Die Estimate Window

The Die Estimate is generated by submitting your configured data to an online service that calculates the costs involved in your project quickly and accurately. There are seven pages of configurable quote data that can be edited in the browser to provide a final report.

Note: You can provide information about your company such as your address details, engineering capabilities, and machine specifications, to customize the estimate. A set of default parameters are provided under each tab. Edit these values by clicking Settings and opening the relevant tab. For more, see Configuring Persistent Data.
When you have made the required changes, click Return to Last Estimate.

The estimate window contains eight pages:

Estimate Info
Plan Die
Die Specification
Calculate Die
Custom Items
Estimate Die
Estimate Part
Report

When you click Calculate Quote, the estimate window displays the first page. Each page displays the settings imported from DieQuote to the Estimate (* Indicates a required field).

Estimate Info

Provide basic Request-for-Quote information that will be added to the generated Report.

Section

Content

General Information

Name	Description	Required
Estimate Name	Auto-generated label assigned to the estimate.
Estimate Date	Date and time the estimate was created. Click the Update button after making any changes to the estimate.
Customer*	Click in the field to select the customer from your list of customers, or select Confidential.	Yes
New Customer	Add a customer to the available list in the Customer drop down.
Project	Click in the field to select the project from your list of projects, or select Confidential.
New Project	Add a project to the list available in the Project drop down.
Estimator	Username of the person creating the quote.

Part

Name	Description	Required
Part Name(s)	Assign a name to the part if required.
Part Number(s)	Identify the part with a unique number if required.
Revision/EC	The Revision or Engineering Change number if applicable - Click Datestamp button to populate the field with the current fate.

Operation

Name	Description	Required
Die Type	Select from Progressive Die or Transfer Die.	Yes
Parts Per Stroke	The number of parts produced each press cycle, used to calculate setup costs.

Plan Die

Section

Content

Blank and Carrier

Name	Description	Required
Material Thickness*	The value specified in the material window in DieQuote.	Yes
Blank Size F-B (coil width)	Blank dimension measured across the width of the strip.
Blank Size L-R (feed)	Blank dimension measured along the length of the strip.
Part Height (formed)*	Final height of the part after all forming processes are complete.	Yes
Carrier Type*	Method used to move components of the strip through the die process. For more see Carrier Info.	Yes
Add Carrier Width to F-B	Define the width of the Carrier if you want to add it to the strip width.
Die Step (Pitch)	Distance between the Die stations.

Cutting & Forming

The length and quantity of all cutting and forming features are imported from the DieQuote model and displayed in this table. All values can be edited.

Wire EDM

The Punch Path, Punch Path Plate, Stripper Path, and Die Plate Path lengths are estimated from the cutting lengths specified in the die and are shown here.

All fields can be updated with a single value if required. Enter the new value in Punch Path Length then click paste to copy that value to all Wire EDM fields.

Standard Cams

The size of the Die Mount, Aerial, Cast, and Filler, and the quantity of these plus the Bump or Box can be edited in this table

Die Stations

The total number of Die stations relative to the selected Die method are shown here.

Click Estimate Die Stations to update the number of Total Stations with a suitable value.
Click Show Details to see the calculated results. The number of pilots can be updated in the detail window.

Part Dimensions

The part dimensions can be updated in this table. Click Estimate Dimensions to generate data for the Critical and Non-Critical Dimensions fields.

Die Specification

Section

Content

Die Specification

The information on this page complies with the default Die Specification (Plate Die (high production)). An alternative specification can be uploaded using the Click Here link in the top pane.

Design

The following parameters can be removed from the quote by unmarking the checkbox: 3d Design Required, Fully Detailed Design, Replaceable Details, Documentation Required, and Document "As Built".

Punch and Die Options

The following parameters can be removed from the quote by unmarking the checkbox: Heavy Duty Catalog Retainers, Hardened Backing Plates, Ball Lock Catalog Punches, Scrap Ejector Pins, Cutting Die Inserts, Die Buttons, Forming Inserts, Adjustable Forms, Punch Guiding, and ID Die Details.

Stripper / Spring Pad Options

Name	Description
Stripper & Pad Spring Type	Use the dropdown to select from the following options: No Stripper Springs (Solid SPrings) Coil Die Springs Nitrogen Drop-In Springs
Stripper & Pad Spring Retention	Select No Spring retention or Spring Pockets
Stripper Retention	Use the dropdown to select from the following options: Solid Bridge Stripper Bolts Spools Keeper Block 'Standard' Guide
Stripper Guiding	If stripper guiding is required, choose from Stripper Pin and Bushing or Stripper pin and Ball Bushing.
Stripper Inserts/Windows	Mark the checkbox if you require Stripper Inserts or Windows.
Draw Pressure Type	Select from Tankers Connected, Tankers Manifold, or Press Cushion.

