A connector terminal progressive die integrates piercing, blank development, forming, calibration and final cut-off operations into a continuously fed strip. For copper electrical terminals, the tooling must control not only part dimensions but also strip stability, feed pitch, burr direction, forming sequence and the condition of the functional contact or mounting features.
Dongguan Changdong Tool & Die Co., Ltd. designs and manufactures custom terminal progressive dies and related electrical connector tooling. The project shown on this page is a real Changdong tooling case for a formed copper eyelet-type electrical terminal produced from 2.0 mm copper material.
The documented tooling layout uses 13 progressive stations, a 40 mm feed pitch, an 80T press specification and a compact 580 × 450 × 320 mm tool structure. A separate dimensional report was used to validate multiple finished samples after tooling development.
The project drawing specifies copper sheet with a material thickness of 2.0 mm.
Cutting and forming are divided across thirteen stations before the finished terminal is released at final cut-off.
A 65 mm-wide strip advances at a 40 mm pitch through the progressive tooling sequence.
The project tooling layout specifies an 80-ton press and a 150 mm material feeding height.
A connector terminal progressive die is a strip-fed stamping tool that converts copper, brass or another suitable conductive sheet into terminal or contact geometry through a sequence of controlled operations. The part remains connected to a carrier while different stations pierce, trim, bend and form the geometry. The terminal is separated only after the required features have been completed and stabilized.
The supplied project records provide a complete link between the strip layout, finished copper part and dimensional inspection results. This makes the case useful for showing how a terminal progressive die is engineered rather than only displaying a finished stamped component.
| Project Parameter | Actual Case Data |
|---|---|
| Part type | Copper electrical eyelet / terminal-type stamped component |
| Material | Copper |
| Material thickness | 2.0 mm |
| Strip width | 65 mm |
| Feed pitch | 40 mm |
| Progressive stations | 13 stations including final cut-off |
| Tooling size | 580 × 450 × 320 mm |
| Die shut height | 320 mm |
| Press specification | 80T |
| Feeding height | 150 mm |
| Material utilization shown on layout | 38.6% |
The finished part contains both a flat mounting-eyelet region and a three-dimensional formed terminal section. Attempting to create this geometry in too few forming steps would increase local deformation and make strip stability more difficult to control.
The progressive layout therefore divides blank development and piercing from successive forming operations. The part remains connected to the carrier while its geometry develops, followed by calibration or flattening where required and final cut-off at the last station.
Station count should not be minimized only to shorten the die. The correct number depends on copper ductility, thickness, bend geometry, carrier strength, pitch, dimensional requirements and the amount of deformation that can be completed reliably at each stroke.
For the broader engineering principles behind pitch and carrier design, see the Progressive Die Strip Layout Design Guide.
This project uses a 65 mm strip width with a 40 mm feed pitch. The carrier must maintain part location while the copper terminal is progressively pierced and formed.
Carrier design is especially important when a flat blank develops into a three-dimensional terminal. If the carrier becomes too weak too early, the part can rotate, lift or shift relative to the pilot and working stations. If excessive material is retained only to make the carrier stronger, material utilization decreases.
The documented material utilization for this tooling is 38.6%. This is a project-specific result rather than a target for all terminal dies. For this geometry, tooling stability and the required progressive forming route were part of the strip-layout trade-off.
Terminal and connector tooling is often associated with material-utilization optimization because copper can represent a significant part of the finished-part cost. But utilization cannot be optimized independently from process stability.
Carrier strength, pilot location, forming direction, pitch, part rotation and scrap integrity all affect whether a progressive die can run consistently. A strip layout should therefore be evaluated as a manufacturing system rather than judged by one utilization percentage.
The finished copper terminal includes a mounting hole and several cut features that must remain correctly positioned relative to the formed geometry. Piercing operations should therefore be placed in the strip sequence according to datum stability and how later forming may move or distort the feature.
Cutting clearance affects burr formation, hole condition, cutting load and working-component wear. Burr direction must also be reviewed against the functional and assembly requirements of the terminal.
