Calculate Hardening and Tempering
You can use the Calculate Hardening and Calculate Tempering cost models to calculate the process times and costs for the annealing 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 required thermal energy, and
- the primary and secondary processing times.
You need knowledge of the
Sequence
The following example illustrates the process and structure of the
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 for Hardening
Insert Process 
- In the Structure view, select the project element you wish to insert under the process.
- In the ribbon, click on Edit > Insert > Process.
A process is inserted in the calculation structure.
- Change the label to "
- Define the following properties for the process in the Details > General Properties
view scheme view: -
In the Details (Calculation view scheme
), select the
| Material Classification* | |
| Manufacturing Method* | |
| *FACTON recommends the matching materials and machines in the queries for the processes by allowing you to select the material classification and manufacturing method. | |
Step 3: Insert Material for Hardening
In order to use FACTON Benchmark data for the calculation, the Material Classification must be set at the material.
You can insert
The latter is shown in the following, because it illustrates the inputs required for calculation.
Insert Local Material
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In the Structure view, select "Hardening" process.
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In the ribbon, click on Edit > Insert >
Insert New Local Material (Mass).A local material is inserted under the "Hardening" process.
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Change the label to "Hardening Material.
- Under Details >Technical Data view scheme, select
- Steel
- Cast Iron
- Specific Heat Capacity
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In the Details > Overview view scheme (combobox) of the
Calculation Density Net Quantity Price per Unit 
Technical Data Carbon Content 0.60 %
You can use the following
Values are determined at the process in the Manufacturing Valuation > Material group for the following property according to the material classification:
Step 4: Describe Part for Hardening
The part properties are required in order to determine the cycle time.
Describe
- In the Structure view, select the process "
- Enter the following values for the part in the Details > Calculation > Manufacturing Valuation
These values are required in order to calculate additional values:
Based on these inputs, additional values are calculated and shown at the process "
Step 5: Insert Relevant Cooling Rate or Cooling Time
Values for either the relevant cooling rate or for the cooling time are required in order to determine the cycle time.
Insert Relevant Cooling Rate or Cooling Time
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In the Structure view, select "Hardening" process. Either:
- define a value for the Relevant Cooling Rate (e. g. 100,000.00 K / h) in the Details > Manufacturing Valuation > Temperature & Rates,or
- define a value for the Cooling Time (e. g. 26.28 s / cycle) in the Details > Manufacturing Valuation > Primary Processing Times.
or
Step 6: Insert Machine for Hardening
For calculating the properties Number of Parts, Max. Heating Rate etc. values must be entered and maintained at the machine for the properties Machine Type, Power Rating and Furnace Capacity.
You can insert
The latter is shown in the following, because it illustrates the inputs required for calculation.
Insert Local Machine
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In the Structure view, select "Hardening" process.
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In the ribbon, click on Edit > Insert >
Insert New Local Machine.A machine is inserted under the "Hardening" process.
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Change the label to "Hardening Furnace".
- Under Details >Technical Data view scheme, select
- Hardening Furnace
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In the Details > Overview view scheme (combobox) of the
Calculation > Investment Purchase Value Calculation > Fixed Machine Cost Depreciation Period 6 a Technical Data Power Rating 70,000.00 W Furnace Capacity 665.00 l
You can use the following
Calculated values of the Hardening cost model:
The following values are calculated using the data entered and then shown in the Details > Calculation view scheme:
- Cycle Time
- Output per Cycle
- Output per Time
- Time per Unit Output
- Absolute Frequency of Occurrence
- Percentaged Frequency of Occurrence
Step 7: Insert Process for Tempering
Insert Process
- In the Structure view, select the project element you wish to insert under the process.
- In the ribbon, click on Edit > Insert > Process.
A process is inserted in the calculation structure.
