High-Speed Multi-Station Progressive Die For Automotive Terminals

Dimensional & Performance Parameters

Pilot diameter tolerance: +0/-0.003 mm, shank diameter precision ground to g5 tolerance.

Straightness of 0.002 mm over the entire length, with a head concentricity within 3µm relative to shank.

Available in two tip geometries: bullet-nose for thick stock and steep-angle conical for thin foils. Lengths from 40 to 150 mm.

Material, Coating & Surface Finish

Punch tip fabricated from ultra-fine grain tungsten carbide (similar to K10/K20 grade), hardness HRA 93.

Shank made from high-speed steel M2 for tough press-fit retention.

Advanced a-C:H diamond-like carbon (DLC) coating deposited via PECVD, 3μm thick, with a coefficient of friction below 0.1 against copper alloys.

Working surface lapped to Ra 0.02μm to eliminate microscopic burr nucleation sites.

Forming Engagement & Manufacturing Process

Centerless grinding on Swiss-type CNC machines guarantees shank roundness within 1µm. The carbide tip is brazed under vacuum, then finish-ground as an assembly.

During stamping, the pilot enters a pre-pierced guide hole slightly ahead of the punches, correcting any strip misalignment by the tapered nose. The DLC layer allows smooth withdrawal without stripping marks.

Every pilot is inspected on a ZEISS optical comparator; a batch certificate details geometry and coating thickness.