Punches and die inserts should be designed for alignment, support and maintenance rather than treated as isolated cutting components. For general cutting principles, see the Stamping Die Clearance and Burr Control Guide.
The submitted dimensional report for this case records five samples across 28 numbered inspection items. The report includes linear dimensions, diameters, radii, angles, flatness, stamping identification, punch direction and grain-direction checks. The recorded result fields for the inspected items are marked OK.
Selected dimensional results are shown below to illustrate the type of evidence used during sample validation.
| Feature | Drawing Requirement | Five-Sample Recorded Range |
|---|---|---|
| Linear dimension | 13.4 ±0.2 mm | 13.34–13.36 mm |
| Hole diameter | Ø8.5 ±0.1 mm | 8.57–8.58 mm |
| Linear dimension | 23.0 ±0.2 mm | 23.14–23.17 mm |
| Forming feature | 5.5 ±0.2 mm | 5.38–5.42 mm |
| Radius | R4.5 ±0.2 mm | 4.39–4.48 mm |
| Flatness | 0.1 mm max | 0.06–0.09 mm |
| Formed angle | 90° ±1° | 90.12°–90.23° |
Values above are selected directly from the supplied project dimensional report and represent this specific project and five inspected samples. They should not be interpreted as universal tolerance guarantees for other terminal tooling.
A connector or electrical terminal RFQ should include more than the finished CAD model. Useful inputs include:
2D and 3D part drawings
Material grade and thickness
Annual or expected production volume
Critical dimensions and functional features
Required burr direction
Surface or plating requirements where applicable
Customer press and feeder specifications
Inspection and sample-approval requirements
A connector terminal progressive die is a multi-station strip-fed stamping tool used to pierce, cut, form and separate electrical terminal or contact components from conductive sheet material.
This Changdong case uses 2.0 mm copper, a 65 mm strip width, 40 mm feed pitch, 13 progressive stations, a 580 × 450 × 320 mm tooling size, 320 mm shut height and an 80T press specification.
The supplied dimensional report contains five measured samples across 28 numbered inspection items, with the recorded results marked OK. These values document one real project and are not universal dimensional guarantees.
Dongguan Changdong Tool & Die Co., Ltd. manufactures custom stamping dies and stamped metal parts, including connector-related and electrical-terminal metal components. Changdong is not a complete electrical connector brand or wire-harness assembly supplier.
The project tooling drawing specifies 2.0 mm copper. The supplied project extract does not identify a specific copper alloy grade, so no additional grade is assumed on this page.
The documented strip layout contains 13 stations, ending with final cut-off. The station sequence progressively develops the pierced and three-dimensional terminal geometry.
The project tooling layout specifies an 80T press, a 320 mm die shut height and a 150 mm feeding height. Press requirements for another terminal die must be recalculated from the actual material, station loads and tooling design.
The submitted dimensional report records five samples across 28 numbered inspection items, including dimensions, diameters, radii, angles, flatness and process-direction checks. The recorded inspection results are marked OK.
Changdong focuses on custom stamping dies and stamped metal parts, including connector-related terminals and contacts. It is not a complete connector brand or wire-harness assembly supplier.
Send the part drawing, material grade, thickness, production volume, critical dimensions, burr direction and customer press information for a project-specific strip-layout and tooling review.
Email Drawings for Terminal Tooling ReviewChangdong is good at making metal stamping dies up to 4.2 meters, also we produce small size metal stamping toolings. The company manages the complete stamping die program from the CAE Simulation, layout designs and stamping tooling designs, and finish the machining to tryout and home line tryout to your hands. Meanwhile, the company produces the prototyping parts and stamping parts range from 45-880T. The successful cases include: stamping tools of Leoni connectors, automotive stamping dies of PSA P8 & B618, metal stamping toolings of Cummins exhaust pipe assembly, automobile stamping dies of NISSAN H60B projects, and stamping tools of car audio system, Canon printers, refrigerators, ovens and washing machines and so on.If you need metal stamping dies ,stamping parts or metal prototypings,
Email to us: sales@chang-dong.com
A connector terminal progressive die integrates piercing, blank development, forming, calibration and final cut-off operations into a continuously fed strip. For copper electrical terminals, the tooling must control not only part dimensions but also strip stability, feed pitch, burr direction, forming sequence and the condition of the functional contact or mounting features.
