Cutting Parameters

TOOL NUMBER PART NUMBER INPUT DATA INPUT TOOL# INPUT PART# Mild Steel 28.000 0.079 35,000 Semi-hard Mild 28.000 0.079 55,000 Mild Stainless 28.000 0.079 80,000 Tough Stainless 28.000 0.079 120,000

Cut Length= 28.000 Stock Thickness= 0.079 Ultimate Shear Strength= 40,000

Cutting Force Required

RESULT
77,420 39 121,660 61 176,960 88 265,440 133

LBS: 88,480 TONS: 44

Stripping Force Required
8% 5% 3% 7,078 4,424 2,654

Use The "Spring Pressure" Calculator To Determine The Required Number of Springs

Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before use for tool design.

Forming Tonnage
Form Length= Stock Thickness= Ultimate Tensile Strength= Form Radius= Wipe Radius= 24.000 0.031 100,000 0.008 0.125

Forming Forces Required
Lbs: Tons: 4683 2.34 Safe Factor 3 = 7.02 Tons

Press Tonnage= MAX Pad Pressure= Actual Reserve Tonnage:

60 TONS 9 TONS 51

GIVEN 15% OF PRESS RATING DIFFERENCE

Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before use for tool design.

Spring Pressure

Spring Pressure Calculator
Free Length of Spring= Spring Force / .100"= Preload= Travel= Total Travel: % Compression: Force / spring: # of Springs= Total Force: LIGHT DUTY MEDIUM DUTY HEAVY DUTY EXTRA HEAVY DUTY 2.500 2.500 2.500 2.500 40 66 154 197 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.250 10% 100 11 1100 0.250 10% 165 11 1815 0.250 10% 385 11 4235 0.250 10% 493 11 5418

Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or eng figures shown here should be verified by qualified personnel before use for too

Page 3

Spring Pressure

TONS 245

LBS 490000

19600

o risk for improper use or engineering based on using this calculator. All personnel before use for tool design.

Page 4

Tolerance

Tolerance Transformation
DEVIATION TOLERANCE Plus= 0.70 Nominal= 343.50 Minus= 0.30 SYMETRIC TOLERANCE Nominal 344.00 ± 0.50

Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before use for tool design.

Page 5

Threads

Thread Calculators
Finds useful thread data.

ENGLISH TAP DRILL
OUTSIDE DIA : Ø 0.500 %THREAD : 0.75 PITCH (THD / INCH) : 13.00 TAP DRILL =

METRIC TAP DRILL
OUTSIDE DIA : Ø 16.00 MM %THREAD : 75.00 METRIC PITCH : 1.00 MM TAP DRILL : Ø 15.03 MM NUMBER THREADS THREAD # : 7 MAJOR DIAMETER : Ø 0.151

Ø 0.592

Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before use for tool design.

Page 6

Air Cylinders

Air Cylinder Forces & Inputs
INPUT BORE DIA RESULTING AREA= FORCE PER 10 PSI= 2.000 3.142 31.42 INCHES SQUARE INCHES POUNDS OF FORCE

INPUT LINE PRESSURE FORCE= INPUT LINE PRESSURE FORCE= INPUT LINE PRESSURE FORCE=

50 157.08 70 219.91 100 314.16

PSI POUNDS PSI POUNDS PSI POUNDS

Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before use for tool design.

Page 7

Air Cylinders

assumes no risk for hown here should be gn.

Page 8

Bend Dev

Bend Variables
Set Radius Given Form Radius Form Radius= R .032” Stock Thickness= .0470” Degrees of Arc= 90.00º Neural Axis (%)= 33% RADIUS OF NEUTRAL AXIS: R .047” BEND DEDUCTION: .0738” SET RADIUS (1.35 X STOCK): R .097”

1.88

Form Radius Given Set Radius (REFERENCE - BASED ON 8% THINNING) Set (Outside) Radius= R .060” Stock Thickness= .0375” Degrees of Arc= 90.00º Neural Axis (%)= 42% RADIUS OF NEUTRAL AXIS: R .420” BEND DEDUCTION: .6598” Form (inside) RADIUS: R .019”

Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before use for tool design.

Page 9

Clearance

Clearance
Material= 0.47 Hole/Feature Size: 0.1637 Clearance: Clearance Hole/Feature Size: 5.0% 0.0235 0.2107 8.0% 0.0376 0.2389

Percentage Per Side= Clearance:

12.00% 0.06

Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before use for tool design.

