Calculate Electroplating

Electroplating is an electrochemical process for producing metal coatings on a solid surface using electrical current. Electroplating is widely used to improve the surface quality and resistance.

You can use the cost model Electroplating to calculate the process times and cost in metalworking for electrochemical coatings of manufacturing parts.

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 Electroplating manufacturing process in order to use the cost model.

Sequence

The following example illustrates the process and structure of the Electroplating 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 scheme ) select the manufacturing valuation Calculate Electroplating.

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

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

Step 3: Select 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 Electroplating cost model:

  • 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 scheme view:

      2. Material Classification* Basic Materials > Metal > Nonferrous Metal > Heavy Metal > Nickel
      Manufacturing Method* Coating
      *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. "NiCu30Fe (NiCu30)".

    • 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 process "Electroplating".
    2. Enter the following values for the part in the Details > Calculation > Manufacturing Valuation > 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 "Electroplating in the Details > Calculation > Manufacturing Valuation.

    Step 5: Select Machine and Times

    You can select the desired machine in the group Details > Calculation > Manufacturing Valuation > Machine. The selection list only contains machines that fit to the manufacturing method "Coating".

    Select Machine and Define Times for Electroplating

    1. In the group Details > Calculation > Manufacturing Valuation > Machine, select one of the available machines in the Machine Selection, e.g. "Nickel-plate Fa Blasberg Automatic plant Electroless Nickel, 250 kg/h".

    2. In the group Cleaning/Degreasing, enter the value "56.00 s/cycle" for the property Primary Processing Time (Cleaning).

    3. In the groups Machine and Cleaning/Degreasing, enter the value "85.00 s/cycle" for each property Loading/Unloading Time.

    Based on the defined details, the Cycle Time is calculated.

    Step 6: Define Fixtures

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

    Define Details for Fixtures for Electroplating

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

    Step 7: Complete Structure

    If all previous steps have been completed and the data entered are correct, the final bill of materials (BOM) structure of the "Electroplating" 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
      • fixtures

    Calculated values of the Electroplating cost model:

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

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

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

    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.

    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.

    Electrochemical Equivalent

    Equivalent value to indicate how much or how strong the material is deposited during electroplating.

    Indirect input is possible using F12.

    Depends on: Material Classification

    Current Density

    Enter the electrical current per area that is set for the coating of the part.

    Indirect input is possible using F12.

    Depends on: Material Classification

    Total Material Weight

    Display of the total weight of the material used for electroplating.

    Is calculated from:

    • Plating Surface Area per Part ("Part" group)
    • Plating Thickness ("Part" group)
    • Number of Parts ("Part" group)

    Depends on:

    • Density

    Part group

    The properties of the part to be electroplated that are used for calculating the cost model are shown in this group.

    Plating Surface Area per Part

    Enter the area that is electroplated per part.

    This value is required.

    Direct input is possible.

    Plating Thickness

    Enter the thickness of the layer to be electroplated.

    This value is required.

    Direct input is possible.

    Material Usage Weight

    Displays the material weight per electroplated part.

    Is calculated from:

    • Total Material Weight ("Material" group)

    Number of Parts

    Enter how many parts (covered by a jig or barrel) are electroplated. Initially, the value "1" is set.

    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 Selection

    Select a machine. A suitable selection list of machines is offered based on the previously set manufacturing method in the Details > General Properties view.

    This value is required.

    Selection from list directly possible.

    Galvanic Efficiency

    Efficiency of galvanic electrolytes. The value is taken from the master data and has direct impact on the Electroplating Time.

    Indirect input is possible using F12.

    Depends on: Material Classification

    Loading/Unloading Time

    Enter the time required to load and unload the machine for the electroplating process.

    Direct input is possible.

    Total Plating Surface Area

    Total surface that is electroplated.

    Is calculated from:

    • Plating Surface Area per Part
    • Number of Parts

    Electroplating Time

    Displays the total time required for electroplating.

    Is calculated from:

    • Electrochemical Equivalent
    • Current Density
    • Plating Thickness
    • Loading/Unloading Time ("Machine" group)

    Depends on:

    • Material Classification
    • Galvanic Efficiency

    Cleaning/Degreasing group

    The times required to clean the electroplating machine are displayed in this group.

    Primary Processing Time (Cleaning)

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

    Direct input is possible.

    Loading/Unloading Time

    Enter the time required to load and unload the machine for the cleaning process.

    Direct input is possible.

    Total Cleaning Time

    Displays the total time required for cleaning and degreasing the electroplating machine.

    Is calculated from:

    • Primary Processing Time (Cleaning)
    • Loading/Unloading Time (Cleaning/Degreasing)

    Fixtures group

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

    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.