die-calculator.xls
DESCRIPTION
calculation related to tool designTRANSCRIPT
Cutting Parameters
INPUT DATATOOL NUMBER INPUT TOOL#PART NUMBER INPUT PART#
Mild Steel Semi-hard Mild Mild Stainless Tough StainlessCut Length= 20.000 20.000 20.000 20.000 20.000
Stock Thickness= 0.079 0.079 0.079 0.079 0.079Ultimate Shear Strength= 75,000 35,000 55,000 80,000 120,000
Cutting Force Required RESULTLBS: 118,500 55,300 86,900 126,400 189,600
TONS: 59 28 43 63 95
Stripping Force Required8% 9,4805% 5,9253% 3,555
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= 24.000Stock Thickness= 0.031
Ultimate Tensile Strength= 100,000Form Radius= 0.008Wipe Radius= 0.125
Forming Forces RequiredLbs: 4683
Tons: 2.34 Safe Factor 3 = 7.02 Tons
Press Tonnage= 60 TONS GIVENMAX Pad Pressure= 9 TONS 15% OF PRESS RATING
Actual Reserve Tonnage: 51 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
Page 3
Spring Pressure CalculatorLIGHT DUTY MEDIUM DUTY HEAVY DUTY EXTRA HEAVY DUTY
Free Length of Spring= 2.500 2.500 2.500 2.500Spring Force / .100"= 40 66 154 197
Preload= 0.125 0.125 0.125 0.125Travel= 0.125 0.125 0.125 0.125
Total Travel: 0.250 0.250 0.250 0.250% Compression: 10% 10% 10% 10%
Force / spring: 100 165 385 493
# of Springs= 11 11 11 11
Total Force: 1100 1815 4235 5418
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
Page 4
TONS LBS245 490000
19600
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.
Tolerance
Page 5
Tolerance Transformation
DEVIATION TOLERANCE SYMETRIC TOLERANCEPlus= 0.70
Nominal= 343.50 Nominal 344.00 ± 0.50Minus= 0.30
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.
Threads
Page 6
Thread CalculatorsFinds useful thread data.
ENGLISH TAP DRILLOUTSIDE DIA : Ø 0.500
%THREAD : 0.75PITCH (THD / INCH) : 13.00
TAP DRILL =
METRIC TAP DRILLOUTSIDE DIA : Ø 16.00 MM
%THREAD : 75.00METRIC PITCH : 1.00 MM
TAP DRILL : Ø 15.03 MM Ø 0.592
NUMBER THREADSTHREAD # : 7
MAJOR 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 calculator. All figures shown
here should be verified by qualified personnel before use for tool design.
Air Cylinders
Page 7
Air Cylinder Forces & Inputs
INPUT BORE DIA 2.000 INCHESRESULTING AREA= 3.142 SQUARE INCHESFORCE PER 10 PSI= 31.42 POUNDS OF FORCE
INPUT LINE PRESSURE 50 PSIFORCE= 157.08 POUNDS
INPUT LINE PRESSURE 70 PSIFORCE= 219.91 POUNDS
INPUT LINE PRESSURE 100 PSIFORCE= 314.16 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.
Air Cylinders
Page 8
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.
Bend Dev
Page 9
Bend Variables
Set Radius Given Form RadiusForm Radius= R .032”
Stock Thickness= .0470”Degrees of Arc= 90.00ºNeural Axis (%)= 33%
RADIUS OF NEUTRAL AXIS: R .047”BEND DEDUCTION: .0738” 1.875673756
SET RADIUS (1.35 X STOCK): R .097”
Form Radius Given Set Radius (REFERENCE - BASED ON 8% THINNING)Set (Outside) Radius= R .060”
Stock Thickness= .0375”Degrees of Arc= 90.00ºNeural 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.
Clearance
Page 10
Clearance
5.0% 8.0%Material= 0.47 Clearance: 0.0235 0.0376
Hole/Feature Size: 0.1637 Clearance Hole/Feature Size: 0.2107 0.2389
Percentage Per Side= 12.00%Clearance: 0.0564
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.
