Cutting Parameters TOOL NUMBER PART NUMBER
INPUT DATA INPUT TOOL# INPUT PART#
Cut Length= 28.000 Stock Thickness= 0.079 Ultimate Shear Shear Strength= 40,000
Cutting Force Required
Mild Mild Steel teel 28.000 0.079 35,000
Semi Semi-h -har ard d Mild Mild 28.000 0.079 55,000
Mild Mild Sta Stainle inles ss 28.000 0.079 80,000
Toug Tough h Sta Stainle inless ss 28.000 0.079 120,000
77,420 39
121,660 61
176,960 88
265,440 133
RESULT
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:
Press Tonnage= MAX Pad Pressure= Actual Reserve Tonnage:
4683 2.34
Safe Factor
60 TONS 9 TO TONS 51
3
= 7.02 Tons
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:
LIGH LIGHT T DUTY DUTY MEDI MEDIUM UM DUT DUTY Y HEAV HEAVY Y DUTY DUTY EXTR EXTRA A HEAV HEAVY Y DUTY 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
0.250 10% 165
0.250 10% 385
0.250 10 % 493
11
11
11
11
1100
1815
4235
5418
Note: This calculator is is supplied for reference purposes only. The author assumes no risk for imp figures shown here should be verified by qualified personnel b
Page 3
Spring Pressure
TONS 245
LBS 490000
19600
roper use or engineering based on using this calculator. calculator. All efore use for tool design.
Page 4
Tolerance
Tolerance Transformation 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 purposes only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be verified 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 15.03 MM
Ø 0.592
NUMBER THREADS THREAD THREAD # : 7 MAJOR DIAMETER DIAMETER : Ø 0.151
Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this 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 A AR REA= FORCE PE PER 10 PS PSI=
2.000 3.142 31.42
INCHES SQUARE IN INCHES POUNDS OF OF FORCE
INPUT LINE PRESSURE FORCE=
50 157.08
PSI POUNDS
INPUT LINE PRESSURE FORCE=
70 219.91
PSI POUNDS
INPUT LINE PRESSURE FORCE=
100 314.16
PSI POUNDS
Note: This calculator is is supplied for reference purposes only. The author assumes n improper use or engineering based on using this calculator. calculator. All figures shown here s verified by qualified personnel before use for tool design.
Page 7
Air Cylinders
risk for ould be
Page 8
Bend Dev
Bend Variables Set Radius Given Form Radius Form Radius= Radius= R .032” Stock Thickness= .0470” Degrees of Arc= 90.00º Neural Axis Axis (%)= 33% RADIUS OF NEUTRAL AXIS: AXIS: R .047” BEND DEDUCTION: .0738” SET RADIUS (1.35 (1.35 X STOCK): R .097”
1.88
Form Radius Radius Given Given Set Set Radius Radius (REFERENCE (REFERENCE - BASED BASED ON 8% THINNIN THINNING) G) Set (Outside) (Outside) Radius= R .060” Stock Thickness= .0375” Degrees of Arc= 90.00º Neural Axis Axis (%)= 42% RADIUS OF NEUTRAL AXIS: AXIS: R .420” BEND DEDUCTION: .6598” Form (inside) (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= Material= 0.47 Hole/Featur Hole/Feature e Size: Size: 0.1637 0.1637
Percentage Per Side= Clearance:
Clearance: Clearance Ho Hole/Feature Si Size:
5.0% 0.0235 0.2107
8.0% 0.0376 0.2389
12.00% 0.06
Note: This calculator is is supplied for reference purposes only. The author assumes no risk for im or engineering based on using this calculator. All figures shown here should be verified verified by q 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
proper use alified
Page 11
Design Estimator
Quick Design Estimator Part Develop Development ment 4 Strip Strip Develpoment Develpoment 3 Tool Design Design 12 Material Material / BOM BOM 4 Review Reviews s2 Detailing Detailing 8 Die Set Prepar Preparation ation 2 Total Total Hours Hours 35 Note: This calculator is is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. 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= Material= 0.05 Hole/Featur Hole/Feature e Size= Size= 0.2120 0.2120 Shear Factor= Factor= 40,000 40,000 Cut Area: Area: 0.0313 0.0313 Cut Length: Length: 0.6660 0.6660 Req'd Cutting Cutting Pressure (lbs): (lbs): 1252 Tonnage: Tonnage: 0.63 Perf Body= Body= 0.250 Perf Head: 0.375 Perf Head Head Area: Area: 0.110 Forc Force e on on per perff hea head: d: 11,3 11,337 37 PSI PSI Note: This calculator calculator is supplied for reference purposes only. The au based on using this calculator. All figures shown here should be verif
