DAYComp composite products

The Total Cost of Ownership (TCO) model

In order to make the economic added value of our innovative composite material (DAYComp) measurable, we have developed an interactive Total Cost of Ownership (TCO) model. It enables you to analyze the total operating costs of DAYComp compared to conventional bronze sliding plates with solid lubricant. In addition to purchase costs, the model also takes into account invisible costs such as maintenance and labor costs, so that you can see the long-term savings and efficiency gains of DAYComp at a glance.

Compare the costs of both materials and see how factors such as service life and maintenance intervals affect your long-term profitability. The figures below are based on a test we conducted with one of our customers in a demanding application.

How to use the TCO model:

The fields outlined in green are variable - please enter the values that suit you here.

Description

Bronze/Graphite & Hardend Steel Plate Pairing

DAYComp composite material & Soft Steel Plate Pairing

1. Sliding Plate price [EUR] 20x125x160 mm

2. Steel Plate price [EUR] 20x125x160 mm

3. Sliding & Steel plate [EUR]

4. Number plates in one die [pcs./set]

5. Total 1 die with all sets [EUR]

6. Max. production number [# stroks]

7. Total sliding plates per 1.000.000 parts

8. Replacement time 1 set [hour]

9. Labor cost 1h [EUR]

10. Labor cost total [EUR]

11. Total Sliding & Steel Plate Cost per 1.000.000 press parts

12. Labor cost all sets

13. Total Cost Δ

Savings

%
11. Total Sliding & Steel Plate Cost per 1.000.000 press parts
12. Labor cost all sets
13. Total Cost Δ

Contact:

Improve your production processes and reduce costs with Dayton Progress - your partner for future-oriented toolmaking. Fill out the contact form now and download your TCO model. Our sales representatives will be happy to contact you to calculate your individual cost advantage.

 

The following parameters are taken into account in the TCO analysis:

  1. Acquisition cost of a sliding plate [EUR]: The price per sliding plate. DAYComp sliding plates are more expensive than bronze plates with solid lubricant, but offer a longer service life.
  2. Acquisition costs for mating partners [EUR]: Bronze sliding plates with solid lubricant require hardened steel plates as mating partners, while DAYComp sliding plates can use unhardened steel or cast iron, which reduces material costs.
  3. Costs for sliding plate and mating partner [EUR]: The sum of the costs for a sliding plate and its mating partner.
  4. Number of sliding plates per tool [pcs./set]: The number of sliding plates required for a tool.
  5. Total costs for 1 tool with all sets [EUR]: The total cost of a tool set including all sliding plates and their sliding partners.
  6. Maximum number of production cycles [cycles]: The maximum number of production cycles a tool set can achieve with the respective materials. In the conducted test, the bronze sliding plates needed to be replaced after 75,000 cycles, whereas the DAYComp sliding plates were still operational after 1,140,000 cycles.
  7. Number of sliding plates required per 1,000,000 cycles: The number of sliding plates required for 1,000,000 cycles. In the test, the DAYComp sliding plates only needed to be replaced once, while the bronze sliding plates with solid lubricant required 13 replacements.
  8. Change time required per set of sliding plates [hours]: The time required to replace a set of sliding plates.
  9. Labor costs per 1 hour [EUR]: The hourly rate for the repair.
  10. Total labor costs [EUR]: The total labor costs incurred to change a set of skid plates.
  11. Total costs for sliding plates and mating partners per 1,000,000 cycles: The total costs for sliding plates and mating partners for 1,000,000 cycles.
  12. Labor costs for all sets: The total labor costs for all necessary sets at 1,000,000 cycles.
  13. Total costs Δ: The difference in total costs for both materials.
  14. Savings: The savings that can be achieved by using the durable composite material DAYComp instead of the bronze-graphite sliding plate.

The sliding and guide elements currently used for cold and hot forming processes often have an inadequate service life of just a few weeks. In critical applications, frequent replacement is required after short production cycles, which leads to increased downtimes and rising costs for replacement material and maintenance.

Our solution:

Our specially developed sliding and guide elements made from DAYComp composites extend service life in cold and hot forming processes, reducing both downtime and overall costs.

Advantages of DAYComp at a glance:

- Increased heat resistance: DAYComp can withstand temperatures of up to 390 °C, whereas conventional bronze sliding elements with solid lubricant are often only suitable up to 150 °C. This makes DAYComp ideal for demanding production conditions.

- Lower weight: With a density of 1.15 g/cm³, DAYComp is around eight times lighter than bronze sliding plates with solid lubricant. This reduces the energy requirement and makes handling easier.

- Low coefficient of friction: DAYComp's coefficient of friction is between 0.01 and 0.06, which minimizes wear and extends the service life of the components. The special surface finish also prevents scale and dust from sticking, further reducing abrasive wear.

- Longer service life: The combination of the above factors ensures that DAYComp offers a significantly longer service life than conventional materials, reducing the need for replacement and lowering maintenance costs.

Overall, these properties contribute to reduced operating costs, higher productivity and an extended service life of the components used. In addition, the lower weight reduces CO₂ emissions and makes DAYComp a more environmentally friendly choice.

Further information:

Download catalog now!

Download flyer now!

Contact:

Improve your production processes and reduce costs with Dayton Progress - your partner for future-oriented toolmaking. Fill out the contact form now and download your TCO model. Our sales representatives will be happy to contact you to calculate your individual cost advantage.