Clearance
Page 11
10.0% 12.0% 15.0% 18.0%0.0470 0.0564 0.0705 0.08460.2577 0.2765 0.3047 0.3329
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
Design Estimator
Page 12
Quick Design Estimator
Part Development 4Strip Develpoment 3
Tool Design 12Material / BOM 4
Reviews 2Detailing 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.
Perf Pressure
Page 13
Perf Pressure Load Distribution
Round PunchesMaterial= 0.047
Hole/Feature Size= 0.2120Shear Factor= 40,000
Cut Area: 0.0313Cut Length: 0.6660
Req'd Cutting Pressure (lbs): 1252Tonnage: 0.63
Perf Body= 0.250Perf Head: 0.375
Perf Head Area: 0.110Force on perf head: 11,337 PSI
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.
Perf Pressure
Page 14
Shape PunchesMaterial= 0.125
Cut Length= 19.8550Punch Base Area (Sq. In.)= 19.875
Shear Factor= 40,000 Cut Area: 2.4819
Req'd Cutting Pressure (lbs): 99275Tonnage: 49.64
Force on punch base: 4,995 PSI
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.
Parallel Calculator
Detail / Name TYPE X Y Z VOLUME1.500 6.000 25.000 225.002.500 6.000 12.000 180.00
0.000.000.000.00
Detail / Name TYPE X Y Z VOLUME1.500 1.500 19.500 43.88
0.000.000.000.000.00
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 WEIGHT PRICE/LB Grind Charge PRICE Per 1 QTY Total0.284 63.90 $0.80 $12.50 $63.62 6 $ 381.72 0.284 51.12 $0.80 $12.50 $53.40 1 $ 53.40 0.284 0.00 $0.80 $12.50 $12.50 0 $ - 0.284 0.00 $0.80 $0.00 $0.00 0 $ - 0.284 0.00 $0.80 $0.00 $0.00 0 $ - 0.284 0.00 $0.80 $0.00 $0.00 0 $ -
$ 435.12
Density WEIGHT PRICE/LB Grind Charge PRICE Per 1 QTY Total0.284 12.46 $0.80 $15.00 $24.97 7 $ 174.78 0.284 0.00 $0.80 $15.00 $15.00 0 $ - 0.284 0.00 $0.80 $15.00 $15.00 0 $ - 0.284 0.00 $0.80 $0.00 $0.00 0 $ - 0.284 0.00 $0.80 $0.00 $0.00 0 $ - 0.284 0.00 $0.80 $0.00 $0.00 0 $ -
$ 174.78
Block Cost Analysis
Page 17
Block & Raw Stock Calculator
Detail / Name TYPE X Y Z VOLUME Density WEIGHT PRICE/LB HEAT TREAT/LB PRICE Per 1 QTY TotalA2 1.250 13.620 20.000 340.50 0.284 96.70 $1.20 $0.00 $116.04 2 $ 232.08 A2 1.625 21.400 4.875 169.53 0.284 48.15 $2.20 $0.00 $105.92 1 $ 105.92 A2 1.000 6.000 12.500 75.00 0.284 21.30 $3.06 $1.50 $97.13 3 $ 291.38 A2 1.000 35.500 10.250 363.88 0.284 103.34 $2.00 $1.50 $361.69 4 $ 1,446.77 A2 1.000 2.500 0.000 0.00 0.284 0.00 $2.00 $1.50 $0.00 2 $ - A2 0.000 0.000 0.000 0.00 0.284 0.00 $0.00 $0.00 $0.00 0 $ -
269.49 TOTAL $680.78 $ 2,076.16