Page 10

Clearance

10.0% 0.0470 0.2577

12.0% 0.0564 0.2765

15.0% 0.0705 0.3047

18.0% 0.0846 0.3329

no risk for improper use verified by qualified

Page 11

Design Estimator

Quick Design Estimator
Part Development 4 Strip Develpoment 3 Tool Design 12 Material / BOM 4 Reviews 2 Detailing 8 Die Set Preparation 2 Total Hours 35 Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before use for tool design.

Page 12

Perf Pressure

Perf Pressure Load Distribution
Round Punches Material= 0.05 Hole/Feature Size= 0.2120 Shear Factor= 40,000 Cut Area: 0.0313 Cut Length: 0.6660 Req'd Cutting Pressure (lbs): 1252 Tonnage: 0.63 Perf Body= 0.250 Perf Head: 0.375 Perf Head Area: 0.110 Force on perf head: 11,337 PSI

Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineer based on using this calculator. All figures shown here should be verified by qualified personnel before use for tool desig

Page 13

Perf Pressure

Shape Punches Material= 0.13 Cut Length= 19.8550 Punch Base Area (Sq. In.)= 19.875 Shear Factor= 40,000 Cut Area: 2.4819 Req'd Cutting Pressure (lbs): 99275 Tonnage: 49.64 Force on punch base: 4,995 PSI

nly. The author assumes no risk for improper use or engineering ould be verified by qualified personnel before use for tool design.

Page 14

Parallel Calculator
Detail / Name TYPE X 1.500 2.500 Y 6.000 6.000 Z 25.000 12.000 VOLUME 225.00 180.00 0.00 0.00 0.00 0.00

Detail / Name

TYPE

X 1.500

Y 1.500

Z 19.500

VOLUME 43.88 0.00 0.00 0.00 0.00 0.00

Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before use for tool design.

Density 0.284 0.284 0.284 0.284 0.284 0.284

WEIGHT PRICE/LB Grind Charge 63.90 $0.80 $12.50 51.12 $0.80 $12.50 0.00 $0.80 $12.50 0.00 $0.80 $0.00 0.00 $0.80 $0.00 0.00 $0.80 $0.00

PRICE Per 1 $63.62 $53.40 $12.50 $0.00 $0.00 $0.00

QTY 6 1 0 0 0 0

Total $381.72 $53.40 $$$$$435.12

Density 0.284 0.284 0.284 0.284 0.284 0.284

WEIGHT PRICE/LB Grind Charge 12.46 $0.80 $15.00 0.00 $0.80 $15.00 0.00 $0.80 $15.00 0.00 $0.80 $0.00 0.00 $0.80 $0.00 0.00 $0.80 $0.00

PRICE Per 1 $24.97 $15.00 $15.00 $0.00 $0.00 $0.00

QTY 7 0 0 0 0 0

Total $174.78 $$$$$$174.78

Block Cost Analysis

Block & Raw Stock Calculator
Detail / Name TYPE A2 A2 A2 A2 A2 A2 X 1.250 1.625 1.000 1.000 1.000 0.000 Y 13.620 21.400 6.000 35.500 2.500 0.000 Z 20.000 4.875 12.500 10.250 0.000 0.000 VOLUME 340.50 169.53 75.00 363.88 0.00 0.00 Density 0.284 0.284 0.284 0.284 0.284 0.284 WEIGHT PRICE/LB HEAT TREAT/LB PRICE Per 1 96.70 $1.20 $0.00 $116.04 48.15 $2.20 $0.00 $105.92 21.30 $3.06 $1.50 $97.13 103.34 $2.00 $1.50 $361.69 0.00 $2.00 $1.50 $0.00 0.00 $0.00 $0.00 $0.00 269.49 TOTAL $680.78 WEIGHT PRICE/LB HEAT TREAT/LB 289.34 $2.09 $0.00 192.89 $2.20 $0.00 DIFFERENCE WEIGHT PRICE/LB HEAT TREAT/LB 34.08 $18.00 $1.00 34.08 $4.00 $1.50 DIFFERENCE WEIGHT PRICE/LB HEAT TREAT/LB 289.34 $2.09 $1.00 192.89 $2.09 $1.00 DIFFERENCE WEIGHT PRICE/LB 0.284 0.284 0.284 0.284 76.68 76.68 38.34 61.34 $1.00 $3.00 $1.00 $0.00 Add'l Cost $1.00 $1.00 $1.00 $0.00 TOTAL PRICE $604.72 $424.36 $180.35 PRICE $647.52 $187.44 $460.08 PRICE $894.06 $596.04 $298.02 PRICE $153.36 $306.72 $76.68 $0.00 $536.76 QTY 2 1 3 4 2 0 Total $232.08 $105.92 $291.38 $1,446.77 $$$2,076.16

