What are the most effective ways to reduce cycle time in stamping?

1 Die design

Designing a die that optimizes the number and sequence of operations, minimizes material waste and scrap, and ensures dimensional accuracy and quality of the stamped parts is a key element of reducing cycle time in stamping. This kind of die can reduce the number of strokes, setup time, tooling costs, and maintenance requirements. Die design techniques that can help reduce cycle time in stamping include using progressive dies that perform multiple operations in one stroke, such as blanking, piercing, forming, and trimming; using compound dies that cut and form the part in one stroke; utilizing transfer dies that move the part from one station to another using a mechanical or robotic system; and employing simulation software to test and optimize the die design before manufacturing. This helps to avoid trial and error and rework.

2 Material properties

The material properties of the metal sheet or coil that is being stamped can significantly influence the cycle time in stamping. These properties can affect the forming behavior, springback, surface quality, and strength of the stamped parts. By selecting the right material for the stamping application, you can reduce the cycle time. This is done by decreasing the forming force and energy required to deform the material, reducing springback, which is the elastic recovery of the material after stamping, and minimizing surface defects such as scratches, dents, and burrs. Additionally, choosing a material with reduced variability in its properties such as thickness, hardness, and grain size can lead to a more consistent and repeatable stamping process.

3 Machine settings

Adjusting the machine settings to match the die design and the material properties is a third aspect of reducing cycle time in stamping. This includes the stroke rate, the press force, the press speed, the lubrication, and the temperature. For example, increasing the stroke rate and press force can reduce cycle time as long as it does not compromise quality or safety. Additionally, increasing the press speed can reduce cycle time so long as it does not cause excessive heat or vibration that can damage the die or machine. Applying the right amount and type of lubrication can reduce friction, heat, and wear between the die and material, while controlling temperature can affect material properties and prevent thermal expansion or contraction that can cause dimensional errors.

4 Quality control

Implementing a quality control system is a key factor in reducing cycle time in stamping. This system can detect and correct any deviations or errors in the process parameters, such as stroke rate, press force, press speed, lubrication, and temperature. It can also detect and correct any defects or damage in the die, such as cracks, wear, or misalignment. Additionally, it can detect and correct any defects or nonconformities in the stamped parts, such as dimensional errors, surface defects, or strength issues. Finally, statistical methods like Six Sigma and Lean Manufacturing can be used to analyze and optimize the process performance, reduce variation and waste, and increase efficiency and profitability of the stamping operation.