Cost Model - Extrusion

You can use the Extrusion cost model to calculate the process times and costs for the extrusion manufacturing process in metalworking. In FACTON, there are value rule tables, and at the cost model there are formulas defined that offer you information on:

  • The anticipated cycle time,
  • the possible process output per time and cycle,
  • the material consumption,
  • the press force and stroke frequency of the machine and
  • primary and secondary processing times.

In the cost model Extrusion a distinction is made between direct extrusion and indirect extrusion.

Note

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

Procedure

The following example illustrates the process and structure of the Extrusion cost model.

Tip

The black triangle helps you identify values that you can enter .

The Consistency Rule Violation check is available to you when entering values. The consistency rule violations check notifies you of 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

Create Calculation

  • You are logged in as Calculator.
  • You are in the Calculations workspace.
  1. In the ribbon, click on Manage.
  2. Select the Should Cost Calculation .

    The created calculation opens in a new tab.

    You are the owner of the calculation that was created.

  3. Define the following properties for the Should Cost Calculation in the Details view:
    4. Reference Company*
    Industrial Sector Manufacture of fabricated metal products, except machinery and equipment
    Production Location World » Europe » Germany
    Reference Company Revenue 100m EUR
    Reference Company Material Share 50%
    Reference Company Degree of Automation Medium
    Production Planning
    Production Quantity 100,000 pc / a
    Target Profit Rates
    Target Profit Rate on Raw Material 2 %
    Target Profit Rate on Purchased Material 2 %
    Target Profit Rate on Manufacturing 2 %

    * Values are determined for the following properties using value rules based on your inputs under reference companies:

    • Material Overhead Rate
    • Manufacturing Overhead Rate
    • Administrative Overhead Rate
    • Sales Overhead Rate
    • Development Overhead Rate
    • Logistics Overhead Rate

Step 2: Insert Process

Insert Process

  1. In the Structure view, select the calculation element you wish to insert under the process.
  2. Click Edit ► Insert ► Process in the ribbon.

    A process is inserted in the calculation structure.

  3. Change the label to »Extrusion«.
  4. Define the following properties for the process in the Details view:
    5. Technical Descriptions
    Material Classification* Basic Materials » Metal » Nonferrous Metal » Light Metal » Aluminum
    Manufacturing Method* Shaping » Pressure Forming » Thrusting » Cold Extrusion
    * FACTON recommends the appropriate materials and machines in the queries for the processes by allowing you to select the material classification and manufacturing process.
  5. In the Details ► General ► Valuation view, select the valuation Cost Model: Extrusion.

    A new Cost Model group appears with subgroups.

Note

When changing valuations the sub-elements are greyed-out and no longer considered in the calculation.

For more information on the Extrusion cost model, see: Cost Model Properties

Step 3: Insert Material

Values must be entered at the material for the Density and the Material Classification properties for the calculation.

Note

Values are determined for the following properties using value rules by selecting the material classification:

  • Yield Stress Before Working
  • Yield Stress at 100% Reduction Ratio
  • Strain Hardening Exponent
  • Allowable Deformation

You can view the properties under Details ► General ► Cost Model ► Material.

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 »Extrusion« process in the Structure view.
  2. Click on Edit ► Insert ► Insert New Local Material (Mass) in the ribbon.

    A local material is inserted under the »Extrusion« process.

  3. Change the label to »Extrusion Material«.
  4. In the Details ► Technical Description view, enter a value for the Density (e.g. 7.85 kg/cm³).
  5. Under Details ► Technical Description ► Material Classification, select a material classification.
    Note

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

    • Alloyed Steel / Construction Steel / Chemical Resistant Steel
    • Steel with Special Physical Properties
    • Stainless Steel Unalloyed
    • Tool Steel
    • Quality Steel Alloyed
    • Quality Steel Unalloyed
    • Basic Steel
    • Aluminum
    • Copper

    6. The Material Classification Properties group appears under Technical Description.

  6. Define the following property in the Details view:
    General
    Price per Unit 0.50 EUR / kg
  7. Select the »Extrusion« process in the Structure view.
  8. Enter a value in the Details ► Cost Model ► Material ► Cross-Sectional Area of Blank view (e.g. 1.661 mm²).

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 »Extrusion«.
  2. Enter the following values for the part in the Details ► Cost Model ► Part view.

    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 process »Extrusion« under Details ► General ► Cost Model.

Step 5: Insert Work Steps

The Extrusion process requires a wide range of individual work steps in order to manufacture a part. To visualize complex extrusion parts in detail, they must be broken down into separate work steps.

With FACTON, you can define multiple work steps at the Extrusion cost model.

