Cost Model - Deep Drawing

You can use the Deep Drawing cost model to calculate the process times and costs for the deep drawing manufacturing process in plastics processing. 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,
  • the material consumption,
  • the press force and stroke frequency of the machine and
  • the primary and secondary processing times.
Note

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

Procedure

The following example illustrates the process and structure of the Deep Drawing 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 »Deep Drawing«.
  4. Define the following properties for the process in the Details view:
    5. Technical Descriptions
    Material Classification* Basic Materials » Metal » Steel
    Manufacturing Method* Shaping » Push-Pull Forming » Deep-Drawing
    * 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: Deep Drawing.

    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 the Material Thickness, Material Classification and the Tensile Strength properties in order to calculate the primary processing times.

Note

Values are determined for the following properties using value rules by selecting the material classification:

  • Squared Material Factor (for Drawing Clearance)

You can view the properties under Details ► General ► Cost Model ► Material.

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 »Deep Drawing« process in the Structure view.
  2. Click on Edit ► Insert ► Insert New Local Material (Mass).

    A local material is inserted under the »Deep Drawing« process.

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

    Only the following combinations of Valuation and Geometric Shape are supported for the Deep Drawing cost model. Depending on the valuation you choose, 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 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. 1.6 mm).

    This value is required and displayed at the »Deep Drawing« process in the Details ► General ► Cost Model ► Material view under Material Thickness.

  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. Enter a value for the Tensile Strength (e.g. 600 N/mm²).

    This value is required and displayed at the »Deep Drawing« process in the Details ► General ► Cost Model ► Material view under Tensile Strength.

  9. Define the following properties for the material in the Details view:
    General
    Price per Unit 0.75 EUR / kg
  10. Select the »Deep Drawing« process in the Structure view.
  11. Enter a value in the Details ► Cost Model ► Material ► Sheet Metal Blank Area view (e.g. 2,042,035 mm²).

Step 4: Describe Part

The part properties are required to determine the cycle time.

Describe Part

  1. In the Structure view, select the process »Deep Drawing«.
  2. Enter the following values for the part in the Details ► Cost Model ► Part view.

    These values are required in order to calculate additional values:

    3. Additional values are calculated based on the input values for the part and shown at the process »Deep Drawing« under Details ► General ► Cost Model.

Step 5: Insert Work Steps

The Deep Drawing process requires a wide range of individual work steps in order to manufacture a part. To visualize complex deep drawing parts in detail, they must be broken down into separate work steps.

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

Insert Work Steps

  1. Select the »Deep Drawing« 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 Drawing Work Steps row.

    The Local List: Drawing Work Steps tab opens.

    For more information on the work step, 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. Change the label to »1st Draw«
  6. Repeat step 4.
  7. Change the label to »2nd Draw«

Work Step Properties

General group

This group shows the general work step properties.

Properties Description Input
Possible		 Calculated
 Required
Label Work Step Name direct   x
Initial Area The surface area of the part region before the draw
Corresponds to the value for the Area of the Sheet Metal Blank.		 with F12   x
Deep Drawn Area Area to be deep drawn in this step with F12   x
Perimeter of the Deep Drawn Area Perimeter of the areas to be deep drawn in this step with F12   x
Actual Drawing Ratio

Actual drawing ratio of the deep drawing surfaces before and after the drawing work step
depends on:

  • Initial Area
  • Deep Drawn Area
   x  
Allowable Drawing Ratio

Maximum allowable ratio of the deep drawing surfaces before and after the drawing work step
depends on:

  • Drawing Behavior of the Material
      
Min. Deep Drawing Area

Minimum size of the deep drawing area after the drawing work step
is calculated from:

  • Initial Area
  • Allowable Drawing Ratio
 with F12 x  
Draw Correction Factor

Factor for determining the deep drawing force depending on the drawing ratios
is calculated from:

  • Actual Drawing Ratio
  • Allowable Drawing Ratio
   x  
Theoretical Press Force

Calculated press force for this work step
is calculated from:

  • Tensile Strength
  • Material Thickness
  • Perimeter of the Deep Drawn Area
  • Draw Correction Factor
   x  
Drawing Corner Radius

The drawing corner radius prevents the wrinkling or tearing of the material
is calculated from:

  • Material Thickness
  • Actual Drawing Ratio
 with F12 x  
Blank holder Area

The area of the material, which has to be held during the deep drawing in order to avoid wrinkling
is calculated from:

  • Initial Area
  • Deep Drawn Area
  • Drawing Corner Radius
  • Drawing Clearance
  • Perimeter of the Deep Drawn Area
 with F12    
Blank holder Pressure

The pressure with which the blankholder area has to be held
is calculated from:

  • Deep Drawn Area
  • Actual Drawing Ratio
  • Tensile Strength
  • Material Thickness
 with F12    
Blank holder Force

The force with which the blankholder area has to be held
is calculated from:

  • Blank holder Area
  • Blank holder Pressure
   x  
% Additional Press Force Percentaged additional press force
Calculated when you enter a value for the surcharge for press force.		 direct    
Additional Press Force Absolute additional press force
Calculated when you enter a value for the percentaged additional press force		 direct    
Necessary Press Force

Necessary total press force for this work step
is calculated from:

  • Theoretical Press Force
  • Additional Press Force
  • Blank holder Force
   x  

Technical Description Group

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

Step 6: Insert Machine

You can use the Relevant Press Force from the work steps to determine and insert the required machine.

