Total Tool Material Cost Calculation
Total Tool Material Cost = Raw Tool Material Cost + Purchased Tool Components Cost
Raw Tool Material Cost: This is the sum of the following costs:
Material Cost – Top Clamp Plate: This is the raw material cost of the top clamping plate of the mold. This is calculated as: (Top Clamp Plate Starting Weight * Top Clamp Plate Material (Cost)):
Top Clamp Plate Starting Weight: This is calculated as (Top Clamp Plate Starting Volume * Top Clamp Plate Material (Density)):
Top Clamp Plate Starting Volume: This is calculated as: (Top Clamp Plate X * Top Clamp Plate Y * Top Clamp Plate Z):
Top Clamp Plate Y: This is the top clamp width and is calculated as (Mold Base Size – Width + cmClampPlateOverhangAllowance (as described above)).
Top Clamp Plate Z: This is the top clamp plate thickness and is specified by the cmTopClampPlateThickness cost model variable; 75 mm in starting point Digital Factories).
Top Clamp Plate Material (Density): This is specified as the Density corresponding to the material specified by the Select Mold Material – Clamp Plates setup option.
Top Clamp Plate Material (Cost): This is specified as the Material Cost corresponding to the material specified by the Select Mold Material – Clamp Plates setup option.
Material Cost – Bottom Clamp Plate: This is the raw material cost of the bottom clamping plate of the mold. This is calculated as: (Bottom Clamp Plate Starting Weight * Bottom Clamp Plate Material (Cost)):
Bottom Clamp Plate Starting Weight: This is calculated as: (Bottom Clamp Plate Starting Volume * Bottom Clamp Plate Material (Density)):
Bottom Clamp Plate Starting Volume: This is calculated as: (Bottom Clamp Plate X * Bottom Clamp Plate Y * Bottom Clamp Plate Z):
Bottom Clamp Plate X: This uses the same calculation described above for Material Cost – Top Clamp Plate.
Bottom Clamp Plate Y: This uses the same calculation described above for Material Cost – Top Clamp Plate.
Bottom Clamp Plate Z: This is the bottom clamp plate thickness and is specified by the cmBottomClampThickness cost model variable; 75 mm in starting point Digital Factories).
Bottom Clamp Plate Material (Density): This uses the same calculation described above for Material Cost – Top Clamp Plate.
Bottom Clamp Plate Material (Cost): This uses the same calculation described above for Material Cost – Top Clamp Plate.
Material Cost – Cavity Plate: This is the raw material cost of the cavity plate of the mold. This is calculated as: (Cavity Plate Starting Weight * Cavity Plate Material (Cost)):
Cavity Plate Starting Weight: This is calculated as: (Cavity Plate Starting Volume * Cavity Plate Material (Density)):
Cavity Plate Starting Volume: This is calculated as: (Mold Base X Cavity * Mold Base Y Cavity * Mold Base Cavity Height):
Mold Base X Cavity: This is specified by the Mold Base Size – Length setup option.
Mold Base Y Cavity: This is specified by the Mold Base Size – Width setup option.
Mold Base Cavity Height: This is specified by the Cavity Plate Height setup option.
Cavity Plate Material (Density): This is specified as the Density corresponding to the material specified by the Select Mold Material – Main Plates setup option.
Cavity Plate Material (Cost): This is specified as the Material Cost corresponding to the material specified by the Select Mold Material – Main Plates setup option.
Material Cost – Core Plate: This is the raw material cost of the core plate of the mold. This is calculated as: (Core Plate Starting Weight * Core Plate Material (Cost)):
Core Plate Starting Weight: This is calculated as: (Core Plate Starting Volume * Core Plate Material (Density)):
Core Plate Starting Volume: This is calculated as: (Mold Base X Core* Mold Base Y Core * Mold Base Z Core):
Mold Base X Core: This is specified by the Mold Base Size – Length setup option.
Mold Base Y Core: This is specified by the Mold Base Size – Width setup option.
Mold Base Z Core: This is specified by the Core Plate Height setup option.
Core Plate Material (Density)): This uses the same calculation described above for Material Cost – Cavity Plate.
Core Plate Material (Cost): This uses the same calculation described above for Material Cost – Cavity Plate.
Material Cost – Ejector Box: (This is included only when Part Ejection Method is set to Hydraulic Ejector Pins.) This is the cost of the selected material for the ejector box, that is, the remaining structure of the mold base. This is calculated as: (Ejector Base Starting Weight * Ejector Box Material (Cost):
Ejector Base Starting Weight: This is calculated as (Ejector Box Rails Weight + Ejector Plates Weight + Support Pillars Weight):
Ejector Box Rails Weight: This is calculated as (Ejector Box Rails Starting Volume * Ejector Box Material (Density)):
Ejector Box Rails Starting Volume: This is calculated as: Number of Ejector Box Rails * (Ejector Box Rails Height * Ejector Box Rails Width * Mold Base Length):
Number of Ejector Box Rails: This is specified by the cmEjectorBoxRailsNumber cost model variable (2 in starting point Digital Factories).