Insert Work Steps

  1. Select the »Extrusion« process in the Structure view.
  2. In the Details view, open the group Cost Model ► Work Steps.
  3. Click on the button next to the Value column in the Press Work Steps row.

    The Local List: Press Work Steps tab opens.

    For more information on the work step, see:Work Step Properties

  4. Right-click in the empty area of the tab ► New.

    A new row is added for you to define your work step.

  5. Change the label to »Pressing 1«

Work Step Properties

General Group

This group shows the general work step properties.

Properties Description Input
Possible		 Calculated
 Required
Name Work Step Name direct   x
Initial Cross-Section The cross-sectional area of the component before the impact extrusion step
Corresponds to the value for the Cross-Sectional Area of Blank		 with F12   x
Target Cross-Section Cross-sectional area of the worked part with F12   x
Actual Deformation

Actual drawing ratio of the extrusion surfaces before and after the extrusion work step
Depends on:

  • Initial Cross-Section
  • Target Cross-Section
   x  
Allowable Deformation The maximum allowable ratio of the cross-section to be deformed 'before' and 'after' the work step. with F12    
Min. Cross-Section

Indicates the minimum size of the cross-sectional area depending on the allowable change in shape
is calculated from:

  • Initial Cross-Section
  • Allowable Deformation
   x  
Theoretical Press Force

Calculated press force for this work step
is calculated from:

  • Tensile Strength
  • Material Thickness
  • Initial Cross-Section
   x  
% Additional Press Force Percentaged additional press force
Calculated when entering a value for the surcharge for press force.		 direct    
Additional Press Force Absolute additional press force
Calculated when entering a value for the percentaged additional press force		 direct    
Necessary Press Force

Necessary total press force for this work step
is calculated from:

  • Theoretical Press Force
  • Additional Press Force
   x  
Extrusion Deformation Efficiency Describes the loss of force during extrusion due to the friction on the press tool as well as the displacements within the material with F12    
Yield Stress at the End of the Working The yield stress of the material on reaching the actual reduction ratio   x  
Average Yield Stress Is the average value of the yield stress of the material 'before' and 'after' working   x  

Technical Description Group

The technical descriptions of the work step, such as name and description, are shown and managed in this group.

Step 6: Insert Machine

You can use the Relevant Press Force from the work steps to determine and insert the required machine.

To calculate the press time and time per stroke, 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 »Extrusion« process in the Structure view.
  2. Click on Edit ► Insert ► Insert New Local Machine in the ribbon.

    A machine is inserted under the »Extrusion« process.

  3. Change the label to »Extrusion Machine«.
  4. Under Details ► Technical Description ► Machine Type, select a machine type for the »Extrusion Machine«.
    Note

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

    • Transfer Press
    • C-Frame Press
    • 4-Column Press
    • Toggle Press

    The Machine Type Properties group appears under Technical Description.

  5. In the Details ► Technical Description view, enter a value for the following properties:
    • Press Force
    • Stroke Frequency
    • Number of Press Stations

    This entry is used to calculate the relevant stroke frequency.

  6. Define the following properties for the machine in the Details view:
    Acquisition Costs
    Acquisition Value 1,500,000 EUR
    Fixed Machine Costs
    Depreciation Period6 a

Calculated values of the Extrusion cost model:

The following values are calculated using the data entered and then shown in the Details ► General ► Cost Model view:

  • Cycle Time
  • Ʃ Measure Values Cycle Time
  • Cycles per Time
  • Output per Cycle
  • Output per Time
  • Time per Unit Output
  • Manufacturing Scrap Rate
  • Production Cost

Step 7: Insert Worker and Tool

Insert Worker

  1. In the Structure view, select the »Extrusion« process.
  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 »Extrusion«.
  2. Click Edit ► Insert ► Insert New Local Tool.

    The tool is inserted under the process.

Step 8: Additional Fine Tuning

You can continue fine tuning the settings in the Details ► General ► Cost Model view:

Group Properties
Work Steps
  • Additional Work Steps
  • Parallel Processing
Machine
  • Relative Stroke Frequency
  • Relevant Stroke Frequency
Secondary Processing Times
  • Loading Time
  • Unloading Time
  • Machine Loading Per Stroke
  • Machine Loading Per Stroke
  • Transfer Time between Strokes
  • Additional Secondary Processing Times
Primary Processing Times
  • Additional Primary Processing Times

Cost Model Properties

Material Group

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

Material Properties Description Input
Possible		 Calculated
 Required
Allowable Deformation

Tensile strength of the material


This value is required and can be managed at the material (Details View ► Technical Description), or is applied when global templates are inserted.		     x
Yield Stress Before Working

