Cost Model - Blanking

You can use the Blanking cost model to calculate the process times and costs for the blanking manufacturing process. In FACTON, there are value rule tables, and at the cost model formulas are defined that provide you with information on:

  • The anticipated cycle time,
  • the possible process output per time and cycle,
  • clamping force of the machine,
  • material consumption and
  • primary and secondary processing times.

Machines and material parameters are required for the calculation.

Note

You need knowledge of the Blanking manufacturing process in order to use the cost model.

Procedure

The following example illustrates the process and structure of the Blanking cost model:

Tip

The black triangle helps you identify values that you can enter .

The Consistency Rule Violation check is available to you when entering values. The consistency rule violations check notifies you of missing values and verifies the accuracy of the values entered.

When you hover over one of the Consistency rule violations icons with your mouse, a tooltip appears with the specific reason for the consistency rule violations.

Step 1: Create Should Cost Calculation

Create Should Cost Calculation

  • You are logged in as Calculator.
  • You are in the Calculations workspace.
  1. In the ribbon, click on Manage.
  2. Select the Should Cost Calculation.

    The created calculation opens in a new tab.

    You are the owner of the calculation that was created.

  3. Define the following properties for the Should Cost Calculation in the Details view:
    4. Reference Company*
    Industrial Sector Manufacture of fabricated metal products, except machinery and equipment
    Production Location World » Europe » Germany
    Reference Company Plant Revenue 100m EUR
    Reference Company Material Share 50%
    Reference Company Degree of Automation Medium
    Production Planning
    Production Quantity 100,000 pc / a
    Target Profit Rates
    Target Profit Rate on Raw Material 2 %
    Target Profit Rate on Purchased Material 2 %
    Target Profit Rate on Manufacturing 2 %

    * Values are determined for the following properties using value rules based on your inputs under reference companies:

    • Material Overhead Rate
    • Manufacturing Overhead Rate
    • Administrative Overhead Rate
    • Sales Overhead Rate
    • Development Overhead Rate
    • Logistics Overhead Rate

Step 2: Insert Process

Insert Process

  1. In the Structure view, select the calculation element you wish to insert under the process.
  2. Click Edit ► Insert ► Process in the ribbon.

    A process is inserted in the calculation structure.

  3. Change the label to »Blanking«.
  4. Define the following properties for the process in the Details view:
    5. Technical Descriptions
    Material Classification* Basic Materials » Metal » Steel
    Manufacturing Method* Separating » Cutting » Shearing
    * FACTON recommends the appropriate materials and machines in the queries for the processes by allowing you to select the material classification and manufacturing process.
  5. In the Details ► General ► Valuation view, select the valuation Cost Model: Blanking.

    A new Cost Model group appears with subgroups.

Note

When changing valuations the sub-elements are grayed-out and no longer considered in the calculation.

Step 3: Insert Material

Values must be entered at the material for Material Thickness and Tensile Strength in order to calculate the relevant stroke frequency and maximum shear strength.

Note

You can insert the material as a master data using queries (see Insert Global Calculation Element) or insert your own material locally (see Insert Local Calculation Element).

The latter is shown in the following, because it illustrates the inputs required for calculation.

Insert Local Material

  1. Select the »Blanking« process in the Structure view.
  2. Click on Edit ► Insert ► Insert New Local Material (Mass) in the ribbon.

    A local material is inserted under the »Blanking« process.

  3. Change the label to »Blanking Material«
  4. In the Details ► General ► Valuation view, select Sheet.
    Note

    Only the following combinations of »Valuation« and »Geometric Shape« are supported for the Blanking cost model. Depending on the chosen valuation, you may see different material properties or you may be required to enter different information.

    ValuationGeometric ShapeRequired Input (Material Thickness)
    Solid ProfileFlatHeight (s)
    CoilStripStrip Thickness
    SheetSheetSheet Thickness

    Selecting this valuation creates a new property group Form Type & Geometry with additional material properties.

  5. In the Form Type & Geometry group, select the geometric shape Sheet.

    Sheet width and sheet thickness will be displayed as additional material properties.

  6. Enter a value for the Sheet Thickness (e.g. 2 mm).

    This value is required, and it is displayed at the »Blanking« process in the Details ► General ► Cost Model ► Material view under Material.

  7. Under Details ► Technical Description ► Material Classification, select a material classification (e.g. Basic Materials » Metal » Steel).
    Note

    You can use the following material classification with the cost model:

    All material classifications under »Metals« and »Plastics«. You can enter the tensile strength for these materials.

    The Material Classification Properties group appears under Technical Description.

