Corner Radius vs. Sharp Slots: Tooling Trade-Offs in Compound & Progressive Dies Explained скачать в хорошем качестве

Corner Radius vs. Sharp Slots: Tooling Trade-Offs in Compound & Progressive Dies Explained

Why does a compound die need a corner radius and what does it cost to shrink it? Let's walk through the physics: the ≈0.007" minimum radius matches the standard EDM wire diameter and spreads impact to extend tool life, especially in nickel- and cobalt-based steels. Drop to 0.005" and you’ll pay extra for finer wire, slower cutting passes, and more frequent re-sharpening. The message: sharper isn’t always smarter for your budget or uptime. Need truly square corners for slot ends or finger tips? That’s the domain of a progressive die. Each added sharp feature means another station—often driving tooling costs 2.5-4x higher and lengthening lead time. Derek and Steve break down when those stations make sense, how tool steels (not brittle carbide) still deliver 2-3 million hits, and why 95% of customers choose a compound die once they see the economics. #lasertechnologies #Tooling #CompoundDie #ProgressiveDie #CornerRadius #WireEDM #MetalStamping #MotorLamination #Manufacturing #CostReduction #Engineering #DieDesign #ToolLife #NickelSteel #CobaltSteel Timestamps 0:07 – Why customers ask about corner radius 0:51 – Standard 0.007" radius: EDM wire & tool life 1:20 – Going to 0.005": finer wire = higher cost 1:49 – Sharp corners become failure points 2:14 – Need square slots? Enter progressive dies 2:57 – Extra stations & 2.5-4x tooling cost 3:53 – Economics: radius vs. more stations 5:06 – Compound tools aren’t “soft” tools; heat-treated steels 6:42 – Why carbide isn’t the answer 7:52 – Longevity: 2-3 million parts from a compound die