As an electric motor engineer, you are often required to design and develop electronics. When it comes to the final motor core, precision is of utmost importance. As such, the process of stamping parts is a crucial step in the process that cannot be ignored.
This blog will discuss the difference between progressive and compound die stamping. We will also cover their benefits and disadvantages. Lastly, we’ll compare these two metal stamping methods for motor lamination so that you are better equipped to make an informed decision when faced with multiple options.
Progressive Die Stamping
Progressive die stamping is a metal stamping process that uses a progressive stamping machine and dies to produce parts with complex shapes.
It is beneficial because it has long run lengths, cost-effectiveness, fast production, short setup times, and minimal scrap.
The process involves using a metal stamping press and servo press-feed technology feeding system to form metal into desired shape and form.
A progressive stamping press can be used for various automotive, aerospace, and consumer goods applications. It is suitable for medium- to high-volume production runs.
Advantages of Progressive Die Stamping
Faster setup times:
Progressive die stamping requires less time than other processes and can produce parts much faster.
Higher quality parts:
The progressive die process can achieve higher quality parts than most traditional processes as it has tight tolerances and can handle more intricate designs.
Greater flexibility with design capabilities:
With progressive die stamping, multiple operations can be combined into a single stage to produce complex components. This means that more intricate shapes and sizes can be achieved by using fewer dies.
Reduced scrap material:
Much of the wastage and scrap material produced during the traditional processes are eliminated with progressive die stamping since it produces parts from a single sheet at once.
Cost-effective:
Since it eliminates the need for extra presses and dies, progressive die stamping can save businesses money.
Disadvantages of Progressive Dies
Complex die designs can take longer to develop and manufacture, thus resulting in higher manufacturing costs.
Pressing dies is expensive, significantly increasing the time spent on the die and the cost of producing the part. This may lead to parts unsuitable for high-volume production or parts requiring manual handling, which can add to labor costs.
These factors make progressive die stamping more expensive than compound die stamping. However, complex die stamping offers improved precision and surface finish benefits.
Overall, progressive die stamping is a cost-effective option for certain applications but requires careful consideration of the tradeoffs involved.
Compound Die Stamping
Compound die stamping is a process of stamping metal parts using dies. Simply, it involves feeding a metal strip through a compound die that cuts, punches, and bends the part in a single stroke. This process is cost-effective and can reduce waste, making it a suitable option for modern manufacturing.
Benefits of Compound Die Stamping
One advantage is that compound stamping can often be faster than progressive stamping simply because fewer dies are needed. Each station performs multiple operations, so fewer stations are needed overall.
In contrast, with progressive stamp, since each station only performs one operation, each part requires multiple passes through the die, which can take longer overall.
Another advantage is that it can often lead to less scrap material. With compound stamping, each station performs multiple operations on each side of the stock material so that more material can be used before it needs to be scrapped.
In contrast, with progressive stamping, each station only operates the stock material from one side, and as a result, more material needs to be scrapped since both sides cannot be used.
Disadvantages of Compound stamping
However, compound die stamping comes with a cost that increases with the size of the produced parts.
Furthermore, tool development is costly and not suitable for small runs. To ensure high-quality and repeatable parts, post-processing finishing is required after compound die stamping.
Comparison Between Progressive and Compound Stamping
Number of Dies:
Compound dies stamping typically uses fewer dies than progressive die stamping as it combines several operations.
Design Complexity:
Progressive die stamping offers greater flexibility in design complexity, allowing more intricate shapes and sizes to be created. Compound die stamping is usually more limited in terms of designs.
Production Volume:
Compound die stamping is better suitable for producing high-volume parts due to its quick setup times and efficient process. However, progressive die stamping can handle large and small batches relatively easily.
Cost:
Since compound dies stamping requires fewer dies, and it is generally more cost-effective than compound die stamping.
Accuracy:
Compared to the compound method, progressive die stamping provides greater accuracy, tighter tolerances, and better-finished components.
What Kind of Stamping Method For Motor Lamination Should You Use?
Motor lamination stamping has various methods, such as progressive stamping, rotary notching, and compound stamping dies. Each method offers different features and benefits, making it the best option for various applications.
Compound stamping: It is a highly efficient process that uses cutting, punching, and forming operations on metal sheets. It combines multiple steps, making it cost-effective and reducing set-up times. We purchase silicon steel strips according to the size of the products we need. We then transfer the material to the punching machine and form the motor stack, including the stator and rotor stacks.
Rotary notching: We cut the silicon steel sheet to the desired size, and each sheet will be individually stamped into the desired shape. Single-slot stamping is a suitable method for stator laminates with large outside diameters and large sample sizes.
Progressive die stamping: This is a multi-step process that uses multiple processes such as blanking, drawing, cutting, embossing, and piercing to create parts from metal sheets or strips. Progressive stamping can only be fed with a suitable width of material. It is directly in the die to complete the stamping self-locking, forming a fixed rotor laminated. It can quickly produce high volumes of parts but requires more setup time than compound stamping.
Our stamping capability for motor lamination
We have a strong stamping capability for motor lamination. We are well-versed in the various methods of progressive stamping, rotary notching, compound stamping, and single-slot stamping. All of which can be suitable for creating intricate, accurate motor laminations.
We use only the highest quality silicon steel materials and equipment to ensure that each part meets our strict quality and performance standards. No matter what your needs may be, our team is here to provide you with superior results.
progressive stamping vs. transfer stamping
Progressive and transfer stamping are two of the most common die-stamping methods that involve metal parts production.
And progressive die stamping is the most widely suitable for the three today, and it involves each operation being completed in its own station. It also allows manufacturers to meet unique design specifications, tolerances, and volumes.
On the other hand, transfer die stamping completes several operations in one cycle but requires more complex tooling layouts.
How much does progressive stamping die cost?
The cost of progressive stamping dies on the complexity of the product you want to produce, the material used, and the die size.
Generally speaking. However, progressive stamping dies can range in cost from a few thousand dollars to tens of thousands. The cost also depends on whether you purchase a new or used die and whether a domestic or overseas manufacturer produces it.
As with any tooling or machinery purchase, it pays to shop around and compare prices between different vendors before deciding. It is important to note that while the initial cost may seem high, using progressive stamping dies can help save time and money over time due to their efficiency and accuracy.
Conclusion
Overall, both progressive and compound stamping offers unique advantages when producing metal parts. And these two stamping methods are both suitable for stamping motor lamination.
While one process may be more suitable for certain applications than the other, it ultimately comes down to the specific needs of a project to determine which type of process is the best fit. Let our experts guide you further on selecting the right stamping process for motor lamination. Contact us today!
