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    2.17. Design Procedure For Progressive Dies

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    Anand Prajapati
    1. The document outlines guidelines for designing progressive dies, which perform multiple operations in a single press stroke. Key considerations include developing the blank shape based on the metal grain direction, plotting scrap strip layout, and sequencing operations from piercing to bending. 2. When establishing the operation sequence, direct or indirect piloting should be used to properly position the stock, and pierced areas should be distributed across stations. Blanked areas can be partially cut at one station and finished at later stations. 3. Idle stations help distribute load and allow for future changes, while bending/forming should occur at later stations. Strip layout should minimize scrap and avoid interference during ejection.

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    2.17. Design Procedure For Progressive Dies

    Uploaded by

    Anand Prajapati
    159 views2 pages
    1. The document outlines guidelines for designing progressive dies, which perform multiple operations in a single press stroke. Key considerations include developing the blank shape based on the metal grain direction, plotting scrap strip layout, and sequencing operations from piercing to bending. 2. When establishing the operation sequence, direct or indirect piloting should be used to properly position the stock, and pierced areas should be distributed across stations. Blanked areas can be partially cut at one station and finished at later stations. 3. Idle stations help distribute load and allow for future changes, while bending/forming should occur at later stations. Strip layout should minimize scrap and avoid interference during ejection.

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    1. The document outlines guidelines for designing progressive dies, which perform multiple operations in a single press stroke. Key considerations include developing the blank shape based on the metal grain direction, plotting scrap strip layout, and sequencing operations from piercing to bending. 2. When establishing the operation sequence, direct or indirect piloting should be used to properly position the stock, and pierced areas should be distributed across stations. Blanked areas can be partially cut at one station and finished at later stations. 3. Idle stations help distribute load and allow for future changes, while bending/forming should occur at later stations. Strip layout should minimize scrap and avoid interference during ejection.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as DOC, PDF, TXT or read online from Scribd
    Download as doc, pdf, or txt
    159 views2 pages

    2.17. Design Procedure For Progressive Dies

    Uploaded by

    Anand Prajapati
    1. The document outlines guidelines for designing progressive dies, which perform multiple operations in a single press stroke. Key considerations include developing the blank shape based on the metal grain direction, plotting scrap strip layout, and sequencing operations from piercing to bending. 2. When establishing the operation sequence, direct or indirect piloting should be used to properly position the stock, and pierced areas should be distributed across stations. Blanked areas can be partially cut at one station and finished at later stations. 3. Idle stations help distribute load and allow for future changes, while bending/forming should occur at later stations. Strip layout should minimize scrap and avoid interference during ejection.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as DOC, PDF, TXT or read online from Scribd
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    2.17.

    DESIGN PROCEDURE FOR PROGRESSIVE DIES

    A progressive die, also known as cut-and-carry die, is a multi station die that performs several operations in succession in a single stroke of the press ram. The various operations may be all cutting operations or a combination of cutting and forming operations. The first step in the design of the die is the development of the blank. For this, the direction of metal grain is kept in mind. Normally, the grain of coiled strip is parallel to its length. To eliminate any tendency to fracture, the forming operating are usually performed perpendicular to the grain. Thus, while making a scale labout of the developed blank, the bend line is kept perpendicular to the strip. The next step is to plot the probable design of the scrap strip. In a progressive die, the individual operations (which are normally relatively simple) are combined in several stations. Due to this, it is usually difficult to evolve the most practical and economical strip design for optimum operations of the die. However, when establishing the sequence of operations for progressive dies, the following guide lines should be considered :

    1.

    While evolving the strip design, the positioning and proper location of the stock in each station is of prime importance. For this, pilots are incorporated in the die. Advantage should be taken of any required holes in the workpiece for piloting. This method is known as "Direct piloting". Thus piering operations must be placed first in the sequence. However, sometimes (when direct piloting is not ideal or satisfactory) special piloting holes can e placed in the scrap part of the strip. This is called "Indirect piloting". Advantages of indirect piloting are : greater freedom of size or location and not affected by workpiece change. However, the material width and lead may increase. Care must be taken to avoid having pierced holes tool close to a bend.

    2.
    opening.

    Distribute pierced areas over several stations if they are close together or are close to the edge of die

    3.

    Check, if the blanked areas can be divided into simple shapes, so that commercially available punches of simple contours may be used. A blanked area will be partially cut at one station and the remaining area will be cut in later stations.

    4. Use idle stations. They help the designer to distribute the total load uniformly over complete length of
    the die. They also strengthen die blocks, stripper plates and punch retainer etc. and facilitate strip movement. Also, they permit later changes in workpiece design by providing for additional operations.

    5. Bending and forming operations must be at the last stations. 6. Cutting and forming areas should be located to provide uniform loading of the press slide 7. While designing strip layout, try for minimum scrap. Use a multiple layout if possible 8. Design the strip so that scrap and workpiece can be ejected without interference.
    The next step is to design the die. The design of the various die elements (die block, punches, strippers etc.) is done on the same lines as has been discussed for blanking die and piercing die. A progressive die is usually a heavy construction. Note. Some hints on Press work : 1. The counterbores in the die-block, the tapped holes in the die shoe and the reamed dow holes in the die shoe must all be made from 6.35 mm to 9.5 mm deeper than needed to allow for grinding of the die block. 2. If the punch diameter is twice the material thickness, it need not be guided.

    3. 4.

    If the punch produces a hole 40% deeper than its own diameter, the shank diameter must be at least twice the punch size. Punches should be a tap fit in punch plates. For purposes of stability, the flange of the punch should never be smaller in diameter than the length of the punch. 5. Punches should be secured with pins, flats, keys etc. against rotating in the punch holders.

    Die Maintenance
    The following main rules should be kept in mind for the proper maintenance of forging dies 1. Before forging begins, warm the dies to a temperature of not less than 150-200C by placing a heated slab of metal between the top and bottom dies.

    2. Before starting to work, always remove scale from hot stock. 3. Do not forge metal which has cooled below the permissible minimum forging temperature. 4. 5.
    Scale, which is knocked off of forging, should be removed from the die surfaces by blowing off with jets of To prevent forgings from sticking in die impressions, the die surfaces should be swabbed or sprayed compressed air. lubricating oil before each new forging operation.

    6.

    The forging dies should not get overheated (temperature above 400C). If they do get overheated, cool them with compressed air.

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