  8. Under Technical Description , enter a value for the Tensile Strength.
    This value is required, and it is displayed at the »Blanking« process in the Details ► General ► Cost Model ► Material view under Tensile Strength. The maximum shear strength is calculated based on the tensile strength.
  9. Define the following properties for the material in the Details view:
    General
    Price per Unit 0.75 EUR / kg

You can define further properties for the sheet material, such as sheet width, sheet length, and output per sheet in the Details view. This data is used for calculating the cross-sectional area, volume, gross weight, and weight per length.

Step 4: Insert Work Steps

The Blanking process requires a wide range of individual work steps in order to manufacture a part. To visualize complex blanking parts in detail, they must be split into separate work steps.

With FACTON, you can define multiple work steps at the Blanking cost model.

Insert Work Steps

  1. Select the »Blanking« process in the Structure view.
  2. In the Details view, open the group Cost Model ► Work Steps.
  3. Click on the button next to the Value column in the Work Steps row.

    The Local List : Work Steps tab opens.

    Further information on the work steps, see:Work Step Properties

  4. Right-click in the empty area of the tab ► New.

    A new row is added for you to define your work step.

  5. In the Local List view enter a value for the following properties of the work step:
    • Label
    • Cutting Length
    • Cutting Distance
    • Number of Cuts
    • Additional Cutting Force

    These values are required in order to calculate additional values.

Work Step Properties Cost Model Group Calculated Value
Cutting Length Primary Processing Times Theoretical Cutting Force
Number of Cuts Number of Strokes
Cutting Length Work Steps Max. Necessary Cutting Force
Cutting Distance Average Cutting Distance
Number of Cuts Sum of Strokes

Work Step Properties

General Group

This group shows the general work step properties, such as Label.

Primary Processing Times Group

This group shows the primary processing times for the work step.

Properties Description Input
Possible		 Calculated
 Required
Cutting Length The length of the cutting edge or contour of the workpiece, which is machined in the work step or the total length cut by the tool.
This value is required.		 direct   x
Cutting Distance Distance to the next hole or cut (e.g. hole spacing)
This value is required.		 direct   x
Bevel Factor The bevel at a cutting tool reduces the press force. If no bevel is available, the value is »1«. direct

 

  
Number of Cutting Tools The number of the cutting stamps / tools that are used simultaneously during a machine stroke direct    
Number of Cuts Number of required cuts for this work step. This value is required. direct   x
Number of Strokes

The number of strokes for the production of all cuts in this work step
is calculated from:

  • Number of Cutting Tools
  • Number of Cuts
   x  
Theoretical Cutting Force

Calculated cutting force for this work step
is calculated from:

  • Max. Shear Strength
  • Material Thickness
  • Cutting Length
  • Bevel Factor
  • Number of Cutting Tools
   x  
% Additional Cutting Force Percentaged additional cutting force
is calculated, when entering a value for the additional cutting force.
 direct    
Additional Cutting Force Absolute additional cutting force
is calculated, when entering a value for the % additional cutting force		 direct    
Necessary Cutting Force

Necessary cutting force for a machine stroke in this work step
is calculated from:

  • Theoretical Cutting Force
  • Additional Cutting Force
   x  

Secondary Processing Times Group

This group shows the secondary processing times for the work step.

Properties Description Input
Possible		 Calculated
 Required
Tool Changes Selection whether time is required for changing the tool or not. direct

 

  
Tool Change Time Shows the time to change a tool. with F12    

Technical Description Group

The technical descriptions of the work step, such as label and description, are shown and managed in this group.

Step 5: Insert Machine

You can use the calculated maximum Necessary Cutting Force from the work steps to determine the required machine and insert it.

Values must be entered at the machine for Press Force and Stroke Frequency to calculate the cutting pressure (blanking) and speed.

Note

You can insert the machine as a master data using queries (see Insert Global Calculation Element) or insert your own machine locally (see Insert Local Calculation Element).

The latter is shown in the following, because it illustrates the inputs required for calculation.

Insert Local Machine

  1. Select the »Blanking« process in the Structure view.
  2. Click on Edit ► Insert ► Insert New Local Machine in the ribbon.

    A machine is inserted under the »Blanking« process.

  3. Change the label to »Blanking Machine«.
  4. Under Details ► Technical Description ► Machine Type, select a machine type for the »Blanking Machine«.
    Note

    You can use the following machine type with the cost model:

    • Fine Blanking Press
    • Toggle Press
    • Blanking Line
    • Transfer Press
    • Swing Beam Machine

    The Machine Type Properties group appears under Technical Description.

  5. In the Details ► Technical Description ► Machine Type Properties view, enter a value for the following properties:
    • Press Force
    • Stroke Frequency

    This entry is used for calculating the relevant stroke frequency.