- Change the label to "
- Define the following properties for the process in the Details > General Properties view scheme view:
-
In the Details (Calculation view scheme
), select the
| Material Classification* | |
| Manufacturing Method* | |
| *FACTON recommends the matching materials and machines in the queries for the processes by allowing you to select the material classification and manufacturing method. | |
Step 8: Describe Part for Tempering
The part properties are required in order to determine the cycle time.
Describe
- In the Structure view, select the process "
- Enter the following values for the part in the Details > Calculation > Manufacturing Valuation
These values are required in order to calculate additional values:
Based on these inputs, additional values are calculated and shown at the process "
Step 9: Select Tempering Stage
The tempering stage is required in order to determine the cycle time.
Select Tempering Stage
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In the Structure view, select the "Tempering" process.
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In the Details > Calculation > Manufacturing Valuation > Temperature and Rates, select a tempering stage (e. g. Tempering Stage 2).
Step 10: Use Same Machine
For calculating the properties Number of Parts, Max. Heating Rate etc. values must be entered and maintained at the machine for the properties Machine Type, Power Rating and Furnace Capacity.
Please use the same machine (instance) from the "Hardening" process.
Using the same Machine
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In the Structure view, select the "Hardening Furnace" machine.
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Right-click and Copy it.
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In the Structure view, select the "Tempering" process.
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Right-click and Paste it.
The identical machine is inserted under the "Tempering" process.
Calculated values of the Tempering cost model:
The following values are calculated using the data entered and then shown in the Details > Calculation view scheme:
- Cycle Time
- Output per Cycle
- Output per Time
- Time per Unit Output
- Absolute Frequency of Occurrence
- Percentaged Frequency of Occurrence
Step 11: Insert Worker and Tool
Insert worker
- In the Structure view, select the process "
- 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
- In the Structure view, select the process "
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Click on Edit > Insert >
Insert New Local Tool.The tool is inserted under the process.
Properties of the Hardening cost model (Calculation > Manufacturing Valuation)
Material Group
The material properties used to calculate the cost model are shown in this group.
Specific Heat Capacity
Specific heat capacity that is required for a particular material per area.
Depends on: Material Classification
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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.
Carbon Content
Amount of carbon content 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.
Part Group
The part properties used to calculate the cost model are shown in this group.
Max. Wall Thickness
Maximum wall thickness of the part.
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Part Weight
Weight of the part.
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Number of Parts
Number of parts.
Is calculated from:
- Density
- Part Weight
- Furnace Capacity
Indirect input is possible using F12.
Total Part Weights
Total weight of parts.
Is calculated from:
- Part Weight
- Number of Parts
Total Volume of Parts
Total volume of parts.
Is calculated from:
- Density
- Total Part Weights
Temperature and Rates Group
The data for temperature and speed properties used to calculate this cost model are shown in this group.
Initial Temperature
The temperature of the parts before heating. Is initially room temperature (25 °C).
Direct input is possible.
This property is a default value which is automatically set. You can change it by directly entering another value.
If you delete the input, the value is being reset to the default.
Heating Temperature
Temperature to which the part is heated up to. Is within temperature range.
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Heating Temperature Difference
The difference between initial and target temperature when heating the parts.
Is calculated from:
- Heating Temperature
- Initial Temperature
Required Thermal Energy
The energy required to heat the parts.
Is calculated from:
- Specific Heat Capacity
- Total Part Weights
- Heating Temperature Difference
Cooling Temperature
The temperature of the parts to be achieved during cooling. Is initially room temperature.
Direct input is possible.
This property is a default value which is automatically set. You can change it by directly entering another value.
If you delete the input, the value is being reset to the default.
Cooling Temperature Difference
The difference between initial and target temperature when cooling the parts.
Is calculated from:
- Heating Temperature
- Cooling Temperature
Max. Heating Rate
Maximum heating rate of the furnace.
Is calculated from:
- Heating Temperature Difference
- Required Thermal Energy
- Power Rating
Relevant Heating Rate
The heating rate used for further calculation.
Is calculated from:
- Heating Temperature
- Cooling Temperature
Indirect input is possible using F12.
