Design Cutter Path Hours Calculation

Design Cutter Path Hours = CNC Programming Hours Core and Cavity Plates + CNC Programming Hours Inserts

CNC Programming Hours Core and Cavity Plates: This is calculated as (CNC Machining Hours * Cutter Path Complexity Factor * Mold Closure Complexity):
- CNC Machining Hours: This is the time for CNC machining. It is calculated as CNC Machining Hours Core and Cavity + CNC Machining Hours Rib Inserts:
  - CNC Machining Hours Core and Cavity: This is calculated as (Cavity Core Roughing CNC Hours + Part Cavity CNC Finishing Hours + Flash Channel CNC Finishing Hours + Rib Machining CNC Hours) * Mold Machinability Index:
    - CNC - Cavity Core Roughing CNC Hours: This is the cavity and core CNC rough machining time. This is calculated as: (Cavity Plate Material Removed + Core Plate Material Removed) / Cavity Core Plate Roughing Rate + (Cavity CNC Setup + Core CNC Setup):
      - Cavity Plate Material Removed: This depends on the shape of the part:
        If the part is cup-shaped, this is calculated as (Parting Line Projected Area * Part Height) + Part Volume). The Parting Line Projected Area, Part Height and Part Volume properties are visible in the Geometric Cost Drivers panel.
        Otherwise, this is calculated as: Part Volume / 2.
      - Core Plate Material Removed: This depends on the shape of the part:
        If the part is cup-shaped, this is calculated as (((Mold Base Area – Parting Line Projected Area) * Part Height) + Part Volume). Mold Base Area is the product of the setup options Mold Base Size – Length and Mold Base Size – Width. The Parting Line Projected Area, Part Height, and Part Volume properties are visible in the Geometric Cost Drivers panel.
        Otherwise, this is calculated as: Part Volume / 2.
      - Cavity Core Plate Roughing Rate: aPriori performs a lookup in the cmToolMachiningRates table and returns the Rate corresponding to Cavity Core Plate Roughing.
      - Cavity CNC Setup: aPriori performs a lookup in the cmToolMachiningSetups table and returns the value of (Number of Setups * Setup Time) corresponding to Cavity Plate CNC.
      - Core CNC Setup: aPriori performs a lookup in the cmToolMachiningSetups table and returns the value of (Number of Setups * Setup Time) corresponding to Core Plate CNC.
    - CNC - Part Cavity CNC Finishing Hours: This is the cavity and core CNC finishing time. This is calculated based on the Number of Surfaces geometric property of the part:
      - If Number of Surfaces is less than or equal to the cmMoldSurfaceCountThresholdSimple cost model variable (500 in starting point Digital Factories), this is calculated as (part Surface Area * the Hrs Per Sq Meter value in the finishingHrsPerSqMeter lookup table that corresponds to a Complexity value of Simple and a Surface Area less than or equal to the part’s Surface Area).
      - If Number of Surfaces is less than or equal to the cmMoldSurfaceCountThresholdAverage cost model variable (2500 in starting point Digital Factories), this is calculated as (part’s Surface Area * the Hrs Per Sq Meter value in the finishingHrsPerSqMeter lookup table that corresponds to a Complexity value of Average and a Surface Area less than or equal to the part’s Surface Area).
      - Otherwise, this is calculated as (part’s Surface Area * the Hrs Per Sq Meter value in the finishingHrsPerSqMeter lookup table that corresponds to a Complexity value of Complex and a Surface Area less than or equal to the part’s Surface Area).
    - CNC - Flash Channel CNC Finishing Hours: This is the time for cavity side CNC finishing of the flash channel. This is calculated based on the Parting Line Parting Type geometric property:
      - If Parting Type is FLAT, this is calculated as ((Flash Channel Area * Hrs Per Sq Meter Average) * Mold Closure Complexity):
        Flash Channel Area: This is based on the Mold Closure Type being used:
        Flash type: This is calculated as Flash Ridge Area + Flash Cavity Area. See Flash Ridge and Cavity Area Calculations.