Die Set and Build Up Options

Name	Description
Die Set Type	Select from No Die Set, Plate, or Cast.
Die Set Guide Type	Select from No Die Set Guide, Plain Bushing, Precision Ball, or Cast Set Square Guide.
Die Set Bosses	Mark the checkbox if Die Set Bosses are required.
Die Set Thrust Blocks	Mark the checkbox if Die Set Thrust Blocks are required.
Setup Blocks	Mark the checkbox if Setup Blocks are required.
Build Up Type	Select from No Build Up, Parallel Build Up or Solid Build Up (Not available if Die Set Type is Cast).
Change / Master Plate	Select from No Quick Change, Plate-Bottom Only Material, Plates Top and Bottom Material, or Key or Pin Locators Set.
Die Handling	Select from No Die Set Handling Items, Tapped Holes Set of Four, or Rings, Hooks, or Lugs Set of Four.
Data Label	Mark the checkbox to add an identifying Data Label to the Die Shoe.

Tool Steel Types

Define the steels that will be used for each of the following positions:

Die Set Steel, Cutting Punch Steel, Forming Steel, Draw Die Steel, Draw Punch Steel, Stripper Steel, Form Pad Steel, Draw Binder Steel, Cutting Die Insert Steel, Punch Plate Steel, Die Plate Steel, Backing Plate Steel, Riser Plate Steel, and Pilot Punch Steel.

Edit these values by clicking Settings and opening the relevant tab. For more, see Configuring Persistent Data.

Die and Part Approval

Name	Description
Parts To Inspect 100%	Define how many production parts require all dimensions to be inspected by QA.
Parts To Inspect Criticals Only	Define how many production parts should be inspected to check critical dimensions.
Number of Inspections	Define the inspection frequency.
Process Capability Studies	Unmark this checkbox if Process Capability Studies are not required.
Run Off Location	Select from No Run Off, Run Off at Seller, Run Off at Buyer, or Run Off at Seller and Buyer.
Run Off Quantity	Specify how many parts should be allocated as sample parts to ensure the final product meets requirements.
Run Off Time	Specify how much time should be assigned to the run off process.

Calculate Die

Review Sizing and Machining values based on selections made in the Plan Die and Die Specification tabs.

Section

Content

Die Set (Shoe)

Name	Description
Calculate All	Use this button to reset any changes on the Calculate Die page back to the values sent from DieQuote including selections made in the Plan Die and Die Specification tabs.
Size Die Shoe	Use this button to reset any changes in the Die Set (shoe) section back to the values sent from DieQuote.

The Calculate All button will populate the following fields based on the values configured in Settings; These values can be edited:

Number of Die Sets, Total Die Set Length(L-R), Die Set Width (F-B), Die Set Top Thickness, Die Set Bottom Thickness, Guides Per Die Set, and Setup Blocks per Die Set.

Die Plates and Punch Lengths

The following dimensions can be edited:

Punch Backing Plate Thickness, Punch Plate Thickness, Cutting Punch Length, Form Punch Length, Draw Punch Length;
Stripper/Pad Plate Sections and Stripper Cap Thickness;
Draw Binder Thickness;
Cutting Die Insert Thickness;
Die Plate Thickness, Die Backing Plate Thickness, and Riser Plate Height.

Press

The available press configurations are shown in the Select Press dropdown. Edit these values by clicking Settings and opening the relevant tab. For more, see Configuring Persistent Data.

Use the Select Press dropdown to define the press.
Click Check Press to verify the press meets the requirements of the Die configuration. Any values that do not satisfy the requirements are highlighted in red.

You cannot change these values in the tab, either select another press or change the press specifications in Settings.

Build Up

The buildup is the parallels and plates that fit the die to the press. The Number of Parallels, Width of Parallels, Change / Master Top Plate Thickness, Change / Master Bottom Plate Thickness, Change / Master Plate L-R, and Change / Master Plate F-B values are determined by your configuration but can be edited in the tab.

Die Surface Machining

Details any complex machining required in the Die (typically milling). A table details the Details, Face Area, and Depth of Cut for each of the Punch and Die Faces, Restrike Faces, Face Recuts, and Posts in the Die assembly. These value are used to estimate the time needed for die service machining.

Die Stock Control

The Die Stock Control section shows how many stock items will be required for the die. The values are die-dependent.

Sensors

The Sensors section shows how many sensors are suggested for the die. The values are die-dependent. Additional custom sensors can be added in Custom Items.

Custom Items

Add items that are not part of the standard configuration.

Section	Content
Add Standard Custom Item	Click the button to add a row to the tab page. Click the Name dropdown to select one of the global custom items available in Settings > Custom. Enter the details (quantity, UOM, material costs and labor time).
Add NonStandard Custom Item	Click the button to add a row to the tab page. Enter the details (name, quantity, UOM, material costs and labor time).
New Custom Item	Click this button to add a new Custom item in Settings > Custom.
Remove/Delete button	Click the button in the Actions column to remove the row.

