Copyright © 2008 Society of Manufacturing Engineers
FUNDAMENTALS OF TOOL DESIGN
Progressive Die Design
SCENE 1.
FTD01A, CGS: FBI warning
white text centered on black to
transparent gradient
FTD01B, motion background
WARNING
Federal law provides severe civil and
criminal penalties for the unauthorized
reproduction, distribution or exhibition
of copyrighted media.
Copyright © 2008
Society of Manufacturing Engineers
SCENE 2.
continue motion background
FTD02A, CGS: disclaimer
white text centered on black to
transparent gradient
Always read the operating manual and
safety information provided by the
manufacturer before operating any
manufacturing equipment.
Make sure all machine guards are
in place, and follow all safety
procedures when working with or near
manufacturing equipment.
SCENE 3.
FTD03A, SME logo open, with music
SCENE 4.
FTD04A, FTD open, with music
PD04B, edited peter carey narration
PD04C, unedited peter carey narration
MUSIC UP AND UNDER
NARRATION (VO):
THE FUNDAMENTALS OF TOOL DESIGN VIDEO
SERIES, EXAMINING THE DIVERSE FIELD OF
TOOL DESIGN MATERIALS AND TECHNOLOGIES.
SCENE 5.
continue FTD open
PD05A, CGS: Progressive Die Design
white text, centered on background
FTD05B, blue background
NARRATION (VO):
SCENE 6.
PD06A, tape FTD29, 09:14:22:00-09:14:48:00
pan, progressive die operation
NARRATION (VO):
THIS PROGRAM EXPLORES THE FUNDAMENTALS
OF PROGRESSIVE DIE DESIGN.
PROGRESSIVE DIES PERFORM A SERIES OF
FUNDAMENTAL CUTTING AND FORMING
Copyright © 2008 Society of Manufacturing Engineers
OPERATIONS TYPICALLY ON CONTINUOUS SHEET
METAL STRIP, OR COIL, STOCK. THESE
OPERATIONS ARE PERFORMED SIMULTANEOUSLY
AT TWO OR MORE STATIONS DURING EACH
PRESS STROKE AS THE STRIP PROGRESSES
THROUGH THE DIE TO PRODUCE A PART.
SCENE 7.
PD07A, tape FTD35, 15:36:20:00-15:36:45:00
zoom in, pilot hole during progressive
stamping
NARRATION (VO):
STRIPS ARE FED THROUGH THE PROGRESSIVE
DIE USING AUTOMATIC FEEDS AND THEN ARE
POSITIONED AT EACH STATION BY PILOT
HOLES OR SLOTS.
SCENE 8.
PD08A, tape FTD35, 15:20:25:00-15:21:00:00
scrap cut from progressive strip
NARRATION (VO):
UNWANTED PORTIONS OF THE STRIP ARE CUT
OUT AS IT ADVANCES THROUGH THE DIE
STATIONS. ONE OR MORE TABS, RIBBONS OR
BRIDGES CONNECT THE PARTIALLY COMPLETED
PART TO THE STRIP AS IT’S CARRIED
THROUGH THE DIE STATIONS.
SCENE 9.
PD09A, tape FTD28, 08:52:03:00-08:52:23:00
wide, progressive die
NARRATION (VO):
COMBINING STRIP TRANSFER, CUTTING AND
FORMING IN A SINGLE PROGRESSIVE DIE,
GREATLY REDUCES THE TIME AND COST OF
PERFORMING THESE OPERATIONS SEPARATELY.
SCENE 10.
PD10A, tape FTD28, 08:31:24:00-08:32:02:00
zoom out, part ejected from die
PD10B, tape 271, 01:23:02:00-01:23:26:00
manual stamping operation
NARRATION (VO):
PROGRESSIVE DIES ARE ESPECIALLY COSTEFFECTIVE IF PRODUCTION RATES ARE HIGH,
IN WHICH CASE DIE COST CAN BE
Copyright © 2008 Society of Manufacturing Engineers
APPRECIABLY LESS THAN THE TOTAL COST OF
INDIVIDUAL OPERATIONS AND RELATED
MATERIALS HANDLING.
SCENE 11.
PD11A, tape FTD29, 09:16:37:00-09:17:02:00
pan, progressive die operation
PD11B, tape FTD30, 10:04:27:00-10:04:47:00
pan, progressive die operation
NARRATION (VO):
THE DECISION TO PRODUCE A PART USING
PROGRESSIVE TOOLING IS USUALLY
DETERMINED BY PRODUCTION VOLUME AND PART
COMPLEXITY. ALTHOUGH THEY ARE NOT THE
ONLY FACTORS, PRODUCTION VOLUMES AND
PART COMPLEXITY ARE INSTRUMENTAL IN THE
DESIGN AND CONSTRUCTION OF THE
PROGRESSIVE TOOLING.
SCENE 12.