        Semi-Positive type: This is calculated as Flash Ridge Area, see Flash Ridge Area Calculation.
        Otherwise, a value of 0 is used.
        Hrs Per Sq Meter Average: This is calculated as (part’s Surface Area * the Hrs Per Sq Meter value in the finishingHrsPerSqMeter lookup table that corresponds to a Complexity value of Average and a Surface Area less than or equal to the part’s Surface Area).
        Mold Closure Complexity: This is a complexity factor applied to mold base considerations based on the Mold Closure Type being used. See Mold Closure Complexity Calculation.
      - Otherwise, this is calculated in the same way as described above with the exception that Hrs Per Sq Meter Complex replaces the Hrs Per Sq Meter Average calculation. Hrs Per Sq Meter Complex is calculated as (part’s Surface Area * the Hrs Per Sq Meter value in the finishingHrsPerSqMeter lookup table that corresponds to a Complexity value of Complex and a Surface Area less than or equal to the part’s Surface Area).
    - CNC - Rib Machining CNC Hours: This is the rib feature machining time. It is calculated as (Total Rib Volume / Rib Machining CNC Rate):
      - Total Rib Volume: aPriori sums the values of the geometric property Volume for all machining artifacts of type Rib. Only ribs with a height greater than or equal to the machinedRibThreshold cost model variable are machined (20 mm in starting point Digital Factories).
      - Rib Machining CNC Rate: aPriori performs a lookup in the cmToolMachiningRates table and returns the Rate corresponding to Rib CNC Machining.
    - Mold Machinability Index: This is the Machinability Index of the material specified by the Select Mold Material – Main Plates setup option. This property is visible in the Digital Factory tool shop under Plastic Molding > Processes > Compression Molding > Tool Shops > Default.
  - CNC Machining Hours Rib Inserts: This is calculated as Insert CNC Hours * Insert Machinability Index:
    - Insert CNC Hours: This is calculated as (Total Rib Insert Volume / Insert Machining Rate) + (Insert Setup * Total Number of Rib Inserts):
      - Total Rib Insert Volume: See Total Rib Insert Volume Calculation.
      - Insert Machining Rate: aPriori performs a lookup in the cmToolMachiningRates table and returns the Rate corresponding to Rib CNC Machining.
      - Insert Setup: aPriori performs a lookup in the cmToolMachiningSetups table and returns the value of (Number of Setups * Setup Time) corresponding to Tool Insert Machining.
      - Total Number of Rib Inserts: This is the sum of the Number of Small Rib Inserts, Number of Medium Rib Inserts, and Number of Large Rib Inserts setup options.
    - Insert Machinability Index: This is the Machinability Index of the material specified by the Select Mold Material – Rib Inserts setup option. This property is visible in the Digital Factory tool shop under Plastic Molding > Processes > Compression Molding > Tool Shops > Default.
- Cutter Path Complexity Factor: This is a complexity factor applied to the base mold tool CNC time to increase this according to the complexity of the mold.
  - If the Parting Line Parting Type property is FLAT, this is specified by the cmCutterPathComplexityFactorSimple cost model variable (0.1 in starting point Digital Factories).
  - If the Parting Line Parting Type property is NON_FLAT, this is specified by the cmCutterPathComplexityFactorComplex cost model variable (0.18 in starting point Digital Factories).
- Mold Closure Complexity: This is a complexity factor applied to mold base considerations based on the Mold Closure Type being used. See Mold Closure Complexity Calculation.
CNC Programming Hours Inserts: This is the time for insert cutter path design. It is calculated as Cutter Path Hours Per Insert * Total Number of Rib Inserts:
- Cutter Path Hours Per Insert: This is the CNC cutter path time per rib insert, as specified by the cutterPathHrsPerInsert cost model variable (5 hours in starting point Digital Factories).
- Total Number of Rib Inserts: As described above.