Quick Comparison - Different Size TYPE X Y Z VOLUME WEIGHT PRICE/LB HEAT TREAT/LB PRICEExpensive Material: Block1 1.500 24.000 28.300 1019 0.284 289.34 $2.09 $0.00 $604.72 Cheaper Material: Block2 1.000 24.000 28.300 679 0.284 192.89 $2.20 $0.00 $424.36
DIFFERENCE $180.35
Quick Comparison - Different Materia TYPE X Y Z VOLUME WEIGHT PRICE/LB HEAT TREAT/LB PRICEExpensive Material: CPM10V 4.000 20.000 1.500 120 0.284 34.08 $18.00 $1.00 $647.52 Cheaper Material: D2 4.000 20.000 1.500 120 0.284 34.08 $4.00 $1.50 $187.44
DIFFERENCE $460.08
Quick Comparison - Different Plate TYPE X Y Z VOLUME WEIGHT PRICE/LB HEAT TREAT/LB PRICEThick Plate Thick 1.500 24.000 28.300 1019 0.284 289.34 $2.09 $1.00 $894.06 Thin Plate Thin 1.000 24.000 28.300 679 0.284 192.89 $2.09 $1.00 $596.04
DIFFERENCE $298.02
Quick Compound Mat'l TYPE X Y Z VOLUME WEIGHT PRICE/LB Add'l Cost PRICEGross Sizes 15.000 18.000PUNCH PLATE HRS 15.000 18.000 1.000 270 0.284 76.68 $1.00 $1.00 $153.36 DIE D2 15.000 18.000 1.000 270 0.284 76.68 $3.00 $1.00 $306.72 STRIPPER D2 15.000 18.000 0.500 135 0.284 38.34 $1.00 $1.00 $76.68 PARALLELS CRS 1.500 24.000 6.000 216 0.284 61.34 $0.00 $0.00 $0.00
TOTAL $536.76
PRICE PER POUNDTYPE RAW GR PLATE PARASCRS $0.75 $10.00 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
Detail / Name TYPE X Y Z VOLUME WEIGHT PRICE/LB HEAT TREAT/LB PRICE Per 1 QTY TotalPlatten CRS 3.000 72.000 0.250 54.00 0.284 15.34 $0.80 $0.00 $12.27 1 $ 12.27
4.940 0.000 0.000 0.00 0.284 0.00 $4.00 $0.00 $0.00 2 $ - 0.500 0.000 0.000 0.00 0.284 0.00 $4.00 $0.00 $0.00 3 $ - 0.500 0.000 0.000 0.00 0.284 0.00 $4.00 $0.00 $0.00 3 $ -
11.000 0.000 0.000 0.00 0.284 0.00 $4.00 $0.00 $0.00 2 $ - 14.000 0.000 0.000 0.00 0.284 0.00 $4.00 $0.00 $0.00 5 $ -
Detail / Name TYPE Area Z VOLUME WEIGHT PRICE/LB HEAT TREAT/LB PRICE Per 1 QTY TotalMain Holder Block ALUM 27.510 6.000 165.060 0.099 16.34 $0.80 $0.00 $13.07 1 $ 13.07 Angle Iron CRS 6.360 6.000 38.160 0.284 10.84 $4.00 $0.00 $43.35 2 $ 86.70 Tapped Holes In Platten CRS 1.373 0.250 0.343 -0.284 -0.10 $4.00 $0.00 ($0.39) 3 $ (1.17)Reducer holes in Platten CRS 60.000 0.250 15.000 -0.284 -4.26 $4.00 $0.00 ($17.04) 3 $ (51.12)
60.000 0.000 0.000 0.284 0.00 $4.00 $0.00 $0.00 2 $ - 14.000 0.000 0.000 0.284 0.00 $4.00 $0.00 $0.00 5 $ -
Detail / Name TYPE VOLUME WEIGHT PRICE/LB HEAT TREAT/LB PRICE Per 1 QTY TotalShaker 13.00Misc 5.00
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.
