Tooling, Fixtures, Dies & Mold Economics worked example

Insert Replacement Cost at 68% share of edges fully spent: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop share of edges fully spent to 68%, then walk the calculation through step by step. Estimate carbide insert consumption cost for a run based on quantity indexed, unit price and edges spent.

The inputs for this scenario

  • Inserts indexed per production run: 120 inserts (held at the documented default)
  • Cost per cutting insert: 14 $/insert (held at the documented default)
  • Share of edges fully spent: 68 % (the input this scenario stresses; the baseline uses 95)
  • Toolholder wear adder: 180 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total insert cost = inserts x cost per insert x edges spent share% + toolholder adder.
  • Total insert replacement cost works out to 1,322 $ at these inputs, and this is the headline figure for the scenario.
  • Insert replacement cost per unit works out to 11.02 $ / piece at these inputs.
  • Variable insert replacement cost works out to 1,142 $ at these inputs.
  • Fixed insert replacement cost adder works out to 180 $ at these inputs.

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 25.54% below the baseline at 1,322 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to share of edges fully spent, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. 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: 1,322 $ (headline result)
  • Insert replacement cost per unit: 11.02 $ / piece
  • Variable insert replacement cost: 1,142 $
  • Fixed insert replacement cost adder: 180 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Insert Replacement Cost calculator, set share of edges fully spent to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.