Cutting Parameters

INPUT DATATOOL NUMBER INPUT TOOL#PART NUMBER INPUT PART#

Mild Steel Semi-hard Mild Mild Stainless Tough StainlessCut Length= 28.000 28.000 28.000 28.000 28.000

Stock Thickness= 0.079 0.079 0.079 0.079 0.079Ultimate Shear Strength= 40,000 35,000 55,000 80,000 120,000

Cutting Force Required RESULTLBS: 88,480 77,420 121,660 176,960 265,440

TONS: 44 39 61 88 133

Stripping Force Required8% 7,0785% 4,4243% 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= 24.000Stock 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