Tooling, Fixtures, Dies & Mold Economics worked example

Insert Replacement Cost at 99% share of edges fully spent: a worked example

What does the result look like when share of edges fully spent reaches 99%? The full calculation is worked below with real intermediate numbers. A turning department forecasts indexable insert spend for a high-volume part to validate its consumable rate.

The inputs for this scenario

  • Inserts indexed per production run: 120 inserts (unchanged)
  • Cost per cutting insert: 14 $/insert (unchanged)
  • Share of edges fully spent: 99 % (raised for this scenario; the documented default is 95)
  • Toolholder wear adder: 180 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total insert cost = inserts x cost per insert x edges spent share% + toolholder adder) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,843 $ for total insert replacement cost, the number this scenario is built around.
  • At this operating point the engine returns 15.36 $ / piece for insert replacement cost per unit.
  • At this operating point the engine returns 1,663 $ for variable insert replacement cost.
  • At this operating point the engine returns 180 $ for fixed insert replacement cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where share of edges fully spent sits at 95% and the headline result is 1,776 $, this scenario comes in 3.78% above the baseline at 1,843 $.
  • A figure at this level is achievable when share of edges fully spent is genuinely sustained, not just peaked for a shift. It treats all inserts at one blended cost and one edges-spent share; if a run mixes cheap roughing inserts with expensive finishing grades, cost each grade separately for accuracy.

Results at a glance

  • Total insert replacement cost: 1,843 $ (headline result)
  • Insert replacement cost per unit: 15.36 $ / piece
  • Variable insert replacement cost: 1,663 $
  • Fixed insert replacement cost adder: 180 $

Run it with your numbers

  • Every input above is editable in the live Insert Replacement Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.