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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 formulas defined at the cost model providing you with information on:

  • the anticipated cycle time,
  • the possible process output per time and cycle,
  • the material consumption,
  • the deformation rate and deformation efficiency, and the
  • 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:

Hint

The black triangle ◣ helps you identify editable values.

The Consistency Rule Violation check is available to you when entering values. The consistency rule violations check notifies when there are 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

Further Information ► Create Should Cost Calculation

 

Step 2: Insert Process

Insert Process

  1. In the Structure view, highlight the project 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. 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 ► Calculation, select the Cost Model: Die Forging valuation.

    A new group Cost Model 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 for the following property are determined via value rules by selecting the material classification:

  • Material Exponent
  • Yield Stress kf1

You can view the properties at the process under Details ► Calculation ► 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 Edit ► Insert ► Insert New Local Material (Mass).

    A local material is inserted under the »Die Forging« process.

  3. Change the label to »Die Forging Material«.
  4. Under Details ► Technical Data, select a material classification.
    5. Note

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

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

  5. Define the following properties for the material in the Details view:

    Price per Unit 0.75 EUR / kg
    Calculation
    Density 7.85 g / cm³
    Net Quantity 1.00 kg / cycle
  6. Select the »Die Forging« process in the Structure view.
  7. Enter a value in the Details ► Calculation ► 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 ► Calculation ► 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« in the Details ► Calculation ► Cost Model.

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

Projected Area of Part with Burr
  Forming Work

Ø 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 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 Data, select a machine type.
    5. Note

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

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

  5. Define the following properties for the machine in the Details view:

    Calculation ► Investment
    Purchase Value 400,000 EUR
    Fixed Machine Cost
    Depreciation Period 6 a
    Technical Data
    Impact Velocity 2.00 m / s
    Energy Capacity 150.00 kJ / stroke

Calculated values of the Die Forging cost model:

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

  • 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 ► Calculation ► Cost Model:

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.

Density

Density of the material.

This value is required.

This value can be managed at the material in the Details ► Calculation or Technical Data, or is applied when global templates are inserted.

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

Indirect input is possible using F12.

Deformation Temperature of the Material

Temperature of the material during the forming process.

This value is required.

This value can be managed at the material in the Details ► Calculation or Technical Data, or is applied when global templates are inserted.

Blank Part Height

Height of the material before working (initial height).

This value is required.

Direct input is possible.

Material Usage Weight

Required material mass of the blank part.

Is calculated from:

  • Part Weight
  • Mass Ratio Coefficient

Material Usage Volume

Required material volume of the blank part.

Is calculated from:

  • Density
  • Material Usage Weight

Part Group

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

Part Weight

Weight of the part.

This value is required.

Direct input is possible.

Part Volume

Volume of the part.

Is calculated from:

  • Density
  • Part Weight

Projected Area of Part

The area of the part projected in the mold parting surface.

This value is required.

Direct input is possible.

% Additional Projected Area of Burr

Percentaged additional projected area of burr in relation to the projected part area. Is calculated when entering a value for the »Projected Area of Burr«.

Direct input is possible.

Projected Area of Burr

The projected area of the burr of the part. Is calculated when entering a value for the »% Additional Projected Area of Burr«.

Direct input is possible.

Projected Area of Part with Burr

Projected area of the part incl. burr.

Is calculated from:

  • Projected Area of Part
  • Projected Area of Burr

Forging Form Group of Part

Selection of form group for determination of mass ratio coefficient.

Variety:

  1. »1: Simple Forging Form«, e.g. parts like sphere, cylinder or cube, perhaps with single-side variant or small flanges.
  2. »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. »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.

Mass Ratio Coefficient

Factor depending on the forging form group and the material usage weight.

Indirect input is possible using F12.

Burr and Part Form

Selection of burr in relation to the part.

Variety:

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

Forming Work Group

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

Deformation Rate

Speed for forming the material.

Is calculated from:

  • Blank Part Height
  • Impact Probability

Indirect input is possible using F12.

ø Main Deformation

Average deformation using the average target height.

Is calculated from:

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

Deformation Efficiency

Efficiency of the deformation work. Depends on:

  • Burr and Part Form

Deformation Work

Theoretical deformation work needed to manufacture the part.

Is calculated from:

  • Yield Stress kf
  • Material Usage Volume
  • Ø Main Deformation
  • Deformation Efficiency
  • Yield per cycle

% Additional Deformation Work

Percentaged additional deformation work. Is calculated when entering a value for the »Additional Deformation Work«.

Direct input is possible.

Additional Deformation Work

Absolute additional deformation work. Is calculated when entering a value for the »% Additional Deformation Work«.

Direct input is possible.

Required Deformation Work

Deformation work that is actually required.

Is calculated from:

  • Deformation Work
  • Additional Deformation Work

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

Indirect input is possible using F12.

Machine

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

Machine Type

Assignment of a machine to a specific group with the corresponding properties.

This value is required.

This value is required and can be managed at the material (Details ► Technical Data), or is applied when global templates are inserted.

Impact Velocity

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

This value is required.

This value is required and can be managed at the material (Details ► Technical Data), or is applied when global templates are inserted.

Energy Capacity of the Machine

Machine energy capacity with one stroke.

This value is required.

This value is required and can be managed at the material (Details ► Technical Data), or is applied when global templates are inserted.

Stroke Frequency of the Machine

Maximum stroke frequency of the machine that is available.

This value is required.

This value is required and can be managed at the material (Details ► Technical Data), or is applied when global templates are inserted.

Relative Stroke Frequency

Share of the stroke frequency that is actually used.

This value is required.

Direct input is possible.

If you do not enter a value, the client uses a relative stroke frequency of 100% for further calculation.

Relevant Stroke Frequency

Stroke frequency that is actually used.

Is calculated from:

  • Stroke Frequency of the Machine
  • Relative Stroke Frequency

This value is required.

Indirect input is possible using F12.

Time per Stroke

The time required for a machine stroke.

Is calculated from:

  • Relevant Stroke Frequency

Secondary Processing Times

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

Properties

Time for loading the machine with a part.

Direct input is possible.

Work Steps

Time for unloading the part.

Direct input is possible.

Transfer Time between Strokes

Additional time between strokes.

Direct input is possible.

Secondary Processing Time

Description

Is calculated from:

  • Loading Time
  • Unloading Time
  • Transfer Time between Strokes
  • Number of Strokes

Primary Processing Time

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

Press Time

Time to press all strokes.

Is calculated from:

  • Number of Strokes
  • Time per Stroke

Additional Primary Processing Time

Possibility to add primary processing times that have not been considered

Direct input is possible.

Primary Processing Time

Time in which the actual activity of a process is performed

Is calculated from:

  • Press Time
  • Additional Primary Processing Times