PD12A, tape FTD31, 08:18:06:00-08:18:20:00
pan, cad design of progressive die
PD12B, tape FTD30, 10:06:10:00-10:06:36:00
zoom in, progressive die operation
PD12C, CGS: Part Orientation
Part Transport
Stock Positioning
Number of Progressions
NARRATION (VO):
COMMONLY, DESIGN TRADE-OFFS ARE REQUIRED
IN STRIP DEVELOPMENT TO ADDRESS FACTORS
CONTRIBUTING TO PART QUALITY, TOOL
MAINTENANCE, TOOL LIFE, AND ULTIMATELY
TOOL COST. SOME OF THE PRIMARY FACTORS
INCLUDE:
PART ORIENTATION,
PART TRANSPORT,
STOCK POSITIONING,
AND THE NUMBER OF PROGRESSIONS.
--- TOUCH BLACK ---
SCENE 13.
PD13A, CGS: Part Orientation
PD13B, tape FTD31, 08:24:28:00-08:24:49:00
pan, cad design of progressive die
PD13C, tape FTD35, 15:24:40:00-15:25:15:00
pan, part running through progressive die
NARRATION (VO):
STRIP DEVELOPMENT BEGINS BY DETERMINING
THE ORIENTATION OF THE PART AS IT WILL
Copyright © 2008 Society of Manufacturing Engineers
BE RUN THROUGH A PROGRESSIVE DIE. PART
ORIENTATION IS GOVERNED BY THE PART
FEATURES, CRITICAL TOLERANCES, AND THE
LOCATION OF DATUM POINTS AND SURFACES.
SCENE 14.
continue previous shot
PD14A, ANI: strip with grain, part stamped
in it, part rotated
NARRATION (VO):
SINCE PROGRESSIVE DIES ARE STRIP FED,
OPTIMIZING MATERIAL USAGE MAY REQUIRE
ROTATING THE PART IN THE STRIP. THIS CAN
CHANGE THE GRAIN DIRECTION OF THE STEEL
UNFAVORABLY, AFFECTING PART STRENGTH
WITHIN PART FORMS.
SCENE 15.
PD15A, tape FTD35, 15:19:41:00-15:20:06:00
zoom out, progressive die operation
NARRATION (VO):
IN MANY CASES ROTATING THE PART TO
ENSURE MORE CONSISTENT FORMS DOES NOT
PROVIDE THE MOST EFFICIENT MATERIAL USE,
BUT IT MAY BE NECESSARY TO ADDRESS PART
TOLERANCE CONCERNS.
SCENE 16.
PD16A, tape FTD28, 08:21:57:00-08:22:24:00
zoom out, use of cams during progressive
die operation
NARRATION (VO):
THE USE OF CAM FORMING OR PIERCING
OPERATIONS ALSO INFLUENCE PART
ORIENTATION. CAM FORMING TOOLS CAN TAKE
UP A SIGNIFICANT AMOUNT OF ROOM, SO
PARTS ARE TYPICALLY ORIENTED TO ALLOW
CAM FUNCTIONS PERPENDICULAR TO THE COIL.
THIS PROVIDES THE EASIEST AND MOST
ACCESSIBLE CONDITION FOR THE CAMS.
SCENE 17.
PD17A, tape FTD36, 16:09:21:00-16:09:46:00
NARRATION (VO):
Copyright © 2008 Society of Manufacturing Engineers
zoom out, progressive die with cams
OFTEN, A COMPROMISE BETWEEN ROTATING A
PART TO OPTIMIZE MATERIAL USE AND
POSITIONING THE CAMS SAFELY OUTSIDE THE
COIL IS THE RESULT.
SCENE 18.
PD18A, tape FTD35, 15:45:15:00-15:45:35:00
zoom out, part lifted during progression
NARRATION (VO):
THE AMOUNT OF LIFT NEEDED TO CARRY THE
STRIP THROUGH THE DIE ALSO AFFECTS PART
ORIENTATION. LIFT CAN SOMETIMES BE
REDUCED SIGNIFICANTLY OR ELIMINATED BY
PROPERLY ORIENTING A PART.
SCENE 19.
PD19A, tape FTD28, 08:55:59:00-08:56:18:00
zoom in, part being formed upward
NARRATION (VO):
IF ALL THE FORMS IN A PART ARE IN THE
SAME DIRECTION, LIFT CAN BE ELIMINATED
BY FORMING UPWARD. THOUGH THIS USUALLY
ADDS COST TO THE PROGRESSIVE DIE.
SCENE 20.
PD20A, tape FTD35, 15:42:16:00-15:42:35:00
pan, part being formed in both directions
NARRATION (VO):
WHEN A PART HAS FORMS IN BOTH
DIRECTIONS, COMPROMISES MUST BE MADE
REGARDING EXCESSIVE LIFT, MATERIAL USE,
AND TOOL COMPLEXITY AND COST.
