Tooling Calculation
Total progressive die tooling cost can be specified with the PSO Total Stage Tooling Tool 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 Stages, 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 Mass of Material per Stage) • Average material rate (specified by the PSO Average Material Rate of Mold Materials or the toolshop variable Avg Matl Rate). Average Material Mass per Die Station
Average material mass 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 between sets of coefficients to be used in the linear combination based on whether the part requires side actions (that is, whether there are cam bending stations--see the formula below)
The sets of coefficients are derived from large, representative data sets of sample of parts.
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 Toolshop Labor Hours per Stage) • Average labor rate (specified by the PSO Average Toolshop Labor Rate or the toolshop variable Avg Labor Rate). 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 between sets of coefficients to be used in the linear combination based on whether the part requires side actions (that is, whether there are cam bending stations--see the formula below)
The sets of coefficients are derived from large, representative data sets of sample of parts.
Number of Stages =
Number of Trimming Stages
+ Number of Piercing Stages
+ Number of Up Extruding Or Countersinking Stages
+ Number of Down Extruding Or Countersinking Stages
+ Number of Bending Up Stages
+ Number of Bending Down Stages
+ Number of Cam Bending Stages
+ Number of Forming Up Stages
+ Number of Forming Down Stages
+ Number of Restriking Up Stages
+ Number of Restriking Down Stages
The number of stages is the sum of the number of each of the types of stages—see below.
Number of Trimming Stages = {
1, if rounddown(Blank Perimeter / Trim Punch Length) – 1) <= 1;
2, if rounddown(Blank Perimeter / Trim Punch Length) – 1) == 2;
3, otherwise}
Trimming stages include trimming, piercing, and scoring operations.
The number of trimming stations depends on the following:
• Blank perimeter length (see the PSO Perimeter of the flat pattern blank) • 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 of the flat pattern blank) 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 Piercing Stages = {
1, if the number of holes is > 50;
0, otherwise}
Piercing stages include piercing, trimming, and forming operations.
The number of piercing stages is 1 if the PSO Number of Holes is greater than 50. Otherwise, the number of piercing stations is 0. Number of UP Extruding or Countersinking Stages = {
1, if both the following hold:
there are up flanged or countersunk holes, and
the number of up bends plus the number of up forms is 0 or 1;
0, otherwise}
Up extruding or countersinking stages include up extruding, countersinking, forming, and bending operations.
The number of up extruding or countersinking stages is 1 if both the following hold:
Otherwise, the number of up extruding or countersinking stages is 0.
Number of DOWN Extruding or Countersinking Stages = {
1, if both the following hold:
there are down flanged or countersunk holes, and
the number of down bends plus the number of down forms is 0 or 1;
0, otherwise}
Down extruding or countersinking stages include down extruding, countersinking, forming, and bending operations.
The number of down extruding or countersinking stages is 1 if both the following hold:
Otherwise, the number of down extruding or countersinking stages is 0.
Number of UP Bending Stages = Roundup (Number of UP Bending Operations/2)
Up bending stages include up bending, forming, and restriking operations.
The number of up bending stages is half the number of up bending operations (see the formula below), rounded up to the nearest integer.
Number of UP Bending Operations = Roundup (number of up bends/3)
The number of up bending operations is PSO Number of UP Bends divided by 3, rounded up to the nearest integer. Number of DOWN Bending Stages = Roundup (Number of DOWN Bending Operations/2)
Down bending stages include down bending, forming, and restriking operations.
The number of down bending stages is half the number of down bending operations (see the formula below), rounded up to the nearest integer.
Number of DOWN Bending Operations = Roundup (number of down bends/3)
The number of up bending operations is PSO Number of DOWN Bends divided by 3, rounded up to the nearest integer. Number of Cam Bending Stages = {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 Stages = {
Roundup(Number of UP Forming Operations/4) – Number of UP Bending Stages, if this value > 0;
0, otherwise}
Up forming stages include up forming, bending, and restriking operations.
The number of UP forming stations is the difference between the following two values, assuming the first value is greater than the second value:
• Number of up forming operations (see the formula below) divided by 4, rounded up to the nearest integer.
• Number of up bending stages—see the formula above.
If the first value is not greater than the second value, the number of UP forming stages is 0.
Number of UP Forming Operations = Roundup (number of up forms/2)
The number of up forming operations is PSO Number of UP Forms divided by 2, rounded up to the nearest integer. Number of DOWN Forming Stages = {
Roundup(Number of DOWN Forming Operations/4) – Number of DOWN Bending Stages, if > 0;
0, otherwise}
DOWN forming stages include up forming, bending, and restriking operations.
The number of DOWN forming stations is the difference between the following two values, assuming the first value is greater than the second value:
• Number of down forming operations (see the formula below) divided by 4, rounded up to the nearest integer.
• Number of down bending stages—see the formula above.
If the first value is not greater than the second value, the number of DOWN forming stages is 0.
Number of UP Restriking Stages = Roundup (Number of UP Restriking Operations/2)
Up restriking stages include up restriking, bending, and forming operations.
The number of up restriking stages is half the number of up restriking operations (see the formula below), rounded up to the nearest integer.
Number of UP Restriking Operations = Roundup (number of up forms/4)
The number of up restriking operations is PSO Number of UP Forms divided by 3, rounded up to the nearest integer. Number of DOWN Restriking Stages = Roundup (Number of Down Restriking Operations/2)
Down restriking stages include down restriking, bending, and forming operations.
The number of down restriking stages is half the number of down restriking operations (see the formula below), rounded up to the nearest integer.
Number of DWON Restriking Operations = Roundup (number of down forms/4)
The number of down restriking operations is PSO Number of DOWN Forms divided by 3, rounded up to the nearest integer.