One of the highly essential steps to ensure long-term success in the production rate is designing the metal stamping die for generating new precision parts. The hot metal stamping company should be able to design that generates several parts in a single stroke of the press, considered the multiple-up die, as it depends on the manufacturers’ requirements for this part.
There are several benefits of the multiple-up die, which can significantly reduce the part of the piece and the cost involved in increasing the production volume.
How Hot Metal Stamping Works
The multiple-up die might produce two or even more similar portions or varied different parts nesting together under a single metal strip. You should start comparing it to the baker to roll out cookie dough for cutting them into shapes. The smart baker will always locate the way of cutting like cookies from a single piece of dough which might appear to be using a single shape that nests under several shapes.
The engineers will consider the amount of material required, the dimensions of the portion, the operations involved in forming the part, and the number of parts that start fitting together under the single metal strip layout. However, designing the metal stamping tool is a highly complex process.
But, not each part is produced with the help of the multiple-up dies. Hot metal stamping engineers should consider several factors while designing a new tool and die, along with the layout of the metal strip. These optimal designs result in generating a single part instead of multiple parts.
Handling Higher Volumes of Productions
Some electrical stamping manufacturers are launching a new product under tight time frames, which might involve a huge quantity of metal getting stamped into parts that are produced instantly. Some quantities call in for several dies rise in their numbers as high as every week. It depends on the metal stamping company’s pressing capacities offering the ideal solution producing more than two parts under a single pass through this press.
By forming several parts on a single strip of metal, the production times can get reduced to half, although the presses run slower with several dies. There are greater quantities manufactured under a single die, often resulting in greater variances across the measurement of each part. At the same time, these tools are designed to produce as many as 18 parts for every die.
Reducing Scrap & Cost of Materials
When designing a layout of the metal strip, engineers consider the material costs and the amount of scrap generated after the part undergoes the press. There is a greater expensive material, and the more expensive the scrap happens.
Generally, the metal strip layout design gets created to keep this scrap under a rare minimum. However, different forms of metal are manufactured under this portion which involves dictating the number of parts produced under a single press pass.
For accommodating several parts, the design for the strip for the several dies might use a wider piece of metal fitting by interlacing varied parts or the parts working under offset by facing the varied end of the press. The dies start increasing the material yields by about 20 to 50%.
Keeping the Cost of the Maintenance & Tool Down
The massive cost of metal stamping involves greater tool development and dies for the latest part. The tool produces a part of the precise specifications. However, it can consistently get it done over time, meeting with target qualifies. Considering the complex design, the cost for the tools of the dies is about 50% greater than the single dies.
The single die is easier to maintain whenever the multiple dies involve greater maintenance resulting in massive downtime and greater maintenance costs.
Reducing the Difference & Achieving Better Tolerance
The multiple-up dies the problematic for the complex, precise metal stampings. Whenever there is a part having several important measurements and no room for any difference as there is a single die which is a much better choice.
In reality, several manufacturers are willingly forgoing the cost and the benefits of volume for the multiple dies to avoid the bimodal distributions on the rigidly tolerated parts. Alternatively, whenever the manufacturer accepts the distinctive, varied part of measurement with a multiple-die becomes more efficient.
Always remember that the piece’s price does not narrate the entire story. At the same time, the maintenance and tooling costs and the ability to maintain stronger tolerances over the life of the production part are considered. The company dealing with hot metal stamping recommends the options and the optimal die type for the designated projects.