SCENE 21.
continue previous shot
PD21A, tape FTD28, 08:27:15:00-08:27:34:00
progressive die operation, heavy narrow
material
PD21B, tape 799, 18:15:10-18:15:28
zoom in, slitting of thick coil
NARRATION (VO):
PROGRESSIVE FEED MUST ALSO BE CONSIDERED
WHEN DETERMINING PART ORIENTATION. FEED
SHOULD BE AS SHORT AS POSSIBLE,
ESPECIALLY FOR HEAVIER MATERIALS AND
NARROW COILS. THIS IS DUE TO THE CAMBER
THAT CAN BE CAUSED BY THE COIL SLITTING
Copyright © 2008 Society of Manufacturing Engineers
PROCESS, WHICH CAN MAKE STOCK FEED
DIFFICULT.
SCENE 22.
PD22A, tape FTD30, 10:04:59:00-10:05:21:00
pan, short progressive feed
NARRATION (VO):
A SHORTER PROGRESSIVE FEED RUNS FASTER
AND HAS LESS CHANCE OF CAUSING MISFEEDS.
WHEN A SUBSTANTIAL DIFFERENCE BETWEEN
PART LENGTH AND WIDTH EXISTS, IT IS
USUALLY MORE COST-EFFECTIVE TO BUILD THE
TOOLING WITH THE SHORTER LEAD.
--- TOUCH BLACK ---
SCENE 23.
PD23A, CGS: Part Transport
PD23B, tape FTD28, 08:12:30:00-08:13:05:00
zoom out, progressive die operation
NARRATION (VO):
BECAUSE PROGRESSIVE STAMPINGS ARE LINKED
IN THE STRIP, A CARRYING DEVICE BETWEEN
PARTS IS NECESSARY. HOW PARTS ARE
ATTACHED TO THE STRIP AFFECTS HOW WELL
THE DIE FEEDS, THE ABILITY TO LIFT THE
STRIP FOR FEEDING, AND THE PRODUCTION OF
CONSISTENT-QUALITY PARTS.
SCENE 24.
PD24A, tape FTD28, 08:34:36:00-08:34:55:00
pan, progressive die operation, parts held
with material between them
PD24B, tape FTD35, 15:10:24:00-15:10:35:00
zoom out, parts carried on one side of
part
PD24C, tape FTD27, 07:13:05:00-07:13:18:00
progressive die operation, parts carried
on both sides of part
NARRATION (VO):
THERE ARE THREE BASIC METHODS FOR
CARRYING A PART, THOUGH VARIATIONS OF
EACH ARE COMMONLY USED:
PARTS THAT ARE CARRIED BY THE MATERIAL
BETWEEN THEM...,
PARTS CARRIED BY ONE SIDE OF THE
STRIP...,
AND PARTS CARRIED BY BOTH SIDES OF THE
Copyright © 2008 Society of Manufacturing Engineers
STRIP.
SCENE 25.
PD25A, tape FTD28, 08:57:20:00-08:57:45:00
zoom out, progressive die operation
NARRATION (VO):
PARTS THAT ARE CARRIED BY THE MATERIAL
BETWEEN THEM IS THE MOST STRAIGHTFORWARD
CARRIER METHOD. EXCESS MATERIAL EQUAL TO
ONE OR TWO MATERIAL THICKNESSES PER SIDE
ARE REQUIRED FOR TRIMMING. THIS METHOD
TYPICALLY PRODUCES MINIMAL SCRAP, OR NO
SCRAP IF THE TWO ADJACENT PARTS HAVE
SYMMETRICAL EDGES.
SCENE 26.
PD26A, tape FTD35, 15:08:55:00-15:09:22:00
progressive die operation, parts carried
on one side of part
NARRATION (VO):
PARTS CARRIED BY ONE SIDE OF THE STRIP
ARE SUITABLE FOR PARTS REQUIRING FORMING
ON AS MANY AS THREE SIDES. THIS STYLE
CARRIER ALSO IMPROVES ACCESSIBILITY IF
CAM-PIERCING OR CAM-FORMING IS REQUIRED.
SCENE 27.
PD27A, tape FTD29, 09:11:38:00-09:12:14:00
pan, progressive die operation, parts
carried on both sides of part
NARRATION (VO):
PARTS CARRIED BY BOTH SIDES OF THE
STRIP, OFTEN CALLED LADDER-STYLE
CARRIERS, ALLOW A STRIP TO FEED EASILY,
AND ARE OFTEN USED IN HIGH FEED-RATE
APPLICATIONS. LADDER-STYLE CARRIERS WORK
WELL WITH COMPLEX PARTS AND WITH THOSE
REQUIRING A LARGE AMOUNT OF LIFT.
SCENE 28.
