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Electrical connector terminal stamping is one of the most demanding servo press applications ??high SPM, tight tolerances, and complex progressive dies.
## Typical Requirements
- Part: connector terminals, 0.2-0.6mm phosphor bronze or copper alloy
- Tolerance: ?0.02mm on critical dimensions
- SPM: 200-800 SPM (high-speed applications)
- Die: progressive die, 8-24 stations
## Press Selection Criteria
For terminal stamping, direct-drive servo presses are preferred over gear-reducer types:
- No backlash in drive train
- Faster response to motion profile changes
- Better repeatability at high SPM
Recommended: Aida NS series, Komatsu H1F series, or equivalent direct-drive presses.
## Motion Profile Optimization
At 400 SPM, each stroke takes 150ms. Typical profile breakdown:
- Approach (TDC to 5mm above material): 60ms at maximum speed
- Forming zone (5mm above to BDC): 30ms at controlled speed
- Dwell at BDC: 5ms (for spring-back control)
- Return (BDC to TDC): 55ms
**Key parameter:** Forming speed in the last 5mm before BDC. For phosphor bronze:
- Too fast (>200mm/s): burr formation, die wear
- Optimal: 80-150mm/s
- Too slow: cycle time penalty
## Feed System Synchronization
Progressive die stamping requires precise synchronization between press and material feed:
- Feed timing: typically 270-330? of press cycle (feed during upstroke)
- Feed length tolerance: ?0.05mm for 8mm pitch
- Use press encoder output to trigger feed servo
## Quality Control Points
- Check first article after every die change: measure 5 critical dimensions
- Monitor tonnage signature ??deviation >5% from baseline indicates die wear or material variation
- Burr height: measure every 2 hours, replace punch when burr >0.02mm