Stamped Electromagnetic Shield Cover with Irregular Structure

I. Principles of Precision Stamping
Precision stamping is an advanced manufacturing technology that uses molds to apply pressure to metal or non-metal sheets, causing plastic deformation or separation, thereby obtaining high-precision parts with high surface quality.
Progressive Die: A multi-station stamping die that integrates multiple stamping processes (such as punching, blanking, bending, stretching, etc.) into one die. The material passes through each station sequentially via continuous feeding, ultimately completing the forming of complex parts. Its core principle: through station division of labor and sequential processing, the forming of complex parts is broken down into multiple simple processes, achieving efficient production of "multiple processes in one die, multiple parts in one stamping."

II. Relationship between Progressive Die and Transfer Die
Progressive Die: Emphasizes the "continuity" of the die, meaning the material strip moves continuously within the die, with each station processing simultaneously.
Transfer Die: Emphasizes the "step-by-step progression" of the stations, but in practical applications, the two terms are often used interchangeably, both referring to multi-station continuous stamping dies.
Core characteristics: Multi-station integration, automated production, and efficient processing of complex parts.

III. Structure and Composition of Progressive Dies
Die Set: The overall structure supporting the die, including the upper and lower plates.
Guide Pins/Bushings: Ensure precise alignment of the upper and lower dies.
Stations:
Blanking Station: Completes punching and blanking.
Forming Station: Achieves plastic deformation such as bending, stretching, and flanging.
Idle Station: Reserved position for adjusting material tension or subsequent processes.
Pilots: Precisely position the material strip to ensure consistency in processing at each station.
Stripper Plate: Separates the stamped material strip from the punch.
Feeding Mechanism: Achieves automatic material feeding through rollers or robotic arms.

IV. Key Design Elements
(1). Workstation Layout and Process Breakdown
Process Sequence: Blanking (punching, blanking) first, then forming (bending, deep drawing), to avoid difficulty in separating scrap after forming; complex bending parts require multi-step forming (e.g., pre-bending followed by precision bending) to reduce springback.
Carrier Design:
Edge Carrier: Utilizing scrap from the edges of the blank as a carrier, suitable for simple parts.
Middle Carrier: Retaining a strip-shaped carrier in the middle of the blank, suitable for symmetrical parts (such as motor cores).
Double Carrier: Carriers on both sides provide high stability, suitable for precision parts (such as connector terminals).
(2). Pitch Accuracy Control
Side Edge Positioning: Punching positioning notches on the edge of the material strip, accuracy ±0.02mm, suitable for general accuracy requirements.
Guide Pin Positioning: Punching guide holes (diameter ≥2mm) at specific positions on the material strip; when the mold closes, the guide pins are inserted into the holes to correct the position, accuracy ±0.005mm, used for high-precision applications.
(3). Mold Strength and Wear Control
Punch Protection: Slender punches (such as punching punches with a diameter ≤0.5mm) use a protective sleeve structure (multi-layer cemented carbide nesting) to prevent breakage during stamping.
Wearable Part Design: Easily worn parts such as punching dies and bending dies use quick-change inserts, which can be replaced individually during maintenance, shortening downtime.
Surface Treatment: The working parts of the mold are coated with a diamond-like carbon (DLC) coating (hardness 2000~3000HV) or nitrided to reduce the friction coefficient and extend the lifespan to over 5 million cycles.
(4). Scrap Handling and Safety Detection
Scrap Sliding Design: Inclined discharge grooves are provided at the bottom of the die, combined with compressed air blowing, to prevent scrap accumulation from damaging the mold.
Online Detection: Photoelectric sensors are installed to detect abnormalities such as material strip misalignment, material shortage, and scrap rebound, providing real-time shutdown and alarm to prevent mold damage.

V. Comparison with other types of molds

VI. Advantages of Jiesen's Precision Stamping Technology

 VII. Materials Suitable for Precision Stamping Processes

1.High speed and precision
In conjunction with high-speed punching machines (stroke speed ≥1000 times/minute), a feeding system with microsecond response is developed to meet the ultra-high-speed production needs of 5G communication parts (such as high-frequency terminals).
Micro-progressive mold technology: For the MEMS field, the mold accuracy reaches ±1μm, and the processing size is ≤0.1mm for micro gears and sensor structural parts.
2. Intelligence and digitalization
AI process optimization: Analyze historical stamping data through machine learning algorithms, automatically optimize parameters such as station arrangement and punching gaps, and reduce the number of mold trials.
Digital twin monitoring: Embed pressure sensors and temperature sensors in the mold to simulate the stamping process in real time, predict mold wear trends, and achieve preventive maintenance.
3. Green and low cost
Lubrication-free molds: Use self-lubricating coatings (such as molybdenum disulfide coating) or ceramic molds to reduce the use of lubricating oil, subsequent cleaning costs and environmental pollution.
Modular design: Standardized modules are used for general workstations (such as punching and trimming). Only the special molding module needs to be replaced to adapt to new products, shortening the mold change time by more than 30%.
4. Composite process integration
The progressive die is combined with hot stamping, electromagnetic forming, laser welding and other technologies. For example, the preforming of titanium alloy parts is first completed in the progressive die, and then the component assembly is completed through online laser welding to achieve "stamping-welding-inspection" integrated production.

Summary
Continuous die (progressive die) is one of the core technologies of modern stamping manufacturing industry. Its characteristics of high efficiency, high precision and high integration make it the first choice for the production of high-volume precision parts. Although it faces challenges such as high mold development costs and complex design, its in-depth integration with intelligent and high-speed technology is driving the industry to develop in a more flexible, precise, and green direction.