This property is a default value which is automatically set. You can change it by directly entering another value.
If you delete the input, the value is being reset to the default.
Relevant Cooling Rate
The cooling rate used for further calculation. Depends on: Maximum Wall Thickness
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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 scheme), or is applied when global templates are inserted.
Power Rating
Maximum available power of the furnace.
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.
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.
Is calculated from:
- 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.
Heating Time
Is calculated from:
- Heating Temperature Difference
- Relevant Heating Rate
Indirect input is possible using F12.
Holding Time
Depends on: Maximum Wall Thickness
Indirect input is possible using F12.
Cooling Time
Is calculated from:
- Cooling Temperature Difference
- Relevant Cooling Rate
Additional Primary Processing Times
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:
- Heating Time
- Holding Time
- Cooling Time
- Additional Primary Processing Time
Properties of the Cost Model - Tempering
Material Group
The material properties used to calculate this cost model are taken from the "Hardening" process and are also used for further calculation.
Part Group
The part properties used to calculate the cost model are shown in this group.
Max. Wall Thickness
Maximum wall thickness of the part.
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Part Weight
Weight of the part.
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Number of Parts
Number of parts.
Is calculated from:
- Density
- Part Weight
- Furnace Capacity
Indirect input is possible using F12.
Total Part Weights
Total weight of parts.
Is calculated from:
- Part Weight
- Number of Parts
Total Volume of Parts
Total volume of parts.
Is calculated from:
- Density
- Total Part Weights
Temperature and Rates Group
The data for temperature and speed properties used to calculate this cost model are shown in this group.
Tempering Stage
Selection from four tempering stages. The heating temperature is determined depending on the selected tempering stage.
You can define the heating temperature of the tempering stages via value rules (Master Data > Global Properties > Cost Model: Tempering > Heating Temperature).
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Initial Temperature
The temperature of the parts before heating. Is initially room temperature (25 °C).
Direct input is possible.
This property is a default value which is automatically set. You can change it by directly entering another value.
If you delete the input, the value is being reset to the default.
Heating Temperature
Temperature to which the part is heated up to. Selecting the "Tempering Stage" determines the heating temperature via vale rules.
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Heating Temperature Difference
The difference between initial and target temperature when heating the parts.
Is calculated from:
- Heating Temperature
- Initial Temperature
Required Thermal Energy
The energy required to heat the parts.
Is calculated from:
- Specific Heat Capacity
- Total Part Weights
- Heating Temperature Difference
Cooling Temperature
The temperature of the parts to be achieved during cooling. Is initially room temperature.
Direct input is possible.
This property is a default value which is automatically set. You can change it by directly entering another value.
If you delete the input, the value is being reset to the default.
Cooling Temperature Difference
The difference between initial and target temperature when cooling the parts.
Is calculated from:
- Heating Temperature
- Cooling Temperature
Max. Heating Rate
Maximum heating rate of the furnace.
Is calculated from:
- Heating Temperature Difference
- Required Thermal Energy
- Power Rating
Relevant Heating Rate
The heating rate used for further calculation.
Is calculated from:
- Heating Temperature
- Cooling Temperature
This property is a default value which is automatically set. You can change it by directly entering another value.
If you delete the input, the value is being reset to the default.
Relevant Cooling Rate
The cooling rate used for further calculation. Depends on: Maximum Wall Thickness
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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 scheme), or is applied when global templates are inserted.
Power Rating
Maximum available power of the furnace.
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.
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.
Is calculated from:
- 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.
Heating Time
Is calculated from:
- Heating Temperature Difference
- Relevant Heating Rate
Indirect input is possible using F12.
Holding Time
Depends on: Maximum Wall Thickness
Indirect input is possible using F12.
Cooling Time
Is calculated from:
- Cooling Temperature Difference
- Relevant Cooling Rate
This value is required.
Additional Primary Processing Times
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:
- Heating Time
- Holding Time
- Cooling Time
- Additional Primary Processing Times