Calculate Hardening and Tempering

You can use the Calculate Hardening and Calculate Tempering cost models to calculate the process times and costs for the annealing 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 required thermal energy, and
  • the primary and secondary processing times.
Note

You need knowledge of the Hardening and Tempering manufacturing process in order to use the cost model.

Procedure

The following example illustrates the process and structure of the Hardening and Tempering 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 for Hardening

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 »Hardening«.
  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* Change of Material Properties » Heat-Treatment » Hardening
    *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 Hardening .

 

Step 3: Insert Material for Hardening

In order to use FACTON Benchmark data for the calculation, the Material Classification must be set at the 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 »Hardening« process in the Structure view,
  2. Click on Edit ► Insert ► Insert New Local Material (Mass).

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

  3. Change the label to »Hardening 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:

    • Steel
    • Cast Iron

    Values are determined at the process in the Manufacturing Valuation ► Material group for the following property according to the material classification:

    • Specific Heat Capacity

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

    Calculation
    Density 7.85 g / cm³
    Net Quantity 1.00 kg / cycle
    Price per Unit 0.75 EUR / kg
    Technical Data
    Carbon Content 0.60 %

 

Step 4: Describe Part for Hardening

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

Describe Part

  1. In the Structure view, select the »Hardening« 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 »Hardening« process in the Details ► Calculation ► Manufacturing Valuation.

 

Step 5: Insert Relevant Cooling Rate or Cooling Time

Values for either the relevant cooling rate or for the cooling time are required in order to determine the cycle time.

Insert Relevant Cooling Rate or Cooling Time

  1. Select the »Hardening« process in the Structure view, and either:
    1. define a value for the Relevant Cooling Rate (e. g. 100,000.00 K / h) in the Details ► Manufacturing Valuation ► Temperature & Rates,

      2. or

    2. define a value for the Cooling Time (e. g. 26.28 s / cycle) in the Details ► Manufacturing Valuation ► Primary Processing Times.

 

Step 6: Insert Machine for Hardening

To calculate the properties Number of Parts, Max. Heating Rate, etc. values must be entered at the machine for Machine Type, Power Rating and Furnace Capacity.

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

    A machine is inserted under the »Hardening« process.

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

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

    • Hardening Furnace

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

    Calculation ► Investment
    Purchase Value 400,000 EUR
    Calculation ► Fixed Machine Cost
    Depreciation Period 6 a
    Technical Data
    Power Rating 70,000.00 W
    Furnace Capacity 665.00 l

Calculated values of the Hardening 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 Process for Tempering

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 »Tempering«.
  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* Change of Material Properties » Heat-Treatment » Tempering
    *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 Tempering .

 

Step 8: Describe Part for Tempering

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

Describe Part

  1. In the Structure view, select the »Tempering« 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 »Tempering« process in the Details ► Calculation ► Manufacturing Valuation.

 

Step 9: Select Tempering Stage

The tempering stage is required in order to determine the cycle time.

Select Tempering Stage

  1. Select the »Tempering« process in the Structure view.
  2. In the Details ► Calculation ► Manufacturing Valuation ► Temperature & Rates, select a tempering stage (e. g. Tempering Stage 2).

 

Step 10: Use Same Machine

To calculate the properties Number of Parts, Max. Heating Rate, etc. values must be entered at the machine for Machine Type, Power Rating and Furnace Capacity.

Please use the same machine (instance) from the »Hardening« process.

Using the same Machine

  1. In the Structure view, select the »Hardening Furnace« Machine.
  2. Right-click and Copy it.
  3. Select the »Tempering« process in the Structure view.
  4. Right-click and Paste it.

    The identical machine is inserted under the »Tempering« process.

Calculated values of the Tempering 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 11: Insert Worker and Tool

Insert Worker

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

    The tool is inserted under the process.