Mold Refractory Coat
There is one occurrence of this process for each refractory coating application that the mold receives (see Number of Coating Applications).
Cycle Time = Process Time * Cycle Time Adjustment Factor
Cycle time is the product of the following:
• Process time (see formula below)
• Cycle time adjustment factor: specified by the cost model variable cycleTimeAdjustmentFactor; 1 in aPriori starting point VPEs.
Process Time =
(Total Surface Area / Application Rate per Mold) / Number of Operators
Process time depends on the following:
• Total surface area: this is the area covered by one coat. It is the sum of the Finished Area of all the part’s surfaces, as well as the Surface Area of all the part’s voids.
• Application rate: this is looked up by Application Method in the lookup table tblRefractoryCoating.
The value is converted to square millimeters per second for use in this formula.
• Number of operators: by default, this is specified by the cost model variable defaultMoldRefractoryCoatingNumOperators. (1 in starting point VPEs). Users can override the default on a per-part basis with the setup option Number of Operators.
Process time is rounded up to a whole number of seconds.
Additional Direct Costs =
(Coating Volume * Refractory Coating Cost * Number of Operators) / Final Yield
Additional direct costs include the cost for the volume of refractory coating material used for one coat of one mold. It depends on the following:
• Coating volume: volume of refractory coating material applied by one operator during the current process. See formula.
• Refractory coating cost: unit cost of coating material, specified by the toolshop variable refractoryCoatingCost.
• Number of operators: by default, this is specified by the cost model variable defaultMoldRefractoryCoatingNumOperators. (1 in starting point VPEs). Users can override the default on a per-part basis with the setup option Number of Operators.
• Final yield (see Yields for Sand Casting)
Coating Volume = Process Time * Coating Output Rate
This is the volume of refractory coating material applied to the mold by one operator during the current process. This is the product of the following:
• Process time (see formula)
• Coating output rate: this is the volume per unit time of coating material that is expended during application. It is looked up by Application Method in the lookup table tblRefractoryCoating.
• This value is converted to liters per second for use in this formula.