PD28A, tape FTD29, 09:13:10:00-09:13:25:00
progressive die operation, parts carried
on both sides of part
NARRATION (VO):
LADDER-STYLE CARRIERS USE MORE MATERIAL
PER PART. OFTEN, HOWEVER, A PART CANNOT
Copyright © 2008 Society of Manufacturing Engineers
BE STAMPED PROGRESSIVELY USING ANY OTHER
CARRIER METHOD.
SCENE 29.
PD29A, tape FTD35, 15:15:30:00-15:15:51:00
tilt, part with drawn form
PD29B, CGS: Stretch Webs
Ribbon Strips
Bridges
PD29C, tape FTD27, 07:03:46:00-07:04:07:00
zoom out, bridge distorted by formed part
NARRATION (VO):
PROGRESSIVE BLANKS FOR DRAWING OR
FORMING OPERATIONS SHOULD BE DEVELOPED
TO PROVIDE FREE METAL MOVEMENT WITHOUT
AFFECTING PART POSITIONING IN EACH
SUBSEQUENT DIE STATION. THIS IS ACHIEVED
THROUGH SEVERAL MEANS, SUCH AS STRETCH
WEBS, RIBBON STRIPS AND BRIDGES. THESE
CARRIERS PROVIDE SUSPENSION AND ALLOW
FOR LITTLE OR NO DISTORTION OF STRIP
EDGES DURING DRAWING AND FORMING.
SCENE 30.
PD30A, tape FTD35, 15:16:10:00-15:16:29:00
zoom out, strip guided with carrier rail
NARRATION (VO):
CARRIER RAILS OR PINS ARE COMMONLY USED
TO SUPPORT AND GUIDE THE STRIP AS IT IS
MOVED FROM DIE STATION TO DIE STATION.
--- TOUCH BLACK ---
SCENE 31.
PD31A, CGS: Stock Positioning
PD31B, tape FTD29, 09:31:12:00-09:31:36:00
zoom out, progressive die operation, parts
held with material between them
PD31C, tape FTD26, 06:31:05:00-06:31:30:00
pan, pilots in die
NARRATION (VO):
OF PRIME IMPORTANCE IN STRIP DEVELOPMENT
IS THE STOCK POSITIONING IN EACH
PROGRESSIVE DIE STATION. THE STOCK MUST
BE POSITIONED ACCURATELY IN EACH STATION
SO THAT THE OPERATION CAN BE DONE IN THE
PROPER LOCATION ON THE STRIP. A COMMONLY
USED METHOD OF STOCK POSITIONING
INCORPORATES PILOTS IN THE PROGRESSIVE
Copyright © 2008 Society of Manufacturing Engineers
DIE.
SCENE 32.
continue previous shot
PD32A, CGS: Direct
Indirect
NARRATION (VO):
THERE ARE TWO METHODS OF PILOTING IN
DIES:
DIRECT,
AND INDIRECT.
SCENE 33.
PD33A, CGS: Direct Piloting
PD33B, tape FTD35, 15:06:16:00-15:06:30:00
tilt, holes in part used as pilot
NARRATION (VO):
DIRECT PILOTING INVOLVES PILOTING IN
HOLES OR SLOTS PUNCHED IN THE PART AT A
PREVIOUS STATION.
SCENE 34.
PD34A, CGS: Indirect Piloting
PD34B, tape FTD35, 15:39:00:00-15:39:28:00
zoom out, indirect pilots
NARRATION (VO):
INDIRECT PILOTING INVOLVES PIERCING
HOLES IN THE CARRIER STRIP AND LOCATING
THEM WITH PILOTS IN LATER OPERATIONS.
SCENE 35.
continue previous shot
PD35A, tape FTD29, 09:12:30:00-09:12:56:00
zoom out, indirect piloting holes
NARRATION (VO):
LOCATING INDIRECT PILOTS IN THE SCRAP
REGION HAS TWO ADVANTAGES: THEY ARE NOT
READILY AFFECTED BY PART CHANGES AND
THEIR SIZE AND LOCATION ARE NOT AS
LIMITED AS DIRECT PILOTS.
SCENE 36.
PD36A, tape FTD35, 15:37:36:00-15:38:00:00
zoom out, indirect piloting holes
NARRATION (VO):
ON THE OTHER HAND, THERE ARE TWO
DISADVANTAGES: MATERIAL WIDTH AND LEAD
MAY INCREASE TO ACCOMMODATE PILOT HOLES,
AND CARRIER STRIPS MAY DISTORT ON SOME
FORMING OPERATIONS, ELONGATING PILOT
HOLES OUT OF TOLERANCE.
Copyright © 2008 Society of Manufacturing Engineers
SCENE 37.