Ejector Box Rails Height: This is specified by the cmEjectorBoxRailsHeight cost model variable (152.4 mm in starting point Digital Factories).
Ejector Box Rails Width: This is specified by the cmEjectorBoxRailsWidth cost model variable (76.2 mm in starting point Digital Factories).
Mold Base Length: This is specified by the Mold Base Size – Length setup option.
Ejector Box Material (Density): This is specified as the Density corresponding to the material specified by the Select Mold Material – Ejector Box setup option.
Ejector Plates Weight: This is calculated as (Ejector Plates Starting Volume * Ejector Box Material (Density)):
Ejector Plates Starting Volume: This is calculated as: Number of Ejector Plates * (Ejector Plate Thickness * Ejector Plate Area):
Number of Ejector Plates: This is 2 by default.
Ejector Plate Thickness: This is specified by the cmEjectorPlateThickness cost model variable (25.4 mm in starting point Digital Factories).
Ejector Plate Area: This is calculated as: Mold Base Size – Length setup option * (Mold Base Size – Width setup option - cmEjectorPlatesWidthReduction cost model variable; 152.4 mm in starting point Digital Factories).
Ejector Box Material (Density): As described above.
Support Pillars Weight: This is calculated as (Support Pillars Starting Volume * Ejector Box Material (Density)):
Support Pillars Starting Volume: This is calculated as: Number of Support Pillars * (PI * Support Pillars Radius2 * Ejector Box Rails Height):
Number of Support Pillars: This is calculated as (Ejector Plate Area * Support Pillar Coverage / (PI * (Support Pillars Radius)2)):
Ejector Plate Area: As described above.
Support Pillar Coverage: This is calculated as the cmSupportPillarCoveragePercentage cost model variable (10 in starting point Digital Factories) / 100.
Support Pillars Radius: This is calculated as: Support Pillars Diameter / 2. ‘Support Pillars Diameter’ is specified by the cmEjectorPlateSupportPillarDiameter cost model variable (76.2 mm in starting point Digital Factories).
Support Pillars Radius: As described above.
Ejector Box Rails Height: This is specified by the cmEjectorBoxRailsHeight cost model variable (152.4 mm in starting point Digital Factories).
Ejector Box Material (Density): As described above.
Ejector Box Material (Cost): This is specified as the Material Cost corresponding to the material specified by the Select Mold Material – Ejector Box setup option.
Material Cost – Electrode: This is the raw material cost of the electrodes used for EDM. This is calculated as: (EDM Electrode Cost * Ribs Electrode Volume):
EDM Electrode Cost: This depends on the material used for the EDM electrode (as specified by the Select EDM Electrode Material setup option):
If copper, this is specified in the Digital Factory tool shop under Plastic Molding > Processes > Compression Molding > Tool Shops > Default > Edm Material Cost_Copper.
If carbon, this is specified in the Digital Factory tool shop under Plastic Molding > Processes > Compression Molding > Tool Shops > Default > Edm Material Cost_Carbon.
Ribs Electrode Volume: This is the total sum of the following:
(Number of Small Rib Inserts setup option * smallCalcRibInsertElectrodeSize cost model variable (4.6875 inch3 in starting point Digital Factories) * numSmallInsertsBurns cost model variable (2 in starting point Digital Factories).
(Number of Medium Rib Inserts setup option * mediumCalcRibInsertElectrodeSize cost model variable (31.6875 inch3 in starting point Digital Factories) * numMediumInsertsBurns cost model variable (2 in starting point Digital Factories).
(Number of Large Rib Inserts setup option * largeCalcRibInsertElectrodeSize (cost model variable; 117.1875 inch3 in starting point Digital Factories) * numLargeInsertsBurns cost model variable (2 in starting point Digital Factories).
Material Cost – Insert: This is the total cost of rib insert material. This is calculated as: (Rib Insert Total Weight * Rib Insert Material (Cost)):
Rib Insert Total Weight: This is calculated as: (Total Rib Insert Volume * Rib Insert Material (Density)):
Total Rib Insert Volume: See Total Rib Insert Volume Calculation.
Rib Insert Material (Density): This is specified as the Density corresponding to the material specified by the Select Mold Material – Rib Inserts setup option.
Rib Insert Material (Cost): This is specified as the Material Cost corresponding to the material specified by the Select Mold Material – Rib Inserts setup option.
Purchased Tool Components Cost: This is the cost of the purchased items for making the tool. See Purchased Tool Components Cost Calculation.