Powder metal costing details
The Powder Metal process group uses the following feasibility rules:
Part size
Check part length and width against machine maximum dimensions.
Check fill height against maximum machine fill height
Part shape
Check for fillets along edges against die perpendicular to the draw direction.
Check against minimum thicknesses
Cycle time
Compaction time is driven by the stroke time of the presses. Stroke time considers the time for the shoe to move into place, fill the cavity, press the part, then lift it out of the cavity. This is one stroke. Stroke time is driven by the compaction force required to make a part and the size of the part.
Sintering time dependent on the size and weight of the parts. It is also dependent on the length of the furnace and the belt speed.
Labor time cost drivers
Machine set up
Handling time, including part removal from press, part movement to sintering furnace, and final stacking
Processing time per machine is driven by machine cycle time and the number of operators manning the machine
Tooling cost drivers
The major cost of tooling is the cost of machining the tool steels to form the dies.
Part length, width, number of faces, and surface finish drive cost of dies.
Complexity of top and bottom faces of the part drive the cost of the punches.
Multi step parts, or parts with multiple direction of pressing thicknesses may require multi stage punches used to aid in uniform density throughout the part.
The cost of core rods for a simple hole is driven by the size of the hole and the length of the rod required for a particular machine.
Complex core rods costs are driven by the number of faces in addition to those of simple core rods.