Video of Faculty

15ME328E
Process Planning
and Cost
Estimation
 Video of Faculty
Basic Requirement
L T P C
PROCESS PLANNING AND COST
15ME328E 3 0 0 3
ESTIMATION
Co-requisite Nil
Prerequisite Nil
Data Book /
codes / Nil
Standards
Course
P PROFESSIONAL ELECTIVE
Category
 Instructional Objectives Video of Faculty

and Student Outcomes

To impart clear knowledge about process planning,

PURPOSE
costing, and estimation of machining time.
STUDENT OUTCOMES
INSTRUCTIONAL OBJECTIVES (IO)
(SO)
At the end of the course., student will be
able to
Acquire knowledge about Process
1 c
planning.
Understand Different Cost and its
2 c e
components.
3 Estimate different Costs. c e
Calculate Machining time for different
4 c e
process.
 Learning Resources Video of Faculty

Sl.
TEXT BOOKS
No.
Banga.T.R and Sharma.S.C, “Estimating and Costing”, Khanna publishers,
1
New Delhi, 17th Edition, 2015.
Adithan.M.S and Pabla, “Estimating and Costing”, Konark Publishers Pvt., Ltd,
2
1989. REFERENCE BOOKS/OTHER READING MATERIAL
Nanua Singh, “System Approach to Computer Integrated Design and
3
Manufacturing”, John Wiley & Sons, New York, 1996.
Joseph G. Monks, “Operations Management, Theory and Problems”,
4
McGraw Hill Book Company, New Delhi, 1982.
Narang.G.B.S and Kumar.V, “Production and Planning” , Khanna Publishers,
5
New Delhi, 1995.
Chitale.A.K and Gupta.R.C, “Product Design and manufacturing”, Prentice
6
Hall of India, New Delhi, 2007.
 Learning Assessment Video of Faculty

Course Nature Theory

Assessment Method (Weightage 100%)
Assess Cycle
Cycle Cycle Surpris
In ment Test Quiz Total
Test I Test II e Test
semes tool III
ter Weigh
10% 15% 15% 5% 5% 50%
tage
End Semester Examination Weightage : 50%
 Course Designers Video of Faculty

Course
Department of Mechanical
Designed
Engineering
by
Academic Council Meeting , 23rd July
Approval
2016
 UNIT IV: ESTIMATION OF COSTS IN Video of Faculty
FABRICATION SHOPS

Sessio Contac c-D-I Referenc

Description of Topic IOs
n t hours -O e
Welding, Types of weld joints, Gas
20 1 C 3 1
welding
Estimation of Gas welding cost, Gas
21 1 C 3 1
cutting
Arc welding: Equipment, Cost
22 1 C 3 1
Estimation
Cost estimation in Welding shop:
23 2 C,D 3 1,2
Tutorials
Estimation in sheet metal shop,
24 2 C 3 1
Shearing and forming
Cost estimation in Sheet metal
25 2 C,D 3 1,2
shop
 Video of Faculty
Welding

The Welding is a process of joining two or more,

similar or dissimilar metals by heating them to a
suitable temperature , with or without the application
of pressure, filler materials and flux.
Welding is used for making permanent joints.
 Video of Faculty
TYPES OF WELDING

⚫ Plastic Welding or Pressure Welding:

• The piece of metal to be joined are heated to a
plastic state and forced together by external
pressure
• (Ex) -Resistance welding
∙ Fusion Welding or Non-Pressure Welding:
• The material at the joint is heated to a molten
state and allowed to solidify
• (Ex)- Gas welding, Arc welding
 CLASSIFICATION OF Video of Faculty
WELDING PROCESSES

✔ Gas welding(Oxy- Acetylene)

✔ Arc welding(Metal Arc)
✔ Resistance welding
✔ Solid state welding
✔ Thermo-chemical welding
✔ Low Temperature welding
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Gas Welding