Dongguan Changdong Tool & Die Co., Ltd. designs and manufactures custom terminal progressive dies and related electrical connector tooling. The project shown on this page is a real Changdong tooling case for a formed copper eyelet-type electrical terminal produced from 2.0 mm copper material.
The documented tooling layout uses 13 progressive stations, a 40 mm feed pitch, an 80T press specification and a compact 580 × 450 × 320 mm tool structure. A separate dimensional report was used to validate multiple finished samples after tooling development.
The project drawing specifies copper sheet with a material thickness of 2.0 mm.
Cutting and forming are divided across thirteen stations before the finished terminal is released at final cut-off.
A 65 mm-wide strip advances at a 40 mm pitch through the progressive tooling sequence.
The project tooling layout specifies an 80-ton press and a 150 mm material feeding height.
A connector terminal progressive die is a strip-fed stamping tool that converts copper, brass or another suitable conductive sheet into terminal or contact geometry through a sequence of controlled operations. The part remains connected to a carrier while different stations pierce, trim, bend and form the geometry. The terminal is separated only after the required features have been completed and stabilized.
The supplied project records provide a complete link between the strip layout, finished copper part and dimensional inspection results. This makes the case useful for showing how a terminal progressive die is engineered rather than only displaying a finished stamped component.
| Project Parameter | Actual Case Data |
|---|---|
| Part type | Copper electrical eyelet / terminal-type stamped component |
| Material | Copper |
| Material thickness | 2.0 mm |
| Strip width | 65 mm |
| Feed pitch | 40 mm |
| Progressive stations | 13 stations including final cut-off |
| Tooling size | 580 × 450 × 320 mm |
| Die shut height | 320 mm |
| Press specification | 80T |
| Feeding height | 150 mm |
| Material utilization shown on layout | 38.6% |
The finished part contains both a flat mounting-eyelet region and a three-dimensional formed terminal section. Attempting to create this geometry in too few forming steps would increase local deformation and make strip stability more difficult to control.
The progressive layout therefore divides blank development and piercing from successive forming operations. The part remains connected to the carrier while its geometry develops, followed by calibration or flattening where required and final cut-off at the last station.
Station count should not be minimized only to shorten the die. The correct number depends on copper ductility, thickness, bend geometry, carrier strength, pitch, dimensional requirements and the amount of deformation that can be completed reliably at each stroke.
For the broader engineering principles behind pitch and carrier design, see the Progressive Die Strip Layout Design Guide.
This project uses a 65 mm strip width with a 40 mm feed pitch. The carrier must maintain part location while the copper terminal is progressively pierced and formed.
Carrier design is especially important when a flat blank develops into a three-dimensional terminal. If the carrier becomes too weak too early, the part can rotate, lift or shift relative to the pilot and working stations. If excessive material is retained only to make the carrier stronger, material utilization decreases.
The documented material utilization for this tooling is 38.6%. This is a project-specific result rather than a target for all terminal dies. For this geometry, tooling stability and the required progressive forming route were part of the strip-layout trade-off.
Terminal and connector tooling is often associated with material-utilization optimization because copper can represent a significant part of the finished-part cost. But utilization cannot be optimized independently from process stability.
Carrier strength, pilot location, forming direction, pitch, part rotation and scrap integrity all affect whether a progressive die can run consistently. A strip layout should therefore be evaluated as a manufacturing system rather than judged by one utilization percentage.
The finished copper terminal includes a mounting hole and several cut features that must remain correctly positioned relative to the formed geometry. Piercing operations should therefore be placed in the strip sequence according to datum stability and how later forming may move or distort the feature.
Cutting clearance affects burr formation, hole condition, cutting load and working-component wear. Burr direction must also be reviewed against the functional and assembly requirements of the terminal.
Punches and die inserts should be designed for alignment, support and maintenance rather than treated as isolated cutting components. For general cutting principles, see the Stamping Die Clearance and Burr Control Guide.
