Weld Prep Calculations

Bevel Cutting Operation Cycle Time

Cycle Time = Pierce Time + Cut Time

Cycle time is the sum of the following:

• Pierce time: looked up by weld depth in the lookup table bevelCutInfo. Weld depth is determined by geometry extraction or (for virtual welds) specified by the user in the Welding dialog when the weld was created.

• Cut time (see formula)

Cut Time = Weld Length / Cut Speed * Number of Cuts

Cut time depends on the following:

• Weld length: determined by geometry extraction or (for virtual welds) specified by the user in the Welding dialog when the weld was created.

• Cut speed: looked up by weld depth in the lookup table bevelCutInfo. The table value is in millimeters per minute; it is converted to millimeters per second in order to calculate cut time. Weld depth is determined by geometry extraction or (for virtual welds) specified in the Welding dialog when the weld was created.

• Number of cuts: depends on the weld type as specified by the geometric property Type. Number of cuts is 2 for the following types:

  • V-Groove

  • U-Groove

  • Flared V-Groove

Number of cuts is 1 for all other types.

Grinding Operation Cycle Time

Cycle Time = Weld Length * Number of Passes / Grinding Speed

Cycle time depends on the following:

• Weld length: determined by geometry extraction or (for virtual welds) specified by the user in the Welding dialog when the weld was created.

• Number of passes: 2

• Grinding speed: specified by the machine property Grinding Speed.

Wire Brushing Operation Cycle Time

Cycle Time = Weld Length * Number of Passes / Wire Brushing Speed

Cycle time depends on the following:

• Weld length: determined by geometry extraction or (for virtual welds) specified by the user in the Welding dialog when the weld was created.

• Number of passes: 2

• Wire brushing speed: specified by the machine property Wire Brushing Speed.

Weld Prep Process Accounting

Labor Time = Operation Cycle Times * Labor Time Standard

Labor time is the product of the following:

• Operation cycle times is sum of the cycle times of all child operations for all subcomponents.

• Labor time standard: specified as the machine property Labor Time Standard. This multiplier is used to account for otherwise unaccounted for factors that affect labor time, such as operator fatigue or time spent by the operator for cleaning or maintenance.

Labor Cost = Labor Time * Labor Rate / Final Yield

Labor cost depends on the following:

• Labor time (see formula)

• Labor rate: this is the product of the following:

  • Machine property Labor Rate
  • Cost model variable laborRateAdjustmentFactor (1 in starting point Digital Factories)
  • Machine property Work Center Labor Rate Factor (1 in starting point Digital Factories)

• Final yield (see Yields)

Amortized Batch Setup = (Setup Time * (Labor Rate + Direct Overhead Rate)) / Batch Size

Amortized batch setup depends on the following:

• Setup time (specified as the machine property Setup Time)

• Labor rate: this is the product of the following:

  • Machine property Labor Rate
  • Cost model variable laborRateAdjustmentFactor (1 in starting point Digital Factories)
  • Machine property Work Center Labor Rate Factor (1 in starting point Digital Factories)

• Direct overhead rate (see Direct and Indirect Overhead)

Weld Prep process Cycle Time

Cycle Time = (Labor Time / Number of Operators) *
Cycle Time Adjustment Factor

• Labor time (see Weld Prep Process Accounting)

• Number of operators: specified by the machine property Number of Operators.

• Cycle time adjustment factor: specified by the cost model variable cycleTimeAdjustmentFactor; 1 in aPriori starting point Digital Factories. If you want to model an unbalanced, push assembly line, set cycleTimeAdjustmentFactor to a value greater than 1 in order to account for the cost of extra buffer capacity.

Note that indirect overhead depends on cycle time, while direct overhead depends on labor time. Cycle time contributes to part cost only via indirect overhead.