•Gas Welding is a fusion welding process, in which the

heat for welding is obtained by the combustion of oxygen
and fuel the gas may be acetylene ,hydrogen or propane .
•Types:
•Oxy- Acetylene
•Air-Acetylene
•Oxy-Hydrogen
•Oxy-Fuel
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Oxy-Acetylene Welding

• When a combination
of Oxygen and
acetylene is used in
correct proportions to
produce an Intense
gas flame, the
process is known as
oxy-acetylene
welding
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Gas Welding Equipment

1. Gas Cylinders Pressure-

• Oxygen – 125 kg/cm2 Acetylene – 16 kg/cm2
2. Regulators
• Working pressure of oxygen 1 kg/cm2
• Working pressure of acetylene 0.15 kg/cm2
• Working pressure varies depends upon the thickness of the work
pieces welded.
3. Pressure Gauges
4. Hoses
5. Welding torch
6. Check valve
7. Non return valve
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Gas Welding: Advantages

•Advantages:
▪ Portable and most versatile process.
▪ Better control over the temperature.
▪ Suitable to weld dissimilar matter.
▪ Low cost & maintenance.
•Disadvantages:
▪ Not suitable for heavy section.
▪ Less working temperature of gas flame.
▪ Slow rate of heating
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Arc Welding

• Arc welding is a fusion welding process in which

the heat required to fuse the metal is obtain from
the electric arc between the base metal and an
electrode.
• Types:
1. Metal Arc Welding
2. Submerged Arc Welding
3. Tungsten Inert Gas Welding
4. Metal Inert Gas Welding
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Equipment

A welding generator (D.C.) or Transformer (A.C.)

Two cables- one for work and one for electrode
Electrode holder
Electrode
Protective shield
Gloves
Wire brush
Chipping hammer
Goggles
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Metal Arc Welding

Uses an electric arc to

coalesce metals

Arc welding is the most

common method of welding
metals

Electricity travels from

electrode to base metal to
ground
 Advantages and Disadvantages of Video of Faculty
Arc Welding

Advantages Disadvantages
▪Most efficient way to join ▪Manually applied,
metals
therefore high labour cost.
▪Lowest-cost joining
method ▪Need high energy causing
▪Affords lighter weight danger
through better utilization of ▪Not convenient for
materials disassembly.
▪Joins all commercial metals
▪Defects are hard to detect
▪Provides design flexibility
at joints.
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Applications

It is used in the manufacture of automobile bodies.

Aircraft Frames
Railway Wagons
Machine Frames
Structural works, tanks, furniture, boilers, general repair
work and ship building etc.
 Video of Faculty
Estimation in welding shop

• Welding is the process of joining similar metals by the application

of heat. Welding can be done with or without the application of
pressure. Welding is used for making permanent joints.
• Two main types of welding process are
– Plastic Welding
– Fusion Welding
• In plastic welding the metal pieces are heated to a plastic state.
They are pressed together to make the joint. This welding is also
known as Pressure welding.
• In Fusion welding the metal at the joint is heated to molten state.
Then it is allowed to solidify. Pressure is not applied in this
welding process. So it is known as non pressure welding.
 Video of Faculty
Estimation: Gas welding

• It is the process of joining two metal pieces by a gas flame

obtained by the combustion of fuel gas and oxygen. It comes
under a fusion or non pressure welding process.
• In this process, gas flame is used to melt the edges of metal parts
to be joined and allowing it to solidify, thus forming a required
joint.
• A filler material of similar composition and melting temperature
may also be also used to fill the gap between the parts to be
welded.
• There are different combinations of gases used to obtain the hot
flame, e.g., oxygen and acetylene, oxygen and hydrogen etc.
• Gas welding technique:
– Leftward or forward welding
– Rightward or backward welding
 Video of Faculty
Estimation: Gas welding

