Calculate Aluminum Extrusion

Aluminum Extrusion is a manufacturing process used to create parts of a specific cross-sectional profile by pushing billet material through a die of the desired cross section. The model is designed to calculate the extrusion process for aluminum and aluminum alloys. The manufactured part is characterized by a profile with a defined length, as well as a defined cross-sectional area.

You can use the Aluminum Extrusion cost model to calculate the process times and costs for the aluminum extrusion involved manufacturing processes in metalworking, which include:

  • Tempering
  • Extrusion
  • Quenching
  • Stretching
  • Cutting

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 Aluminum Extrusion manufacturing process in order to use the cost model.

Sequence

The following example illustrates the process and structure of the Aluminum Extrusion 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 Part

Insert part (piece) 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 part.
  2. In the ribbon, click on Edit > Insert > Part (Piece).

    A part is inserted in the calculation structure.

  3. In the Details (Calculation view scheme ), select the manufacturing valuation Calculate Aluminum Extrusion.

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

    The label of the part automatically changes to "Aluminum Profile".

Step 3: Describe Part

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

Enter Details for Part/Profile

  1. In the Structure view, select the part Aluminum Profile.
  2. Enter the following values in the Details > Calculation > Manufacturing Valuation > Part/Profile:

    3. These values are required in order to calculate additional values. Based on these values, new values are being displayed in the Details view schema Calculation > Manufacturing Valuation.

Step 4: Select and Describe Material

Based on the Material Classification (Aluminum), you can select a desired material in the Details > Calculation > Manufacturing Valuation > Material view. The respective material will later be added to the structure.

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

  • Aluminum

  • Select Material and Manufacturing Method

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

      2. Material Classification* Basic Materials > Metal > Nonferrous Metal > Light Metal > Aluminum
      Manufacturing Method* Primary Shaping > Extrusion
      *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. "AlZn5Mg".

    • Based on the entered dimensions of the part (profile) and the selected material, the final Material Usage Weight will be calculated, and later be assigned to the material in the bill of materials structure.

    Step 5: Select Machine and Times for Process Extrusion

    The Aluminum Extrusion model requires several individual (sub-)processes in order to manufacture a part. At first, the respective machine, times and other details are determined for the extrusion sub-process.

    Import Machine for Aluminum Extrusion (Master Data)

    1. Download the Excel file and save it locally:

      2. Excel template: Machine for Aluminum Extrusion

    2. Follow the steps for importing master data into FACTON using the downloaded Excel file:

    According to the defined part and material dimensions, the required Extrusion Pressure and the Extrusion Force are calculated. Based on these values, you can select the desired machine in the Details > Calculation > Manufacturing Valuation > Extrusion (the selection list usually only contains machines of type "Extrusion" that match the cost model based on the previously entered parameters -> the machine imported here in the example already fulfills these requirements).

    Select Machine and Define Times for Extrusion

    1. Switch to Calculations workspace and select the part "Aluminum Profile" in your calculation. In the group Details > Calculation > Manufacturing Valuation > Extrusion, select one of the available machines in the Machine Selection, e.g. "Aluminum Extrusion Press (25,000 kN)".

      The machine selection provides a value for Max. Extrusion Speed, Number of Operators, Extrusion Time, and Press Force (calculated based on machine data).

    Step 6: Select Machine and Times for Processes Tempering, Quenching, Stretching, and Cutting

    Next, the parameters for the other (sub-)processes involved in manufacturing the final aluminum extrusion part are to be determined.

    The sub-processes Tempering and Cutting require an individual machine selection. All sub-processes have their own individual cycle times.

    Select Machine and Define Details for Tempering

    1. In the group Manufacturing Valuation > Tempering, select an available machine from the Machine Selection, e.g. "AEG Elotherm UVH 600 / I-1 Induction hardening system with workpiece rotation".
    2. Enter the value "2.00" for Number of Operators.
    3. Enter the value "13.00 min/cycle" for Additional Furnace Time.

    Define operators for Quenching

    1. In the group Manufacturing Valuation > Quenching, enter the value "3.00" for Number of Operators.

    Define operators for Stretching

    1. In the group Manufacturing Valuation > Stretching, enter the value "1.00" for Number of Operators.

    Select Machine and Define Details for Cutting

    1. In the group Manufacturing Valuation > Cutting, select an available machine from the Machine Selection, e.g. "Behringer VMS-300-PV Circular Sawing".
    2. Enter the value "2.00" for Number of Operators.

