Basic Difference Between Progressive Die Stamping Process and Transfer Dies

Metal is used in almost everything that we see around us. From household items to heavy industrial equipment, we see metal being used in almost every size and shape. Progressive die stamping process is one of the most commonly opted for by industries to keep up with the increasing requirements. There are different types of dies and processes that are used in the metal stamping industry. If you are planning to delegate a project to a metal stamping manufacturers it is important to understand the differences between the techniques and which one to use for your particular project.

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A Little About the Progressive Die Stamping Process

A progressive tool is used in projects wherein the manufacturer is stamping complex or simple parts in large quantities. Metal is fed through the feeding station in coil form and as the name suggests the metal goes through a progressive tool. There are a series of stamping stations that run in the punch press to perform the required operation. The material is precisely uncoiled and straightened throughout the process and then the precise increments are planned throughout the tools to convert the coil into metal stamping. Every workstation is designed to add to the work of the previous station and complete the cycle. Once the material goes through the entire tool, the stamping process is complete.

In progressive die stamping process, it is important to ensure that the metal is precisely fed into each station. This requires a deep understanding of metal stamping, sophisticated technology for the placements of sensors, and the likes. Overall, it is complex to develop progressive metal stamping process. There are a number of complex processes that progressive tooling system can perform such as blanking, lancing, coining, piercing, notching, perforating, embossing, forming, drawing, and so on.

A Little About the Transfer Die Stamping Process

Transfer die stamping is similar to progressive die stamping process, the only difference being that the part if free from metal strip. So instead of designing a system to feed the metal in different stations progressively, this die is designed to manually transfer the strip from one station to the other. In a transfer die, there could be a single die, multiple dies, or a range of dies arranged in a row to form a production line.

The process is fairly easy to understand. In this process, a strip of metal is fed into the first station wherein the blank is cut. Then the blank is transferred through various forming stations mechanically or manually. This die is versatile and so there are a lot of designs possible in the primary operations such as cut-offs, chamfering, knurls, ribs, pierced holes, etc. Some of the processes where transfer dies are preferred are shells, tube applications, frames and structural components, large parts that require transfer among several presses for completion.
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Key Features and Benefits of Progressive Vs. Transfer Die Stamping

Choosing the appropriate metal stamping technique.  The size, production volume, and cost are the primary factors that help to choose a technique that gives optimum results with the highest possible accuracy. 

The best way to judge which metal stamping technique is best for your application is to compare its features and benefits. Here&#;s a quick yet-to-the-point comparison to help you out!

Features & Benefits of Progressive die stamping versus transfer die stamping

PROGRESSIVE DIE STAMPINGTRANSFER DIE STAMPINGMultiple workstations but Single DieSingle or multiple workstations, and different dies for eachNo lift and shift of metal sheet during the processMeta sheet is lifted and placed from one workstation to anotherHigh speedSlow to moderate stamping speed.Produces multiple of the same or different parts from a single die.Produces different parts from different dies.Suitable for small or medium sized partsSuitable for large sized partsLess run-time, as the whole process goes on without any metal sheet transfersMore run-time, as the metal sheet is transferred to different dies for each operation

Things to Consider When Choosing Between Progressive Tooling and Transfer Die

There are a number of things that you need to consider when choosing between the type of stamping process that you opt for. Here are some of the important things that you should consider:

• Progressive Die Stamping

This stamping process is suitable to produce small to large components and is considered to be the most economical to run for large production requirements. It provides faster production speeds and is preferred for stamping projects with tight tolerances. It only requires one set up to produce the parts and in this way helps you save time, money, and a lot of extra settings that are normally required before, during, and after a production run.

• Transfer Die Stamping

It is considered to be the best option especially when producing large parts. For shorter production runs, this is one of the most cost-effective approaches. These dies do not need a lifter or sheet guides because these are carried out with independent dies. The single or multiple dies used in this process is beneficial because it comes with a lower tooling cost.

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The best stamping process that you choose will mainly depend upon your unique or custom stamping requirements. Every manufacturer is different and the recommendations that come from these professionals will also make a difference in this regard.

