Calculate Injection Molding

You can use the Calculate Injection Molding cost model to calculate the process times and costs for the injection molding manufacturing process in plastics processing. 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 clamping force and the shot volume of the machine, and
  • the primary and secondary processing times.

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

Typical Parts Typical Industries
  • Toys / Tools
  • Packaging / Containers
  • Furniture / Furnishings
  • Panel Systems in Cars
  • Automotive Sector / Aerospace Sector
  • Electrical Industry
  • Food Processing Industry
  • Consumer Goods / Everyday Items
Note

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

Procedure

The following example illustrates the process and structure of the Injection Molding 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 »Injection Molding«.
  4. Define the following properties for the process in the Details ► General Properties view schema (combobox):
    5. Material Classification* Basic Materials » Plastic Material » Thermoplast » PA - Polyamide » PA 6 - Polyamide 6
    Manufacturing Method* Primary Shaping » Casting » Injection Molding
    *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 manufacturing valuation Calculate Injection Molding.

    A new group Manufacturing Valuation appears with sub-groups.

 

Step 3: Insert Material

Values must be entered at the material for the Density and the Material Classification 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:

  • Available Clamping Force
  • Melt Temperature
  • Tool Temperature
  • Demolding Temperature
  • Defusion Rate

You can view the properties at the process under Details ► Calculation ► Manufacturing Valuation ► Miscellaneous Values ► Component 1 ► 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 »Injection Molding« process in the Structure view.
  2. Click on Edit ► Insert ► Insert New Local Material (Mass).

    A local material is inserted under the »Injection Molding« process.

  3. Change the label to »Injection Molding 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:

    For Thermoplastics (Basic Materials » Plastic Material » Thermoplast):

    • PE - Polyethylene » PE-HD - Polyethylene high density
    • PE - Polyethylene » PE-HD - Polyethylene low density
    • PP - Polypropylene
    • PA - Polyamide » PA 6 - Polyamide 6
    • PA - Polyamide » PA 66 - Polyamide 66
    • PA - Polyamide » PA 11 - Polyamide 11
    • PA - Polyamide » PA 12 - Polyamide 12
    • PS - Polystyrene
    • ABS - Acrylnitrile-Buthadiene-Styrene
    • SAN - Styrene-Acrylnitrile
    • ASA - Acrylonitrile Styrene Acrylate
    • PC - Polycarbonate
    • PC / ABS - Polycarbonate/Acrylnitrile Buthadiene Styrene
    • PVC - Polyvinylchloride » PVC-U - Polyvinylchloride Unplasticized (hard)
    • PVC - Polyvinylchloride » PVC-P - Polyvinylchloride Plasticized (soft)
    • PMMA - Polymethyl methacrylate
    • PET - Polyethylene terephthalate
    • PBT - Polybutylene terephthalate
    • POM - Polyoxymethylene
    • PPE/PA - Polyphenylene ether/Polyamide
    • PSU - Polysulfone
    • PES - Polyethersulfone
    • CA - Cellulose acetate
    • CP - Cellulose proprionate
    • CAP - Cellulose acetopropionate
    • CAB - Cellulose acetobutyrate
    • PTFE - Polytetrafluoroethylene
    • ETFE - Ethylene tetrafluorethylene
    • FEP - Tetrafluorethylene/Hexafluorpropylene
    • PCTFE - Polychlortrifluorethylene

    For Elastomers (Basic Materials » Plastic Material » Elastomer):

    • EVA - Ethylene Vinyl Acetate

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

    Calculation
    Density 1.14 g / cm³
    Net Quantity 1.00 kg / cycle
    Price per Unit 0.75 EUR / kg

 

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 »Injection Molding« process.
  2. Enter the following values for the part in the Details ► view schema Calculation ► Manufacturing Valuation.

    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 »Injection Molding« process in the Details ► Calculation ► Manufacturing Valuation.