• Leftward welding :
In this method, welding is started from right hand side of the joint
and proceeds towards left.
This method is used for welding plates upto 5 mm thick. No edge
preparation is required in case of the plates of thickness upto 3 mm.
• Rightward welding :
This method is adopted for welding thicker plates. Welding proceeds
from left to right.
The flame is directed towards the deposited metal and rate of cooling
is very slow.
This method is employed for welding plates more than 5mm
thickness.
In plates upto 8 mm thickness, edge preparation is not required but
beyond 8 mm thickness plates should be bevelled to about 30 degree.
 Video of Faculty
Estimation: Welding

• The Total welding cost consists of the following elements:

1. Direct material cost.
2. Direct labour cost.
3. Direct other expenses.
4. Overheads.
Direct Material Cost
– Cost of base materials to be welded. i.e. Sheet, Plate, rolled
section, casting or forging.
– Cost of consumables such as electrodes, flux, O2, C2H2, etc.
2. The electrode consumption can be estimated by using the charts
supplied by the suppliers. Another way to find the actual weight
of weld metal deposited is to weigh the component before and
after the welding and making allowance for stub end and other
losses during welding.
3. Also, the weight of weld metal = Volume of weld × Density of
weld material
 Video of Faculty
Estimation Welding

2. Direct Labour Cost

•The direct labour cost includes the cost of labour for preparation,
welding and finishing operations. Preparation or pre-welding labour
cost is the cost involved with preparation of job for welding, like
edge preparation, machining the sections to be welded etc.
•If gas is used in cutting/preparation of edges, its cost is also taken
care of. Cost of labour in actual welding operation is calculated
considering the time in which arc is actually in operation.
•The cost of labour for finishing operation is the cost of labour
involved in grinding, machining, sand or shot blasting, heat
treatment or painting of welded joints.
•Direct labour cost=preparation or pre-welding labour cost+ welding
cost + post welding or finishing cost.
 Video of Faculty
Estimation Welding

•
 Video of Faculty
Estimation Welding

4. Overheads
•The overheads include the expenses due to office and supervisory
staff, lighting charges of office and plant, inspection, transport, cost
of consumables and other charges. The cost of equipment is also
apportioned to the individual components in the form of
depreciation.
Types of Root configuration
A lap welded joint is to be made as shown in Fig.
Estimate the cost of weld from the following data
Welded water tank
 Video of Faculty
Problem 01

A lap welded joint is to be made as shown in Fig.

Estimate the cost of weld from the following data :
Thickness of plate = 10 mm
Electrode diameter = 6 mm
Minimum arc voltage = 30 Volts
Current used = 250 Amperes
Welding speed = 10 meters/hour
Electrode used per meter of weld = 0.350 kgs
Labour rate = Rs. 40 per hour
Power rate = Rs. 3 per kWh
Electrode rate = Rs. 8.00 per kg
Efficiency of welding m/c = 50 percent
Connecting ratio = 0.4
Overhead charges = 80 percent of direct charges
Labour accomplishment factor = 60 percent
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Problem 01
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Problem 02
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Problem 02
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Problem 02
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Problem 03
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Problem 04
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Problem 04
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Problem 05
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Problem 05
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Problem 06
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Problem 06
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SHEET METAL SHOP

• It deals with working of thin sheets with hand tools

and simple machines into various cutting forms by:
– Cutting
– Forming into shapes
– joining
• Examples: Makingof canisters, boxes, funnels, pipes,
bends, cans etc.
 Video of Faculty
FEATURES

1. Less Expensive
2. Lighter in weight
3. Good surface finish
4. Requires lesser force of deformation
5. Can easily replace the use of casting or forging
 Video of Faculty
MATERIAL USED
•Galvenised Iron:
– it is a Zn coated iron Popularly
known as GI Sheets Zn coating :
•resist rusting,
•improves the appearance of
•metal
•permit to be soldered at greater
ease
•Reduce weldability by
producing toxic fumes and
residues
•Use to make pans, buckets,
heating ducts, gutters etc.
 SHEET METAL HAND TOOLS Video of Faculty

