Every Cost Engineer has been tasked with creating a SHOULD COST on a process they are unfamiliar with and the software of choice does not have a method to reliable CYCLE TIME.  So what do you do?  You may do days of research, reading old text books, search the internet and maybe even have to visit manufactures or business that utilize this technology that you are unaware of.

You probably are asking yourself, “Hasn’t someone else had this same request? I can’t be the first to try to model this process.  Is there a place I can get help?”  This is it.

The idea is that if you have developed a method of calculating a CYCLE TIME for a unique process, post it here for others to use.  If you need a CYCLE TIME calculator for a process you are unfamiliar with, check here first.  If you can’t find on  that fits your need, ask the community through the comments section.

NOTE: 1) To add a CYCLE TIME calculator, please use the contact us link on this sight.  The calculator can be in either Excel or Word format.  The site administrator will add it to the list.  2) Use the calculator at your own risk.  It would be strongly advised that you sense check the data, method and results prior to implementing within your own work.

Injection Molding Cycle Time Calculator

Lathe and VMC cycle time calculator

Stamping Blank and Tonnage Calculator

 

 

 

22 Comments

  1. Hariharan

    I am looking for cold forging cycle time calculator.

    Reply
    • Jerry Collins

      I’m not an expert at cold forging but hoping others will correct me.

      Usually, the “forging” is in the order of < a second per hit. I think the key becomes how many hits and method of transfer?

      If this is lower volume, they may be set up on a transfer style line so the time may become additive. If it’s higher volume it may be progressive style and therefore it’s only the time per the longest hit (another topic altogether).

      Video I found on YouTube https://youtu.be/VCUJu-5z–s

      Anyone care to correct?

      Thanks for the help.

      Reply
  2. Chandana

    Please share the excel for calculating cycle time and tonnage for forged parts

    Reply
    • Jerry Collins

      Again, not a forging expert but I found this online. Please try it and let me know what you think. If it’s not accurate we will take it down. Welcome your feedback!

      For a time I would use the “Strike Speed” or Strokes per minute. When you depreciate the cost of the equipment correctly, say over 3 shifts, 5 or 6 days a week and anywhere from 7 to 20 year depreciation, I don’t think the machine cost will be a big driver. Similarly labor should be shared across multiple presses and there labor should be minimal as well.

      COLD FORGING
      F=25 x (3.5~6.3) x K x A

      F = Force Required
      K = Steel Coefficient (0.9 for low carbon, 1 for medium and low carbon alloy steel, 1.1 for medium low alloy steel and 1.25 for high alloy structural steel)
      A = Total deformation area of forging plan (Including Skin and flash) (cm2)
      Use lower limit (3.5) for transfer type or low productivity
      Use higher limit (6.3) for progressive dies and high productivity

      HOT FORGING
      F = (64~73) x K x A

      K = Steel Coefficient (0.9 for low carbon, 1 for medium and low carbon alloy steel, 1.1 for medium low alloy steel and 1.25 for high alloy structural steel)
      A = Projected area of the forging including Flash (cm2)

      Speeds
      Steam Hammer Screw Press Crank Press Die Forging Hammer
      Strike Speed (m/s) 4-7 0.6-0.8 0.3-0.7 4-6
      Cold Strike Time (ms) 2-3 30-60 30-60 2-3
      Forming Time (ms) 5-15 30-150 80-120 5-15
      Strike Speed 80-100 6-15 40-80 80-110

      Source: https://www.machinemfg.com/forging-press-selection-and-tonnage-calculation/

      Reply
  3. Jerry Collins

    A bit easier to read

    Steam Hammer
    Strike Speed (m/s) 4-7
    Cold Strike Time (ms) 2-3
    Forming Time (ms) 5-15
    Strike Speed 80-100 6-15

    Screw Press
    Strike Speed (m/s) 0.6-0.8
    Cold Strike Time (ms) 30-60
    Forming Time (ms) 30-150
    Strike Speed 40-80

    Crank Press
    Strike Speed (m/s) 0.3-0.7
    Cold Strike Time (ms) 30-60
    Forming Time (ms) 80-120
    Strike Speed 40-80

    Die Forging Hammer
    Strike Speed (m/s) 4-6
    Cold Strike Time (ms) 2-3
    Forming Time (ms) 5-15
    Strike Speed 80-110

    Source: https://www.machinemfg.com/forging-press-selection-and-tonnage-calculation/

    Reply
  4. K Laxman Sarat

    Can I have a steel material prices( either link or website) for the grades S235 & S355 and its equivalent from the past six months

    Reply
    • Jerry Collins

      K Laxman Sarat,

      Unfortunately we cannot yet provide you with pricing on materials. We are working on a method to do this but as I think you can confirm, this is s difficult task. There are endless materials in nearly as many forms, i.e rod, billet, sheet, tight tolerance etc. Then there is also the question as to what “price” or “cost” are you looking for? Do you want to know what you can buy it for at a certain volume or do you want to know what it costs to produce? The answer to this depends on how you are using this information.

