Calculate Extrusion

You can use the Calculate Extrusion cost model to calculate the process times and costs for the extrusion 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.

In the cost model Extrusion a distinction is made between direct extrusion and indirect extrusion.

Note

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

Procedure

The following example illustrates the process and structure of the Extrusion 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 »Extrusion«.
  4. Define the following properties for the process in the Details ► General Properties view schema (combobox):
    5. Material Classification* Basic Materials » Metal » Nonferrous Metal » Light Metal » Aluminum
    Manufacturing Method* Shaping » Pressure Forming » Thrusting » Cold Extrusion
    *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 Extrusion .

    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 Density and the Material Classification properties for the calculation.

Note

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

  • Yield Stress Before Working
  • Yield Stress at 100% Reduction Ratio
  • Strain Hardening Exponent Allowable Deformation

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

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

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

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

    • Alloyed Steel / Construction Steel / Chemical Resistant Steel
    • Steel with Special Physical Properties
    • Stainless Steel Unalloyed
    • Tool Steel
    • Quality Steel Alloyed
    • Quality Steel Unalloyed
    • Basic Steel
    • Aluminum
    • Copper

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

    Calculation
    Density 7.85 g / cm³
    Price per Unit 0.75 EUR / kg
  6. Select the »Extrusion« process in the Structure view.
  7. Enter a value in the Details ► Calculation ► Manufacturing Valuation ► Material ► Cross-Sectional Area of Blank (e. g. 1,661 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 »Extrusion« 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 »Extrusion« process in the Details ► Calculation ► Manufacturing Valuation.

 

Step 5: Insert Work Steps

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

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

Insert Work Steps

  1. Select the »Extrusion« 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 Press Work Steps row.

    The Local List: Press Work Steps tab opens.

    Further Information ► 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 »Pressing 1«

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 Cross-Section

The cross-sectional area of the component before the impact extrusion step. Corresponds to the value for the cross-sectional area of blank.

This value is required.

Indirect input is possible using F12.

Target Cross-Section

Cross-sectional area of the worked part.

This value is required.

Indirect input is possible using F12.

Actual Deformation

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

  • Initial Cross-Section
  • Target Cross-Section

Allowable Deformation

The maximum allowable ratio of the cross-section to be deformed 'before' and 'after' the work step.

Indirect input is possible using F12.

Min. Cross-Section

Indicates the minimum size of the cross-sectional area depending on the allowable change in shape.

Is calculated from:

  • Initial Cross-Section
  • Allowable Deformation

Theoretical Press Force

Calculated press force for this work step.

Is calculated from:

  • Tensile Strength
  • Material Thickness
  • Initial Cross-Section

% 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

Extrusion Deformation Efficiency

Describes the loss of force during extrusion due to the friction on the press tool, as well as the displacements within the material.

This value is required.

Indirect input is possible using F12.

Yield Stress at the End of the Working

The yield stress of the material on reaching the actual reduction ratio.

Average Yield Stress

Is the average value of the yield stress of the material 'before' and 'after' working.

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 »Extrusion« 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 »Extrusion 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
    • 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 1,500,000 EUR
    Calculation ► Fixed Machine Cost
    Depreciation Period 6 a
    Technical Data
    Press Force 3,500.00 kN / stroke
    Stroke Frequency 120.00 stroke / min
    Number of Press Stations 5

    This entry is used to calculate the relevant stroke frequency.

Calculated values of the Extrusion 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 »Extrusion« 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 »Extrusion«.
  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
Work Steps
  • 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 Extrusion cost model (Calculation ► Manufacturing Valuation)

Material Group

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

Allowable Deformation

The maximum allowable ratio of the cross section to be deformed 'before' and 'after' the work step.

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.

Yield Stress Before Working

The yield stress of the material at reduction (extrusion) ratio 0%. Depends on: Material Classification

Yield Stress at 100% Reduction Ratio

The yield stress of the material at reduction (extrusion) ratio 100%.

Is calculated from:

  • Sheet Metal Blank Area
  • Deep Drawn Area
  • Perimeter of the Deep Drawn Area
Note The perimeter of the sheet metal blank is calculated based on a circular area.

Strain Hardening Exponent

Material exponent for determining the yield stress.

This value is required.

This value is required and can be managed at the material (Details ► Calculation ► Form Type & Geometry), or is applied when global templates are inserted.

Cross-Sectional Area of Blank

Cross-sectional area of the worked part.

This value is required.

Direct input is possible.

Density

Density 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.

Blank Part Height

Height of the material before working (initial height).

Part Group

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

Part Weight

Weight of the part. Is calculated when entering a value for the »Part Volume«.

This value is required.

Direct input is possible.

Part Volume

Volume of the part. Is calculated when entering a value for the »Part Weight«.

This value is required.

Direct input is possible.

Smallest Worked Cross-Section

The smallest cross-sectional area of the component that is to be produced in this process.

This value is required.

Direct input is possible.

Extrusion Form

Selection of the main characteristics of the part to be produced and the extrusion method.

This value is required.

Direct input is possible.

Extrusion Form Image

Shows a sample image of the selected extrusion form/mold.

Work Steps Group

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

Extrusion Method

Displays the extrusion method.

Press Work Steps

Displays the work steps of the extrusion process.

This value is required.

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

Used Press Work Steps

Displays the number of press work steps used.

Necessary Annealing Processes

Displays the number of annealing processes required during working.

Additional Work Steps

The number of additional work steps, e.g. for the calibration or the control of the part.

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

Displays the maximum stroke frequency 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.

Relative Stroke Frequency

Share of the stroke frequency that is actually used.

Direct input is possible.

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.

Amount of Press Stations

Displays the number of available press stations of the machine.

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 Secondary 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 Primary Processing Times

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