At New Microfil, we produce parts by deep drawing in progressive die tooling out of a continuous coil of metal strip.
Deep drawing is a metal sheet forming process where material is pushed into a die by a punch to form a curved body.
The starting point is generally the cut of a disk or a blank of material. It stays partially fixed to the strip that is fed by a feeder throughout the tooling. For each stroke of the press, the strip moves of a given distance corresponding to the distance between stations. At each station, the material is worked given at the end a finished part which is cut off the strip.
Reduced production costs
Inside a progressive die tooling, in addition to drawing, we can do piercing, stamping, forming, trimming, bending,… The number of stations depends on the complexity of the geometry of the part to achieved.
Progressive tool are specially adapted to the mass production because of the high speed of the process contributing to a significant reduction of the price compare with other technologies.
The productivity in terms of machine capacity and decrease of raw material consumption can be improved by the use of multi-lines tooling.
The high repeatability is another advantage which permits to guarantee very tight tolerances on most of the dimensions of a product.
Advantages of progressive tool
High production capacities
A production of 60 to more than 1000 parts/minute per machine can be reached.
Reduced production costs
The process allows to offer attractive prices compare with other technologies.
Consistent and reliable at tight tolerances
Parts coming off a forming press are extremely repeatable. Critical and close tolerances can still be achieved in high volumes with consistency and reliability throughout the production making sure that every piece follows the specifications.
Mechanical properties increase throughout the process giving higher tensile strength after the deformation. Besides, the use of raw material adapted for cold forming permit to make further shaping such as crimping for example.
Thin wall thickness
The technique is ideal for products with thin wall thickness that are sometimes unachievable through other manufacturing process. It allows to create products with minimal weight with significant strength.
Superior surface finish
Typically, the process leads to manufacture products with very good surface finish without machining or tool marks.