Page 13
Perf Pressure
Shape Punches Material= Material= 0.13 Cut Length= Length= 19.8550 19.8550 Punch Base Area Area (Sq. In.)= 19.875 Shear Factor= Factor= 40,000 40,000 Cut Area: Area: 2.4819 2.4819 Req'd Cutting Pressure (lbs): 99275 Tonnage: Tonnage: 49.64 Force on punch base:
4,995 PSI
hor assumes no risk for improper use or engineering ied 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 is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. 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 $0.80 $12.50 63.90 $0.80 $12.50 51.12 0.00 $0.80 $12.50 $0.80 $0.00 0.00 $0.80 $0.00 0.00 $0.80 $0.00 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 $$$$$435.12
Density 0.284 0.284 0.284 0.284 0.284 0.284
WEIGHT PRICE/LB Grind Charge $0.80 $15.00 12.46 0.00 $0.80 $15.00 $0.80 $15.00 0.00 $0.80 $0.00 0.00 0.00 $0.80 $0.00 $0.80 $0.00 0.00
PRICE Per 1 $24.97 $15.00 $15.00 $0.00 $0.00 $0.00
QTY 7 0 0 0 0 0
Total $174.78 $$$$$$174.78
Block Cost Analysis
Block & Raw Stock Calculator Detail / Name
TYPE A2 A2 A2 A2 A2 A2
X 1.250 1.625 1.000 1.000 1.000 0.000
Y 1 3 .6 2 0 2 1 .4 0 0 6.000 3 5 .5 0 0 2.500 0.000
Z 20.000 4 .8 7 5 12.500 10.250 0 .0 0 0 0 .0 0 0
VOLUME 340.50 169.53 75.00 363.88 0.00 0.00
Density 0.284 0.284 0.284 0.284 0.284 0.284
TYPE Block1 Block2
X 1.500 1.000
Y 2 4 .0 0 0 2 4 .0 0 0
Z 28.300 28.300
VOLUME 1019 679
0.284 0.284
WEIGHT PRICE/LB HEAT TREAT/LB $2.09 $0.00 289.34 $2.20 $0.00 192.89 DIFFERENCE
PRICE $604.72 $424.36 $180.35
Quick Comparison - Different Materi TYPE CPM10V Expensive Material: D2 Cheaper Material:
X 4.000 4.000
Y 2 0 .0 0 0 20.000
Z 1.500 1.500
VOLUME 120 120
0.284 0.284
WEIGHT PRICE/LB HEAT TREAT/LB $18.00 $1.00 34.08 $4.00 $1.50 34.08 DIFFERENCE
PRICE $647.52 $187.44 $460.08
Quick Comparison - Different Plate Thick Plate Thin Plate
TYPE Thick Thin
X 1.500 1.000
Y 24.000 24.000
Z 28.300 28.300
VOLUME 1019 679
0.284 0.284
WEIGHT PRICE/LB HEAT TREAT/LB $2.09 $1.00 289.34 192.89 $2.09 $1.00 DIFFERENCE
PRICE $894.06 $596.04 $298.02
Quick Compound Mat'l Gross Sizes PUNCH PLATE DIE STRIPPER PARALLELS
TYPE
X 15.000 15.000 15.000 15.000 1.500
Y 1 8 .0 0 0 18.000 18.000 18.000 24.000
Z
VOLUME
1.000 1.000 0.500 6.000
270 270 135 216
Quick Comparison - Different Size Expensive Material: Cheaper Material:
HRS D2 D2 CRS
PRICE PER POUND TYPE RAW GR PLATE $0.75 CRS HRS $0.75 $1.00 *O1 $3.00 *A2 $4.00 *S7 $4.00 $5.00 *D2 *M4 $12.00 *CMP-10V $19.00
WEIGHT PRICE/LB HEAT TREAT/LB PRICE Per 1 96.70 $1.20 $0.00 $116.04 $2.20 $0.00 48.15 $105.92 $3.06 $1.50 21.30 $97.13 $2.00 $1.50 103.34 $361.69 $2.00 $1.50 0.00 $0.00 0.00 $0.00 $0.00 $0.00 269.49 $680.78 TOTAL
WEIGHT PRICE/LB 0.284 0.284 0.284 0.284
76.68 76.68 38.34 61.34
$1.00 $3.00 $1.00 $0.00
Add'l Cost $1.00 $1.00 $1.00 $0.00 TOTAL
QTY 2 1 3 4 2 0
Total $232.08 $105.92 $291.38 $1,446.77 $$$2,076.16
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
PRICE $153.36 $306.72 $76.68 $0.00 $536.76
PARAS $10.00
*INCLUDES HARDENING COSTS
Detail / Name Platten
TYPE CR S
Detail / Name Main Holder Block Angle Iron Tapped Holes In Platten Reducer holes in Platten
TYPE ALUM CR S CR S CR S
Detail / Name Shaker Misc
TYPE
X 3.000 4.940 0.500 0.500 11.000 14.000 Ar e a 2 7 .5 1 0 6.360 1.373 60.000 60.000 14.000
Y 7 2 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0
Z 0 .2 5 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 Z 6 .0 0 0 6 .0 0 0 0 .2 5 0 0 .2 5 0 0 .0 0 0 0 .0 0 0
