Calculate Powder Compaction and Sintering

Powder metallurgy comprises two independent processes (powder compaction and sintering) that can run separately from each other. However, both processes are required in order to create a finished product.

You can use the two cost models Calculate Powder Compaction and Calculate Sintering to calculate the process times and cost in metalworking for the powder compaction and sintering manufacturing processes. 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 press force of the machine, and
  • the primary and secondary processing times.
Note

You need knowledge of the Powder Compaction and Sintering manufacturing process in order to use the cost model.

Sequence

The following example illustrates the process and structure of the Powder Compaction and Sintering 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 Production Line

Create a production line for the two cost models Powder Compaction and Sintering.

Insert Production Line

  1. In the Structure view, select the calculation element under which you want to insert the production line.
  2. In the ribbon, click on Edit > Insert > Production Line (Piece).

    A production line is inserted into the calculation structure.

 

Step 3: Insert Process for Powder Compaction

Insert Process

  1. In the Structure view, select the project element you wish to insert under the process.
  2. In the ribbon, click on Edit > Insert > Process.

    A process is inserted in the calculation structure.

  3. Change the label to "Powder Compaction".
  4. Define the following properties for the process in the Details > General Properties view schema view:
    5. Material Classification* Basic Materials > Metal > Steel
    Manufacturing Method* Primary Shaping > Sintering and Powder Compaction
    *FACTON recommends the matching materials and machines in the queries for the processes by allowing you to select the material classification and manufacturing method.

  5. In the Details (Calculation view schema ), select the Valuation Calculate Powder Compaction .

    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 4: Describe Part

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

Describe Part

  1. In the Structure view, select the "Powder Compaction" 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 "Powder Compaction" process in the Details > Calculation > Manufacturing Valuation.

Part Property Group Calculated Value
Projected Area of Part Press Force
  • Specific Press Power
  • Required Press Force
  • Relevant Press Force
Mechanical Requirement
Part Complexity Machine Relative Stroke Frequency

 

Step 5: Insert Machine for Powder Compaction

You can use the Relevant Press Force to determine the required machine and insert it.

To calculate the number of cavities, values must be entered at the machine for the Machine Type, Press Force and Stroke Frequency 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 "Powder Compaction" process in the Structure view.
  2. Click on Edit > Insert > Insert New Local Machine in the ribbon.

    A machine is inserted under the "Powder Compaction" process.

  3. Change the label to "Powder Press".
  4. Under Details >Technical Data view schema, select a machine type.
    5. Note

    You can use the following machine type with the cost model:

    • Powder Metal Press

  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 6,000.00 kN / stroke
    Stroke Frequency 20.00 stroke / min

Calculated values of the Powder Compaction 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 Process for Sintering

Insert Process

  1. In the Structure view, select the project element you wish to insert under the process.
  2. In the ribbon, click on Edit > Insert > Process.

    A process is inserted in the calculation structure.

  3. Change the label to "Sintering".
  4. Define the following properties for the process in the Details > General Properties view schema view:
    5. Material Classification* Basic Materials > Metal > Steel
    Manufacturing Method* Primary Shaping > Sintering and Powder Compaction
    *FACTON recommends the matching materials and machines in the queries for the processes by allowing you to select the material classification and manufacturing method.

  5. In the Details (Calculation view schema ), select the Valuation Calculate Sintering .

    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 7: Insert Material for Sintering

Values must be entered at the material for the Material Usage Weight and the Material Classification properties in order to calculate the primary processing times.

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 "Sintering" process in the Structure view.
  2. Click Edit > Insert > Insert New Local Material (Mass).

    A local material is inserted under the "Sintering" process.

  3. Change the label to "Sintering Material".
  4. Under Details >Technical Data view schema, select a material classification.
    5. Note

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

    • Steel
    • Heavy Metal
    • Copper
    • Alnico
    • Ferrite
    • Molybdenum
    • Tantalum
    • Tungsten
    • Tungsten Carbide
    • Light Metal
    • Titanium Alloy

    Values are determined at the process in the Calculation > Manufacturing Valuation > Primary Processing Times group for the following properties using value rules:

    • Unwaxing Time
    • Sintering Time
    • Cooling Time

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

    Calculation
    Net Quantity 1.00 kg / cycle
    Price per Unit 1.50 EUR / kg
  6. Select the "Sintering" process in the Structure view.
  7. Enter a value (e. g. 0.50 kg) in the Details > Calculation > Manufacturing Valuation > Material > Material Usage Weight.
  8. Activate the checkbox under Details > Calculation > Manufacturing Valuation > Primary Processing Times > Requires Unwaxing.

