Cost Model - Chipping

You can use the Chipping cost model for calculating the process times and costs for the chipping manufacturing process in metal working. 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 cutting speed and feed per tooth, and
  • primary and secondary processing times.

The table shows typical application scenarios of the cost model for parts and tools:

Typical parts Typical tools
  • Shafts, sleeves, gear teeth, other mechanical components
  • Gears and steering components
  • Small and large machine parts
  • Drills, countersinks, tappers
  • Milling cutters, interlocking milling machines, indexable insert milling cutters
  • Turning and parting tools, indexable insert holders
Note

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

Procedure

The following example illustrates the process and structure of the Chipping 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 »Chipping«.
  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* Separating » Chipping with Geometrically Determined Cutting Edge
    * 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: Chipping.

    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

To use FACTON content for tool data, the Material Classification must be entered at the material.

Note

Values are determined for the following work step properties using value rules via the Selection of the Material Classification that is assigned to a chipping material group and the Selection of the Chipping Tool:

  • Cutting Speed
  • Number of Teeth
  • Feed per Tooth

You can view the »Chipping Material Group« property 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 »Chipping« process in the Structure view.
  2. Click on Edit ► Insert ► Insert New Local Material (Mass).

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

  3. Change the label to »Chipping Material«.
  4. Under Details ► Technical Description ► Material Classification, select a material classification.
    Note

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

    • Basic Steel
    • Quality Steel Unalloyed & Alloyed
    • Stainless Steel Unalloyed
    • Tool Steel
    • Steel with Special Physical Properties
    • Alloyed Steel / Construction Steel / Chemical Resistant Steel
    • Special Purpose Steel
    • Cast Iron
    • Nonferrous Metal
    • Titanium Alloy
    • Plastic Material

    The Material Classification Properties group appears under Technical Description.

  5. Define the following properties for the material in the Details view:
    General
    Price per Unit 1.75 EUR / kg

The following property is shown at the process in the Cost Model ► Material group based on the material classification

  • Chipping Material Group

Step 4: Insert Work Steps

A range of separate work steps is required in order to manufacture a component in the chipping process. To visualize complex chipping parts in detail, they must be broken down into separate work steps.

FACTON lets you define multiple work steps at the Chipping cost model. You can assign the work steps to the machining units via a selection list.

Insert Work Steps

  1. Select the »Chipping« process in the Structure view.
  2. In the Details view, expand 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.

    For more 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 to define your work step.

  5. Create two additional rows for the work step.
  6. In the Local List: Work Step tab, enter a value for Rotating Chipping for the following properties of the work step:
    LabelTurning or Tool DiameterCutting LengthChipping Tool
    Milling 120 mm100 mmMilling » Solid carbide end mill (< 8 mm)
    Turning 130 mm200 mmTurning » Indexable Insert Turning Tool (Avg. Machining)
    Turning 240 mm300 mmTurning » Indexable Insert Turning Tool (Finishing)
    Note

    Rotating Chipping is selected by default. You can see it, when the checkbox is activated under the Local List: Work Steps tab ► View Details.

    These values are required in order to calculate additional values.

    7. Note

    Values are determined for the following work step properties using value rules via the Selection of the Material Classification, which is assigned to a chipping material group and the Selection of the Chipping Tool:

    • Cutting Speed
    • Number of Teeth
    • Feed per Tooth

    You can see these properties in the Local List: Work Steps tab and in the Details ► Primary Processing Times ► Rotating view.

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

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

  8. In the Details view, enter a value for Non-rotating Chipping for the following properties of the work step:
    General
    Name»Sawing«
    Primary Processing Times
    Rotating ChippingCheckbox: »No«
    Cutting Length»100 mm«
    Non-rotating ► Feed Speed»400 mm / min«

    These values are required in order to calculate additional values.

  9. Close the Local List: Work Steps tab.

    The tab is shown with your calculation and the Chipping cost model.

