Jigs and Fixtures Design PTB41002

Cost calculation Raja Aziz Raja Ma’arof

Main cost components
Design Raw materials and standard parts Machining Heat treatment Handling Delivery Administration Profit margin Quotation

Design cost
RM / hr Design duration
Design objective (based on problem statement) Design needs analysis Research ideas Design alternatives Final design

Raw material & standard part cost
Raw material, by:
Request for quotation from suppliers Weight Size or volume

Standard part catalogue
Price list from suppliers Request for quotation from suppliers

Machining cost
Machine type
Milling Turning Grinding Wirecut Diesink Welding

Machining accuracy Machining time calculation RM / hr rate

Machining time calculation: turning
L×i th = n× f

vc n= π ×d
L

th = Machining time L = Feeding length i = Number of cutting stage n = RPM f = feed length per revolution Vc = Cutting speed
l = 1240mm, la = 2mm, f = 0.6mm, Vc = 120m/min, i = 2, d = 160mm
L = 1240 + 2 = 1242 mm

l la

m min = 238.7rpm n= π × 0.16m 120

th =

1242mm × 2 = 17.3 min 1 238.7 × 0.6mm min

Machining time calculation: milling
L×i th = vf
L×i th = n× f

f = fz × z

vf = n× f

d

th = Machining time L = Feeding length i = Number of cutting stage n = RPM f = feed length per mill tool revolution fz = feed per mill tooth z = Nr of teeth Vf = Feeding speed a = Depth of cut
l = 176mm, la = 3mm, d = 100mm, z = 8, n = 64 rpm, fz = 0.1mm, a= 8mm, i = 1

a1 T a2

L = d / 2 + la + l = 100 / 2 + 3 + 176 = 229 mm
L la

f = fz× z = 0.1×8 = 0.8mm vf = n× f = 64rpm 0.8mm= 512 ; × .
th = L×i 229 mm × 1 = = 4 . 47 min 1 vf 51 . 2 min

mm min

Machining time calculation: cylindrical grinding
Machining time

L×i th = n× f
n= vf

Workpiece rpm

π × d1

th = Machining time L = Feeding length i = Number of cutting stage n = RPM f = feed length per tool revolution Vf = Feeding speed a = Depth of cut d1 = Raw workpiece diameter d = Workpiece finished diameter

Nr of cutting

d − d1 i= +8 2× a
External grinding

i=

d1 − d +8 2×a

Internal grinding

Machining time calculation: surface grinding
Machining time

L×i th = n× f
n= vf L

Nr of stroke/min

th = Machining time L = Feeding length i = Number of cutting stage n = RPM f = feed length per tool revolution Vf = Feeding speed a = Depth of cut per penetration t = Total cutting depth

Nr of cutting

i=

t + 81) a

1) 8 pre-cut travels

Machining time calculation: EDM
Wirecut
Machining time

L th = vf

th = Machining time L = Cutting length, direction of cut Vf = Feeding speed H = Cut height T = surface tolerance (µm)

Diesink

Machining time

V th = vW

th = Machining time S = Electrode surface area V = volume to remove Vw = Material removing rate (mm3/min

Heat treatment
RM / kg rate RM for special requirement
Material Heat treatment method
Induction Process control

Handling cost
Machine setting Assembly and dismantling Storage RM/hr

Delivery
Transportation mode RM / km
Weight category Size or volume category

Administration cost
Apportionment: % to be costed to a machine RM/hr Eg.
Admin staff payroll: Total RM50,000 per month Power & utility: RM5,000 per month Rentals: RM10,000 month 2 shift, 8 hours / shift, 22 days / month. Equals to 352 hours / month

Administration cost
Admin cost / month: RM65,000 Rate: RM65,000 / 352 hours RM185 / hr 50 production machines in total. Apportionment equals 1/50. or RM3.70 / hr / machine

Profit margin
% of total production cost % value depends on:
Difficulty level Timeline given by customer Wisdom:
Can others do it? Rule of thumb

Quotation to customer
Project name Project reference number Price Warranty Delivery date

Cost summary
Item Design Raw material Std. part Machining Heat treatment Handling Delivery Admin Total Profit margin Quotation Basis Hrs Kg L/s Hrs Kg Hrs Km, weight, volume Hrs % 50 to 200 Rate (e.g.) RM25/hr RM7/kg As manufacturer list RM5 to RM60/hr RM5/kg RM5/hr RM5 to RM60/km RM4 RM