Cutting Parameters

TOOL NUMBER
PART NUMBER

INPUT DATA
INPUT TOOL#
INPUT PART#

Cut Length= 20.000

Stock Thickness= 0.079
Ultimate Shear Strength= 75,000

Cutting Force Required

Mild Steel
20.000
0.079
35,000

Semi-hard Mild
20.000
0.079
55,000

Mild Stainless
20.000
0.079
80,000

Tough Stainless
20.000
0.079
120,000

55,300
28

86,900
43

126,400
63

189,600
95

RESULT

LBS: 118,500
TONS: 59

Stripping Force Required

8%
5%
3%

9,480
5,925
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=
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 TONS
51

= 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:

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

0.250
10%
165

0.250
10%
385

0.250
10%
493

11

11

11

11

1100

1815

4235

5418

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

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 : 0.500
%THREAD : 0.75
PITCH (THD / INCH) : 13.00
TAP DRILL =

METRIC TAP DRILL

OUTSIDE DIA :
%THREAD :
METRIC PITCH :
TAP DRILL :

16.00 MM
75.00
1.00 MM
15.03 MM

0.592

NUMBER THREADS
THREAD # : 7
MAJOR DIAMETER : 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
RESULTING AREA=
FORCE PER 10 PSI=

2.000
3.142
31.42

INCHES
SQUARE INCHES
POUNDS 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 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
n.

Page 8

Bend Dev

Bend Variables
Set Radius Given Form Radius
Form Radius=
Stock Thickness=
Degrees of Arc=
Neural Axis (%)=
RADIUS OF NEUTRAL AXIS:
BEND DEDUCTION:
SET RADIUS (1.35 X STOCK):

R .032
.0470
90.00
33%
R .047
.0738
R .097

Form Radius Given Set Radius

Set (Outside) Radius=
Stock Thickness=
Degrees of Arc=
Neural Axis (%)=
RADIUS OF NEUTRAL AXIS:
BEND DEDUCTION:
Form (inside) RADIUS:

(REFERENCE - BASED ON 8% THINNING)

R .060
.0375
90.00
42%
R .420
.6598
R .019

1.875673756

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

Percentage Per Side=

Clearance:

Clearance:
Clearance Hole/Feature Size:

5.0%
0.0235
0.2107

8.0%
0.0376
0.2389

12.00%
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.

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

o risk for improper use

erified by qualified

Page 11

Design Estimator

Quick Design Estimator

Part Development
Strip Develpoment
Tool Design
Material / BOM
Reviews
Detailing
Die Set Preparation

4
3
12
4
2
8
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= 0.047
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=
Perf Head:
Perf Head Area:
Force on perf head:

0.250
0.375
0.110
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=
Cut Length=
Punch Base Area (Sq. In.)=
Shear Factor=
Cut Area:
Req'd Cutting Pressure (lbs):
Tonnage:
Force on punch base:

0.125
19.8550
19.875
40,000
2.4819
99275
49.64
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

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
381.72
53.40
435.12

$
$
$
$
$
$
$

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

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

WEIGHT PRICE/LB
289.34
$2.09
192.89
$2.20

HEAT TREAT/LB
$0.00
$0.00
DIFFERENCE

PRICE
$604.72
$424.36
$180.35

Quick Comparison - Different Materia 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

WEIGHT PRICE/LB
34.08
$18.00
34.08
$4.00

HEAT TREAT/LB
$1.00
$1.50
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
289.34
$2.09
192.89
$2.09

HEAT TREAT/LB
$1.00
$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
18.000
18.000
18.000
18.000
24.000

VOLUME

WEIGHT PRICE/LB

Add'l Cost

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
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

0.284
0.284
0.284
0.284

WEIGHT PRICE/LB HEAT TREAT/LB

96.70
$1.20
$0.00
48.15
$2.20
$0.00
21.30
$3.06
$1.50
103.34
$2.00
$1.50
0.00
$2.00
$1.50
0.00
$0.00
$0.00
269.49
TOTAL

76.68
76.68
38.34
61.34

$1.00
$3.00
$1.00
$0.00

$1.00
$1.00
$1.00
$0.00
TOTAL

PRICE Per 1
$116.04
$105.92
$97.13
$361.69
$0.00
$0.00
$680.78

QTY
2
1
3
4
2
0

Total
$ 232.08
$ 105.92
$ 291.38
$ 1,446.77
$
$
$ 2,076.16

PRICE
$153.36
$306.72
$76.68
$0.00
$536.76

PARAS
$10.00

*INCLUDES HARDENING COSTS

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

Detail / Name
Shaker
Misc

TYPE

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

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
15.34
$0.80
0.00
$4.00
0.00
$4.00
0.00
$4.00
0.00
$4.00
0.00
$4.00
WEIGHT PRICE/LB
16.34
$0.80
10.84
$4.00
-0.10
$4.00
-4.26
$4.00
0.00
$4.00
0.00
$4.00
WEIGHT PRICE/LB
13.00
5.00

HEAT TREAT/LB
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
HEAT TREAT/LB
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
HEAT TREAT/LB

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

PRICE Per 1
$12.27
$0.00
$0.00
$0.00
$0.00
$0.00
PRICE Per 1
$13.07
$43.35
($0.39)
($17.04)
$0.00
$0.00
PRICE Per 1

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

Brake Tool Radii

Standard Brake Tool Radii

RADIUS
0.015
0.031
0.062
0.078
0.09
0.125

AVAILABILITY
VERY COMMON
VERY COMMON
COMMON
COMMON
AVAILABLE
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

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
22.000

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
$3,292.13
PRICE/TOTAL
$800.00
$160.00
$100.00
$100.00

50

$800.00

$4,092.13
40%
$5,728.98

GRIND Charge
$10.00

PRICE
$54.99

Shoe Cost Analysis

16

QTY
5

TOTAL
274.928

Page 20

Stock Utilization

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

Y
1.523

X
Gross Sheet Size: 24.000
Dead Stock Zone: 3.500
Usable Stock Size= 20.500

Y
36.000
0.250
35.750

X
Parts= 8.000

Y
23.000

Total=

1.523

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.

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

AREA (sq. in.) THICKNESS

36.700
0.500

HEIGHT DENSITY Weight

1.000
0.284
0.284

Density Weight
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

Spot Drill Depth Calculations For CNC

STD DRILL

SPOT DRILL

DIA
RAD
POINT EXTENSION

0.1250
0.0625
0.0376

DIA
RAD
POINT EXTENSION

0.1250
0.0625
0.0361

STD DRILL
OVERAGE
BASE DIA
FINAL DIAMETER
RAD
POINT EXTENSION

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

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:

Large Radii
Mild Steel
Stainless 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 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

Large Radii Estimator

assumes no risk for

here should be verified

Page 26

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

PUNCH PLATE

.750

STICK PUNCHES

1.750

Page 27

63.250

TOTAL DIE PATH

63.000

QTY
7
PATH
143

IRREGULAR INTERNAL CAVS

LEAD-IN
1.750
62.750

IRREGULAR INTERNAL CAVS

PATH SUB-TOTAL
61.000

EDM Calculator - In Progress

QTY
10

REGULAR INTERNAL CAVS

LEAD-IN
PATH SUB-TOTAL
2.500
9.000

PATH

11.500

Page 28

DOWELS
QTY
4

DIA
.375

PATH

5.462

EDM Calculator - In Progress

DOWELS
LEAD-IN PATH
.750

PATH SUB-TOTAL
4.712

Page 29

Ref-Eecel Limits Equations

NUMBER LIMITS
1.55
3.5

Page 30