die structure is simple and the cost is low. Automatic-fed progressive dies use mechanical feeding mechanisms (such as roller feeding and clamp feeding) to achieve continuous feeding of the strip, with a feeding accuracy of ±0.05-±0.1mm. They are suitable for medium-batch production and are widely used in the automotive and home appliance industries. Servo-fed progressive dies are the most automated type. The feeding mechanism is driven by a servo motor, with a feeding accuracy of up to ±0.01-±0.03mm. The feed distance can be adjusted in real time to compensate for material deformation, making them suitable for high-precision, high-speed stamping, such as in mobile phone parts, medical devices, and other fields.
Based on the degree of mold enclosure, multi-station progressive dies can be divided into open and closed progressive dies. Open progressive dies have separate upper and lower die blocks, with open sides for easy observation of strip feeding and waste removal. They are suitable for stamping wide strips or simple parts. However, their rigidity is poor, limiting stamping speeds to generally no more than 200 strokes/min. Closed progressive dies utilize an integral frame structure, with the upper and lower die blocks connected by columns on either side to form a closed frame. This structure offers excellent rigidity and impact resistance, capable of withstanding the substantial loads associated with high-speed stamping. Stamping speeds can reach over 600 strokes/min, making them suitable for precision, high-speed stamping applications, such as the continuous stamping of electronic components.
Multi-station progressive dies can be categorized by industry, including those used in the automotive, electronics, and medical device industries. Progressive dies in the automotive industry are primarily used to produce small parts for large panels (such as door locks and seat adjustment components). These dies are relatively large (up to 3-5 meters in length) and typically have a material thickness of 1-3 mm, emphasizing mold rigidity and longevity. Progressive dies in the electronics industry primarily produce small, precision parts such as connector pins and chip lead frames. These parts are small (with an accuracy of ±0.01 mm) and made of thin materials (0.1-0.5 mm), requiring extremely high guiding and positioning accuracy. Progressive dies for medical devices must meet cleanliness requirements, requiring special surface treatments (such as passivation and polishing) to prevent material contamination. They are suitable for the production of syringe accessories and surgical instrument parts. Progressive dies in different industries have different focuses on structural design, material selection, and precision control, reflecting their unique technical requirements.