Estimate Die

Create a Bill of Material style estimate.

Section

Content

Upper pane

Name	Description
Die Difficulty	Select a value from this list - Parameters are taken from the values in Settings > Engineering.
Standard Group	Select a value from this list - Parameters are taken from the values in Settings > Standards.
Labor Rate	Select a value from this list - Parameters are taken from the values in Settings > Labor Rates.
Profit	Select a value from this list - Parameters are taken from the values in Settings > Profit.

Build Estimate

Click this button to use the upper pane values you have entered to create an Estimate.

Estimate Detail

This table is displayed after the Estimate is built. Blue fields show material costs, Green fields show labor costs. Data shown in white boxes can be edited; If a field value is changed, the lock symbol is enabled which preserves the value if the estimate is rebuilt.

Name	Description
Filter	Enter a text string in this field to hide non-matching rows.
Hide lines with no cost	Unmark this checkbox to show parameters with zero associated cost.
	Click this symbol to lock or unlock the adjacent field value.
Complete Estimate	If you are satisfied with the output, click this button to display the Complete Estimate dialog. You can modify the Price and the Delivery time and add Notes if required. Click OK to set the Estimate Status to Completed.
Download Spreadsheet	Use this button to download the details of a Completed Estimate as an Excel file.
Estimate Status	Set the status by selecting from In-Process, Completed, or Awarded. Clicking the Complete Estimate button will also set this value to Completed.

Estimate Part

Note: The Estimate Part tab in DE is optional and not always used. Here are two use cases:

Tool builders can use it to compare processes (such as prog vs transfer, one up vs multi out die, and so on) and determine the best die type for the application (If the buyer has not specified the type of die they want).
Production shops and OEMs can use it when they want a quick production-stamped part cost estimate. This type of user will have internal production cost estimating systems for calculating production cost and not use this DE tab.

Section

Content

Part Cost Estimate

Enter the Sheet Material Cost, Lot SizeLot SizeParts Qty per year/Set up Qty per Year , Rate of OperationRate of OperationParts Qty/Hour, Setup Time, Press Cost, and Amortization Parts QuantityAmortization Parts QuantityAmortization is the cost of the tool on a per-part basis. This value is used to calculate the amortization cost per part (does not including time value of money or sinking fund)..

Calculate Part Cost

Execute the Part Cost Calculation.

Part Cost

This pane displays the results of the Part Cost Calculation. You can make changes to the Part Cost Estimate figures to recalculate these results.

Cost Item	Calculation
Material	(Blank L x blank W x mat. thick, x density) x sheet cost)/parts per stroke
Setup	(Setup time x press rate)/lot size
Run	(1/parts per hours) x press rate
Preventive Maintenance	Maintenance cost per event/cycles between maintenance
Tool Amortization	Die cost/Amortization parts quantityAmortization parts quantityAmortization Years Qty x Parts Qty per year

Calculation Notes:

Lot size: Based on the estimated annual part production quantity. Buyers will release quantities to be ordered but inventory stocking quantity and lot quantity are often very different depending on the inventory control strategy of the metal stamper.
Maintenance cost per event: Based on a percentage of total punch and die cost as this is what wears and has to be regularly maintained.
Cycles between maintenance: Based on the cutting tool steel type. For example, D2 tool steel should be sharpened approximately every 100-200k cycles (Cycle or Press Stroke Qty between Maintenance Operations).
Tool amortization: Based on estimated annual usage. Amortization time or quantity is usually dictated by the end-user accounting group and often depends on tax depreciation schedules.
Run could be associated with the speed of the press, but press speed is variable. Presses may be of mechanical, hydraulic or servo type. The final run speed depends on factors such as stroke, die type, length of feed, and so on.

Report

The final report is displayed on this tab. It can be downloaded as a pdf or saved as an Excel file.

Parameter	Description
Cycles between maintenance	A cycle is the same as a press stroke. The number of parts is not used because the die may be a muti-off die. The die is regularly maintained based on the number of cycles run, not parts. This value is used to calculate die maintenance cost per part.
Maintenance Cost per event	A die maintenance event is when the die is sent to the die maintenance area for regular maintenance (not repair). Some shops plan die maintenance at a given interval. This may be sharpening the cutting parts of a tool, replacing springs, or regrinding worn form punches and dies, depending on the die. The cost per event is the estimated material and labor cost expected for each maintenance cycle for the given die.
Run	This value shows the labor costs per part based on the press and operator(s) costs. There are two types of labor cost associated with production stamping. Run Labor cost is for when the press is making parts. Setup is the labor hours associated with setting up and tearing down the die. Setup labor cost is calculated based on the Setup hours and lot size. Metal stampers typically use presses to run a variety of dies therefore they must be set up before each production run. Dedicated presses are not set up and lot size is theoretically infinite.