PD37A, ANI: part with close tolerance
holes
PD37B, ANI: part with holes too close to
part edges
NARRATION (VO):
IF PART HOLES ARE CLOSE TOLERANCE,
DIRECT PILOTS CAN AFFECT HOLE SIZE IN
THEIR EFFORT TO MOVE THE STRIP TO PROPER
LOCATION. IF DIRECT PILOT HOLES ARE TOO
CLOSE TO PART EDGES, WEAK OUTER PORTIONS
ARE APT TO DISTORT ON PILOT CONTACT.
SCENE 38.
PD38A, zoom in, part with holes close to
the part edges
NARRATION (VO):
AS TO HOW CLOSE A HOLE MAY BE TO PART
EDGES, TWICE STOCK THICKNESS IS
GENERALLY PREFERRED, ALTHOUGH HALF THAT
AMOUNT IS ACCEPTABLE WITH PROPER STOCK
CONTROL.
SCENE 39.
PD39A, ANI: part with holes in weak area
indirect piloting of part
NARRATION (VO):
IF HOLES ARE IN A WEAK PART OF THE
INSIDE PART AREA, THE PART MAY BUCKLE
BEFORE DIRECT PILOTS CAN POSITION THE
STOCK. THEREFORE, INDIRECT PILOTING IN
THE CARRIER STRIP IS ADVISABLE.
SCENE 40.
PD40A, tape FTD35, 15:08:22:00-15:08:33:00
zoom in, progressive parts with direct
piloting holes
PD40B, ANI: part with holes too close
together
NARRATION (VO):
MOREOVER, FOR ACCURATE PART LOCATION,
PILOTS SHOULD BE AS FAR APART AS
POSSIBLE. IF PART HOLES ARE TOO CLOSE
TOGETHER, INDIRECT PILOTING IN THE
CARRIER STRIP SHOULD BE USED.
SCENE 41.
PD41A, tape FTD28, 08:25:01:00-08:25:39:00
pan, progressive die operation
PD41B, CGS: Dwell
NARRATION (VO):
SEVERAL OTHER PARAMETERS AFFECT STOCK
Copyright © 2008 Society of Manufacturing Engineers
Pitch
Press Stroke
Operational Speed
POSITIONING, INCLUDING:
DWELL,
PITCH,
PRESS STROKE,
AND OPERATIONAL SPEED.
SCENE 42.
PD42A, CGS: Dwell
PD42B, tape FTD29, 09:27:15:00-09:27:48:00
zoom in, progressive die operation
NARRATION (VO):
‘DWELL’ IS THE UPWARD PORTION OF THE
PRESS STROKE NECESSARY TO COMPLETELY
CLEAR DIE AND PUNCH ELEMENTS FROM THE
PART SO THAT THE PART MAY BE ADVANCED.
DWELL HAS TO BE A MINIMUM OF TWICE THE
HEIGHT OF THE PART. THE DWELL PERIOD
CANNOT BE USED TO MOVE THE STRIP INTO
THE NEXT DIE STATION.
SCENE 43.
PD43A, CGS: Pitch
PD43B, ANI: top view, progressive die
showing pitch
PD43C, ANI: top view, progressive die
showing successive pitches
NARRATION (VO):
‘PITCH’, WHICH IS ALSO CALLED THE
‘PROGRESSION’ OR ‘ADVANCE’ IS THE
DISTANCE BETWEEN THE CENTERLINES OF TWO
ADJACENT DIE STATIONS. PITCH DIMENSION
MUST BE CONSTANT BETWEEN ALL SUCCESSIVE
STATIONS THROUGHOUT THE DIE.
SCENE 44.
PD44A, tape FTD28, 08:16:06:00-08:16:29:00
short pitch progressive die operation
PD44B, tape FTD28, 08:26:08:00-08:26:33:00
zoom out, progressive die operation with
thick stock
NARRATION (VO):
ADDITIONALLY, PITCH MUST BE THE SHORTEST
PRACTICAL DISTANCE BETWEEN DIE STATIONS
WITHOUT SACRIFICING DIE STRENGTH. THE
SHORTER THE PITCH, THE LESS SCRAP
MATERIAL THAT’S CREATED. PITCH MUST BE
Copyright © 2008 Society of Manufacturing Engineers
INCREASED IN PROPORTION TO ANY INCREASES
IN MATERIAL THICKNESS.
SCENE 45.
PD45A, CGS: Press Stroke
PD45B, tape FTD29, 09:31:46:00-09:32:08:00
wide, press stroke of stamping press
during progressive die operation
NARRATION (VO):
THE PROGRESSIVE DIE PRESS STROKE MUST BE
LONGER THAN WHAT IS ACTUALLY REQUIRED TO
FORM A PART. THE EXCESS PORTION OF THE
STROKE IS NECESSARY TO PROVIDE TIME FOR
STRIP POSITIONING IN SUBSEQUENT DIE
STATIONS.
SCENE 46.