Rotating Chipping Non-rotating Chipping
Enter the following in the Local List tab:
  • Name
  • Chipping Tool
  • Cutting Length
  • Turning or Tool Diameter
 Enter the following via the Details view:
  • Name
  • Rotating Chipping: No
  • Cutting Length
  • Feed Speed

Entering this information calculates the following values:
  • Cutting Speed
  • Feed per Tooth
  • Number of Teeth
  • Rotational Speed
  • Feed Speed
  • Primary Processing Time
  • Primary Processing Time

Work Step Properties

General group

This group shows the general work step properties.

Properties Description Input
Possible		 Calculated
 Required
Label Work Step Label direct   x
Material Classification Shows the material classification that was defined at the material      
Chipping Material Group Shows the chipping material group that was determined by selecting the material classification via value rules with F12    
Chipping Tool Selection of the tool for determining the cutting data direct   x
Assigned Machining Unit The assigned machining unit for this work step      

Primary Processing Times

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

Properties Description Input
Possible		 Calculated
 Required
Rotating Chipping Specifies, whether the part is rotary machined or not direct   x
Cutting Length Length of the cutting edge or contour of the workpiece that is machined in the work step direct   x
Number of Cuts Number of repetitions necessary for achieving the desired cutting depth direct    
Primary Processing Time

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

  • Cutting Length
  • Number of Cuts
  • Feed Speed
   x  

Primary Processing Times ► Rotating Subgroup

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

Properties Description Input
Possible		 Calculated
 Required
Turning or Tool Diameter Turning: Diameter of the cutting part level
Milling/Drilling: Diameter of the tool		 direct   x
Number of Teeth The count of teeth of the tool
Note: For turning or drilling, the count is always 1.		 with F12   x
Cutting Speed The operating speed of the tool with F12   x
Feed per Tooth Specifies, how deep a tool edge can move into a material with F12   x
Rotational Speed Turning: Rotational speed of part Milling/Drilling: Rotational speed of tool with F12    
Feed Speed

The speed of the tool during rotating chipping
is calculated from:

  • Rotating Chipping
  • Rotational Speed
  • Feed per Tooth
  • Number of Teeth
   x  

Primary Processing Times ► Non-rotating Subgroup

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

Properties Description Input
Possible		 Calculated
 Required
Feed Speed The speed of the tool during non-rotating chipping
is not calculated.
direct input required for non-rotating chipping		 direct   x

Secondary Processing Times Group

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

Properties Description Input
Possible		 Calculated
 Required
Loading
 Selection whether time is required for loading or not direct    
Loading Time

Time for loading the machine with a part
depends on

  • Machine Type
 with F12 x  
Unloading Selection, whether time is required for unloading or not direct    
Unloading Time

Shows the time for unloading the part
depends on:

  • Machine Type
 with F12 x  
Change tool Selection, whether time is required for changing the tool or not direct    
Chip to Chip Time

Shows the time to change a tool, including positioning at a similar point on the part
depends on:

  • Machine Type
   x  
Reclamping Part Selection, whether time is required for reclamping the tool or not direct    
Reclamping Time

Shows the time for changing the clamping base of a part
depends on:

  • Machine Type
 with F12 x  
Positioning Tool Selection, whether time is required for positioning the tool or not direct    
Positioning Time

Shows the time for the additional positioning of a tool
depends on:

  • Machine Type
 with F12 x  
Positioning Count Specifies, how often the part is positioned direct    
Secondary Processing Time Waiting periods due to expiration of a process in which the actual activity cannot be performed.   x  

Process Time Group

This group shows the processing time for the work step. The processing time is derived from the sum of the primary and secondary processing times.

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 Rotating Speed from the work steps to determine the required machine and insert it.

To calculate the cutting force and speed the Machine Type, Machining Units Count, Parallel Processing and Rotating Speed must be entered at the machine:

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

    A machine is inserted under chip removal »Chipping« process.

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

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

    • Band Saw Machine
    • Machining Center
    • Hacksaw Machine
    • Multi-Spindle Automatic Machine
    • Rotary Transfer Machine
    • Automatic Bar Turning Machine
    • Universal Turning Center
    • Universal Milling Center
    • Gear Milling Machine

    The Machine Type Properties group appears under Technical Description.