For calculating the press time and time per stroke, values must be entered at the machine for the Machine Type, Press Force and Stroke Frequency properties.

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 »Deep Drawing« process in the Structure view.
  2. Click on Edit ► Insert ► Insert New Local Machine in the ribbon.

    A machine is inserted under the »Deep Drawing« process.

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

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

    • Transfer Press
    • C-Frame Press
    • Deep Drawing Press
    • 4-Column Press
    • Toggle Press

    The Machine Type Properties group appears under Technical Description.

  5. In the Details ► Technical Description view, enter a value for the following properties:
    • Press Force
    • Stroke Frequency
    • Number of Press Stations

    This entry is used to calculate the relevant stroke frequency.

  6. Define the following properties for the machine in the Details view:
    Acquisition Costs
    Acquisition Value 3,500,000 EUR
    Fixed Machine Costs
    Depreciation Period6 a

Calculated values of the Deep Drawing 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 7: Insert Worker and Tool

Insert Worker

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

    The tool is inserted under the process.

Step 8: Additional Fine Tuning

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

Group Properties
Material
  • Sheet Metal Blank Perimeter
Work Steps
  • Intermediate Annealing
  • Max. Drawing Ratio 1st Draw
  • Max. Drawing Ratio Subsequent Draws
  • Blanking of Sheet Metal Blank
  • Max. Necessary Cutting Force
  • Additional Work Steps Blanking
  • Additional Work Steps
  • Parallel Processing
Machine
  • Relative Stroke Frequency
  • Relevant Stroke Frequency
Secondary Processing Times
  • Loading Time
  • Unloading Time
  • Machine Loading Per Stroke
  • Machine Loading Per Stroke
  • Transfer Time between Strokes
  • Additional Secondary Processing Times
Primary Processing Times
  • Additional Primary Processing Times

Properties of the Cost Model - Deep Drawing

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.		 with F12   x
Sheet Metal Blank Area Sheet Metal Blank Area direct   x
Sheet Metal Blank Perimeter

Perimeter of the sheet metal blank
is calculated from:

  • Sheet Metal Blank Area
  • Deep Drawn Area
  • Perimeter of the Deep Drawn Area

The perimeter of the sheet metal blank is calculated based on a circular area. For other geometries value

 with F12    
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
Drawing Behavior of the Material

Variety of the drawing behavior of the material
Variety of:

»Normal«
»Good«
»Very good«

 direct   x

Part Group

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

Part Properties Description Input
Possible		 Calculated
 Required
Deep Drawn Area Area that was deep drawn in this step direct   x
Perimeter of the Deep Drawn Area Perimeter of the deep drawn area for this draw direct   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
Intermediate Annealing Selection of intermediate annealing. The intermediate annealing allows a higher drawing ratio in the next drawing work step direct    
Max. Drawing Ratio 1st Draw

The maximum drawing ratio in the 1st drawing work step
depends on:

  • Drawing Behavior of the Material
 with F12    
Max. Drawing Ratio Subsequent Draws

The max. drawing ratio from the 2nd drawing work step on
depends on:

  • Drawing Behavior of the Material
 with F12    
Drawing Clearance

Gap between the cavity and the drawing punch
is calculated from:

  • Material Thickness
  • Squared Material Factor (for Drawing Clearance)
   x  
Drawing Work Steps Displays the work steps of the deep drawing process
the button opens the Local List: Drawing Work Steps tab, where you can manage the work steps.		     x
Used Drawing Work Steps Displays the number of used drawing work steps      
Blanking of Sheet Metal Blank Selection of additional blanking work steps within the process (e.g.: with a transfer tool / transfer machine). direct    
Max. Necessary Cutting Force Maximum necessary cutting force of all work steps. with F12    
Additional Work Steps Blanking The number of work steps to be used for blanking. with F12    
Additional Work Steps The number of additional work steps, e.g. for the calibration or the control of the part direct    
Total Number of Required Work Steps Displays the total number of work steps in this process      
Parallel Processing Displays, whether all work steps are carried out at the same time (e.g.: with a transfer tool / transfer machine) with F12    
Number of Strokes The number of strokes for production of all parts inside the die   x  
Relevant Press Force Displays the relevant press force incl. all surcharges   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.		     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.

     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.

     x
Relative Stroke Frequency Share of the stroke frequency that is actually used direct    
Relevant Stroke Frequency

Stroke frequency that is actually used
is calculated from:

  • Stroke Frequency of the Machine
  • Relative Stroke Frequency
 with F12    
Number of Press Stations

Display the number of press stations

   x  
Time per Stroke

Time required for a machine stroke
is calculated from:

  • Relevant Stroke Frequency
   x  

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 Time Time for loading the machine with a part direct    
Unloading Time Time for unloading the machine with a part direct    
Machine Loading Per Stroke Time to load the machine per stroke direct    
Machine Unloading per Stroke Time to unload the machine per stroke direct    
Transfer Time between Strokes Additional time between strokes direct    
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 Time
  • Unloading Time
  • Additional Secondary Processing Times
  • Number of Strokes
  • Transfer Time between Strokes
   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
Press Time

Time to press all strokes
is calculated from:

  • Number of Strokes
  • Time per Stroke
   x  
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:

  • Press Time
  • Additional Primary Processing Times
   x