Calculate Annealing

You can use the Calculate Annealing cost model 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 Annealing manufacturing process in order to use the cost model.

Sequence

The following example illustrates the process and structure of the Annealing 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, select 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 »Annealing«.
  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 » Annealing
    *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 Annealing .

    A new group Manufacturing Valuation appears with sub-groups.

Note

When changing valuations, the subelements are grayed-out and no longer considered in the calculation.

 

Step 3: Insert Material

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

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

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

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

    • Steel
    • Aluminum
    • Cast Iron

    According to the material classification, values are determined at the process in the Calculation ► Manufacturing Valuation ► Material group for the following property:

    • Specific Heat Capacity

    According to the material classification, values are determined at the process in the Calculation ► Manufacturing Valuation ► Temperature & Rates group for the following property:

    • Temperature Range
    • Heating Temperature

  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: Describe Part

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

Describe Part

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

 

Step 5: Insert Machine

For calculating the properties Number of Parts, Max. Heating Rate, etc., values must be entered and maintained at the machine for the properties 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 »Annealing« process in the Structure view.
  2. Click Edit ► Insert ► Insert New Local Machine in the ribbon.

    A machine is inserted under the »Annealing« process.

  3. Change the label to »Annealing 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 200,000 EUR
    Calculation ► Fixed Machine Cost
    Depreciation Period6 a
    Technical Data
    Power Rating22,000.00 W
    Furnace Capacity105,000.00 cm³
-->

Calculated values of the Annealing 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 »Annealing« 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 »Annealing«.
  2. Click Edit ► Insert ► Insert New Local Tool.

    The tool is inserted under the process.

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

Material Group

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

Specific Heat Capacity

Specific heat capacity that is required for a particular material per area.

Depends on: Material Classification

This value is required.

Indirect input is possible using F12.

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.

Part Group

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

Max Wall Thickness

Maximum wall thickness of the part.

This value is required.

Direct input is possible.

Part Weight

Weight of the part.

This value is required.

Direct input is possible.

Number of Parts

Number of parts.

This value is required.

Direct input is possible.

Total Part Weights

Total weight of parts.

Is calculated from:

  • Part Weight
  • Number of Parts

Total Volume of Parts

Total volume of parts.

Is calculated from:

  • Density
  • Total Part Weights

Temperature & Rates Group

The data for temperature and speed properties used to calculate this cost model are shown in this group.

Annealing Method

Display of the method of annealing.

Indirect input is possible using F12.

Temperature Range

Temperature range of the heating temperature of the material. Depends on: Material Classification

Initial Temperature

The temperature of the parts before heating. Is initially room temperature (25 °C).

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.

Heating Temperature

Temperature to which the part is heated up to. Is within temperature range.

This value is required.

Indirect input is possible using F12.

Heating Temperature Difference

The difference between initial and target temperature when heating the parts.

Is calculated from:

  • Heating Temperature
  • Initial Temperature

Required Thermal Energy

The energy required to heat the parts.

Is calculated from:

  • Specific Heat Capacity
  • Total Part Weights
  • Heating Temperature Difference

Cooling Temperature

The temperature of the parts to be achieved during cooling. Is initially room temperature.

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.

Cooling Temperature Difference

The difference between initial and target temperature when cooling the parts.

Is calculated from:

  • Heating Temperature
  • Cooling Temperature

Max. Heating Rate

Maximum heating rate of the furnace.

Is calculated from:

  • Heating Temperature Difference
  • Required Thermal Energy
  • Power Rating

Relevant Heating Rate

The heating rate used for further calculation.

Is calculated from:

  • Heating Temperature
  • Cooling Temperature

Indirect input is possible using F12.

Relevant Cooling Rate

The cooling rate used for further calculation. Depends on: Maximum Wall Thickness

This value is required.

Direct input is possible.

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.

Furnace Capacity

Maximum loading capacity of the furnace that is available.

This value is required.

This value is required and can be managed at the machine (Details ► Technical Data view schema), or is applied when global templates are inserted.

Power Rating

Maximum available power of the furnace.

This value is required.

This value is required and can be managed at the machine (Details ► Technical Data view schema), 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.

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.

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
  • Additional Secondary Processing Times

Primary Processing Times group

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

Heating Time

Is calculated from:

  • Heating Temperature Difference
  • Relevant Heating Rate

Indirect input is possible using F12.

Holding Time

Depends on: Maximum Wall Thickness

Indirect input is possible using F12.

Cooling Time

Is calculated from:

  • Cooling Temperature Difference
  • Relevant Cooling Rate

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.

Is calculated from:

  • Heating Time
  • Holding Time
  • Cooling Time
  • Additional Primary Processing Times