Calculate Lapping

You can use the Calculate Lapping cost model to calculate the process times and costs for the lapping 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 surface load and stock removal rate, and
  • the primary and secondary processing times.
Note

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

Sequence

The following example illustrates the process and structure of the Lapping 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 »Lapping«.
  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 » Lapping
    *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 Lapping .

 

Step 3: Insert Material

Values must be entered at the material for the Material Classification property and at the process ► Calculation ► Manufacturing Valuation ► Material for Allowance.

Note

Values are determined for the following properties using value rules by selecting the material classification:

  • Total Height of Profile (Rt)
  • Base Stock Removal Rate

You can view the »Lapping Material Group« property at the process under Details ► Calculation ► Manufacturing Valuation ► 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 »Lapping« process in the Structure view.
  2. Click on Edit ► Insert ► Insert New Local Material (Mass).

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

  3. Change the label to »Lapping 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
    • Quality Steel Alloyed
    • Steel with Special Physical Properties
    • Alloyed Steel / Construction Steel / Chemical Resistant Steel
    • Special Purpose Steel
    • Technical Ceramic

  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
  6. Select the »Lapping« process in the Structure view.
  7. Define a value in the Details ► Calculation ► Manufacturing Valuation ► Material ► Allowance view (e. g. 30 µm/cycle).

 

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 »Lapping« 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 »Lapping« process in the Details ► Calculation ► Manufacturing Valuation.

 

Step 5: Insert Machine

You can use the Relevant Press Force from the work steps to determine and insert the required machine.

To calculate the stock removal rate, values must be entered and maintained at the machine for the Lapping Wheels Ø, Number of Trueing Rings, Trueing Ring Inner Ø.

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

    A machine is inserted under the »Lapping« process.

  3. Change the label to »Lapping 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:

    • Lapping Machine

  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
    Number of Trueing Rings 5
    Trueing Ring Inner Ø 155.00 mm
    Lapping Wheel Ø 386.00
    Rotational Speed 70.00 1/min

    The key data for the stock removal rate are calculated with this data.

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

    The tool is inserted under the process.

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

Material Group

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

Lapping Material Group

Display of the lapping material group which is determined through value rules based on the selected material classification.

Indirect input is possible using F12.

Allowance

Allowance of the workpiece.

This value is required.

Direct input is possible.

Part Group

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

Part Weight

Weight of the part.

This value is required.

Direct input is possible.

Part Diameter

Diameter of the part.

This value is required.

Direct input is possible.

Contact Area

Contact area of the part. Round parts were used for the calculation.

Is calculated from:

  • Part Weight
  • Part Diameter

Indirect input is possible using F12.

Total Height of Profile (Rt)

Selection of the maximum roughness depth of profile. The vertical distance between highest and lowest point of the profile within the considered length.

This value is required.

Direct input is possible.

Arithmetic Mean Height (Ra)

Selection of the arithmetic mean value of total profile height value within the considered length.

This value is required.

Direct input is possible.

Stock Removal Rate Group

The key data for the stock removal rate used to calculate the cost model are shown in this group.

Parts per Ring

Number of parts per trueing ring.

Is calculated from:

  • Contact Area
  • Trueing Ring Inner Ø

Indirect input is possible using F12.

Parts Weight

Weight of the part per trueing ring.

Is calculated from:

  • Part Weight
  • Parts per Ring

Parts Contact Area

Contact area of the part per trueing ring.

Is calculated from:

  • Contact Area
  • Parts per Ring

Surface Load

Is calculated from:

  • Parts Weight
  • Parts Contact Area

Lapping Pressure

Effective force-related surface load between the workpiece and the lapping tool.

Is calculated from:

  • Parts Contact Area
  • Parts Weight Force

Parts Weight Force

Weight force of the parts per trueing ring.

Is calculated from:

  • Parts Weight

Required Weight Compensation

In order to ensure the optimal lapping pressure, a weight compensation with an additional weight or a relief by springs is achieved.

Is calculated from:

  • Parts Weight
  • Parts Contact Area
  • Specific Surface Load

Indirect input is possible using F12.

Required Force Compensation

Required force compensation per trueing ring.

Is calculated from:

  • Required Weight Compensation

Specific Surface Load

Is calculated from:

  • Parts Weight
  • Parts Contact Area
  • Required Force Compensation

Specific Lapping Pressure

Is calculated from:

  • Parts Contact Area
  • Weight Compensation
  • Required Force Compensation

Max Circumferential Speed

Maximum circumferential speed of the lapping wheel depending on the »Speed«. Round parts were used for the calculation.

Is calculated from:

  • Used Rotational Speed
  • Lapping Wheel Ø

Relevant Circumferential Speed

Relevant circumferential speed of the lapping wheel.

Is calculated from:

  • Max Circumferential Speed

Indirect input is possible using F12.

Used Rotational Speed

Used rotational speed of the lapping wheel. Round parts were used for the calculation.

Is calculated from:

  • Relevant Circumferential Speed
  • Lapping Wheel Ø

Stock Removal Rate

Is calculated from:

  • Used Rotational Speed

Indirect input is possible using F12.

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.

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.

Lapping Wheel Ø

Diameter of a lapping wheel.

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.

Number of Trueing Rings

Count of trueing rings.

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.

Trueing Ring Inner Ø

Inner diameter of a trueing ring.

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.

Trueing Ring Inner Area

Inner area of a truering ring. Round parts were used for the calculation.

Is calculated from:

  • Trueing Ring Inner Ø

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.

  • 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.

Lapping Time

Is calculated from:

  • Allowance
  • Stock Removal Rate

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:

  • Lapping Time
  • Additional Primary Processing Times