Calculate Stamping

You can use the Stamping cost model to calculate the process times and costs for the stamping manufacturing process in metalworking which can include the following work steps:

  • Deep drawing
  • Blanking
  • Bending

All these operations above are processed on one single machine.

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, and other process-specific data
  • the material consumption,
  • the press force and stroke frequency of the machine, and
  • the primary and secondary processing times.
Note

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

Sequence

The following example illustrates the process and structure of the Stamping 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 and set cost model

  1. In the Structure view, select the calculation element (e.g. should cost calculation) under which you wish to insert the process.
  2. In the ribbon, click on Edit > Insert > Process.

    A process is inserted in the calculation structure.

  3. In the Details (Calculation view schema ) select the manufacturing valuation Calculate Stamping.

    The property Manufacturing Valuation becomes a property group with sub-groups.

    The label of the process automatically changes to "Stamping".

Step 3: Describe Manufacturing Part

Describe Manufacturing Part

  1. In the Structure view, select the process "Stamping".
  2. Enter the following values for the part in the Details > Calculation > Manufacturing Valuation > Component > Manufacturing Part.

    These values are required in order to calculate additional values:

    3. Based on these inputs, additional values are calculated and shown at the process "Stamping in the Details > Calculation > Manufacturing Valuation.

Step 4: Select and Describe Material

Based on the given Material Classification, you can select a fitting material from master data in the Details > Calculation > Manufacturing Valuation > Material. The respective material will later be added to the structure.

You can use the following material classifications (basic materials) with the StampingElectroplating cost model:

  • Steel
  • Quality Steel Unalloyed
  • Aluminum
  • Titanium Alloy
  • Copper
  • Nickel
  • Zinc
  • Tin
  • Chrome
  • Special Alloy:
    • Alnico

Select Material and Manufacturing Method

  1. Define the following properties for the process in the Details > General Properties view schema view:

    2. Material Classification* Basic Materials > Metal > Steel > Quality Steel Unalloyed
    Manufacturing Method* Shaping > Push-Pull Forming
    *FACTON recommends the matching materials and machines in the queries for the processes by allowing you to select the material classification and manufacturing method.

  2. Switch to view schema Details > Calculation > Manufacturing Valuation > Material and select an available material in the Material Selection, e.g. "DD13".

The entered values for the sheet dimensions Sheet width, length, and thickness are going to be added to the used material later on in the bill of materials (BOM) structure.

Describe Material

  1. In the Structure view, select the process "Stamping".
  2. Enter the following values in the Details > Calculation > Manufacturing Valuation > Material.

    These values are required in order to calculate additional values:

    3. Technical parameters like Density and Tensile Strength are assumed from the material selection(master data).

Based on the entered and provided dimensions of the manufacturing part and the sheet, the Material Utilization will be calculated and added to the used material later on in the BOM structure.

Step 5: Check values for work steps "Deep Drawing", "Blanking", and "Bending"

The stamping process requires a wide range of individual work steps in order to manufacture a part.

Example

To visualize complex deep drawing parts in detail, they must be broken down into separate work steps.

Depending on the Material Classification, each material is characterized by a Maximum Drawing Ratio. Exceeding this ratio can cause the sheet material to break. This is why several draws may be required for complex geometries/part sizes.

With FACTON the number of required work steps is calculated automatically at the stamping model (max. 5 draws). Each draw is characterized by a drawing and a retaining force.

Note

The values for the work steps "Deep Drawing", "Blanking", and "Bending" are provided at the cost model based on previously defined values at the manufacturing part and material, yet they can be edited directly or overridden with F12 (see Step 9: Additional Fine Tuning).

Step 6: Select Machine and Times

According to the calculated Relevant Press Force from the work steps you can select the desired machine in the Details > Calculation > Manufacturing Valuation > Machine. The selection list only contains machines that fit to the manufacturing method "Push-Pull Forming".

Select Machine and Define Times for Stamping

  1. In the group Details > Calculation > Manufacturing Valuation > Stamping, select one of the available machines in the Machine Selection, e.g. "Fully automatic horizontal multi-stage press | Stroke frequency: 60.00 - 100.00 1/min | press force: 8,000.00 kN".

    The machine selection provides a value for Stroke Frequency of the Machine and Press Force of the Machine.

  2. In the group Primary Processing Times, enter the value "56.00 s/cycle" for the property Additional Primary Processing Time.

  3. In the group Secondary Processing Times, enter the value "85.00 s/cycle" for each property Loading/Unloading/Transfer Time and Greasing Time.

    The total primary and secondary processing times are now calculated based on the provided and entered values and sum up to the Cycle Time.

