Tooling Calculation
Total progressive die tooling cost can be specified with the PSO Total Progressive Die Tooling Cost or calculated as described below.
Hard Tooling Cost = Number of Die Stations *
(Average Material Cost per Die Station + Average Labor Cost per Die Station)
Hard tooling cost depends on the following
• Number of die stations (specified by the PSO Number of Non-IDLE Stations, or calculated by using the formula below) • Material cost per die station (see the formula below)
• Labor cost per die station (see the formula below)
Average Material Cost per Die Station = Average Material Mass per Die Station * Average Material Rate
Average material cost per die station is the product of the following:
• Average material mass per die station (calculated as described below, or specified by the PSO Average Progressive Die Tooling Material Mass per Station) • Average material rate (specified by the PSO Average Progressive Die Tooling Material Rate or the toolshop variable avgMatlRate). Average Material Mass per Die Station
Average material mass per active die station is estimated as a linear combination of
• Blank SER area
• Total number of holes
• Total number of bends and forms
aPriori chooses from among various sets of coefficients to be used in the linear combination based on the following:
• Number of concurrent parts (see the PSO Number of Parts Stamped Concurrently) • Whether the part requires side actions (that is, whether there are cam piercing, cam bending, or cam forming stations--see the formulas below)
The sets of coefficients are derived from large, representative data sets of sample of parts. (The material mass of IDLE stations is amortized over the active stations.)
Average Labor Cost per Die Station = Average Labor Hours per Die Station * Average Labor Rate
Average labor cost per die station is the product of the following:
• Average labor hours per die station (calculated as described below, or specified by the PSO Average Progressive Die Tooling Labor Hours per Station) • Average labor rate (specified by the PSO Average Progressive Die Tooling Labor Rate or the toolshop variable avgLaborRate). Average Labor Hours per Die Station
Average labor hours per die station is estimated as a linear combination of
• Blank SER area
• Total number of holes
• Total number of bends and forms
aPriori chooses from among various sets of coefficients to be used in the linear combination based on the following:
• Number of concurrent parts (see the PSO Number of Parts Stamped Concurrently) • Whether the part requires side actions (that is, whether there are cam piercing, cam bending, or cam forming stations--see the formulas below)
The sets of coefficients are derived from large, representative data sets of sample of parts.
Number of Die Stations =
Number of Piloting Stations +
Number of Edge Trimming Stations +
Number of Trimming Stations +
Number of Piercing Stations +
Number of Cam Piercing Stations +
Number of Extruding or Countersinking Stations +
Number of Threading Stations +
Number of Scoring Stations +
Number of Bending Up Stations +
Number of Bending Down Stations +
Number of Cam Bending Stations +
Number of Forming Up Stations +
Number of Forming Down Stations +
Number of Cam Forming Stations +
Number of Restriking Stations +
Number of Cutoff Stations
The number of active die stations is the sum of the number of each of the types of dies station—see below.
Number of Piloting Stations = 1
The number of piloting stations is always 1.
Number of Edge Trimming Stations = 1
The number of edge trimming stations is always 1.
Number of Trimming Stations = rounddown(Blank Perimeter / Trim Punch Length) –
Number of Edge Trimming Stations + Trim Station Adder for Two Out
The number of trimming stations depends on the following:
• Blank perimeter length (see the PSO Perimeter) • Trim punch length (see the formula below)
• Number of edge trimming stations (this is always 1—see above)
• Trim station adder for two out (1 if the number of concurrent parts is 2; 0 otherwise)
Trim Punch Length = {
typical large trim punch length, for large parts;
typical small trim punch length, for small parts;
Blank Perimeter/2, for very small parts}
Large and small trim punch lengths are 406.4 or 355.6 in aPriori starting point VPEs. They are specified in the lookup table toolingComponentAttributes.
Part size (large, small or very small) is determined as follows:
• Large, if blank perimeter (see the PSO Perimeter) is greater than the cost model variable upperBlankPerimeterLengthThreshold. • Small, if the blank perimeter is between the cost model variables upperBlankPerimeterLengthThreshold and lowerBlankPerimeterLengthThreshold (but not equal to the lower threshold).
