Calculate Deep Drawing

You can use the Calculate Deep Drawing cost model to calculate the process times and costs for the deep drawing manufacturing process in metalworking. 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 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:

 

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 »Deep Drawing«.
  4. Define the following properties for the process in the Details ► General Properties view schema (combobox):
    5. 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 ► Calculation view schema, select the valuation Calculate Deep Drawing .

    A new group Manufacturing Valuation appears with sub-groups.

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 at the process under Details ► Calculation ► Manufacturing Valuation ► 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. Under Details ► Technical Data view schema, select a material classification.
    5. 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.

  5. In the Details ► Calculation view schema (combobox) select the Calculate Sheet quantity valuation.

    Note

    Only the following combinations of Quantity Valuation and Geometric Shape are supported for the Calculate 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.

    Quantity Valuation Geometric Shape Required Input (Material Thickness)
    Calculate Solid Profile Flat Height (h)
    Calculate Coil Strip Strip Thickness (t)
    Calculate Sheet (Sheet) Sheet Thickness (t)

    With the selection you can enter additional properties for the material.

  6. In the Details ► Overview view schema (combobox) of the material enter values for the following properties:

    Calculation
    Density 7.85 g / cm³
    Sheet Length (l) 5 mm
    Sheet Width (w) 5 mm
    Sheet Thickness (t) 1.6 mm
    Price per Unit 0.75 EUR / kg
    Technical Data
    Tensile Strength 640.00 N / mm²
  7. Select the »Deep Drawing« process in the Structure view.
  8. Enter a value in the Details ► Calculation ► Manufacturing Valuation ► Material ► Sheet Metal Blank Area (e. g. 2,042,035 mm²).

 

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 »Deep Drawing« process.
  2. Enter the following values for the part in the Details ► view schema Calculation ► Manufacturing Valuation ► Part.

    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 »Deep Drawing« process in the Details ► Calculation ► Manufacturing Valuation.

 

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 Calculation ► Manufacturing Valuation ► 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.

    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 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.

Label

Work step label.

This value is required.

Direct input is possible.

Initial Area

The surface area of the part region before the draw. Corresponds to the value for the Area of the Sheet Metal Blank.

This value is required.

Indirect input is possible using F12.

Deep Drawn Area

Area to be deep drawn in this step.

This value is required.

Indirect input is possible using F12.

Perimeter of the Deep Drawn Area

Perimeter of the areas to be deep drawn in this step.

This value is required.

Indirect input is possible using F12.

Actual Drawing Ratio

Actual drawing ratio of the extrusion surfaces before and after the extrusion work step. Depends on:

  • Initial Area
  • Deep Drawn Area

Limiting Drawing Ratio

Maximum allowable ratio of the deep drawing surfaces before and after the drawing work step. Positioning Count

  • 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
  • Limiting Drawing Ratio

Draw Correction Factor

Factor for determining the deep drawing force depending on the drawing ratios.

Is calculated from:

  • Actual Drawing Ratio
  • Limiting Drawing Ratio

Drawing Corner Radius

The drawing corner radius prevents the wrinkling or tearing of the material.

Is calculated from:

  • Material Thickness
  • Actual Drawing Ratio

Indirect input is possible using F12.

Blankholder 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

Indirect input is possible using 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

Indirect input is possible using F12.

Blank Holder Force

The force with which the blankholder area has to be held.

Is calculated from:

  • Blank holder Area
  • Blank holder Pressure

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

% Additional Press Force

Percentaged additional press force. Is calculated when you enter a value for »Additional Press Force«.

Direct input is possible.

Additional Press Force

Absolute additional press force. Is calculated when you enter a value for »% Additional Press Force«.

Direct input is possible.

Necessary Press Force

Necessary total press force for this work step.

Is calculated from:

  • Theoretical Press Force
  • Additional Press Force
  • Blank Holder Force

Technical Description Group

The technical descriptions of the work step, such as label 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.

To calculate 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 Edit ► Insert ► Insert New Local Machine in the ribbon.

    A machine is inserted under the »Extrusion« process.

  3. Change the label to »Deep Drawing Machine«.
  4. Under Details ► Technical Data view schema, select a machine type.
    5. Note

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

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

  5. In the Details ► Overview view schema (combobox) of the machine enter values for the following properties:

    Calculation ► Investment
    Purchase Value 3,500,000 EUR
    Calculation ► Fixed Machine Cost
    Depreciation Period 6 a
    Technical Data
    Press Force 30,000.00 kN / stroke
    Stroke Frequency 15.00 stroke / min
    Number of Press Stations 5

    This entry is used to calculate the relevant stroke frequency.