Choosing the Progressive Tooling Manufacturer

It is interesting to see all manufacturers promising the best and latest manufacturing techniques. However, the truth is that not all of them have the appropriate tooling, manpower, technology, or even the quality that you are looking for. It is crucial to spend time identifying the best manufacturer that suits your needs and only chooses the one that is best suited. A little research in this regard will go a long way to help you achieve precision and great results at a lower cost as well. The technology curve has shifted in the recent past, and this means that there are a lot of manufacturers that may be playing catch up. Here are some of the important points to help you choose the right manufacturer for your stamping needs:

• Look at the reputation of the manufacturer in the metal stamping industry.
• Carefully consider the kind of clientele that they have and are serving at the moment. This will give you an idea about their expertise.
• Analyze the type of technology that the Progressive die manufacturer is using. The latest technology helps a manufacturer to save a lot of effort, time, and money for the clients.
• ISO certification reflects a lot on the kind of quality that the company has maintained and what you can expect.
• Pay a physical visit to the manufacturing unit if possible to get a clear picture of the quality and type of service to expect from them.

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Progressive Die Design Process

While there are various processes used to shape metal components, progressive metal stamping is one of the most common and cost-effective methods used by manufacturers. Parts produced using progressive die stamping move through various stations, each of which performs a specific function, such as coining, blanking, punching, or embossing. Depending on part requirements, these functions can be mixed and matched to achieve the desired results.

At American Industrial, we offer progressive die stamping services for both small and large-volume projects. Regardless of part complexity, our advanced capabilities allow us to meet your needs with quality stamped components. To ensure you get the most out of progressive die stamping, it&#;s important to understand the various die design considerations, as well as how the process works and its key benefits.

Design Considerations for Progressive Dies

There are various important factors to consider when designing and constructing progressive die tooling. Two of the most important considerations include:

• The volume of parts required
• Part complexity

In addition to the factors mentioned above, it is also critical to assess your requirements for part quality, tool maintenance, and tooling lifespan. By analyzing and weighing each of these factors, you&#;ll be able to make the necessary tradeoffs to optimize costs, time, and output.

Advantages of Using Progressive Die Stamping

Progressive die stamping from American Industrial provides several benefits, including:

• Improved Production Speeds. Because parts are continuously fed, progressive die stamping can create more parts at faster speeds. This makes it especially ideal for businesses requiring high-volume production.
• Less Scrap Waste. Progressive die stamping uses sheet metal to produce components, resulting in less waste generation. The optimized design of progressive dies also aids in reducing scrap materials.
• Freedom of Design. Progressive die stamping can produce parts with various geometries, ranging from simple to complex. This allows broader design freedom for manufacturers.
• Increased Production Capacity. Progressive die stamping can handle high capacities with longer production runs, allowing manufacturers to produce more components in less time.
• High Repeatability. Progressive die stamping uses hard and durable tooling, allowing for high-volume production without die degradation. This enables manufacturers to produce high-quality parts with optimal repeatability.
• Decreased Cost Per Part. Progressive die stamping can lower your cost per part with increased production speeds, repeatability, fast setup, and reduced material waste. Because the process can be easily automated, it decreases labor costs and lowers the risk of workplace injury.
• Produces Tight Tolerances. Progressive die stamping can produce high volumes of components with high precision and accuracy, maintaining tight tolerances over long production runs.

Progressive Die Stamping Process

The progressive die stamping process follows five key steps:

• Tooling creation. Progressive die stamping begins with a toolmaker creating the die set or tooling required to meet the application&#;s requirements. A progressive stamping die set carries out the entire part stamping process, eliminating the need to change tooling between operations.
• Die placement. Once the die is created, it must be placed into the stamping press. As the stamping press moves up, the die opens, and when the stamping press moves down, the die closes.
• Load the metal. Coiled metal is then loaded and continuously fed through the die with each press stroke.
• Perform operations. With a single stroke, the press can perform several stamping operations, including cutting, bending, coining, or embossing. Each time the die closes, the workpiece moves (or progresses) into the next station within the die.
• Part ejection. The workpiece takes on its final shape and size once it has moved through each operation station. At this point, the finished part is ejected from the die and cut from the carrier strip.

Progressive Die Stamping From American Industrial

Progressive die stamping delivers various benefits, including increased speed and volume, less waste, tighter tolerances, and improved freedom of design. To ensure optimal efficiency and part quality, it&#;s important to design progressive dies based on your application&#;s particular requirements.

Contact us to discuss your requirements of progressive die design. Our experienced sales team can help you identify the options that best suit your needs.