• Very small, if the blank perimeter is less than or equal to the cost model variable lowerBlankPerimeterLengthThreshold.
Number of Hole Piercing Stations = {1 if there are holes and either bends or forms; 0 otherwise}
The number of hole piercing stations is 1 if the part has both holes (see the PSO Number of Holes) and either bends (see the PSO Number of Hemmed Bends) or forms (see the PSO Number of Forms); it is 0 otherwise. Number of Piercing Stations = {1 if there are holes and either bends or forms, and
holes are pierced after forming, and there is hole forming; 0 otherwise}
The number of piercing stations is 1 if all the following hold:
• PSO Number of Holes is greater than 0. • Either the PSO Number of Hemmed Bends greater than 0 or the PSO Number of Forms • is greater than 0.
• PSO Pierce Before or After Forms is set to holesAfterForms. Otherwise, the number of piercing stations is 0.
Number of Cam Piercing Stations = {number of plain hole groupings}
The number of cam piercing stations is the value of the PSO Number of Plain Hole Groupings. Number of Extruding or Countersinking Stations = {
0 if there are no holes;
0 if there are no up features and no down features;
1 if there are up features and no down features;
1 if there down features and no up features;
2 otherwise}
The number of extruding or countersinking stations is determined as follows:
• 0 if PSO Number of Holes is 0 • 0 if both the following hold:
• 1 if both the following hold:
• 1 if both the following hold:
• 2 otherwise
Number of Hole Threading Stations = {number of tapped holes}
The number of hole-threading stations is the value of the PSO Number of Tapped Holes. Number of Scoring Stations = {
0 if there are no bends with intersecting holes
0 if there are both up and down bends
1 otherwise}
The number of scoring stations is determined as follows:
• 0 if both the following hold:
o PSO Number of UP Bends is greater than 0 o PSO Number of DOWN Bends is greater than 0 (In this case, any scoring is bundled with one of the bending operations.)
• 1 otherwise
Number of UP Bending Stations = {
2 if there are more than 3 UP bends;
1 if there are between 1 and 3 UP bends;
0 otherwise}
The number of UP bending stations is determined as follows:
• 2 if the PSO Number of UP Bends is greater than 3 • 1 if the PSO Number of UP Bends is between 1 and 3 (inclusive) • 0 otherwise
Number of DOWN Bending Stations = {
2 if there are more than 3 DOWN bends;
1 if there are between 1 and 3 DOWN bends;
0 otherwise}
The number of DOWN bending stations is determined as follows:
• 2 if the PSO Number of DOWN Bends is greater than 3 • 1 if the PSO Number of DOWN Bends is between 1 and 3 (inclusive) • 0 otherwise
Number of Cam Bending Stations = {number of bends over 95 degrees}
The number of cam bending stations is the value of the PSO
Number of Bends that are Greater than 95 Degrees.
Number of UP Forming Stations = {
1 if there are UP forms and no UP bends;
0 otherwise}
The number of UP forming stations is 1 if both the following hold:
• PSO Number of UP Forms is greater than 0. Otherwise the number of UP forming stations is 0. (If there are UP forms and UP bends, the UP forming station is combined with the UP bending station.)
Number of DOWN Forming Stations = {
1 if there are DOWN forms and no DOWN bends;
0 otherwise}
The number of DOWN forming stations is 1 if both the following hold:
• PSO Number of DOWN Forms is greater than 0. Otherwise the number of DOWN forming stations is 0. (If there are DOWN forms and DOWN bends, the DOWN forming station is combined with the DOWN bending station.)
Number of Cam Forming stations = {number of forms over 90 degrees}
The number of cam forming stations is the value of the PSO
Number of Undercut Forms.
Number of Restriking Stations = {1 if there are deep bends or forms; 0 otherwise}
The number of restriking operations is 1 if at least one of the following holds:
Otherwise, the number of restriking stations is 0.
Number of Cutoff stations = 1
The number of cutoff stations is always 1.