Brake Tool Radii
Page 18
Standard Brake Tool Radii
RADIUS AVAILABILITY0.015 VERY COMMON0.031 VERY COMMON0.062 COMMON0.078 COMMON
0.09 AVAILABLE0.125 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.
Shoe Cost Analysis
Page 19
Shoe Cost Calculator
*ALL WEGHT FACTORS ARE FOR STEEL
Quick Shoe Cost Mat'l TYPE A B J,K (THK) PRICE/LB PRICEGross Sizes 32.000 46.000Upper HRS 32.000 46.000 2.500 $1.50 $1,567.68 Lower 32.000 46.000 2.750 $1.50 $1,724.45
SUB-TOTAL $3,292.13
Quantity PRICE/UNIT PRICE/TOTALGuide Pins Roller Pin 4.000 $200.00 $800.00 50Handling Holes 8.000 $20.00 $160.00 Grind Fee 1.000 $100.00 $100.00 Torch Fee 1.000 $100.00 $100.00
SUB-TOTAL $800.00
Internal Total $4,092.13 % MARKUP 40%Marked Up Cost $5,728.98
PARALLELS MAT'L X Y Z PRICE/LB GRIND Charge PRICECRS 1.500 6.000 22.000 $0.80 $10.00 $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.
Shoe Cost Analysis
Page 20
16
QTY TOTAL5 274.928
Stock Utilization
Page 21
Stock Utilization
X YGross Part Footprint: 1.860 1.523Web / Holding Stock: 0.650
Effective Part Envelope= 2.510 1.523
X YGross Sheet Size: 24.000 36.000Dead Stock Zone: 3.500 0.250
Usable Stock Size= 20.500 35.750
X YParts= 8.000 23.000
Total= 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 for tool design.
Screw Strength
Page 22
Screw Strength
MINOR DIAMETER OF SCREW= 0.438 INCHESRESULTANT AREA OF SCREW 0.1503
SCREW MATERIAL TENSILE STRENGTH= 10,000 PSISCREW HOLDING POWER 1,503 LBS
NUMBER OF SCREWS= 10.00TOTAL HOLDING POWER 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.
LENGTH WIDTH HEIGHT DENSITY Weight1.000 1.000 1.000 0.284 0.284
AREA (sq. in.) THICKNESS Density Weight36.700 0.500 0.284 5.2114
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
Page 24
Spot Drill Depth Calculations For CNC
STD DRILL SPOT DRILLDIA 0.1250 DIA 0.1250RAD 0.0625 RAD 0.0625POINT EXTENSION 0.0376 POINT EXTENSION 0.0361
STD DRILL SPOT DRILLOVERAGE 0.0312 OVERAGE 0.0312BASE DIA 0.1250 BASE DIA 0.1250FINAL DIAMETER 0.1562 FINAL DIAMETER 0.1562RAD 0.0781 RAD 0.0781POINT EXTENSION 0.0469 POINT EXTENSION 0.0451
FACTORS118 POINT 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.
Large Radii Estimator
Page 25
Calculator for Large Radii Spring Back
Radius Calculators Given Percent SpringbackPart Dim= 4.3800 Part Dim= 1.5500
Tooled= 4.0000 Percentage= 90.5%Difference: 0.3800 Difference:
Percentage: 91.32% Tool: 1.403
Large RadiiMild Steel 95-85%Stainless Steel 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.
Large Radii Estimator
Page 26
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
EDM Calculator - In Progress
Page 27
EDM Calculator
TOOL NUMBERPART #
DATE
THICKNESS MAIN CONTOUR IRREGULAR INTERNAL CAVSQTY LEAD-IN PATH SUB-TOTAL QTY LEAD-IN
DIE 1.000 1 .250 63.000 7 1.750
PATH 63.250 PATH 62.750
TOTAL DIE PATH 143STRIPPER .500 1 0 63.000
PUNCH PLATE .750 0
STICK PUNCHES 1.750 0
EDM Calculator - In Progress
Page 28
IRREGULAR INTERNAL CAVS REGULAR INTERNAL CAVS DOWELSPATH SUB-TOTAL QTY LEAD-IN PATH SUB-TOTAL QTY DIA
61.000 10 2.500 9.000 4 .375
PATH 11.500 PATH 5.462
EDM Calculator - In Progress
Page 29
DOWELSLEAD-IN PATH PATH SUB-TOTAL
.750 4.712
Ref-Eecel Limits Equations
Page 30
NUMBER LIMITS1.55 3.5