Part Property Calculated Value

Input Parameters ► Component 1 ► Density

(Precondition: Value for »Material Selection« has been set)

 Miscellaneous Values ► Component 1 ► Part:
  • Material Usage
  • Sprue Weight
  • Recyclable Material

Input Parameters ► Component 1 ► Gating System Volume

(Precondition: Value for »Runner Type« has been set)

 Miscellaneous Values ► Component 1 ► Part:
  • Material Usage
  • Material Usage Volume
  • Recyclable Material
Input Parameters ► Component 1 ► Part Weight Miscellaneous Values ► Component 1 ► Part:
  • Part Volume
Input Parameters ► Component 1 ► Project Area of Part Calculated Values ► Clamping Force:
  • Clamping Force by Projected Area of Part
  • Required Clamping Force for Part
  • Clamping Force by Projected Area of Gating System
  • Relevant Clamping Force
Input Parameters ► Component 1 ► Max Wall Thickness Miscellaneous Values ► Component 1 ► Processing Time:
  • Cooling Time
Miscellaneous Values ► Component 1 ► Part ► Part Volume
  • Material Usage
  • Material Usage Volume
Miscellaneous Values ► Component 1 ► Part ► Project Area of Gating System Calculated Values ► Clamping Force:
  • Clamping Force by Projected Area of Gating System
  • Relevant Clamping Force

 

Step 5: Insert Machine

You can use the Relevant Clamping Force and the Material Usage Volume to determine and insert the required machine. The relevant clamping force is the minimum amount of force a machine must supply in order to manufacture the described part.

To calculate the number of cavities, values must be entered at the machine for the Machine Type, Available Clamping Force and Shot Volume of the Machine 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 »Injection Molding« process in the Structure view.
  2. Click Edit ► Insert ► Insert New Local Machine in the ribbon.

    A machine is inserted under the »Injection Molding« process.

  3. Change the label to »Injection Molding 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:

    • Injection Molding (Horizontally)
    • Injection Molding (Vertically)
    • Screw Extruder

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

    Calculation ► Investment
    Purchase Value 200,000 EUR
    Calculation ► Fixed Machine Cost
    Depreciation Period 6 a
    Technical Data
    Available Clamping Force 600.00 kN
    Machine Shot Volume 70.00 cm³

Calculated values of the Injection Molding 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 6: Insert Worker and Tool

Insert Worker

  1. In the Structure view, select the »Injection Molding« 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 »Injection Molding«.
  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 at the process in the Details ► Calculation ► Manufacturing Valuation group:

Group Properties
Miscellaneous Values ► Component 1 ► Material:
  • Available Clamping Force
  • Melt Temperature
  • Tool Temperature
  • Demolding Temperature
  • Defusion Rate
Calculated Values ► Clamping Force:
  • Additional Clamping Force for Safety (Percentage or Absolute)
  • Additional Clamping Force for Sliders (Percentage or Absolute)
Calculated Values ► Secondary Processing Times:
  • Insertion Parts Necessary
  • Parts Insertion Time
  • Additional Secondary Processing Times
Miscellaneous Values ► Component 1 ► Processing Time:
  • Cooling Time
Calculated Values ► Primary Processing Times:
  • Tool Open Close Time
  • Additional Primary Processing Times
  • Additional Time For Multi Component Process (Precondition: Input Parameters ► Is Multi Component Process)

Properties of the Injection Molding cost model (Calculation ► Manufacturing Valuation)

Component 1 group (under ► Input Parameters)

Material Classification:

The material classification of the process.

Material Selection

Select the material according to the selected material classification of the process. Defines the density.

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.

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.

Cavity Count

 

Runner Type

 

Gating System Volume

Volume of the gating system. The property is only visible, if a value for »Runner Type« has been set.

This value is required.

Indirect input is possible using F12.

Part Weight

Weight of the part.

Projected Area of Part

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

This value is required.

Direct input is possible.

Max Wall Thickness

Maximum wall thickness of the part.

This value is required.

Direct input is possible.

Material group (under ► Miscellaneous Values ► Component 1)

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

 

Available Clamping Force

Clamping force per area for a given material.

Depends on: Material Classification

Indirect input is possible using F12.

Melt Temperature

Temperature the melted material has during injection.

Depends on: Material Classification

Indirect input is possible using F12.

Tool Temperature

Temperature of the tool which causes cooling of the melted material.

Depends on: Material Classification

Indirect input is possible using F12.

Demolding Temperature

Target temperature when cooling is finished and demolding can be done.

Depends on: Material Classification

Indirect input is possible using F12.

Defusion Rate

Factor that specifies how much area of a given material can cool down per time.

Depends on: Material Classification

Indirect input is possible using F12.

Part group (under ► Miscellaneous Values ► Component 1)

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

 

Part Volume

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

Indirect input is possible using F12.

Projected Area of Gating System

The area of the gating system projected in the mold parting surface. Is calculated when entering a value for the »Projected Area of Part«.

Is calculated from:

  • Ratio of area to volume (cm²/cm³)
  • Gating System Volume

Indirect input is possible using F12.

