SwageDie

SwageDie is an offline tooling engineering and fabrication calculator designed for sheet metal fabricators, tool and die makers, press brake operators, and mechanical engineers.

FEATURES & CAPABILITIES

1. PUNCH & DIE CLEARANCE CALCULATOR
- Accurate punch-to-die clearance calculation per side and total die opening for round, rectangular, square, and custom perimeter profiles.
- Pre-calibrated material shear and tensile strengths: Mild Steel (1018/A36), Stainless Steel (304/316), Aluminum (5052-H32 / 6061-T6), Brass (C26000), Copper (C11000), and High Strength Steel (Domex/Hardox), plus custom shop materials.
- Exact punching tonnage (Metric Tons, US Tons, and kN) with automatic stripping force estimation (~15%).
- Recommended straight die land and angular relief draft recommendations.

2. TUBE & SOLID ROD SWAGING ENGINE
- Rotary and push swaging deformation analysis for hollow tubes and solid rods.
- Accurate cross-sectional area reduction percentage, diameter reduction, and diameter ratio.
- Automatic work hardening warning threshold: alerts when reduction per pass exceeds 25%, advising intermediate annealing before cracking occurs.
- True plastic strain deformation force model and die contact length computation.

3. PRESS BRAKE V-DIE SELECTION & TONNAGE
- Air bending tonnage calculation across full workpiece bend length.
- Recommended V-die opening width based on sheet thickness (6t, 8t, 10t, 12t).
- Minimum flange length and internal bend radius validation.
- Telemetry breakdown showing total tonnage and force per meter.

4. REAL-TIME TECHNICAL HUD CANVAS
- Dynamic cross-section schematic illustrating upper punch, sheet metal stock, clearance gaps, and lower die land with relief angle.
- High-precision press load monitor: compares calculated force against active press machine rating with color-coded safety thresholds (Safe, Heavy, Overload).

5. SHOP PRESS & TOOLING PRESETS (SQLITE)
- Register your shop machinery (turret punches, press brakes, rotary swagers, hydraulic presses) with custom tonnage limits.
- Save and load frequently used tooling combinations with 1 tap.
- 1-tap copy of calculation report formatted for shop job travelers.

6. DUAL UNITS & WORKSHOP THEMES
- 1-tap switching between Metric (mm, kN, Metric Tons) and Imperial (inches, psi, US Tons).
- High-contrast Light, Dark (obsidian HUD), and Auto themes for optimal readability in workshop environments.
- 100% offline, zero ads, zero telemetry, zero accounts.