Sheet Metal Forming Die

Name: Sheet Metal Forming Die for Auto Panels – Frigate
Price: 249.00 USD
Availability: InStock

Sheet Metal Forming Die must endure cyclic loads from press operations without failure. Using tool steels like SKD11, DC53, or CPM-grade powders with through-hardening up to 62 HRC improves resistance to thermal fatigue, edge cracking, and notch sensitivity. Controlled grain structure and cryogenic treatment after tempering enhance core toughness, increasing die life during continuous forming of high-strength alloys.

Material Specification

GG25 Cast Iron (for prototypes), D2 (1.2379), DC53, STAVAX ESR (for high-volume production)

Hardness (HRC)

55-60 HRC (D2/DC53), 48-52 HRC (Cast Iron), 52-56 HRC (STAVAX)

Surface Finish (Ra/RMS)

Forming Surface – 0.2-0.4 µm, Draw Radius – 0.4-0.8 µm, Non-Critical – 1.6-3.2 µm

Dimensional Tolerances

Profile – ±0.05 mm, Critical Features – ±0.02 mm, Flatness – 0.03 mm/m

Forming Surface Geometry

As per 3D CAD Model (STEP/IGES) with ±0.01 mm springback compensation

Product Description

Sheet Metal Forming Die used for ultra-high strength steels or aluminum alloys faces challenges due to elastic recovery. Finite Element Analysis (FEA)-driven die surface compensation, coupled with draw bead optimization, enables accurate part formation. Forming simulations are validated against real press stroke profiles, achieving springback deviation control within ±0.5° on complex geometries.

Radii and Draw Depths

Minimum Radius – 3-5× material thickness, Draw Depth Tolerance – ±0.1 mm per 100mm

Mounting/Alignment Features

Subplate Locators – ±0.01 mm, Guide Post Holes – H7/g6 fit, Bolting – M16-M24 (Class 10.9)

Springback Compensation

Overbend Angle – +1°-5° (material dependent), Crown Adjustment – 0.05-0.2 mm/m

Coating/Surface Treatment

Hard Chrome Plating (0.02-0.05 mm), DLC Coating (for aluminum), Nitriding (for cast iron)

Certification Standard

ISO 9001, VDI 3366 (Forming Tools), IATF 16949 (Automotive), JIS B 5008 (Press Tools)

Technical Advantages

Sheet Metal Forming Die operating in presses above 400 tons requires structural stiffness to avoid punch/die misalignment. Base plates are manufactured from normalized high-grade die sets (e.g., DIN 1.2312) with flatness tolerance below 0.01 mm/m. Deflection analysis is performed under load to verify tooling deformation remains under 15 µm, ensuring part dimensional repeatability.

Sheet Metal Forming Die in servo or progressive stamping setups experiences localized heating, leading to thermal expansion and dimensional drift. Integrated die cooling channels, thermally stable tool coatings, and low-friction inserts (e.g., DLC or CrN coated) reduce surface temperature rise by 30–40%. This maintains die accuracy over extended production cycles.

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Industry Applications

Automotive Structural Panels

Used for stamping inner and outer body panels requiring controlled springback, tight radii, and consistent thickness distribution across draw depth.

Electrical Enclosure Fabrication

Employed to form precise geometries in galvanized or cold-rolled sheets with specific grounding tab dimensions and perforation patterns.

HVAC Duct Components

Forms rolled edges, flanges, and stiffeners in ductwork components to maintain airflow uniformity and mechanical strength under dynamic pressure.

Aerospace Bracket Forming

Used in producing high-strength aluminum and titanium sheet brackets with tight tolerances and minimal distortion under low-formability material conditions.

Appliance Casing Production

Applies to large-area stainless or pre-coated sheet forming with high surface quality requirements and zero galling in forming zones.

Telecom Cabinet Panels

Shapes modular cabinet panels with consistent mounting hole alignment, controlled bend angles, and EMI shielding features in pre-plated steels.

Die Clearance Optimization for Burr-Free Blanking

Sheet Metal Forming Die used for blanking and piercing must maintain critical die-punch clearances. Calculated clearance values, typically 6–10% of sheet thickness depending on material ductility, are implemented with EDM-machined edges. Clearance uniformity is verified to ±2 µm, reducing burring and edge rollover defects in high-speed blanking lines.

Sheet Metal Forming Die must align with upper and lower press platens to avoid off-center loading and premature wear. Die bases are precision-ground and assembled with ISO H7/H8 toleranced dowel and pillar fits. Die reinstallation repeatability is achieved within 10 µm using zero-point clamping or optical fiducials.

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How does Frigate ensure the durability of Sheet Metal Forming Dies under high-cycle production?

Frigate uses premium-grade tool steels such as CPM and SKD11, heat-treated for optimal hardness and toughness. Controlled microstructure and cryogenic tempering reduce crack initiation under cyclic loading. Our precision machining maintains tight tolerances, preventing stress concentrations. This results in dies that consistently perform over millions of strokes with minimal wear.

What methods does Frigate apply to control dimensional accuracy in complex forming dies?

Frigate integrates advanced CAD/CAM software with FEM simulation to predict material behavior and springback accurately. Die surfaces are compensated during design to offset elastic recovery after forming. We use coordinate measuring machines (CMM) to verify critical dimensions post-manufacturing. This ensures Sheet Metal Forming Dies produce parts within ±0.05 mm tolerance consistently.

How does Frigate address thermal expansion challenges during high-speed stamping operations?

Frigate designs Sheet Metal Forming Dies with embedded cooling channels and uses thermally stable tool steels to reduce thermal distortion. Die coatings such as DLC minimize frictional heat generation at contact surfaces. Real-time temperature monitoring guides maintenance intervals to avoid thermal fatigue. These practices maintain dimensional stability throughout extended production runs.

In what way does Frigate’s modular die design improve maintenance and tool life?

Frigate engineers dies with interchangeable inserts to isolate high-wear areas, allowing quick replacement without full die removal. Inserts are manufactured to exacting tolerances to maintain alignment and repeatability. This modularity reduces downtime and maintenance costs significantly. It also allows for easier part variant adaptation in flexible manufacturing.

How does Frigate ensure surface finish quality when forming coated or pre-painted sheets?

Frigate applies micro-polishing techniques to achieve sub-Ra 0.2 µm die surface finishes. Specialized coatings like TiN and CrN are selected based on sheet material to reduce adhesion and galling. Controlled lubrication systems are integrated where necessary to further reduce friction. These measures protect both the die and the part surface quality during forming.

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LOCATIONS

Global Sales Office

818, Preakness lane, Coppell, Texas, USA – 75019

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

Sheet Metal Forming Die

Material Specification

Hardness (HRC)

Surface Finish (Ra/RMS)

Dimensional Tolerances

Forming Surface Geometry

Product Description

Radii and Draw Depths

Mounting/Alignment Features

Springback Compensation

Coating/Surface Treatment

Certification Standard

Technical Advantages

Let's Get Started

Industry Applications

Die Clearance Optimization for Burr-Free Blanking

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Sheet Metal Forming Die

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Sheet Metal Forming Die

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