Quick Comparison - Different Size Expensive Material: Cheaper Material:

TYPE Block1 Block2

X 1.500 1.000

Y 24.000 24.000

Z 28.300 28.300

VOLUME 1019 679

0.284 0.284

Quick Comparison - Different Material TYPE Expensive Material: CPM10V Cheaper Material: D2

X 4.000 4.000

Y 20.000 20.000

Z 1.500 1.500

VOLUME 120 120

0.284 0.284

Quick Comparison - Different Plate Thickness TYPE Thick Plate Thick Thin Plate Thin

X 1.500 1.000

Y 24.000 24.000

Z 28.300 28.300

VOLUME 1019 679

0.284 0.284

Quick Compound Mat'l Gross Sizes PUNCH PLATE DIE STRIPPER PARALLELS

TYPE HRS D2 D2 CRS

X 15.000 15.000 15.000 15.000 1.500

Y 18.000 18.000 18.000 18.000 24.000

Z 1.000 1.000 0.500 6.000

VOLUME 270 270 135 216

PRICE PER POUND TYPE RAW GR PLATE CRS $0.75 HRS $0.75 $1.00 *O1 $3.00 *A2 $4.00 *S7 $4.00 *D2 $5.00 *M4 $12.00 *CMP-10V $19.00 *INCLUDES HARDENING COSTS

PARAS $10.00

Detail / Name Platten

TYPE CRS

Detail / Name Main Holder Block Angle Iron Tapped Holes In Platten Reducer holes in Platten

TYPE ALUM CRS CRS CRS

X 3.000 4.940 0.500 0.500 11.000 14.000 Area 27.510 6.360 1.373 60.000 60.000 14.000

Y 72.000 0.000 0.000 0.000 0.000 0.000

Z 0.250 0.000 0.000 0.000 0.000 0.000 Z 6.000 6.000 0.250 0.250 0.000 0.000

Detail / Name Shaker Misc

TYPE

VOLUME 54.00 0.00 0.00 0.00 0.00 0.00 VOLUME 165.060 38.160 0.343 15.000 0.000 0.000 VOLUME

0.284 0.284 0.284 0.284 0.284 0.284 0.099 0.284 -0.284 -0.284 0.284 0.284

WEIGHT PRICE/LB HEAT TREAT/LB PRICE Per 1 15.34 $0.80 $0.00 $12.27 0.00 $4.00 $0.00 $0.00 0.00 $4.00 $0.00 $0.00 0.00 $4.00 $0.00 $0.00 0.00 $4.00 $0.00 $0.00 0.00 $4.00 $0.00 $0.00 WEIGHT PRICE/LB HEAT TREAT/LB PRICE Per 1 16.34 $0.80 $0.00 $13.07 10.84 $4.00 $0.00 $43.35 -0.10 $4.00 $0.00 ($0.39) -4.26 $4.00 $0.00 ($17.04) 0.00 $4.00 $0.00 $0.00 0.00 $4.00 $0.00 $0.00 WEIGHT PRICE/LB HEAT TREAT/LB PRICE Per 1 13.00 5.00

QTY 1 2 3 3 2 5 QTY 1 2 3 3 2 5 QTY

Total $12.27 $$$$$Total $13.07 $86.70 $(1.17) $(51.12) $$Total

56.16

Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before use for tool design.

Page 17

Brake Tool Radii

Standard Brake Tool Radii
RADIUS AVAILABILITY 0.02 VERY COMMON 0.03 VERY COMMON 0.06 COMMON 0.08 COMMON 0.09 AVAILABLE 0.13 AVAILABLE

Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before use for tool design.

