Cutting Parameters

INPUT DATA
TOOL NUMBER INPUT TOOL#
PART NUMBER INPUT PART#
Mild Steel Semi-hard Mild Mild Stainless Tough Stainless
Cut Length= 28.000 28.000 28.000 28.000 28.000
Stock Thickness= 0.079 0.079 0.079 0.079 0.079
Ultimate Shear Strength= 40,000 35,000 55,000 80,000 120,000

Cutting Force Required RESULT

LBS: 88,480 77,420 121,660 176,960 265,440
TONS: 44 39 61 88 133

Stripping Force Required

8% 7,078
5% 4,424
3% 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= 24.000
Stock Thickness= 0.031
Ultimate Tensile Strength= 100,000
Form Radius= 0.008
Wipe Radius= 0.125

Forming Forces Required

Lbs: 4683
Tons: 2.34 Safe Factor 3 = 7.02 Tons

Press Tonnage= 60 TONS GIVEN

MAX 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

Spring Pressure Calculator

LIGHT DUTY MEDIUM DUTY HEAVY DUTY EXTRA HEAVY DUTY
Free Length of Spring= 2.500 2.500 2.500 2.500
Spring Force / .100"= 40 66 154 197
Preload= 0.125 0.125 0.125 0.125
Travel= 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 eng
figures shown here should be verified by qualified personnel before use for too

Page 3
 Spring Pressure

TONS LBS
245 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 SYMETRIC TOLERANCE
Plus= 0.70
Nominal= 343.50 Nominal 344.00 ± 0.50
Minus= 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.

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 Ø 0.592

NUMBER THREADS
THREAD # : 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.

Page 6
 Air Cylinders

Air Cylinder Forces & Inputs

INPUT BORE DIA 2.000 INCHES
RESULTING AREA= 3.142 SQUARE INCHES
FORCE PER 10 PSI= 31.42 POUNDS OF FORCE

INPUT LINE PRESSURE 50 PSI

FORCE= 157.08 POUNDS

INPUT LINE PRESSURE 70 PSI

FORCE= 219.91 POUNDS

INPUT LINE PRESSURE 100 PSI

FORCE= 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.

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” 1.88
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= 90.00º
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
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: 0.06

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% 12.0% 15.0% 18.0%

0.0470 0.0564 0.0705 0.0846
0.2577 0.2765 0.3047 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 Y Z VOLUME
1.500 6.000 25.000 225.00
2.500 6.000 12.000 180.00
0.00
0.00
0.00
0.00

Detail / Name TYPE X Y Z VOLUME

1.500 1.500 19.500 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 WEIGHT PRICE/LB Grind Charge PRICE Per 1 QTY Total
0.284 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 Total

0.284 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

Block & Raw Stock Calculator

Detail / Name TYPE X Y Z VOLUME Density WEIGHT PRICE/LB HEAT TREAT/LB PRICE Per 1 QTY Total
A2 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 PRICE
Expensive 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 Material TYPE X Y Z VOLUME WEIGHT PRICE/LB HEAT TREAT/LB PRICE
Expensive 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 Thickness

TYPE X Y Z VOLUME WEIGHT PRICE/LB HEAT TREAT/LB PRICE
Thick 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 PRICE
Gross Sizes 15.000 18.000
PUNCH 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 POUND

TYPE RAW GR PLATE PARAS
CRS $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 Total
Platten 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 Total
Main 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 Total
Shaker 13.00
Misc 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.

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 TYPE A B J,K (THK) PRICE/LB PRICE

Gross Sizes 32.000 46.000
Upper 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/TOTAL

Guide Pins Roller Pin 4.000 $200.00 $800.00 50
Handling 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 PRICE

CRS 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.

Page 19
 Shoe Cost Analysis

16

QTY TOTAL
5 274.93

Page 20
 Stock Utilization

Stock Utilization
X Y
Gross Part Footprint: 1.860 1.523
Web / Holding Stock: 0.650
Effective Part Envelope= 2.510 1.523

X Y
Gross Sheet Size: 24.000 36.000
Dead Stock Zone: 3.500 0.250
Usable Stock Size= 20.500 35.750

X Y
Parts= 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 f or tool design.

Page 21
 Screw Strength

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

NUMBER OF SCREWS= 10.00

TOTAL 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.

Page 22
 LENGTH WIDTH HEIGHT DENSITY Weight
1.000 1.000 1.000 0.28 0.28

AREA (sq. in.) THICKNESS Density Weight

36.700 0.500 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 SPOT DRILL
DIA 0.1250 DIA 0.1250
RAD 0.0625 RAD 0.0625
POINT EXTENSION 0.0376 POINT EXTENSION 0.0361

STD DRILL SPOT DRILL

OVERAGE 0.0312 OVERAGE 0.0312
BASE DIA 0.1250 BASE DIA 0.1250
FINAL DIAMETER 0.1562 FINAL DIAMETER 0.1562
RAD 0.0781 RAD 0.0781
POINT EXTENSION 0.0469 POINT EXTENSION 0.0451

FACTORS
118 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.

Page 24
 Large Radii Estimator

Calculator for Large Radii Spring Back

Radius Calculators Given Percent Springback
Part Dim= 4.3800 Part Dim= 1.5500
Tooled= 4.0000 Percentage= 90.5%
Difference: 0.3800 Difference:
Percentage: 91.32% Tool: 1.403

Large Radii
Mild 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.

Page 25
 EDM Calculator _ In Progress

EDM Calculator
TOOL NUMBER
PART #
DATE

THICKNESS MAIN CONTOUR IRREGULAR INTERNAL CAVS

QTY 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 143

STRIPPER .500 1 0 63.000

PUNCH PLATE .750 0

STICK PUNCHES 1.750 0

Page 26
 EDM Calculator _ In Progress

IRREGULAR INTERNAL CAVS REGULAR INTERNAL CAVS DOWELS

PATH 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

Page 27
 EDM Calculator _ In Progress

DOWELS
LEAD-IN PATH PATH SUB-TOTAL
.750 4.712

Page 28
 Ref_Eecel Limits Equations

NUMBER LIMITS
1.55 3.5

Page 29