Material Usage

Required material weight incl. gating system weight. Is calculated if a value for »Material Selection« has been set in the Component 1 group (under ► Input Parameters).

Is calculated from:

  • Density
  • Material Usage Volume

Sprue Weight

Sprue Recycling Weight

Recyclable Material

Material mass of the gating system which can be recycled. Is calculated if a value for »Material Selection« has been set in the Component 1 group (under ► Input Parameters).

Is calculated from:

  • Density
  • Gating System Volume

Clamping Force group (under ► Calculated Values)

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

Clamping Force by Projected Area of Part

Clamping force by projected area of part in the mold parting surface.

Is calculated from:

  • Specific Clamping Force
  • Projected Area of Part

% Additional Clamping Force for Safety

Percentaged additional clamping force for safety ratio by projected area. Is calculated when entering a value for the »Additional Clamping Force for Safety«.

Direct input is possible.

Additional Clamping Force for Safety

Absolute additional clamping force for safety ratio by projected area. Is calculated when entering a value for the »% Additional Clamping Force for Safety«.

Direct input is possible.

% Additional Clamping Force for Sliders

Percentaged additional clamping force for sliders by projected area. Is calculated when entering a value for the »Additional Clamping Force for Sliders«.

Direct input is possible.

Additional Clamping Force for Sliders Ratio

Absolute additional clamping force for sliders by projected area. Is calculated when entering a value for the »% Additional Clamping Force for Sliders«.

Direct input is possible.

Required Clamping Force for Part

Required clamping force for the part with additional clamping forces.

Is calculated from:

  • Clamping Force by Projected Area of Part
  • Additional Clamping Force for Safety
  • Additional Clamping Force for Sliders Ratio

Clamping Force by Projected Area of Gating System

Clamping force by projected area of the gating system in the mold parting surface.

Is calculated from:

  • Available Clamping Force
  • Projected Area of Gating System

Relevant Clamping Force

Required total clamping force for all cavities and the gating system.

Is calculated from:

  • Cavity Count (under ► Input Parameters ► Component 1)
  • Required Clamping Force for Part
  • Clamping Force by Projected Area of Gating System

Machine group (under ► Calculated Values)

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

 

Available Clamping Force

Maximum clamping force 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.

Shot Volume of the Machine

Maximum shot volume 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.

Possible Cavity Count by Clamping Force

The possible count of cavities determined with respect to the available clamping force.

Is calculated from:

  • Available Clamping Force
  • Clamping Force by Projected Area of Gating System
  • Required Clamping Force for Part

Possible Cavity Count by Shot Volume

The possible count of cavities determined with respect to the available shot volume.

Is calculated from:

  • Shot Volume of the Machine
  • Gating System Volume
  • Part Volume

Cavity Count Suggested

Number of cavities.

Is calculated from:

  • Possible Cavity Count by Clamping Force
  • Possible Cavity Count by Shot Volume

Indirect input is possible using F12.

Primary Processing Times group (under ► Calculated Values)

 

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

 

Injection & Cooling Time

Time for injecting and cooling down the part for removal and further usage. Is calculated from:

  • Injection Time (under Miscellaneous Values ► Component 1 ► Processing Time)
  • Cooling Time (under Miscellaneous Values ► Component 1 ► Processing Time)
  • Max Wall Thickness
  • Melt Temperature
  • Tool Temperature
  • Demolding Temperature
  • Defusion Rate

Tool Open Close Time

Time for opening and closing the tool. Depends on: Machine Size (Available Clamping Force)

Direct input is possible.

Additional Time for Multi Component Process

Time required for a multi component injection molding process (i. e. a second component can be specified in the injection molding process). Is calculated if the »Is Multi Component Process« checkbox (under ► Input Parameters) has been activated.

Indirect input is possible using F12.

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

  • Injection & Cooling Time
  • Tool Open Close Time
  • Additional Time for Multi Component Process
  • Additional Primary Processing Times

Secondary Processing Times group (under ► Calculated Values)

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

 

»Insertion Parts Necessary« checkbox

Selection whether insertion parts are necessary or not.

Parts Insertion Time

Time for inserting the parts into the machine. Is calculated when the selection for necessary insertion parts is activated.

Indirect input is possible using F12.

Slider Type

Slider Cycle Tim

Part Removal Type

Two Plate Ejector

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:

  • Parts Insertion Time
  • Additional Secondary Processing Times