Cost Model - Die Casting

You can use the Die Casting cost model to calculate the process times and costs for the die casting 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 clamping force and the machine shot mass and
  • primary and secondary processing times.

In the cost model Die Casting, a distinction is made between hot and cold chamber processes.

The table shows typical application scenarios of the cost model for parts and industries:

Typical Parts Typical Industries
  • Toys
  • Casings, Covers
  • Furnishings
  • Machine Parts
  • Automotive Sector/Aerospace Sector
  • Electrical Industry
  • Consumer Goods
  • Mechanical Engineering
Note

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

Procedure

The following example illustrates the process and structure of the Die Casting 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 Should Cost 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 »Die Casting«.
  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* Primary Shaping » Casting » Die Casting
    * 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: Die Casting.

    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 Die Casting cost model, see: Properties of the Cost Model - Die Casting

Step 3: Insert Material

Values must be entered at the material for the Density and the Material Classification properties in order to calculate the primary processing times.

Note

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

  • Specific Die Casting Pressure
  • Thermal Conductivity
  • Specific Heat Capacity

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

    A local material is inserted under the »Die Casting« process.

  3. Change the label to »Die Casting Material«.
  4. In the Details ► Technical Description view, enter a value for the Density (e.g. 2.7 g/cm³).
  5. Under Details ► Technical Description ► Material Classification, select a material classification.
    Note

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

    • Aluminum
    • Zinc
    • Tin
    • Magnesium Alloy

    The Material Classification Properties group appears under Technical Description.

  6. Define the following property in the Details view:
    General
    Price per Unit 1.75 EUR / kg

Values are determined at the process in the Cost Model ► Material group for the following properties using value rules based on the material classification:

  • Specific Die Casting Pressure
  • Thermal Conductivity
  • Specific Heat Capacity

Step 4: Describe Part

The part properties are required to determine the cycle time.

Describe Part

  1. In the Structure view, select the process »Die Casting«.
  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 »Die Casting« under Details ► General ► Cost Model.

Part Property Group Calculated Value
Gating System Volume Material
  • Material Usage Weight
  • Material Usage Volume
  • Recyclable Material
Part Volume Part Part Weight
Projected Area of Part Projected Area of Gating System
Projected Area of Part Clamping Force
  • Clamping Force by Projected Area of Part
  • Required Clamping Force for Part
  • Clamping Force by Projected Area of Gating System
  • Required Total Clamping Force
Wall Thickness Primary Processing Times
  • Cooling Time
  • Fill Time

Step 5: Insert Machine

You can use the calculated Required Total Clamping Force and the Material Usage Weight to determine and insert the required machine. The required total clamping force is the minimum amount of force a machine must supply in order to manufacture the described part.

To calculate the number of cavities, values must be entered at the machine for the Machine Type, Available Clamping Force and Machine Shot Mass 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 »Die Casting« process in the Structure view.
  2. Click on Edit ► Insert ► Insert New Local Machine in the ribbon.

    A machine is inserted under the »Die Casting« process.

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

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

    • Cold-Chamber Die Casting Machine
    • Hot-Chamber Die Casting Machine

    The Machine Type Properties group appears under Technical Description.

  5. In the Details ► Technical Description view, enter a value for the following properties:
    • Available Clamping Force
    • Machine Shot Mass
    6. Note

    Sufficient clamping force for the machine is determined by the sum of the Required Clamping Force for Part and Clamping Force by Projected Area of Gating System.

  6. Define the following properties for the machine in the Details view:
    Acquisition Costs
    Acquisition Value 200,000 EUR
    Fixed Machine Costs
    Depreciation Period6 a

Calculated values of the Die Casting 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 6: Insert Worker and Tool

Insert Worker

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

    The tool is inserted under the process.

Step 7: Additional Fine Tuning

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

Group Properties
Material
  • Specific Die Casting Pressure
  • Thermal Conductivity
  • Specific Heat Capacity
  • % Additional Value for Material Loss
  • Tensile Strength
Clamping Force
  • Additional Clamping Force for Safety (Percentage or Absolute)
  • Additional Clamping Force for Sliders (Percentage or Absolute)
Secondary Processing Times
  • Insert and Demolding Time
  • Sliders Count
  • Greasing Time
  • Additional Secondary Processing Times
Primary Processing Times
  • Tool Open Close Time
  • Ladle Time
  • Fill Time
  • Additional Primary Processing Times

Properties of the Cost Model - Die Casting

Material Group

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

Material Properties Description Input
Possible		 Calculated
 Required
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
Specific Die Casting Pressure

Specific die casting pressure required per area for a given material
Depends on:

  • Material Classification
 with F12    
Thermal Conductivity

Thermal conductivity of the material
Depends on:

  • Material Classification
 with F12    
Specific Heat Capacity

Specific heat capacity of the material
Depends on:

  • Material Classification
 with F12    
% Additional Value for Material Loss Percentaged additional value on Material Usage Weight for Material Loss which gets lost during the process and cannot be recycled. direct    
Material Usage Weight