  6. Define the following properties for the machine in the Details view:
    Acquisition Cost
    Purchase Value 200,000 EUR
    Fixed Machine Cost
    Depreciation Period6 a

Calculated values of the Blanking cost model:

The following values are calculated using the data entered and then shown in the Details ► General ► Cost Model view:

  • Cycle Time
  • Ʃ Measure Values Cycle Time
  • Cycles per Time
  • Output per Cycle
  • Output per Time
  • Time per Unit Output
  • Manufacturing Scrap Rate
  • Production Cost

Step 6: Insert Worker and Tool

Insert Worker

  1. In the Structure view, select the »Blanking« process.
  2. In the ribbon, click on Edit ► Insert ► Worker.

    The corresponding labor costs for the worker are determined based on the sector, the reference location, the reference date and the labor group.

Insert Tool

  1. In the Structure view, select the process »Blanking«.
  2. Click Edit ► Insert ► Insert New Local Tool.

    The tool is inserted under the process.

Step 7: Additional Fine Tuning

You can continue fine tuning the settings in the Details ► General ► Cost Model view:

Group Properties
Work Steps ► Local List
  • Bevel Factor
  • Number of Cutting Tools
  • Tool Changes
  • Tool Change Time
Secondary Processing Times
  • Loading and Unloading Time
  • Additional Secondary Processing Times
Primary Processing Times

Additional Primary Processing Times

Properties of the Cost Model - Blanking

Material Group

The material properties used to calculate the cost model are shown in this group.

Material Properties Description Input
Possible		 Calculated
 Required
Tensile Strength

Tensile strength of the material


This value is required and can be managed at the material (Details View ► Technical Description) or is applied when global templates are inserted.		     x
Factor for Max. Shear Strength The factor for max. shear strength, is usually entered with »0.8«. with F12    
Max. Shear Strength

Maximum shear strength of the material
is calculated from:

  • Tensile Strength
  • Factor for Max. Shear Strength
   x  
Material Thickness Thickness of the material used
This value is required and can be managed at the material (Details View ► General ► Form Type & Geometry) or is applied when global templates are inserted.		     x

Work Steps Group

The work step properties in the deep drawing process used to calculate the cost model are shown in this group.

Work Step Properties Description Input
Possible		 Calculated
 Required
Work Steps Displays the work steps of the blanking process
The button opens the Local List: Work Steps tab, where you can manage the work steps.		     x
Sum of Strokes Sum of the strokes of all work steps   x  
Average Cutting Distance

Average cutting distance of all work steps
is calculated from:

  • Cutting Distance
  • Number of Strokes
   x  
Max. Necessary Cutting Force Maximum necessary cutting force of all work steps.   x  

Machine

The machine properties used to calculate the cost model are shown in this group.

Machine Properties Description Input
Possible		 Calculated
 Required
Machine Type Assignment of a machine to a specific group with the corresponding properties
This value is required in order to manage additional machine type properties. It can be managed at the machine (Details view ► Technical Description), or is applied when global templates are inserted.		 directly at the machine   x
Press Force of the Machine

Displays the maximum press force of the machine

This value is required and can be managed at the machine (Details View ► Technical Description ► Machine Type Properties), or is applied when global templates are inserted.

 directly at the machine   x
Stroke Frequency of the Machine

Displays the maximum stroke frequency of the machine

This value is required and can be managed at the machine (Details View ► Technical Description ► Machine Type Properties), or is applied when global templates are inserted.

 directly at the machine   x
Relevant Stroke Frequency

Effective stroke frequency
is calculated from:

  • Material Thickness
  • Cutting Distance
  • Stroke Frequency of the Machine
 with F12    
Tool Change Time

Time to change a tool
Depends on:

  • Machine Type
 with F12    

Secondary Processing Times

The secondary processing times used to calculate the cost model are shown in this group.

Secondary Processing Times Description Input
Possible		 Calculated
 Required
Loading and Unloading Time Time for loading and unloading the machine with a workpiece. direct    
Summed Tool Change Time The sum of the tool changing time of all work steps   x  
Additional Secondary Processing Times Possibility to add secondary processing times that have not been considered direct    
Secondary Processing Time

Necessary idle times of a process in which the actual activity of a process are not performed
Is calculated from:

  • Loading and Unloading Time
  • Summed Tool Change Time
  • Additional Secondary Processing Times
   x  

Primary Processing Times

The primary processing times used to calculate the cost model are shown in this group.

Primary Processing Times Description Input
Possible		 Calculated
 Required
Additional Primary Processing Times Possibility to add primary processing times that have not been considered direct    
Primary Processing Time

Time in which the actual activity of a process is performed.
Is calculated from:

  • Sum of Strokes
  • Stroke Frequency per Second
  • Additional Primary Processing Times
   x