  5. In the Details ► Technical Description view, enter a value for the following properties:
    • Machining Units Count
    • Parallel Processing
    • Rotational Speed

    This entry is used for calculating the relevant stroke frequency.

  6. Define the following properties for the machine in the Details view:
    Acquisition Costs
    Acquisition Value 100,000 EUR
    Fixed Machine Costs
    Depreciation Period6 a

Step 6: Insert Machining Units

You can insert a certain number of machining units depending on the machine in use.

A machining unit is that area of the machine, in which the material is clamped and machined. Depending on the machine, multiple machining units can be managed by making parallel processing possible.

Insert Machining Units

  1. Select the »Chipping Machine« in the Structure view.
  2. Click on Edit ► Insert ► Machining Unit in the ribbon.

    A machining unit is inserted under the machine.

  3. Change the label to »Machining Unit 1«.
  4. Repeat steps 1 through 2.
  5. Change the label to »Machining Unit 2«.

Step 7: Assign Work Steps

The next step is to assign work steps to the machining units. Assigning this information calculates the following properties:

Property Description
Primary Processing Time Time in which the actual activity of a process is performed
Secondary Processing Time waiting periods due to expiration of a process in which the actual activity of a process are not performed
Processing Time Time derived from the sum of the primary and secondary processing times

Assign Work Steps

  1. Select the »Machining Unit 1« in the Structure view.
  2. In the Details ► Cost Model ► view, click on .

    The selection list with the work steps opens.

  3. Activate the checkbox in front of the work steps that you wish to assign to »Machining Unit 1«:
    • »Milling 1«
    • »Turning 1«
  4. Select the »Machining Unit 2« in the Structure view.
  5. In the Details ► Cost Model ► Select Work Steps view, click .

    The selection list with the work steps opens.

  6. Activate the checkbox in front of the work steps that you wish to assign to »Machining Unit 2«:
    • »Turning 2«
    • »Sawing«

Calculated values of the Chipping 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 8: Insert Worker and Tool

Insert Worker

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

    The tool is inserted under the process.

Step 9: Additional Fine Tuning

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

Group Properties
Work Steps
  • Number of Teeth
  • Number of Cuts
Secondary Processing Times
  • Loading Time
  • Unloading Time
  • Chip to Chip Time
  • Reclamping Time
  • Positioning Time
  • Indexing Time
Processing Times
  • % Additional Processing Time
  • Additional Processing Time

Properties of the Cost Model - Chipping

Material Group

This group shows the chipping material group of the material that is used for chipping. The substance classification for chipping is based on the ISO 513 standard.

Work Steps Group

The work step properties in the chipping process that are used for calculating the cost model are shown in this group. The button opens the Local List: Work Steps tab, where you can manage the work steps.

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
Machining Units Count Shows the count of available machining units on the machine      
Parallel Processing Selection whether the machining units can be used simultaneously      
Rotational Speed Turning: Rotational speed of part
Milling/Drilling: Rotational speed of tool
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 master data is inserted.		     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
depends on:

  • Machine Type
 with F12    
Unloading Time

Time for unloading the part
depends on:

  • Machine Type
 with F12    
Chip to Chip Time

Time to change a tool, including positioning at a similar point on the part
depends on:

  • Machine Type
 with F12    
Reclamping Time

Time for changing the clamping base of a part
depends on:

  • Machine Type
 with F12    
Positioning Time

Time for the additional positioning of a tool.
depends on:

  • Machine Type
 with F12    
Indexing Time

Necessary time of the machine to hand over the part to the next machining unit
depends on:

  • Machine Type
 with F12    

Primary Processing Times

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

Processing Times Description Input
Possible		 Calculated
 Required
Processing Time

Sum of the primary and secondary processing times
is calculated from:

  • Machining Units Count
  • Parallel Processing
  • Indexing Time
  • Primary Processing Times
  • Secondary Processing Times
   x  
% Additional Processing Time Percentaged additional processing times not considered yet
is calculated, when entering a value for the additional processing time
 direct    
Additional Processing Time Absolute additional processing times not considered yet
is calculated, when entering a value for the % additional processing time		 direct