Multi-Station Progressive Die Stamping – The Servo-Driven Press Advantage

Metal stamping started as a single-operation process, using a mechanical press to perform one operation at a time. Modern systems utilize automation and are capable of producing complex parts using a single pass. The Servo-Driven Stamping Press has been pivotal in reshaping the multi-station and progressive die systems.

Between multi-station and progressive die stamping, we are interested in the advantages a Servo Press can bring to these systems.

Multi-Station and Progressive Die Stamping Explained

Progressive die stamping uses a press system with one slide, and a roll of metal that is fed through a die with multiple stations. The multiple stations perform individual operations, such as: piercing, trimming, bending, blanking, and forming. At the last station, the completed part is separated from the carrier strip.

In Multi-Station stamping, (which is also called transfer stamping) the operations are broken down into a sequential manner, but each individual workpiece is transferred to each station using some type of mechanical or robotic transfer system. Multi-station stamping is ideal for large components because it increases the utilization of the material.

Both of these methods require the stamping press to have high level of precision and control, while also being able to work with large, unbalanced loads over a wide worktable surface. The Servo-Driven Stamping Press meets these requirements.

The Competitive Edge of Servo Technology with Programmable Motion

Programmable slide motion is a major innovation of servo technology in stamping. Whereas motion in flywheel-driven mechanical presses follows a rigid curve, with a Servo-Driven Stamping Press, the speed, motion, and slide position can be programmed in infinite combinations.

Programmable slide motion offers distinct advantages for multi-station and progressive die applications.

•Optimized forming speeds: The slide can move slowly during the actual forming portion of the stroke to reduce friction and heat—significant when processing higher strength steels and aluminum alloys. The slide can move quickly during the non-working portions to maximize throughput.

•Pendulum (half-motion) operation: Servo presses can stroke the die only a half-motion, thereby eliminating unnecessary press movements. This can double production when running progressive dies. The drive gear of the press rotates only between 90 and 270 degrees of the full circle, thereby significantly shortening the time of the empty stroke, while greatly increasing the parts per minute.

•Mid-stroke control: The ability to stop, speed up, slow down, and/or reverse motion of the slide at any point during the stroke offers die designers much more flexibility, especially for progressive dies with many forming operations.

•Tool wear compensation: Programmable slide motion allows direct control for tool wear and expansion issues, both of which improve the accuracy and increase the life of the die.

Engineering Excellence: The GUANGDUAN GD2 Series

The GUANGDUAN Straight Side Double Point Multi-Station Press GD2 utilizes modern engineering design solutions with servo-technology and precision engineering to fully meet the requirements of advanced automation of stamping technology.

1. Heavy-duty Press Construction for Tough Applications

As a rule, the main structural elements of the GD2 series, including the press body and slide, are manufactured by welding the high-quality steel plates and have a high degree of rigidity. For models with a capacity greater than 600 tons, the press has a split body and a pull lever pre-tight construction, which facilitates transportation and installation, while maintaining the integrity of the structure.

This construction is especially required for multi-station and progressive die applications, which require the press to have a high degree of rigidity along an extended worktable while maintaining the required precision.

2. Eight-Surface Full-Guideway Guiding System

The distinguishing feature of the GD2 series is the eight-surface full-guideway guiding system. The slide is mounted on an eight-surface long guideway, which, as compared with other, simpler guiding systems, has a number of advantages, including:

•Better resistance to side forces: The eight-surface guideway system distributes loads more evenly, and, consequently, side forces which adversely affect the accuracy of the parts are minimized.

•Better capacity to accept unbalance loads: Multi-station and progressive dies perform unbalance loads due to the nature of distribution of operations along the worktable. The eight-surface guiding system offers the required resistance to maintain precision.

•Retention of accuracy over an extended period: The robust guiding system of the press offers the advantage of maintaining high precision and significantly reduces the need for recalibration and repairs.

3. Multi-Station Transmission Device with Extended Pressure Point Interval

The GD2 uses a two-level gear transmission and an idler mechanism that enlarges the interval between pressure points. This development has a tremendous effect on multi-station designs.

