Cost Model - Die Forging

You can use the Die Forging cost model to calculate the process costs and times for the die forging 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,
  • the material consumption,
  • the deformation rate and the deformation efficiency and the
  • primary and secondary processing times.
Note

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

Procedure

The following example illustrates the process and structure of the Die Forging 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 »Die Forging«.
  4. Define the following properties for the process in the Details view:
    5. Technical Descriptions
    Material Classification* Basic Materials » Metal » Steel » Quality Steel Unalloyed
    Manufacturing Method* Shaping » Pressure Forming » Forging » Open / Impression Die Forging
    * 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: Die Forging.

    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 Density and the Material Classification properties in order to calculate the necessary press force.

Note

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

  • Material Exponent
  • Yield Stress kf1

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 »Die Forging« 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 »Die Forging« process.

  3. Change the label to »Die Forging Material«.
  4. In the Details ► Technical Description view, enter a value for the Density (e.g. 7.8 g/cm³).
  5. Under Details ► Technical Description ► Material Classification, select a material classification.
    Note

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

    • Quality Steel Unalloyed
    • Alloyed Steel / Construction Steel / Chemical Resistant Steel
    • Copper
    • Aluminum

    The Material Classification Properties group appears under Technical Description.

  6. Define the following properties for the material in the Details view:
    General
    Price per Unit 0.50 EUR / kg
  7. Select the »Die Forging« process in the Structure view.
  8. Enter a value in the Details ► Cost Model ► Material ► Blank Part Height view (e.g. 180 mm).

Values are determined at the process in the Cost Model ► Material group for the following properties using value rules based on the material classification:

  • Material Exponent
  • Yield Stress kf1

Step 4: Describe Part

The part properties are required in order to determine the cycle time.

Describe Part

  1. In the Structure view, select the process »Die Forging«.
  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 »Die Forging« under Details ► General ► Cost Model.

Part Property Group Calculated Value
Part Weight Material
  • Material Usage Weight
  • Material Usage Weight
Part Part Volume
Projected Area of Part Part

Projected Area of Part with Burr
  Forming Work

Main Deformation

Step 5: Insert Machine

To calculate the necessary press force, values must be entered at the machine for the Machine Type, Stroke Frequency, Impact Velocity and Energy Capacity 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 »Die Forging« process in the Structure view.
  2. Click on Edit ► Insert ► Insert New Local Machine in the ribbon.

    A machine is inserted under the »Die Forging« process.

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

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

    • Spindle Press
    • Drop Hammer
    • Impact Hammer
    • Steam Powered Accelerated Hammer

    The Machine Type Properties group appears under Technical Description.

  5. In the Details ► Technical Description view, enter a value for the following properties:
    • Stroke Frequency
    • Impact Velocity
    • Energy Capacity
  6. Define the following properties for the machine in the Details view:
    Acquisition Costs
    Acquisition Value 400,000 EUR
    Fixed Machine Costs
    Depreciation Period6 a

Calculated values of the Die Forging 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 »Die Forging« 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 »Die Forging«.
  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
Material
  • Forming Temperature
  • Material Exponent
  • Yield Stress kf1
  • Tensile Strength
Forming Work
  • Deformation Rate
  • Additional Deformation Work (Percentage or Absolute)
  • Number of Strokes
Machine
  • Relative Stroke Frequency
  • Relevant Stroke Frequency
Secondary Processing Times
  • Loading Time
  • Unloading Time
  • Transfer Time between Strokes
Primary Processing Times
  • Additional Primary Processing Times

Properties of the Cost Model - Die Forging

Material Group

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

Material Properties Description Input
Possible		 Calculated
 Required
Density

Density 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
Yield Stress kf

Yield stress kf of the material depending on deformation rate at a given deformation temperature.
is calculated from:

  • Yield Stress kf1
  • Deformation Rate
  • Material Exponent
 with F12   x
Deformation Temperature of the Material

Temperature of the material during the forming process


This value is required and can be managed at the material (Details View ► Technical Description) or is applied when global templates are inserted.		     x
Blank Part Height

Height of the material before working (initial height).


This value is required in order to calculate the deformation rate.		 direct   x
Material Usage Weight

Required material mass of the blank part
is calculated from:

  • Part Weight
  • Mass Ratio Coefficient
   x  
Material Usage Volume

Required material volume of the blank part
is calculated from:

  • Density
  • Material Usage Weight
   x  
Tensile Strength Tensile strength of the material direct    

Part Group

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

Part Properties Description Input
Possible		 Calculated
 Required
Part Weight Weight of the finished part direct   x
Part Volume

Volume of the finished part
Calculated taking:

  • Density
  • Part Weight
   x  
Projected Area of Part The area of the part projected in the mold parting surface
 direct   x
% Additional Project Area of Burr Percentaged additional projected area of burr in relation to the projected part area
 direct    
Projected Area of Burr The projected area of the burr of the part direct   x
Projected Area of Part with Burr

Projected area of the part incl. burr
is calculated from:

  • Projected Area of Part
  • Projected Area of Burr
   x  
Forging Form Group of Part

Selection of form group for determination of mass ratio coefficient
Variety:

 

»1: Simple Forging Form«, e.g. parts like a sphere, cylinder or cube, perhaps with single-side variant or small flanges
»2: Average Forging Form«, e.g. for rotationally symmetric parts with flange or single side forming and parts with punched holes or thin-walled joints to the outer diameter
»3: Complex Forging Form«, e.g. two-armed, thin-walled levers with thickening in the middle and at the end of part and long parts with multiple cross-section transitions		 direct   x
Mass Ratio Coefficient Factor depending on the forging form group and the material usage weight with F12    
Burr and Part Form

Selection of burr in relation to the part
Variety:

 

»1: Forging Part without Burr«, compression in a forging die without burr
»2: Forging Part with Slight Burr«, compression in a forging die with a slight burr
»3: Forging Part with Burr«, compression of simple parts with burr
»4: Complex Forging Part with Burr«, compression of complex parts with burr		 direct   x

Forming Work Group

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

Forming Work Properties Description Input
Possible		 Calculated
 Required
Deformation Rate

Speed for forming the material
is calculated from:

  • Blank Part Height
  • Impact Probability
 with F12    
Main Deformation

Average deformation using the average target height
is calculated from:

  • Blank Part Height
  • Material Usage Volume
  • Projected Area of Part with Burr
   x  
Deformation Efficiency

Efficiency of the deformation work
Depends on the choice of:

  • Burr and Part Form
   x  
Deformation Work

Theoretical deformation work needed to manufacture the part
is calculated from:

  • Yield Stress kf
  • Material Usage Volume
  • Main Deformation
  • Deformation Efficiency
  • Yield per cycle
   x  
% Additional Deformation Work Percentaged Additional Deformation Work direct    
Additional Deformation Work Absolute additional deformation work
Calculated when entering a value for the % additional deformation work
 direct    
Required Deformation Work

Deformation work that is actually required
is calculated from:

  • Deformation Work
  • Additional Deformation Work
   x  
Number of Strokes

The number of strokes for production of all parts inside the die
is calculated from:

  • Required Deformation Work
  • Energy Capacity of the Machine
 with F12    

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
Impact Velocity

The velocity of the forging tool impact at the die or part

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
Energy Capacity of the Machine

Machine energy capacity with one stroke

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

Maximum stroke frequency of the machine that is available

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    
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    
Transfer Time between Strokes Additional time between strokes 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
  • Transfer Time between Strokes
  • Number of 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 Chance to add primary processing times that have not been considered yet 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