    Based on the defined details, the individual Cycle Times per process are calculated. The Number of Operators will later be assumed to the respective worker in the bill of materials structure (BOM).

    The following default values are provided at the respective processes but can be manually changed or overridden with F12, if required:

    • Loading/Unloading Time (each process)
    • Tempering Time ("Tempering" process)
    • Quenching Time ("Quenching" process)
    • Stretching Time ("Stretching" process)
    • Cutting Time per Part ("Cutting" process)

    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 Aluminum Extrusion

    1. Enter the following values in the Details > Calculation > Manufacturing Valuation > Tools and 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 "Aluminum Extrusion" cost model can be created.

    Complete structure of cost model

    1. In the Structure view select the part.
    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 part.

      • the selected material
      • the individual processes Tempering, Extrusion, Quenching, Stretching, and Cutting with:
        • workers (partially)
        • the selected machines
        • tools and fixtures (partially)

    Properties of the Aluminum Extrusion cost model (Calculation > Manufacturing Valuation)

    Part/Profile group

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

    Profile - Length

    Enter the length of the profile.

    This value is required.

    Direct input is possible.

    Profile - Cross-Sectional Area

    Enter the cross-sectional area of the profile. The value must be smaller than the value of the Billet - Cross-Sectional Area at the material.

    Has direct impact on the Extrusion Ratio.

    This value is required.

    Direct input is possible.

    Geometric Complexity

    Selection of the geometric complexity of the part in percent.

    Has direct impact on the Complexity Extra Amount and the % Max. Extrusion Speed ("Extrusion" group).

    This value is required.

    Selection from list directly possible.

    Extrusion Ratio

    Ratio between the cross-sectional area of the part (profile) and that of the material.

    Is calculated from:

    • Profile - Cross-Sectional Area
    • Billet - Cross-Sectional Area ("Material" group)

    Material Group

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

    The form type of the extrusion material is the billet with a defined length and diameter.

    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.

    Density

    Density of the material.

    This value is required.

    This value can be managed at the material (Details > Technical Data view scheme), 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 scheme), or is applied when global templates are inserted.

    Billet - Length

    Enter the length of the extrusion billet. An initial value of "1,000.00 mm" is provided.

    This value is required.

    Direct input is possible.

    Billet - Diameter

    Enter the diameter of the extrusion billet. An initial value of "50.00 mm" is provided.

    This value is required.

    Direct input is possible.

    Billet - Cross-Sectional Area

    Displays the cross-sectional area of the extrusion billet. The value must be higher than the value of the Profile - Cross-Sectional Area at the part (profile).

    Has direct impact on the Extrusion Ratio at the part (profile).

    Is calculated from:

    • Billet - Diameter

    Numbers of Parts per Billet

    Displays the number of manufactured parts per extrusion section.

    Is calculated from:

    • Profile - Length (Part/Profile)
    • Extrusion Ratio (Part/Profile)
    • Billet - Length
    • Billet - Cross-Sectional Area

    Material Usage Weight

    Displays the material weight per manufactured part.

    Is calculated from:

    • Profile - Length (Part/Profile)
    • Extrusion Ratio (Part/Profile)

    Depends on:

    • Material Selection

    This value is required.

    Indirect input is possible using F12.

    Properties (at part) for defining the "Tempering" process

    Tempering group

    In this group, all properties of the "Tempering" process are displayed.

    Machine Selection

    Selection of a tempering machine (furnace). A suitable selection list of machines is provided.

    This value is required.

    Selection from list directly possible.

    Number of Operators

    Number of workers required to load and unload the tempering machine. If not required, enter value "0".

    Direct input is possible.

    Tempering Time

    Time that is required for the tempering procedure. An initial value of "0.50 min/cycle" is provided.

    Indirect input is possible using F12.

    Additional Furnace Time

    Enter an additional machine (furnace) time.

    Direct input is possible.

    Loading/Unloading Time

    Enter the time required to load and unload the machine for the tempering process. An initial value of "10.00 s/cycle" is provided.

    Direct input is possible.

    Tempering Cycle Time

    Overall time for tempering per cycle.