Step 7: Define Tools and Fixtures

In addition to the machine, you can also maintain values for tools and fixtures, as well as for their maintenance. The corresponding objects are added to the structure later (fields that are not required can be left empty).

Define Details for Tools and Fixtures for Stamping

  1. Enter the following values in the Details > Calculation > Manufacturing Valuation > Fixtures:

Step 8: Complete Structure

If all previous steps have been completed and the data entered are correct, the final bill of materials (BOM) structure of the "Stamping" cost model can be created.

Complete structure of cost model

  1. In the Structure view select the process.
  2. Right-click > Complete Structure.

    3. Alternative: F11 in the Structure view or Details view.

    The structure is automatically generated based on your entries, and costs are being calculated.

    Note

    Further changes are not applied immediately.

    Perform the "Complete Structure" action again after every change to update your cost model.

    All previously selected resources are inserted under the process.

    • the selected material
    • the selected machine
    • a worker
    • tools and fixtures

Calculated values at process Stamping:

The following values are calculated using the data entered and then shown in the Details > Calculation view schema:

  • Cycle Time
  • Cycles per Time
  • Output per Cycle
  • Output per Time
  • Time per Unit Output
  • Absolute Frequency of Occurrence
  • Percentaged Frequency of Occurrence

Step 9: Additional Fine Tuning

Additionally, you can add or edit more details at the process in the Details > Calculation > Manufacturing Valuation (if required, override with F12):

Group Properties
Material
  • Used Blank Area (per Part)
  • Used Blank Perimeter (per Part)

Deep Drawing
  • Complexity Coefficient
  • Perimeter of the Drawn Area
  • Intermediate Annealing
  • Max. Drawing Ratio (1st Draw)
  • Max. Drawing Ratio (Subsequent Draws)

Blanking
  • Press Force for Blanking Operations
  • Press Force for Trimming of Drawn Part

Bending
  • Total Bending Length

(Manufacturing Valuation)
  • % Additional Press Force
Machine
  • Relative Stroke Frequency

Properties of the Stamping cost model (Calculation > Manufacturing Valuation)

Manufacturing Part group

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

Number of Parts per Sheet

Enter the part number that are created per each sheet cut  (by default the value "1" is set).

This value is required.

Direct input is possible.

Part Complexity

Selection of the geometrical complexity of the part in percent.

Has direct impact on the Complexity Coefficient (Deep Drawing) and the Relative Stroke Frequency of the machine.

This value is required.

Selection from list directly possible.

Part Weight

Enter the weight of the finished part.

This value is required.

Direct input is possible.

Drawn Area

The smallest or deepest deep drawn area at the part.

This value is required.

Direct input is possible.

Trimming of the Drawn Part

Decision whether a trimming of the drawn part out of the sheet is required.

Activating/deactivating directly possible via a checkbox.

Add. Cutting Length for Blanking Operations

Enter the additionally required cutting length for the blanking work steps.

Direct input is possible.

Add. Bending Length

Enter the additionally required length for the bending work steps.

Direct input is possible.

Material Group

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

Material Classification

Selection of the material classification as basis for selecting the material. Usually the selection is made in the General Properties view schema and will then be assumed to the "Material" group in the Calculation view schema.

 

Under Details > General Properties:

This value is required.

Selection from list directly possible.

Under Details > Calculation:

Indirect input is possible using F12.

Material Selection

Selection of the material.

This value is required.

Selection from list directly possible.

Sheet Width (w)

Enter the sheet width for the material.

This value is required.

Direct input is possible.

Sheet Length (l)

Enter the sheet length for the material.

This value is required.

Direct input is possible.

Sheet Thickness (t)

Enter the sheet thickness for the material.

This value is required.

Direct input is possible.

Used Blank Area (per Part)

Enter the used area of the sheet metal blank per part. The value must be higher than the value of the Drawn Area.

Direct input is possible.

Used Blank Perimeter (per Part)

Enter the used perimeter of the sheet metal blank per part. The value must be higher than the value of the Perimeter of the Drawn Area.

Direct input is possible.

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.

Tensile Strength

Tensile strength 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.

Material Utilization

Percentage value of the final material utilization.

Is calculated from:

  • Number of Parts per Sheet
  • Part Weight
  • Sheet Width (w)
  • Sheet Length (l)
  • Sheet Thickness (t)

Depends on: Material Classification

Deep Drawing group

In this group the properties of the work step "Deep Drawing" are displayed.

Complexity Coefficient

Percentage surcharge for the perimeter depending on the geometrical complexity. The default values result from the selection of the Part Complexity:

Part Complexity Complexity Coefficient
Low 0.00 %

Medium

 50.00 %

High

 100.00 %

Indirect input is possible using F12.