Required material weight incl. gating system weight

is calculated from:

  • Density
  • Material Usage Volume
   x  
Material Usage Volume

Required material volume incl. gating system volume
is calculated from:

  • Part Volume
  • Cavity Count
  • Gating System Volume
   x  
Recyclable Material

Material mass of the gating system which can be recycled
is calculated from:

  • Density
  • Gating System Volume
   x  
Material Loss

Process-related and non-recyclable material loss
is calculated from:

  • Material Usage Weight
  • % Additional Value for Material Loss
   x  

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    
Part Volume Volume of the part
Is calculated when entering a value for the part weight		 direct   x
Gating System Volume Volume of the gating system direct   x
Projected Area of Part The area of the part projected in the mold parting surface direct   x
Projected Area of Gating System The area of the gating system projected in the mold parting surface
Is calculated when entering a value for the projected area of the part
is calculated from:
  • Ratio of area to volume (cm²/cm³)
  • Gating System Volume
 with F12    
Wall Thickness Average wall thickness of the part direct   x
Part Surface Surface of the part direct   x
Surface of all Cavities Surface of all cavities in the tool direct    

Clamping Force Group

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

Clamping Force Properties Description Input
Possible		 Calculated
 Required
Clamping Force by Projected Area of Part Clamping force by projected area of part in the mold parting surface
is calculated from:
  • Specific Die Casting Pressure
  • Projected Area of Part
   x  
% Additional Clamping Force for Safety Percentaged additional clamping force for safety ratio by projected area
Is calculated when entering a value for the additional clamping force for safety		 direct    
Additional Clamping Force for Safety Absolute additional clamping force for safety ratio by projected area
Is calculated when entering a value for the % additional clamping force for safety		 direct    
% Additional Clamping Force for Sliders Percentaged additional clamping force for sliders by projected area
Is calculated when entering a value for the additional clamping force for sliders		 direct    
Additional Clamping Force for Sliders Ratio Absolute additional clamping force for sliders by projected area
Is calculated when entering a value for the additional clamping force for sliders		 direct    
Required Clamping Force for Part

Required clamping force for the part with additional clamping forces
Calculated taking:

  • Clamping Force by Projected Area of Part
  • Additional Clamping Force for Safety
  • Additional Clamping Force for Sliders Ratio
   x  
Clamping Force by Projected Area of Gating System

Clamping force by projected area of the gating system in the mold parting surface
Calculated taking:

  • Specific Die Casting Pressure
  • Projected Area of Gating System
   x  
Required Total Clamping Force

Required total clamping force for all cavities and the gating system
is calculated from:

  • Required Clamping Force for Part
  • Cavity Count
  • Clamping Force by Projected Area of Gating System
   x  

Machine Group

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

Machine Properties Description Input
Possible		 Calculated
 Required
Clamping Force of the Machine

Maximum clamping force of the machine that is available


This value is required and can be managed at the machine (Details View ► Technical Description ► Machine Type Properties), or is applied when global templates are inserted.		     x
Machine Shot Mass

Maximum shot mass of the machine that is available


This value is required and can be managed at the machine (Details View ► Technical Description ► Machine Type Properties), or is applied when global templates are inserted.		     x
Hot Chamber Displays the hot chamber method      
Possible Cavity Count
by Clamping Force

The possible count of cavities determined with respect to the available clamping force
is calculated from:

  • Clamping Force of the Machine
  • Clamping Force by Projected Area of Gating System
  • Required Clamping Force for Part
   x  
Possible Cavity Count
by Shot Mass

The possible count of cavities determined with respect to the available shot mass
is calculated from:

  • Density
  • % Additional Value for Material Loss
  • Part Volume
  • Gating System Volume
  • Machine Shot Mass
   x  
Cavity Count Number of cavities
is calculated from:
  • Possible Cavity Count by Clamping Force
  • Possible Cavity Count by Shot Mass
 with F12    

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
Insert and Demolding Time Time for inserting and demolding the part direct    
Sliders Count Number of sliders of the tool direct    
Greasing Time Time for greasing all cavities of the tool
Depends on:
  • Greasing Surface
 with F12    
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:
  • Insert and Demolding Time
  • Greasing Time
  • Additional Secondary Processing Times
   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
Cooling Time Time for cooling down the part for removal and further usage
is calculated from:
  • Wall Thickness
  • Part Volume
  • Projected Area of Part
   x  
Tool Open Close Time

Time for opening and closing the tool
Depends on:

  • Machine Size (Available Clamping Force)
 with F12    
Ladle Time Time to ladle the material
Depends on:
  • Machine Shot Mass
 with F12    
Fill Time

Time to fill the tool
Depends on:

  • Wall Thickness
 with F12    
Additional Primary Processing Times Chance to add primary processing times that have not been considered yet direct    
Primary Processing Time

Time in which the actual activity of a process is performed
is calculated from:

  • Cooling Time
  • Tool Open Close Time
  • Ladle Time
  • Fill Time
  • Additional Primary Processing Times
   x