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 $0.80 $0.00 15.34 $12.27 $4.00 $0.00 0.00 $0.00 $4.00 $0.00 0.00 $0.00 0.00 $4.00 $0.00 $0.00 0.00 $4.00 $0.00 $0.00 $4.00 $0.00 0.00 $0.00 WEIGHT PRICE/LB HEAT TREAT/LB PRICE Per 1 $0.80 $0.00 16.34 $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) $4.00 $0.00 0.00 $0.00 $4.00 $0.00 0.00 $0.00 WEIGHT PRICE/LB HEAT TREAT/LB PRICE Per 1 13.00 5.00
56.16
Note: This calculator is supplied for reference purposes only. The author assumes no risk for improper use or engineering based 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 COMMON 0.03 VERY COMMON COMMON 0.06 COMMON 0.08 COMMON 0.09 AVAILABLE AVAILABLE 0.13 AVAILABLE AVAILABLE
Note: This calculator is supplied for reference purposes purposes only. The author assumes 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
Guide Pins Handling Holes Grind Fee Torch Fee
TYPE HRS
A 32.000 32.000 32.000
B 46.000 46.000 46.000
J,K (THK) 2.500 2.750
Quantity 4.000 8.000 1.000 1.000
Roller Pin
PRICE/LB $1.50 $1.50 SUB-TOTAL PRICE/UNIT $200.00 $20.00 $100.00 $100.00 SUB-TOTAL
Internal Total % MARKUP Marked Up Cost
PARALLELS
MAT'L CRS
X 1.500
Y 6.000
Z 2 2 .0 0 0
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
PRICE/LB $0.80
PRICE $1,567.68 $1,724.45 $ 3 ,2 9 2 .1 3 PRICE/TOTAL $800.00 $160.00 $100.00 $100.00
50
$800.00
$ 4 , 0 9 2 .1 3 40 % $5,728.98
GRIND Charge $ 1 0 .0 0
PRICE $54.99
Shoe Cost Analysis
16
QTY 5
TOTAL 274.93
Page 20
Stock Utilization
Stock Utilization X Gross Part Footprint: 1.860 Web Web / Hold Holdin ing g Stoc Stock: k: 0.65 0.650 0 Effective Pa Part En Envelope= 2.510 X Gross Sheet Size: 24.000 Dead Stock Zone: 3.500 Usabl sable e Stock ock Size Size= = 20. 20.500 500 X Parts= 8.000 Total=
Y 1.523 1.523 Y 36.000 0.250 35. 35.750 750 Y 23.000
184 Pa Parts
Note: This calculator is is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this this calculator. All figures shown here should be verified by qualified personnel before use for tool design.
Page 21
Screw Strength
Screw Strength MINOR DIAMETER OF SCREW= RESULTANT AR AREA OF SC SCREW SCRE SCREW W MATE MATERI RIAL AL TENS TENSIL ILE E STRE STRENG NGTH TH= = SCREW HOLDING POWER NUMBER OF SCREWS= TOTAL HOLDING POWER
0.438 INCHES 0.1503 10,0 10,000PSI 00PSI 1,503 L BS BS 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
AREA (sq. in.) THICKNESS 36.700 0.500
HEIGHT DENSITY Weight 1.000 0.28 0.28
Density Weight 0.284 5.21
Note: This calculator is supplied for for reference purposes only. only. The author assumes no risk for improper use or engineering based on using this calculator. All figures shown here should be 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
SPOT DRILL 0.1250 0.0625 0.0376
DIA RAD POINT EXTENSION
0.1250 0.0625 0.0361
0.0312 0.1250 0.1562 0.0781 0.0469
SPOT DRILL OVERAGE BASE DIA FINAL DIAMETER RAD POINT EXTENSION
0.0312 0.1250 0.1562 0.0781 0.0451
STD DRILL OVERAGE BASE DIA FINAL DIAMETER RAD POINT EXTENSION
118 POINT
FACTORS DIVIDE BY 3.3
Note: This calculator is is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. 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:
Large Radii Mild Steel Stainless St Steel
Given Percent Springback Part Dim= 1.5500 Percentage= 90.5% Difference: Tool: 1.403
4.3800 4.0000 0.3800 91.32%
95-85% 90-75%
Note: This calculator is is supplied for reference purposes only. The author assumes no risk for improper use or engineering based on using this calculator. calculator. All figures shown here should be verified 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
STRIPPER
.500
1
PUNCH PLATE
.750
0
STICK PUNCHES
1.750
0
63.250
TOTAL DIE PATH 0 63.000
Page 26
IRREGULA QTY LEAD-IN 7 1.750 PATH 143
62.750
EDM Calculator _ In Progress
INTERNAL CAVS PATH SUB-TOTAL 61.000
REGULAR INTERNAL CAVS QTY LEAD-IN PATH SUB-TOTAL 10 2.500 9.000
QTY 4
DIA .375
PATH
PATH
5.462
11.500
Page 27
EDM Calculator _ In Progress
DOWELS LEAD LEAD-I -IN N PAT PATH H .750
PATH PATH SUBSUB-TO TOTA TAL L 4.712
Page 28
Ref_Eecel Limits Equations
NUMB NUMBER ER LIMI LIMITS TS 1.55 3.5
Page 29