Perimeter of the Drawn Area

The perimeter of the smallest or deepest deep drawn area at the part.

Direct input is possible.

Intermediate Annealing

Decision whether an intermediate annealing process is required. The intermediate annealing allows a higher drawing ratio in the next drawing work step. The default setting is "no".

Has direct impact on the number of required Draws and the Max. Drawing Ratio of subsequent draws.

Activating/deactivating directly possible via a checkbox.

Drawing Clearance

Gap between the cavity and the drawing punch.

Is calculated from:

  • Sheet Thickness (t)

Max. Drawing Ratio (1st Draw)

The maximum drawing ratio in the first drawing work step.

Indirect input is possible using F12.

Max. Drawing Ratio (Subsequent Draws)

The maximum drawing ratio from the second drawing work step on.

Indirect input is possible using F12.

First/Second/... Draw sub-groups

First/Second/... Draw

Sum of the required force of the individual drawing work step (draw).

Is calculated from:

  • Drawing Force of the individual draw
  • Retaining Force of the individual draw

Drawing Force

Enter the required drawing force for this drawing work step.

Depends on:

  • Material Classification
  • Material Utilization
  • Tensile Strength

Indirect input is possible using F12.

Retaining Force

Enter the required retaining (blank holder) force for this drawing work step.

Depends on:

  • Material Classification
  • Material Utilization
  • Tensile Strength

Indirect input is possible using F12.

Required Drawing Force

Required press force for the "Deep Drawing" work step per stroke.

Is calculated from:

  • First/Second/... Draw

Indirect input is possible using F12.

Blanking group

In this group the properties of the work step "Blanking" are displayed.

Press Force for Blanking Operations

Enter the additional press force for blanking work steps.

Indirect input is possible using F12.

Depends on: Material Classification

Press Force for Trimming of Drawn Part

Enter the additional press force for trimming the drawn part.

Indirect input is possible using F12.

Depends on: Material Classification

Required Blanking Force

Required press force for the "Blanking" work step per stroke.

Is calculated from:

  • Press Force for Blanking Operations
  • Press Force for Trimming of Drawn Part

Bending group

In this group the properties of the work step "Bending" are displayed. The group is only available if a value for Add. Bending Length (higher than "0") was defined before in group Manufacturing Part.

Total Bending Length

Enter the total length of all bending edges.

Is calculated from:

  • Number of Parts per Sheet
  • Add. Bending Length

Indirect input is possible using F12.

Required Bending Force

Required press force for the "Bending" work step per stroke.

Is calculated from:

  • Total Bending Length

Depends on:

  • Material Classification
  • Sheet Thickness (t)
  • Tensile Strength

Required Press Force

Displays the theoretical press force for producing the part, without surcharges.

Is calculated from:

  • Required Drawing Force
  • Required Blanking Force
  • Required Bending Force

% Additional Press Force

Enter the percentage surcharge on the required press force.

Direct input is possible.

Additional Press Force

Displays the absolute surcharge on the required press force per stroke.

Relevant Press Force

Displays the relevant press force for producing the part, with 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 Selection

Select a machine. A suitable selection list of machines is offered based on the calculated relevant pressing force.

This value is required.

Selection from list directly possible.

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.

Press Force of the Machine

Displays the maximum press force of the machine.

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. The default values result from the selection of the Part Complexity:

Part Complexity Relative Stroke Frequency
Low 100.00 %

Medium

 75.00 %

High

 50.00 %

Direct input is possible.

Relevant Stroke Frequency

Stroke frequency that is actually used.

Is calculated from:

  • Stroke Frequency of the Machine
  • Relative Stroke Frequency

Primary Processing Time group

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

Primary Processing Time

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

Is calculated from:

  • Press Time
  • Additional Primary Processing Time

Press Time

Entire time to press all strokes.

Is calculated from:

  • Relevant Stroke Frequency

Additional Primary Processing Times

Possibility to add primary processing times that have not been considered.

Direct input is possible.

Secondary Processing Time group

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

Secondary Processing Time

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

Is calculated from:

  • Loading/Unloading/Transfer Time
  • Greasing Time

Loading/Unloading/Transfer Time

Total time for loading and unloading the machine with a workpiece, as well as for the transfer.

Direct input is possible.

Greasing Time

Time for greasing the tool.

Direct input is possible.

Tooling & Fixtures group

In this group you can define the costs for tools and fixtures, as well as their annual maintenance costs.

Tooling Cost

Costs required for used tools.

Direct input is possible.

% Tooling Maintenance

Share of maintenance costs for tools per year.

Direct input is possible.

Fixture Cost

Costs required for used fixtures.

Direct input is possible.

% Fixture Maintenance

Share of maintenance costs for fixtures per year.

Direct input is possible.