    Is calculated from:

    • Tempering Time
    • Additional Furnace Time
    • Loading/Unloading Time

    Properties (at part) for defining the "Extrusion" process

    Extrusion group

    In this group, all properties of the "Extrusion" process are displayed.

    Extrusion Pressure

    Displays the pressure of the extrusion machine, depending on the selected material. The value is calculated based on the definitions for the part (profile) and the material.

    This value is required.

    Depends on:

    • Material Selection

    Complexity Extra Amount

    Surcharge on the extrusion pressure, depending on the complexity degree of the manufactured part. The default values are provided from the master data and result from the selection of the Geometric Complexity at the part (profile):

    Geometric Complexity Complexity Extra Amount
    Low 0.00 %

    Medium

    		 10.00 %

    High

    		 20.00 %

    Indirect input is possible using F12.

    Extrusion Force

    Displays the minimum press force that the machine must provide for extrusion, depending on the selected material.

    Is calculated from:

    • Extrusion Pressure
    • Complexity Extra Amount

    Machine Selection

    Selection of an extrusion machine. A suitable selection list of machines is offered based on the calculated relevant press force.

    This value is required.

    Selection from list directly possible.

    Press Force

    Displays the maximum press force of the selected machine.

    This value is required.

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

    Max. Extrusion Speed

    Displays the maximum speed in which the extrusion can be executed, in meters per minute. The default value is provided from the master data upon selecting the machine.

    % Max. Extrusion Speed

    Displays the maximum speed in which the extrusion can be executed, in percent. An initial value of "85.00 %" is provided.

    Direct input is possible.

    Number of Operators

    Number of workers required to load and unload the extrusion machine. If not required, enter value "0".

    Is calculated from:

    • % Max. Extrusion Speed

    Direct input is possible.

    Extrusion Time

    Time that is required for the extrusion procedure.

    Is calculated from:

    • % Max. Extrusion Speed

    Loading/Unloading Time (Operators)

    Enter the time required to load and unload the machine for the extrusion process. An initial value of "10.00 s/cycle" is provided.

    Direct input is possible.

    Extrusion Cycle Time

    Overall time for extrusion per cycle.

    Is calculated from:

    • % Max. Extrusion Speed

    Properties (at part) for defining the "Quenching" process

    Quenching group

    In this group, all properties of the "Quenching" process are displayed.

    Number of Operators

    Number of workers required to execute the quenching procedure. If not required, enter value "0".

    Direct input is possible.

    Quenching Time

    Time that is required for the quenching procedure. An initial value of "0.42 min/cycle" is provided.

    Indirect input is possible using F12.

    Loading/Unloading Time

    Enter the time required to load and unload the machine for the quenching process. An initial value of "10.00 s/cycle" is provided.

    Direct input is possible.

    Quenching Cycle Time

    Overall time for quenching per cycle.

    Is calculated from:

    • Quenching Time
    • Loading/Unloading Time

    Properties (at part) for defining the "Stretching" process

    Stretching group

    In this group, all properties of the "Stretching" process are displayed.

    Number of Operators

    Number of workers required to execute the stretching procedure. If not required, enter value "0".

    Direct input is possible.

    Stretching Time

    Time that is required for the stretching procedure. An initial value of "10.00 min/cycle" is provided.

    Direct input is possible.

    Loading/Unloading Time

    Enter the time required to load and unload the machine for the stretching process. An initial value of "10.00 s/cycle" is provided.

    Direct input is possible.

    Stretching Cycle Time

    Overall time for stretching per cycle.

    Is calculated from:

    • Stretching Time
    • Loading/Unloading Time

    Properties (at part) for defining the "Cutting" process

    Cutting group

    In this group, all properties of the "Cutting" process are displayed.

    Machine Selection

    Selection of the cutting machine. A suitable selection list of machines is provided.

    This value is required.

    Selection from list directly possible.

    Number of Operators

    Enter the number of workers required to load and unload the cutting machine. If not required, enter value "0".

    Direct input is possible.

    Cutting Time per Part

    Time required for the cutting procedure per part. An initial value of "1.00 s/cycle" is provided.

    Direct input is possible.

    Loading/Unloading Time

    Enter the time required to load and unload the machine for the cutting process. An initial value of "10.00 s/cycle" is provided.

    Direct input is possible.

    Cutting Cycle Time

    Overall time for cutting per cycle.

    Is calculated from:

    • Cutting Time per Part
    • Loading/Unloading Time

    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.