•   Greater eccentric load capacity: Spacing the pressure points apart increases capacity for eccentric loads on multi-station and progressive type die stampings.

•   Space-saving design: The increased pressure point spacing allows a reduction in the overall height of a Press.

•   Wide worktable adaptability: The design works with wide worktables and multi-station type dies.

4. High-Torque Wet-Type Clutch

The GD2 series is equipped with a high-torque wet-type clutch that has the following advantages:

•Oil-filled wet-type friction plates: These provide high torque and long service life with no loss in performance due to wear.

•Multi-plate low inertia design: This design allows very sensitive starting and braking with a guaranteed connection, important in the case of high-speed automation.

•Intermittent operation: The clutch is designed for multiple interruptions of the operation and is therefore suitable for a continuous line.

•Environmental considerations: The wet-type design prevents pollution and operates with low noise.

5. Customized Die Cushions for Multi-Station Pressing

The GD2 can be installed with an upper knockout cylinder on the slide block with multi-section air cushions, customized for multi-station stamping. These die cushions provide:

•High compact force: Die cushions can have varied step distances. Each unit can provide a lot of force with a small size.

•High service life and precision: The die cushions are designed to have long service life and precision.

•Quick pressure stabilization: The cushions quickly stabilize the pressure to ensure the quality of the formations within the mechanisms.

•Independent pressure: Each die cushion can have its pressure adjusted, allowing for the needed independence for complex multi-station dies.

6. Designed for Automation

The GD2 series is especially designed for the automation industries and for progressive die and multi-station stamping. The die cushion series has installation interface dimensions for both 2D and 3D servo production lines, allowing integration with:

•Servo feeders: Precise control over the length of each material feed for progressive die functions.

•Transfer systems: Integration with mechanical/robotic systems for multi-station functions.

•Automated production lines: Integration with the supporting and receiving mechanical equipment for a fully automated manufacturing cell.

7. Eco-Friendly with Reduced Energy Costs

The Servo-Driven Stamping Press has a clear advantage over the mechanical presses due to energy savings, and unlike mechanical presses, these do not use energy to drive a flywheel. These presses use energy to perform a stamping operation. When this is used in conjunction with a pendulum motion in progressive die systems, the same output can be achieved with a 50% savings in electrical energy.

Final Thoughts

The future of efficient automated stamping combines Servo-Driven Stamping Press technology and custom solutions like GUANGDUAN GD2 series. These presses offer manufacturers the programmable slide motion and strong eight-surface guiding along with the multi-station transmission and automation integration necessary to produce more complex parts, reduce energy costs, increase tool life and throughput, and adapt to changing demands. Because of this, the servo-driven press will remain one of the leading stamping solutions for demand on precision, and sustainability.

FAQs

Q: What is a Servo-Driven Stamping Press?

A: A Servo-Driven Stamping Press is a stamping press that is equipped with a servo motor and eliminates the need for a flywheel and clutch. It allows for the programmable control of the press slide motion, giving greater control over the speed and position of the slide in relation to the rest of the stamping operation.

Q: How does servo technology improve progressive die stamping?

A: Because of the motion curve flexibility design, a servo press can slowly advance the slide to perform a stamping operation and quickly retract, which leads to a doubling of the production output of the stamping press, reduced energy consumption, and reduced wear on the stamping tools.

Q: What makes the GD2 series suitable for multi-station stamping?

A: A two-level gear transmission with an idler mechanism increases the pressure point interval, granting a higher eccentric load capacity for larger worktables and multi-station dies.

Q: Why is the eight-surface guideway important?

A: An eight-surface guideway permits resistance to side forces, allows unbalance loading, and the retention of long-term precision that is critical for progressive dies of large complexity.

Q: What are the advantages of the wet-type clutch on the GD2?

A: It provides a large torque, long wear-free life, sensitive start/stop, and low noise and is environmentally clean, which fits the demands of a continuous automated line.