Miscellaneous Costs

This section covers the following miscellaneous costs for Compression Molding:

Misc Cost – Stress Relief Calculation

Misc Cost – Stress Relief = (Stress Relief Rate * (Core Plate Finished Weight + Cavity Plate Finished Weight + Rib Insert Total Weight))

  • Stress Relief Rate: This is specified in the Digital Factory tool shop under Plastic Molding > Processes > Compression Molding > Tool Shops > Default > Stress Relief Rate.

  • Core Plate Finished Weight: This is calculated as (Core Plate Finished Volume * Core Plate Material):

    • Core Plate Finished Volume: This is calculated as (Core Plate Starting Volume - Core Plate Material Removed):

      • Core Plate Starting Volume: This is the product of the setup options Mold Base Size – Length, Mold Base Size – Width, and Core Plate Height.

      • Core Plate Material Removed: This depends on the shape of the part:

        • If the part is cup-shaped, this is calculated as (((Mold Base Area – Parting Line Projected Area) * Part Height) + Part Volume). Mold Base Area is the product of the setup options Mold Base Size – Length and Mold Base Size – Width. The Parting Line Projected Area, Part Height, and Part Volume properties are visible in the Geometric Cost Drivers panel.

        • Otherwise, this is calculated as: Part Volume / 2.

    • Core Plate Material: This is the Density of the material specified by the Select Mold Material – Main Plates setup option.

  • Cavity Plate Finished Weight: This is calculated as (Cavity Plate Finished Volume * Cavity Plate Material):

    • Cavity Plate Finished Volume: This is calculated as (Cavity Plate Starting Volume – Cavity Plate Material Removed):

      • Cavity Plate Starting Volume: This is the product of the setup options Mold Base Size – Length, Mold Base Size – Width, and Cavity Plate Height.

      • Cavity Plate Material Removed: This depends on the shape of the part:

        • If the part is cup-shaped, this is calculated as (Parting Line Projected Area * Part Height) + Part Volume). The Parting Line Projected Area and Part Height and Volume properties are visible in the Geometric Cost Drivers panel.

      • Otherwise, this is calculated as: Part Volume / 2.

    • Cavity Plate Material: This is the Density of the material specified by the Select Mold Material – Main Plates setup option.

  • Rib Insert Total Weight: This is calculated as (Total Rib Insert Volume * Rib Insert Material):

Misc Cost – Heat Treating Calculation

Misc Cost – Heat Treating = Heat Treat Rate * (Core Plate Finished Weight + Cavity Plate Finished Weight + Rib Insert Total Weight)

Misc Cost – Texturing Budget Calculation

Misc Cost – Texturing Budget = ((Mold Base Area * Coarse Texture Cost) * Multiplier Texture * Region Multiplier)

  • Mold Base Area: This is the product of the Mold Base Size – Length and Mold Base Size – Width setup options.

  • Coarse Texture Cost: aPriori performs a lookup in the cmToolMachiningRates table and returns the Rate corresponding to Coarse Texture Finishing.

  • Multiplier Texture: aPriori performs a lookup in the cmToolTexture table and returns the Multiplier corresponding to the texture specified by the Cavity Texture setup option.

  • Region Multiplier: This is specified in the Digital Factory tool shop under Plastic Molding > Processes > Compression Molding > Tool Shops > Default > Region Multiplier.

Misc Cost – Plating Calculation

Misc Cost – Plating = (Core Plate Finished Weight + Cavity Plate Finished Weight) * Plating Cost Per Mass * Region Multiplier

Misc Cost – Freight Calculation

Misc Cost – Freight = (Mold Finished Weight * Freight Rate)

  • Mold Finished Weight: This is calculated as: (Core Plate Finished Weight + Cavity Plate Finished Weight + Ejector Base Starting Weight) * (1 + Default Misc Adder):

  • Freight Rate: This is specified by the Freight Rate setup option.

Misc Cost – Duty Calculation

Misc Cost – Duty = (Mold Finished Weight * Import Duty Rate):

Misc Cost – Tryouts Calculation

Misc Cost – Tryouts = (Tryout Time * Tryout Rate)

  • Tryout Time: This is calculated as: (Number of Try Outs * Time Per Tryout):

    • Number of Try Outs: This is specified by the defaultNumTryOuts cost model variable (3 in starting point Digital Factories), or defaultNumTryOuts + 1 if the Cavity Texture setup option is not set to the default value of none.

    • Time Per Tryout: This depends on the press force:

      • If the Press Force machine property is less than or equal to the cmTryoutPressForceThreshold cost model variable (5000 kN in starting point Digital Factories), this is calculated as: (Time Per Tryout Base * Mold Closure Complexity):

        • Time Per Tryout Base: This is the basic time required for compression molding tooling tryout for presses less than 5000kN. It is specified by the cmTimePerTryoutBase cost model variable (12 hours in starting point Digital Factories).

        • Mold Closure Complexity: This is a complexity factor applied to mold base considerations based on the Mold Closure Type being used. See Mold Closure Complexity Calculation.

      • Otherwise, this is calculated as: (2 * Time Per Tryout Base * Mold Closure Complexity) as described above.

  • Tryout Rate: This is specified in the Digital Factory tool shop under Plastic Molding > Processes > Compression Molding > Tool Shops > Default > Tryout Rate.