 

Step 8: Insert Machine for Sintering

You can use the Material Usage Weight to determine and insert the required machine.

Values must be entered at the machine for the Machine Type and Furnace Capacity 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 "Sintering" process in the Structure view.
  2. In the ribbon, click on Edit > Insert > Insert New Local Machine.

    A machine is inserted under the "Sintering" process.

  3. Change the label to "Sintering 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:

    • Sintering Furnace

  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
    Furnace Capacity 220.00 kg

Calculated values of the Sintering 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 9: Insert Worker and Tool

Insert worker

  1. In the Structure view, select the process "Sintering".
  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 "Sintering".

  2. Click on Edit > Insert > Insert New Local Tool.

    The tool is inserted under the process.

Properties of the Powder Compaction cost model (Calculation > Manufacturing Valuation)

Part Group

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

Projected Area of Part

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

This value is required.

Direct input is possible.

Mechanical Requirement

Selection of the mechanical requirement of the part.

This value is required.

Direct input is possible.

Part Complexity

Selection of the complexity of the geometry and shape of the part.

This value is required.

Direct input is possible.

Press Force Group

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

Specific Press Power

Necessary press power depending on the mechanical requirements of the part. Depends on: Mechanical Requirement

Required Press Force

Necessary press force without surcharges.

Is calculated from:

  • Specific Press Power
  • Projected Area of Part

% Additional Press Force

Percentaged additional press force. Is calculated when you enter a value for "Additional Press Force".

Direct input is possible.

Additional Press Force

Absolute additional press force. Is calculated when you enter a value for "% Additional Press Force".

Direct input is possible.

Relevant Press Force

Necessary press force including all surcharges.

Is calculated from:

  • Required Press Force
  • Additional Press Force

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

Maximum press force of the machine 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.

Stroke Frequency of the Machine

Maximum stroke frequency of the machine 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.

Relative Stroke Frequency

Share of the stroke frequency that is actually used. Depends on: Part Complexity

Indirect input is possible using F12.

Relevant Stroke Frequency

Stroke frequency that is actually used.

Is calculated from:

  • Stroke Frequency of the Machine
  • Relative Stroke Frequency

Indirect input is possible using F12.

Time per Stroke

The time required for a machine stroke.

Is calculated from:

  • Stroke Frequency of the Machine
  • Relative Stroke Frequency

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.

Secondary Processing Time

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

Is calculated from:

  • Loading Time
  • Unloading Time

Primary Processing Times group

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

Press Time

Press time for a process.

Is calculated from:

  • Number of Strokes
  • Time per Stroke

Additional Press Time

Surcharge for additional press force.

Direct input is possible.

Primary Processing Time

Time in which the actual activity of a process is performed.

Is calculated from:

  • Press Time
  • Additional Press Time

Properties of the Cost Model - Sintering

Material Group

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

Material Usage Weight

Weight of the blank part.

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.

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.

Secondary Processing Time

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

Is calculated from:

  • Loading Time
  • Unloading Time

Primary Processing Times group

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

"Requires Unwaxing" checkbox

Selection of the process of unwaxing the parts. The default setting is "no".

Unwaxing Time

The time it takes to unwax the part. Depends on: Material Classification

Indirect input is possible using F12.

Sintering Time

Required time for the sintering process. Depends on: Material Classification

Indirect input is possible using F12.

Cooling Time

Time for cooling down the part for removal and further usage. Depends on: Material Classification

Indirect input is possible using F12.

Furnace Time

Time required to complete one whole furnace cycle.

Is calculated from:

  • Unwaxing Time
  • Sintering Time
  • Cooling Time

Additional Furnace Time

Surcharge for additional furnace time.

Direct input is possible.

Primary Processing Time

Time in which the actual activity of a process is performed.

Is calculated from:

  • Furnace Time
  • Additional Furnace Time