Page 18

Shoe Cost Analysis

Shoe Cost Calculator
*ALL WEGHT FACTORS ARE FOR STEEL

Quick Shoe Cost Mat'l Gross Sizes Upper Lower

TYPE HRS

A 32.000 32.000 32.000

B 46.000 46.000 46.000

J,K (THK) 2.500 2.750

PRICE/LB $1.50 $1.50 SUB-TOTAL PRICE/UNIT $200.00 $20.00 $100.00 $100.00 SUB-TOTAL

PRICE $1,567.68 $1,724.45 $3,292.13 PRICE/TOTAL $800.00 $160.00 $100.00 $100.00 $800.00

Guide Pins Handling Holes Grind Fee Torch Fee

Roller Pin

Quantity 4.000 8.000 1.000 1.000

50

Internal Total % MARKUP Marked Up Cost

$4,092.13 40% $5,728.98

PARALLELS

MAT'L CRS

X 1.500

Y 6.000

Z 22.000

PRICE/LB $0.80

GRIND Charge $10.00

PRICE $54.99

Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before use for tool design.

Page 19

Shoe Cost Analysis

16

QTY 5

TOTAL 274.93

Page 20

Stock Utilization

Stock Utilization
X Gross Part Footprint: 1.860 Web / Holding Stock: 0.650 Effective Part Envelope= 2.510 X Gross Sheet Size: 24.000 Dead Stock Zone: 3.500 Usable Stock Size= 20.500 X Parts= 8.000 Total= Y 1.523 1.523 Y 36.000 0.250 35.750 Y 23.000

184 Parts

Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before use f or tool design.

Page 21

Screw Strength

Screw Strength
MINOR DIAMETER OF SCREW= RESULTANT AREA OF SCREW SCREW MATERIAL TENSILE STRENGTH= SCREW HOLDING POWER NUMBER OF SCREWS= TOTAL HOLDING POWER 0.438 INCHES 0.1503 10,000 PSI 1,503 LBS 10.00 15,033 LBS

Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before use for tool design.

Page 22

LENGTH 1.000

WIDTH 1.000

HEIGHT DENSITY Weight 1.000 0.28 0.28

AREA (sq. in.) THICKNESS 36.700 0.500

Density Weight 0.284 5.21

Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before use for tool design.

Drill Depth Tip Offset

Spot Drill Depth Calculations For CNC
STD DRILL DIA RAD POINT EXTENSION STD DRILL OVERAGE BASE DIA FINAL DIAMETER RAD POINT EXTENSION 0.1250 0.0625 0.0376 SPOT DRILL DIA RAD POINT EXTENSION SPOT DRILL OVERAGE BASE DIA FINAL DIAMETER RAD POINT EXTENSION 0.1250 0.0625 0.0361

0.0312 0.1250 0.1562 0.0781 0.0469

0.0312 0.1250 0.1562 0.0781 0.0451

118 POINT

FACTORS DIVIDE BY 3.3

Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before use for tool design.

Page 24

Large Radii Estimator

Calculator for Large Radii Spring Back
Radius Calculators Part Dim= Tooled= Difference: Percentage: 4.3800 4.0000 0.3800 91.32% Given Percent Springback Part Dim= 1.5500 Percentage= 90.5% Difference: Tool: 1.403

Large Radii Mild Steel Stainless Steel

95-85% 90-75%

Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified by qualified personnel before use for tool design.

Page 25

EDM Calculator _ In Progress

EDM Calculator
TOOL NUMBER PART # DATE THICKNESS DIE 1.000 QTY 1 MAIN CONTOUR LEAD-IN PATH SUB-TOTAL .250 63.000 PATH 63.250 IRREGULAR INTERNAL CAVS LEAD-IN 1.750 62.750

QTY 7

PATH 143

STRIPPER

.500

1

0

TOTAL DIE PATH 63.000

PUNCH PLATE

.750

0

STICK PUNCHES

1.750

0

Page 26

EDM Calculator _ In Progress

IRREGULAR INTERNAL CAVS PATH SUB-TOTAL 61.000

REGULAR INTERNAL CAVS QTY LEAD-IN PATH SUB-TOTAL 10 2.500 9.000 PATH 11.500

DOWELS QTY 4 PATH DIA .375 5.462

Page 27

EDM Calculator _ In Progress

DOWELS LEAD-IN PATH .750

PATH SUB-TOTAL 4.712

Page 28

Ref_Eecel Limits Equations

NUMBER LIMITS 1.55 3.5

Page 29

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