      I hope others see your request and may point you in the right direction. I can tell you that there are a few steel suppliers that that list their prices on line, one I know of for fact is AK Steel.

      Sorry for not providing the answer you wanted but I hope you understand the scope of what you are asking.

      Thanks
      Jerry Collins
      Owner and Founder
      Society of Cost Engnieers

      Reply
  5. Aditya Bogi

    Hello,

    I am looking for cycle time calculator for machining operations.
    Which include operations performed on cnc lathe and milling machines.

    Please provide me with cycle time calculator.

    Thanks and Regards,
    Aditya Bogi

    Reply
    • Dev Joshi

      Hi Aditya,
      I am also working on CNC cycle time calculation in Germany. For cycle time calculation you have to know that on which material the task will be performed e.g Steel or Aluminium. If there is steel then time is definitely lower than steel. The second thing is, how many tools are needed and how many operations are needed e.g one-sided or two-sided if your part is needed two side operation, then add a minimum of 10 sec on each part.

      I will add one link for it, but it is in the German language might be useful for you.
      —-https://baubeaver.de/schnittgeschwindigkeit-berechnen/

      Reply
      • Jerry Collins

        Dev Joshi,

        Thank you for replying to a fellow Cost Engineer in need of help! This is exactly why I started this Society! If I had an award to give you I would!

        Thanks
        Jerry Collins
        Owner and Founder
        Society of Cost Engineers

        Reply
      • Aditya Bogi

        Hello Dev Joshi,

        Thanks for the much needed information.
        I seek the information provided is much useful for me.

        Thanks Again

        Reply
    • Jerry Collins

      Please see Dev Joshi’s very accurate response. Dev is correct that there are multiple inputs required to accurately predict or calculate the cycle time for machined parts. Most if not all the prepackaged software companies include this in their base subscriptions. I might recommend that if you are planning on doing this over and over again you may look to invest in one of them. Not only can they handle it but it will help in consistency. I’m also asking some contacts if there is a simplified method you could utilize.

      Thanks
      Jerry Collins
      Owner and Founder
      Society of Cost Engineers

      Reply
    • Leo Hernandez

      Hello Aditya, you have received several responses and they are all correct. I’ve been doing machining cycle time calculations for over 15 years, and the first resource for getting the proper CUTTING PARAMETERS (speeds and feeds for the specific material you plan to cut) are the cutting-tools catalogues like Sandvik, Guhring, Mikron, Seco, etc, etc.
      If, on the other hand, what you are asking for is the right time formula, that is quite easy, and it’s different for facing, turning, threading, drilling or milling.
      Finally, you have the limitations of your machine-tool, for example, you can’t drill at 100 m/min with a 1.0 mm drill in a cheap lathe (not enough RPMs)
      If you can be more specific in your question or what you are really looking for, I’d be glad to support.

      Reply
      • Aditya Bogi

        Hello Leo Hernandez,

        I appreciate you for taking your valuable time in response to to my inquiry.

        To be more specific I am looking for Cycle time calculator for operations to machine forged parts on lathe and Die casted Housings on CNC milling centre.

        It would be helpful if I get information about mostly used operations in reality such as Turning, Facing , Drilling, Grinding, etc., on a lathe.

        We can also have interactive session if you agree.

        Reply
  6. Leo

    Hello Aditya, you’re welcome.
    For calculating these cycle times you have to think like the programmer of the machine-tool, and add each operation to come up with the total cycle time: loading and unloading time, pure cutting time for each separate step (here is where you need to check for the proper cutting parameters -speeds and feeds-), tool change time, tool approximation time, and any other extra your machine might have, like tool-check sensing, or 4th-5th axis rotation. I suggest using an Excel file, I can share one with you if you send me your email. Mine is lhernandez@societyofcostengineers.com.

    Reply
    • Jeff Guo

      Hi Leo, I sent you a email. I am in similar situation and need some help. Can you please send me a copy? Thanks
      Jeff Guo

      Reply
  7. Sunil

    Can you please share tonnage and cycle time calculator for injection molding parts.

    Reply
    • Jerry Collins

      Sunil,

      Just posted.

      Thanks
      Jerry Collins
      Owner and Founder
      Society of Cost Engineers

      Reply
  8. Arun

    Can any one having template for Estimating Composite parts cost.
    Hand lay up, RTM & Filament winding .

    Reply
    • Jerry Collins

      Arun,

      I do not have one but I’ve asked our members to contribute both here and on LinkedIn.

      Let’s hope someone comes through.

      Jerry Collins
      Owner and Founder
      Society of Cost Engineers

      Reply
  9. Aditya Bogi

    Hello Everyone,

    Anyone is having cycle time calculator for Aluminum Extrusion Process.

    Thanks & Regards,
    Aditya Bogi

    Reply

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