PD46A, CGS: Operational Speed
PD46B, tape 290, 02:03:52:00-02:04:05:00
wide, progressive die operation
NARRATION (VO):
OPERATIONAL SPEED OF THE PRESS CANNOT BE
FASTER THAN THE DRAWING SPEED OF THE
METAL BEING FORMED.
--- TOUCH BLACK ---
SCENE 47.
PD47A, CGS: Number of Progressions
PD47B, tape FTD26, 06:49:51:00-06:50:05:00
zoom out, progressive die tooling
NARRATION (VO):
ONCE A BASIC DESIGN IS DETERMINED, THE
EXACT NUMBER OF DIE STATIONS CAN BE
EVALUATED.
SCENE 48.
PD48A, tape FTD28, 08:37:38:00-08:38:03:00
zoom in, progressive die operation
PD48B, tape FTD25, 06:01:51:00-06:02:06:00
zoom out, progressive die tooling stamping
prototype
NARRATION (VO):
ALTHOUGH INDIVIDUAL OPERATIONS IN A
PROGRESSIVE DIE CAN BE SIMPLE, WHEN
COMBINED IN SEVERAL STATIONS, STRIP
DESIGN CAN BE QUITE COMPLEX. THE
SEQUENCE OF OPERATIONS MUST BE CAREFULLY
DEVELOPED. AS THE COMPLEXITY OF THE
PROGRESSIVE TOOL DESIGN INCREASES,
SEVERAL FACTORS SHOULD BE CONSIDERED.
Copyright © 2008 Society of Manufacturing Engineers
SCENE 49.
PD49A, tape FTD35, 15:31:40:00-15:32:00:00
zoom out, pilot holes punched at first
station
NARRATION (VO):
PILOT HOLES OR SLOTS SHOULD BE PUNCHED
IN THE FIRST STATION. OTHER HOLES ALSO
CAN BE PUNCHED HERE PROVIDED THEY WILL
NOT BE ADVERSELY AFFECTED BY SUBSEQUENT
NONCUTTING OPERATIONS.
SCENE 50.
PD50A, tape FTD28, 08:10:04:00-08:10:26:00
pan, insinkerator grinder being pierced
NARRATION (VO):
PIERCED REGIONS SHOULD BE DISTRIBUTED
OVER SEVERAL STATIONS IF THEY ARE CLOSE
TOGETHER OR NEAR THE EDGE OF THE DIE
OPENING.
SCENE 51.
PD51A, tape FTD35, 15:21:53:00-15:22:23:00
zoom out, material blanked from coil over
progression
NARRATION (VO):
CONSIDER THE SHAPE OF BLANKED REGIONS IN
THE STRIP FOR DIVISION INTO SIMPLE
SHAPES. THIS IS SO PUNCHES OF SIMPLE
CONTOUR CAN PARTIALLY BLANK A REGION AT
ONE STATION AND THE REMAINING REGIONS AT
LATER STATIONS. THIS MAY PERMIT THE USE
OF COMMERCIALLY AVAILABLE STANDARD
PUNCHES AND SAVE TOOLING COSTS.
SCENE 52.
PD52A, tape FTD26, 06:47:31:00-06:47:44:00
zoom out, punch with shedder pin
NARRATION (VO):
PROGRESSIVE DIE PUNCHES SHOULD HAVE
SHEDDER PINS OR OIL-SEALED BREAKER PINS
TO AID IN SLUG DISPOSAL.
SCENE 53.
PD53A, tape FTD36, 16:07:22:00-16:07:43:00
zoom out, idle station
NARRATION (VO):
USE EMPTY, OR IDLE, STATIONS TO SPACE
OUT DIE ELEMENTS AND OPERATIONS. THIS
Copyright © 2008 Society of Manufacturing Engineers
AVOIDS CROWDING PUNCHES AND DIE BLOCKS,
ENABLING UNIFORM WORKLOAD DISTRIBUTION
THROUGHOUT DIE LENGTH AND STRENGTHENING
OF DIE ELEMENTS.
SCENE 54.
PD54A, tape FTD36, 16:05:20:00-16:05:42:00
pan, progressive die operation
NARRATION (VO):
IDLE STATIONS SIMPLIFY DIE CONSTRUCTION,
ADD ACCESS FOR DIE MAINTENANCE, AND
PROVIDE SPACE FOR ANY ADDITIONAL
OPERATIONS BROUGHT ON BY PART DESIGN
ALTERATIONS.
SCENE 55.
PD55A, tape FTD29, 09:18:39:00-09:18:59:00
zoom out, forming in progressive die
PD55B, tape FTD28, 08:42:31:00-08:42:48:00
forming downward in progressive die
PD55C, tape FTD28, 09:00:18:00-09:00:36:00
zoom out, forming upward in progressive
die
NARRATION (VO):
PLAN FORMING OPERATIONS IN AN UPWARD OR
DOWNWARD DIRECTION AND CHOOSE THE ONE
THAT ENSURES THE BEST DIE DESIGN AND
STRIP MOVEMENT. TYPICALLY, PROGRESSIVE
DIES THAT FORM DOWNWARD ARE MORE COST
EFFECTIVE TO PRODUCE, BUT CAN BE
PROBLEMATIC. DIES THAT FORM UPWARD ARE
MORE VERSATILE, YET GENERALLY MORE
COSTLY TO BUILD.
