Calculate Blanking

You can use the Calculate Blanking cost model to calculate the process times and costs for the blanking/shearing 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 clamping force of the machine,
  • the material consumption, and
  • the primary and secondary processing times.

Machines and material parameters are required for the calculation.

Note

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

Procedure

The following example illustrates the process and structure of the Blanking 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 »Blanking«.
  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* Separating » Cutting » Shearing
    *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 Blanking .

    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 Material Thickness and Tensile Strength in order to calculate the relevant stroke frequency and maximum shear strength.

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

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

  3. Change the label to »Blanking 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 Blanking cost model. Depending on the chosen valuation, 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

    It is necessary to enter a value for the tensile strength at the »Blanking« process in the Details ► Calculation ► Manufacturing Valuation ► Material. This value calculates the maximum shear strength.

You can define further properties for the sheet material, such as sheet width, sheet length, and output per sheet in the Details view. These data are used for calculating the cross-sectional area, volume, gross weight, and weight per length.

 

Step 4: Insert Work Steps

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

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

Insert Work Steps

  1. Select the »Blanking« process in the Structure view.
  2. In the Details ► Calculation view schema, click on the group Manufacturing Valuation ► Work Steps.
  3. Click on the button next to the Value column in the Work Steps row.

    The Local List: 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. In the Local List view enter a value for the following properties of the work step:
    • Label
    • Cutting Length
    • Cutting Distance
    • Number of Cuts
    • % Additional Cutting Force

    These values are required in order to calculate additional values.

Work Step Properties Calculated Value in Group
Cutting Length Number of Strokes Primary Processing Times
Number of Cuts Theoretical Cutting Force
Cutting Length Max. Necessary Cutting Force Process ► Calculation ► Manufacturing Valuation ► Soldering group
Cutting Distance Average Cutting Distance
Number of Cuts Sum of Strokes

Work Step Properties

General Group

This group shows the general work step properties, e. g. Label.

Primary Processing Times Group

This group shows the primary processing times for the work step.

Cutting Length

The length of the cutting edge or contour of the workpiece which is machined in the work step or the total length cut by the tool.

This value is required.

Direct input is possible.

Cutting Distance

Distance to the next hole or cut (e. g. hole spacing).

This value is required.

Direct input is possible.

Bevel Factor

The bevel at a cutting tool reduces the press force. If no bevel is available, the value is »1«.

Direct input is possible.

Number of Cutting Tools

The number of the cutting stamps/tools that are used simultaneously during a machine stroke.

Direct input is possible.

Number of Cuts

Number of required cuts for this work step.

This value is required.

Direct input is possible.

Number of Strokes

The number of strokes for the production of all cuts in this work step.

Is calculated from:

  • Number of Cutting Tools
  • Number of Cuts

Theoretical Cutting Force

Calculated cutting force for this work step.

Is calculated from:

  • Max. Shear Strength
  • Material Thickness
  • Cutting Length
  • Bevel Factor
  • Number of Cutting Tools

% Additional Cutting Force

Percentaged additional cutting force. Is calculated when entering a value for the additional cutting force.

Direct input is possible.

Additional Cutting Force

Absolute additional cutting force. Is calculated when entering a value for the % additional cutting force.

Direct input is possible.

Necessary Cutting Force

Necessary cutting force for a machine stroke in this work step.

Is calculated from:

  • Theoretical Cutting Force
  • Additional Cutting Force

Secondary Processing Times Group

This group shows the secondary processing times of the work step.

Change Tool

Selection whether time is required for changing the tool or not.

Direct input is possible.

Tool Change Time

Shows the time to change a tool.

Indirect input is possible using F12.

Technical Description Group

The technical descriptions of the work step, such as label and description, are shown and managed in this group.

 

Step 5: Insert Machine

You can use the calculated maximum Necessary Cutting Force from the work steps to determine the required machine and insert it.

Values must be entered at the machine for Press Force and Stroke Frequency to calculate the cutting pressure (blanking) and speed.

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

    A machine is inserted under the »Blanking« process.

  3. Change the label to »Blanking 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:

    • Fine Blanking Press
    • Toggle Press
    • Blanking Line
    • 4 Columns Press
    • Swing Beam Machine

  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
    Press Force 2,000.00 kN / stroke
    Stroke Frequency 180.00 stroke / min

    This entry is used to calculate the relevant stroke frequency.

Calculated values of the Blanking 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 »Blanking« 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 »Blanking«.
  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
Secondary Processing Times
  • Loading and Unloading Time
  • Additional Secondary Processing Times
Primary Processing Times
  • Additional Primary Processing Times
Work Steps (Local List ► Local List)
  • Bevel Factor
  • Number of Cutting Tools
  • Change Tool
  • Tool Change Time

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

Factor for Max. Shear Strength

The factor for max. shear strength, usually entered with »0.8«.

Direct input is possible.

This property is a default value which is automatically set. You can change it by directly entering another value.

If you delete the input, the value is being reset to the default.

Max. Shear Strength

Maximum shear strength of the material.

Is calculated from:

  • Tensile Strength
  • Factor for Max. Shear Strength

Material Thickness

Thickness of the material used.

This value is required.

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

Further Information ► Only the following combinations of Quantity Valuation and Geometric Shape are supported for the Calculate Blanking cost model. Depending on the chosen valuation, you may see different material properties or you may be required to enter different information.

Work Steps Group

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

Work Steps

Displays the work steps of the blanking process.

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

This value is required.

Sum of Strokes

Sum of the strokes of all work steps.

Average Cutting Distance

Average cutting distance of all work steps.

Is calculated from:

  • Cutting Distance
  • Number of Strokes

Max. Necessary Cutting Force

Maximum necessary cutting force of all work steps.

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.

Relevant Stroke Frequency

Effective stroke frequency.

Is calculated from:

  • Material Thickness
  • Ø Cutting Distance
  • Stroke Frequency of the Machine

This value is required.

Indirect input is possible using F12.

Tool Change Time

Time for changing a tool. Depends on: Machine Type

Indirect input is possible using F12.

Secondary Processing Times Group

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

Loading and Unloading Time

Time for loading and unloading the machine with a part.

Direct input is possible.

Summed Tool Change Time

The sum of the tool changing time of all work steps

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 and Unloading Time
  • Summed Tool Change Time
  • Additional Secondary Processing Times

Primary Processing Times Group

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

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:

  • Sum of Strokes
  • Stroke Frequency per Second
  • Additional Primary Processing Times