The yield stress of the material at reduction (extrusion) ratio 0%
Depends on:

  • Material Classification
     x
Yield Stress at 100% Reduction Ratio

Perimeter of the sheet metal blank
is calculated from:

  • Cross-Sectional Area of Blank
  • Deep Drawn Area
  • Perimeter of the Deep Drawn Area

The perimeter of the sheet metal blank is calculated based on a circular area. For other geometries value

     x
Strain Hardening Exponent Thickness of the material used
This value is required and can be managed at the material (Details View ► General ► Form Type & Geometry), or is applied when global templates are inserted.		     x
Cross-Sectional Area of Blank

Selection of the drawing behavior of the material

Choose between:

»Normal«
»Good«
»Very good«

 Direct   x
Density

Density of the material


This value is required and can be managed at the material (Details View ► Technical Description), or is applied when global templates are inserted.		     x
Blank Part Height Height of the material before working (initial height)      

Part Group

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

Part Properties Description Input
Possible		 Calculated
 Required
Part Weight Weight of the part
Is calculated when entering a value for the part volume		 Direct   x
Part Volume Volume of the part
Is calculated when entering a value for the part weight		 Direct   x
Smallest Worked Cross-Section The smallest cross-sectional area of the component that is to be produced in this process Direct   x
Extrusion Form Selection of the main characteristics of the part to be produced and the extrusion method Direct   x
Image of extrusion form Shows a sample image of the selected extrusion form/mold      

Work Steps Group

The work step properties in the extrusion process used to calculate the cost model are shown in this group.

Work Step Properties Description Input
Possible		 Calculated
 Required
Extrusion Method

Displays the extrusion method

 Direct    
Press Work Steps Displays the work steps of the extrusion process
the button opens the Local List: Press Work Steps tab, where you can manage the work steps.		     x
Used Press Work Steps Displays the number of used press work steps      
Necessary Annealing Processes Displays the number of annealing processes required during working      
Additional Work Steps The number of additional work steps, e.g. for the calibration or the control of the part Direct    
Total Number of Required Work Steps Displays the total number of work steps in this process      
Parallel Processing Displays, whether all work steps are carried out at the same time (e.g.: with a transfer tool / transfer machine) with F12    
Number of Strokes The number of strokes for production of all parts inside the die   x  
Relevant Press Force Displays the relevant press force incl. all surcharges   x  

Machine Group

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

Machine Properties Description Input
Possible		 Calculated
 Required
Machine Type Assignment of a machine to a specific group with the corresponding properties
This value is required in order to manage additional machine type properties. It can be managed at the machine (Details view ► Technical Description), or is applied when master data is inserted.		     x
Press Force of the Machine Displays the maximum press force of the machine
This value is required and can be managed at the machine (Details View ► Technical Description ► Machine Type Properties), or is applied when master data is inserted.		     x
Stroke Frequency of the Machine Displays the maximum stroke frequency of the machine
This value is required and can be managed at the machine (Details View ► Technical Description ► Machine Type Properties), or is applied when master data is inserted.		     x
Relative Stroke Frequency Share of the stroke frequency that is actually used Direct    
Relevant Stroke Frequency

Stroke frequency that is actually used
is calculated from:

  • Stroke Frequency of the Machine
  • Relative Stroke Frequency
 with F12   x
Number of Press Stations

Display the number of press stations

   x  
Time per Stroke

Time required for a machine stroke
is calculated from:

  • Relevant Stroke Frequency
   x  

Secondary Processing Times Group

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

Secondary Processing Times Description Input
Possible		 Calculated
 Required
Loading Time Time for loading the machine with a part Direct    
Unloading Time Time for unloading the machine with a part Direct    
Machine Loading Per Stroke Time to load the machine per stroke Direct    
Machine Unloading per Stroke Time to unload the machine per stroke Direct    
Transfer Time between Strokes Additional time between strokes Direct    
Additional Secondary Processing Times Chance to add secondary processing times that have not been considered yet Direct    
Secondary Processing Time Necessary idle times of a process in which the actual activity of a process are not performed
is calculated from:
  • Loading Time
  • Unloading Time
  • Additional Secondary Processing Times
  • Number of Strokes
  • Transfer Time between Strokes
   x  

Primary Processing Times Group

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

Primary Processing Times Description Input
Possible		 Calculated
 Required
Press Time

Time to press all strokes
is calculated from:

  • Number of Strokes
  • Time per Stroke
   x  
Additional Primary Processing Times Possibility to add primary processing times that have not been considered Direct    
Primary Processing Time Time in which the actual activity of a process is performed
is calculated from:
  • Press Time
  • Additional Primary Processing Times
   x