SCENE 56.
PD56A, tape FTD36, 16:03:29:00-16:03:41:00
zoom out, guideposts
PD56B, tape FTD35, 15:23:57:00-15:24:15:00
alternate shot, zoom out, guideposts
NARRATION (VO):
PRECISION, ANTI-FRICTION GUIDEPOSTS AND
BUSHINGS SHOULD BE USED TO MAINTAIN
ACCURACY BETWEEN UPPER AND LOWER DIE
HALVES.
SCENE 57.
PD57A, tape FTD28, 08:56:52:00-08:57:03:00
zoom out, progressive die operation
NARRATION (VO):
BALANCE THE POSITION OF CUTTING AND
Copyright © 2008 Society of Manufacturing Engineers
FORMING OPERATIONS FOR UNIFORM LOADING
ON THE PRESS SLIDE.
SCENE 58.
PD58A, tape FTD36, 16:02:29:00-16:02:56:00
pan, progressive die operation
NARRATION (VO):
A HIGH CUTTING LOAD AT ONE DIE END AND A
COINING LOAD ON THE OTHER CAN DEFLECT
THE PRESS RAM ON DIE CLOSING EVEN THOUGH
THE LOADS ARE EQUAL. THIS IS BECAUSE THE
OPERATIONS DO NOT OCCUR SIMULTANEOUSLY.
SCENE 59.
PD59A, tape FTD28, 08:33:13:00-08:33:35:00
pan, progressive die operation
NARRATION (VO):
IF THE WORKLOAD HAS BEEN PROPERLY
DISTRIBUTED THROUGHOUT DIE LENGTH, NO
DEFLECTION SHOULD OCCUR. IF REQUIRED
PRESS FORCE IS CONCENTRATED IN ONE
STATION OR DIE REGION, OPERATIONS SHOULD
BE SHIFTED FOR BALANCE.
SCENE 60.
PD60A, tape 272, 02:14:22:00-02:14:44:00
zoom in, two parts per stroke operation
PD60B, tape 272, 02:16:55:00-02:17:19:00
two parts per stroke operation
NARRATION (VO):
CHECK STRIP LAYOUT TO MINIMIZE SCRAP;
USE A MULTIPLE LAYOUT, SUCH AS A TWOPER-STROKE, FOUR-PER-STROKE, OR RIGHTAND LEFT-HANDED PART DESIGN IF FEASIBLE.
SCENE 61.
PD61A, tape 791, 09:05:52:00-09:06:15:00
scrap being ejected
NARRATION (VO):
DESIGN THE STRIP FOR PART AND SCRAP
EJECTION WITHOUT INTERFERENCE.
SCENE 62.
PD62A, tape FTD35, 15:50:16:00-15:50:30:00
zoom out, part ejected from die
NARRATION (VO):
DROPPING THE PART THROUGH THE DIE IS THE
MOST DESIRABLE METHOD OF PART EJECTION
BUT IS NOT ALWAYS POSSIBLE.
Copyright © 2008 Society of Manufacturing Engineers
SCENE 63.
PD63A, tape 785, 02:21:40:00-02:21:55:00
parts falling from die end
PD63B, tape FTD28, 08:17:29:00-08:18:02:00
parts ejected from die end
NARRATION (VO):
WHEN A DIE IS DESIGNED SO THAT PARTS ARE
CUT AND ALLOWED TO FALL OFF THE DIE END,
SEVERAL FACTORS MUST BE CONSIDERED. FOR
INSTANCE, PART WEIGHT MUST BE
SUFFICIENTLY OFF-BALANCE TO ASSIST PART
EJECTION. A SHEDDER PIN OR AIR ASSIST
CAN BE ADDED TO ENSURE PART REMOVAL.
SCENE 64.
PD64A, tape FTD35, 15:47:24:00-15:47:42:00
part with flanges formed down
PD64B, tape FTD27, 07:19:29:00-07:19:44:00
zoom in, part with flanges formed up being
ejected
NARRATION (VO):
IF PART TABS OR FLANGES ARE FORMED DOWN,
CLEARANCES MUST BE ADDED. IF THAT’S NOT
POSSIBLE, IT MAY BE NECESSARY TO
REDESIGN THE DIE TO ENSURE THAT THE PART
EJECTS. IF FLANGES ARE FORMED UP, STRIP
ADVANCEMENT MAY BE ENOUGH TO EJECT THE
PART FROM THE DIE.
SCENE 65.
