Customizable Single-Die Progressive Stamping Dies For Precision Metal Parts

I. Structural Design of Microstructure Stamping Dies for Ultra-Thin Parts
Ultra-thin sheet metal has poor plasticity and low rigidity, making it prone to deformation, wrinkling, and tearing during stamping. Therefore, the die structure design needs targeted optimization focusing on material flow and stress balance.

A segmented, step-by-step blanking structure is adopted, with auxiliary material support and elastic pressure devices added in the microstructure area to balance the material stress and suppress local stress concentration. The die blanking clearance is configured at 3%–5% of the material thickness, combined with a small-rounded transition cutting edge structure to reduce burrs and sheet metal deformation.

The die base is made of high-hardness, high-dimensional-stability powder metallurgy tool steel and microcrystalline alloy tool steel, which undergoes vacuum quenching and deep cryogenic treatment to ensure overall rigidity and wear resistance. The micro-forming insert adopts a modular, insert-type structure, facilitating individual processing, replacement, and dimensional correction, improving the stability of continuous production.

II. Key Processes and Precision Control in Microfabrication The microstructure dimensions of ultra-thin mold parts are mostly at the micrometer level, making conventional machining insufficient to meet precision requirements. Therefore, specialized microfabrication processes are necessary.

Microstructure cavities and irregularly shaped punches are completed using high-precision EDM, CNC micromilling, and laser micromachining. The precision of key feature dimensions is controlled within ±0.5μm. The machining process employs a constant temperature environment and low-stress cutting parameters to minimize machining deformation and material surface damage.

Key dimensions and geometric tolerances of the mold are fully inspected using a coordinate measuring machine and a laser micro-profilometer to ensure consistency in microstructure contour and position. Multi-axis linkage machining equipment is used for the integrated forming of complex curved surface micro-features, reducing repeated clamping errors and improving machining efficiency and mold forming accuracy.