Calculate Honing

You can use the Calculate Honing cost model to calculate the process times and costs for the honing 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 work steps,
  • the stroke and circumferential speed, and
  • the primary and secondary processing times.
Note

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

Procedure

The following example illustrates the process and structure of the Honing 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 »Honing«.
  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 » Chipping without Geometrically Determined Cutting Edge » Honing
    *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 Honing .

 

Step 3: Insert Material

To use FACTON Benchmark data for the work step data, the Material Classification must be entered at the material.

Note

Values for the following work step properties are determined via value rules by selecting the material classification:

  • Stroke Speed
  • Circumferential Speed
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 »Honing« process in the Structure view.
  2. Click on Edit ► Insert ► Insert New Local Material (Mass).

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

  3. Change the label to »Hon-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
    • Basic Steel
    • Quality Steel Unalloyed
    • Stainless Steel Unalloyed
    • Tool Steel
    • Quality Steel Alloyed
    • Steel with Special Physical Properties
    • Alloyed Steel / Construction Steel / Chemical Resistant Steel
    • Special Purpose Steel
    • Cast Iron
    • Aluminum

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

    • Honing Material Group

  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

 

Step 4: Insert Work Steps

A range of separate work steps is required in order to manufacture a component in the honing process. To visualize complex chipping parts in detail, they must be broken down into separate work steps.

FACTON lets you define multiple work steps at the Honing cost model. You can assign the work steps to the machining units via a selection list.

Insert Work Steps

  1. Select the »Honing« 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 Honing Work Steps row.

    The Local List: Honing 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. Create two additional rows for the work step.
  6. Define the following values for the properties of the work step in the Local List: Honing Work Steps tab:
    LabelBore DiameterBore DepthHoning Stone LengthNumber of Strokes
    »Hole 1«»50 mm«»150 mm«»40 mm«»3 strokes«
    »Hole 2«»20 mm«»200 mm«»30 mm«»5 strokes«
    »Hole 3«»10 mm«»80 mm«»20 mm«»2 strokes«

    These values are required in order to calculate additional values.

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.

Assigned Machining Unit

Display of the assigned machining unit this work step is performed at.

Honing Material Group

Display of the honing material group that are determined using value rules based on the material classification.

This value is required.

Indirect input is possible using F12.

Primary Processing Times

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

Bore Diameter

Diameter of the bore.

This value is required.

Direct input is possible.

Bore Depth

Depth of the bore.

This value is required.

Direct input is possible.

Honing Stone Length

Length of the honing stone.

This value is required.

Direct input is possible.

Stroke Length

Length of the stroke.

Is calculated from:

  • Bore Depth
  • Honing Stone Length

Indirect input is possible using F12.

Number of Strokes

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

Direct input is possible.

Stroke Speed

Speed of the strokes. Depends on: Material Classification

Indirect input is possible using F12.

Circumferential Speed

Speed of the outer circle. Depends on: Material Classification

Indirect input is possible using F12.

Work Step Primary Processing Time

Time in which the actual activity of the work step is performed.

Is calculated from:

  • Bore Diameter
  • Stroke Length
  • Number of Strokes
  • Stroke Speed

Rotational Speed

Is calculated from:

  • Bore Diameter
  • Circumferential Speed

Cutting Speed

Is calculated from:

  • Bore Diameter
  • Circumferential Speed
  • Stroke Speed

Crosshatch Angle

Is calculated from:

  • Bore Diameter
  • Circumferential Speed
  • Stroke Speed

Indirect input is possible using F12.

Secondary Processing Times Group

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

Positioning Time

Display of the time for additionally positioning of a tool. Depends on: Machine Type

Indirect input is possible using F12.

Tool Change Time

Time for changing a tool.

Direct input is possible.

Work Step Secondary Processing Time

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

Is calculated from:

  • Work Step Positioning Time
  • Tool Change Time

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 Rotating Speed from the work steps to determine the required machine and insert it.

To calculate the cutting force and speed the Machine Type, Machining Units Count, Parallel Processing and Rotating Speed must be entered at the machine:

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

    A machine is inserted under the »Honing« process.

  3. Change the label to »Honing 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:

    • Honing 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
    Machining Units Count 3
    Parallel Processing
    Rotational Speed 600.00 1 / min

 

Step 6: Insert Machining Units

You can insert a certain number of machining units depending on the machine in use. Depending on the machine, multiple machining units can be managed by making parallel processing possible.

Insert Machining Units

  1. Select the »Honing Machine« in the Structure view.
  2. Click on Edit ► Insert ► Machining Unit in the ribbon.

    Change the label to »Machining Unit 2«.

  3. Change the label to »Machining Unit 1«.
    4. Note

    The possibility of parallel processing depends on the machine.

  4. Repeat Steps 1 and 2.
  5. Change the label to »Machining Unit 2«.
  6. Repeat Steps 1 and 2.
  7. Change the label to »Machining Unit 3«.

 

Step 7: Assign Work Steps

The next step is to assign work steps to the machining units.

Assign Work Steps

  1. Select the »Machining Unit 1« in the Structure view.
  2. In the Details ► Calculation ► Manufacturing Valuation ► Assigned Honing Work Steps, click on the combobox .

    The selection list with the work steps opens.

  3. Activate the following work steps you want to assign to the machining units:
    Machining UnitWork Step
    »Machining Unit 1«»Hole 1«
    »Machining Unit 2«»Hole 2«
    »Machining Unit 3«»Hole 3«

Calculated values of the Honing 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 8: Insert Worker and Tool

Insert Worker

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

    The tool is inserted under the process.

Properties of the Honing cost model (Calculation ► Manufacturing Valuation)

Material Group

This group shows the honing material group of the material that is used for honing.

Work Steps Group

The work step properties in the honing process that are used for calculating the cost model are shown in this group. The button opens the Local List: Honing Work Steps tab where you can manage the 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.

Machining Units Count

Shows the count of available machining units on the machine.

Parallel Processing

Selection whether the machining units can be used simultaneously.

Rotational Speed

Turning: Rotational speed of part.

Milling/Drilling: Rotational speed of tool.

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.

Secondary Processing Times Group

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

Unloading Time

Time for unloading the part.

Direct input is possible.

Unloading Time

Time for unloading the part.

Direct input is possible.

Work Step Secondary Processing Time

Sum of all secondary processing times (work step positioning time and tool change 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
  • Work Step Secondary Processing Time
  • Additional Secondary Processing Times

Primary Processing Times Group

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

Work Step Primary Processing Time

Sum of all primary processing times of all work steps.

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:

  • Work Step Primary Processing Time
  • Additional Primary Processing Time