Calculated values of the Deep Drawing cost model:

The following values are calculated using the data entered and then shown in the Details ► Calculation view schema:

  • Cycle Time
  • Ʃ Measure Values Cycle Time (if a technical measure has been added to the process)
  • Cycle Time including Ʃ Technical Measures (if a technical measure has been added to the process)
  • Cycles per Time
  • Output per Cycle
  • Output per Time
  • Time per Unit Output
  • Absolute Frequency of Occurrence
  • Percentaged Frequency of Occurrence

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 at the process in the Details ► Calculation ► Manufacturing Valuation group:

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 Unloading Per Stroke
  • Transfer Time
  • Additional Secondary Processing Times
Primary Processing Times
  • Additional Primary Processing Times

Properties of the Deep Drawing cost model (Calculation ► Manufacturing Valuation)

Material Group

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

Tensile Strength

Tensile strength of the material.

This value is required.

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

Sheet Metal Blank Area

Sheet metal blank area.

This value is required.

Direct input is possible.

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.

Indirect input is possible using F12.

Material Thickness

Thickness of the material used.

This value is required.

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

Drawing Behavior of the Material

Variety of the drawing behavior of the material.

Variety:

  1. »Normal«
  2. »Good«
  3. »Very good«

Part Group

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

Deep Drawn Area

Area that was deep drawn in this step.

This value is required.

Direct input is possible.

Perimeter of the Deep Drawn Area

Perimeter of the deep drawn area for this draw.

This value is required.

Direct input is possible.

Work Steps Group

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

»Intermediate Annealing« checkbox

Selection of intermediate annealing. The intermediate annealing allows a higher drawing ratio in the next drawing work step.

Max. Drawing Ratio 1st Draw

The maximum drawing ratio in the 1st drawing work step. Depends on: Drawing Behavior of the Material

Indirect input is possible using F12.

Max. Drawing Ratio Subsequent Draws

The max. drawing ratio from the 2nd drawing work step. Depends on: Drawing Behavior of the Material

Indirect input is possible using F12.

Drawing Clearance

Gap between the cavity and the drawing punch.

Is calculated from:

  • Material Thickness
  • Squared Material Factor (for Drawing Clearance)

Drawing Work Steps

Displays the work steps of the deep drawing process.

The button opens the Local List: Work Steps tab where you can manage the work steps.

This value is required.

Total Number of Used Drawing Work Steps

Displays the number of drawing work steps used.

»Blanking of Sheet Metal Blank« checkbox

Selection of additional blanking work steps within the process (e. g.: with a transfer tool / transfer machine).

Max. Necessary Cutting Force

Maximum necessary cutting force of all work steps.

Indirect input is possible using F12.

Additional Work Steps Blanking

Indirect input is possible using F12.

Additional Work Steps

Direct input is possible.

Total Number of Utilized Drawing Work Steps

Displays the total number of work steps in this process.

»Parallel Processing« checkbox

Displays whether all work steps are carried out at the same time (e. g.: with a transfer tool / transfer machine).

Indirect input is possible using F12.

Number of Strokes

The number of strokes for production of all parts inside the die.

Relevant Press Force

Displays the relevant press force incl. all surcharges.

Machine Group

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.

Press Force of the Machine

Displays the maximum press force of the machine.

This value is required.

This value can be managed at the machine (Details ► Technical Data view schema), 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 can be managed at the machine (Details ► Technical Data view schema), 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.

Amount of Press Stations

Display the number of press stations.

Time per Stroke

The time required for a machine stroke.

Is calculated from:

  • Relevant Stroke Frequency

Secondary Processing Times Group

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

Loading Time

Time for loading the machine with a part.

Direct input is possible.

Unloading Time

Time for unloading the part.

Direct input is possible.

Machine Loading Per Stroke

Time to load the machine per stroke-

Direct input is possible.

Machine Unloading Per Stroke

Time to unload the machine per stroke.

Direct input is possible.

Transfer Time

Additional time between strokes.

Direct input is possible.

Additional Secondary Processing Times

Possibility to add secondary processing times that have not been considered.

Direct input is possible.

Secondary Processing Time

Necessary idle time of a process in which its actual activity cannot be performed.

Is calculated from:

  • Loading Time
  • Unloading Time
  • Additional Primary Processing Times
  • Number of Strokes
  • Transfer Time

Primary Processing Times Group

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 Secondary Processing Times

Possibility to add secondary 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