The submitted dimensional report for this case records five samples across 28 numbered inspection items. The report includes linear dimensions, diameters, radii, angles, flatness, stamping identification, punch direction and grain-direction checks. The recorded result fields for the inspected items are marked OK.
Selected dimensional results are shown below to illustrate the type of evidence used during sample validation.
| Feature | Drawing Requirement | Five-Sample Recorded Range |
|---|---|---|
| Linear dimension | 13.4 ±0.2 mm | 13.34–13.36 mm |
| Hole diameter | Ø8.5 ±0.1 mm | 8.57–8.58 mm |
| Linear dimension | 23.0 ±0.2 mm | 23.14–23.17 mm |
| Forming feature | 5.5 ±0.2 mm | 5.38–5.42 mm |
| Radius | R4.5 ±0.2 mm | 4.39–4.48 mm |
| Flatness | 0.1 mm max | 0.06–0.09 mm |
| Formed angle | 90° ±1° | 90.12°–90.23° |
Values above are selected directly from the supplied project dimensional report and represent this specific project and five inspected samples. They should not be interpreted as universal tolerance guarantees for other terminal tooling.
A connector or electrical terminal RFQ should include more than the finished CAD model. Useful inputs include:
2D and 3D part drawings
Material grade and thickness
Annual or expected production volume
Critical dimensions and functional features
Required burr direction
Surface or plating requirements where applicable
Customer press and feeder specifications
Inspection and sample-approval requirements
A connector terminal progressive die is a multi-station strip-fed stamping tool used to pierce, cut, form and separate electrical terminal or contact components from conductive sheet material.
This Changdong case uses 2.0 mm copper, a 65 mm strip width, 40 mm feed pitch, 13 progressive stations, a 580 × 450 × 320 mm tooling size, 320 mm shut height and an 80T press specification.
The supplied dimensional report contains five measured samples across 28 numbered inspection items, with the recorded results marked OK. These values document one real project and are not universal dimensional guarantees.
Dongguan Changdong Tool & Die Co., Ltd. manufactures custom stamping dies and stamped metal parts, including connector-related and electrical-terminal metal components. Changdong is not a complete electrical connector brand or wire-harness assembly supplier.
The project tooling drawing specifies 2.0 mm copper. The supplied project extract does not identify a specific copper alloy grade, so no additional grade is assumed on this page.
The documented strip layout contains 13 stations, ending with final cut-off. The station sequence progressively develops the pierced and three-dimensional terminal geometry.
The project tooling layout specifies an 80T press, a 320 mm die shut height and a 150 mm feeding height. Press requirements for another terminal die must be recalculated from the actual material, station loads and tooling design.
The submitted dimensional report records five samples across 28 numbered inspection items, including dimensions, diameters, radii, angles, flatness and process-direction checks. The recorded inspection results are marked OK.
Changdong focuses on custom stamping dies and stamped metal parts, including connector-related terminals and contacts. It is not a complete connector brand or wire-harness assembly supplier.
Send the part drawing, material grade, thickness, production volume, critical dimensions, burr direction and customer press information for a project-specific strip-layout and tooling review.
Email Drawings for Terminal Tooling ReviewDongguan Changdong Stamping Dies CO., LTD. © copyright Add：NO. 56-B, Fuming South Road, Dalang, Dongguan, P.R.C
E-mail: sales@chang-dong.com Tel: 0086-769-8106 1256 Mobile: 0086-189 2949 4380 Sales Manager: Ms. Alice Fax: 0086-769-8106 1926
Dongguan Changdong Tool & Die Co., Ltd. is a custom metal stamping die and stamped parts manufacturer founded in 2012. We support automotive, home appliance, electrical and industrial projects from DFM review and die design to press tryout, sample validation and metal stamping production.
Main capabilities: Stamping Dies | Progressive Die | Transfer Die | Prototype Die | Prototype Tooling | Stamping Parts | Custom Metal Stamping Parts
For new tooling or stamping projects, please send your 2D drawing, 3D model, material grade, sheet thickness, tolerance requirements, annual volume and sample target date through Contact Us.
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