PD65A, tape FTD27, 07:19:03:00-07:19:15:00
zoom in, scrap cutting at end of
progressive die operation
NARRATION (VO):
CUTTING THE SCRAP INTO SMALL PIECES
SIMPLIFIES MATERIAL HANDLING AND
PROMOTES GREATER SCRAP-SALE RETURN.
--- TOUCH BLACK ---
SCENE 66.
PD66A, tape FTD28, 08:35:20:00-08:35:50:00
progressive die operation using
lubrication
NARRATION (VO):
FRICTION IS INHERENT IN PROGRESSIVE DIE
OPERATIONS. PRESS FORCES APPLIED TO THE
TOOLING ARE TRANSFERRED TO THE STRIP BY
DIRECT CONTACT. FOR THIS REASON,
LUBRICATION IS VITAL FOR SUCCESSFUL
Copyright © 2008 Society of Manufacturing Engineers
PROGRESSIVE-DIE STAMPING.
SCENE 67.
PD67A, tape FTD35, 15:17:50:00-15:18:20:00
zoom out, c.u. lubricant being used in
progressive die operation
NARRATION (VO):
A LUBRICANT'S MAIN FUNCTION IS TO
MINIMIZE SURFACE CONTACT BETWEEN THE
TOOLING AND THE WORKPIECE. AS A RESULT,
WORKPIECE SURFACE QUALITY IS DIRECTLY
RELATED TO THE PROPERTIES AND BEHAVIOR
OF LUBRICANTS.
SCENE 68.
PD68A, tape 272, 02:19:42:00-02:20:10:00
lubrication of progressive die part
NARRATION (VO):
EFFECTIVE LUBRICATION RESULTS IN
CONTROLLED FRICTION, REDUCING FORCE,
POWER REQUIREMENTS, AND TOOLING
STRESSES. PROPER LUBRICATION ALSO
EXTENDS TOOLING LIFE, AND IMPROVES
PRODUCT QUALITY BY ELIMINATING SURFACE
DAMAGE.
SCENE 69.
PD69A, tape FTD35, 15:23:00:00-15:23:20:00
zoom out, light oil lubrication of
progressive die part
PD69B, CGS: Oil-Based Lubricants
Water Soluble Lubricants
Synthetic Lubricants
NARRATION (VO):
LUBRICANTS FOR PROGRESSIVE-DIE
OPERATIONS RANGE FROM LIGHT MINERAL OILS
TO HEAVY DRAWING COMPOUNDS, AND CAN BE
OIL-BASED, WATER SOLUBLE, OR SYNTHETIC.
SCENE 70.
PD70A, tape 272, 02:19:20:00-02:19:37:00
zoom in, lubrication being applied to
progressive die parts
NARRATION (VO):
THE OBJECTIVE IN APPLYING THESE
LUBRICANTS IS TO APPLY THE CORRECT TYPE
WHERE NEEDED, AT THE RIGHT TIME, AND IN
THE PROPER AMOUNT.
SCENE 71.
PD71A, tape 272, 02:11:44:00-02:12:12:00
NARRATION (VO):
Copyright © 2008 Society of Manufacturing Engineers
progressive die parts being lubricated
PD71B, CGS: Drip
Roller
Airless Spraying
Flooding
PD71C, tape FTD28, 08:39:52:00-08:40:20:00
zoom out, light oil lubrication of
progressive die parts
FTD CXM, credit music
continue music, up and under
THE PRIMARY METHODS USED FOR APPLYING
LUBRICANTS IN PROGRESSIVE DIE OPERATIONS
INCLUDE:
DRIP,
ROLLER,
AIRLESS SPRAYING,
AND FLOODING.
--- FADE TO BLACK ---
SCENE 72.
PD CXR, CGS, ROLL: credits
white text, fade up mid-screen
FTD EXM, extended motion background
Produced By:
Society of Manufacturing Engineers
Executive Producer:
Steven R. Bollinger
Producer/Director/Cameraman:
Jerome T. Cook
Written By:
John A. Vaccari
Graphics By:
Jerome T. Cook
Dennis Summers,
Quantum Dance Works
Equipment Access Provided By:
Motor City Stamping, Inc.
Northwest Tool & Die Co., Inc.
Right Line Design LLC
Rockford Toolcraft, Inc.
UEI Incorporated
Copyright © 2008 Society of Manufacturing Engineers
Technical & Editorial Consulting:
Michael Korneli, President
Bestech Tool Corporation
Production Assistance Provided By:
Lance Rosol
Video Editing:
Jerome T. Cook
SCENE 73.
continue motion background
FTD DIS, CGS: disclaimer
white text, centered on background
Some machinery in this program had
safety equipment removed to allow better
recording of certain processes.
Always read the safety information
provided in the manufacturers' manual
before machine operation.
SCENE 74.
FTD03A, SME logo open, with music