1. Measuring tools 2. Straight Edge 9. Hammers

i. Steel rule 3. Steel Square 10. Snips or
ii. Folding rule 4. Scriber shears
iii. Circumference 5. Divider
rule 11. Pliers
6. Trammel Points
iv. Vernier Caliper 12. Stakes
7. Punches 13. Groovers
v. Micrometer
8. Chisel
vi. Thickness Gauge 14. Rivet Set
vii. Sheet Metal Gauge 15. Soldering
Iron
 Video of Faculty
1. MEASURING TOOLS

• Steel Rule: It is made of hardened

steel and used for taking linear
measurements of articles to an
accuracy from 1 to 0.5 mm.
• Folding Rule: This is very useful
in measuring and laying out
larger work with 0.5 mm
accuracy.
• Steel Circumference Rule: It is
used to find out directly the
circumference of a cylinder.
• Swing Blade Protractor used for
marking and measuring angle
 Video of Faculty
MEASURING TOOLS

• Vernier Caliper: used for

measuring both inside and
outside dimensions upto 0.02
mm.
• Micrometer Caliper: used to
measure the thickness of metal
sheets accurately upto 0.01
mm.
• Thickness Gauge: also called
slip gauge and used to
measure the clearance
between parts during assembly
• Sheet Metal Gauge: used to
measure the thickness of sheets
 SHEET METAL HAND TOOLS Video of Faculty

2. Straight Edge: is a flat

graduated steel bar with one
longitudinal edge bevelled. It
is useful for scribing long
straight lines.
3. Steel Square: made of
hardened steel. It is used for
marking in the perpendicular
direction to any base line.
 SHEET METAL HAND TOOLS Video of Faculty

1. Scriber: also known as

metal worker’s pencil. It
has one hardened sharp
pointed edge to scratch line
on sheet metal.
2. Dividers: used for drawing
circles , arc on sheet metal
and also used to mark a
desired distance between
two points.
3. Trammel Points: consist of
a bar with two movable
heads. It is used to draw
large circles or arcs that are
beyond the limit of the
dividers.
 SHEET METAL HAND TOOLS Video of Faculty

• Punch: used for marking out work,

locating centers etc.

• Prick punches is used to make

small marks on layout lines.

• Centre punch is used to make prick

punch markers larger at the centre
holes that are to be drilled
• Hand lever punch is used for
marking holes with a punch and die
incorporated in the tool when a
large number of holes are to be
punched.
 SHEET METAL HAND TOOLS Video of Faculty

• Mallet: used to strikea light

and soft blow on metal., this is
soft hammer made of rubber,
copper, brass, wood etc.

• Snips or shears: used to cut

thin sheets.

• Stakes: sheet metal worker’s

anvils, i.e., supporting tool.
 SHEET METAL OPERATIONS Video of Faculty

1. Shearing
2. Bending
3. Drawing
4. Squeezing
 SHEET METAL OPERATIONS Video of Faculty

• Shearing: it has
three basic stages-
– Plastic Deformation
– Fracture
– Shear
This procedure gives a
clean edge on the
piece of metal.
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1. SHEARING

•Some basic shearing

operations are:
•A. Cutting off: cutting off
a piece from a strip
•Parting: cutting a strip
between two pieces to part
them
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1. SHEARING

Blanking:
•It is an operation of
cutting a flat shape from
a sheet metal. The part
punched out is called the
blank and the remaining
sheet is the scrap.
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1. SHEARING

Notching: removing the

metal from the edge of
sheet metal.
Slitting: In this shearing is
conducted between
rotary blades.
.
 Video of Faculty
Forming Operations

■ In this operation, the stresses are below the ultimate

strength of the metal. In this operation, there is no cutting
of the metal but only the contour of the work piece is
changed to get the desired product. The forming
operations include

❑ Bending
❑ Drawing
❑ Squeezing
 Video of Faculty
Forming Operations

■ Bending: In this operation, the material in the form of flat sheet

or strip, is uniformly strained around a linear axis which lies in
the neutral plane and perpendicular to the lengthwise direction
of the sheet or metal
■ Drawing : This is a process of a forming a flat work piece into a
hollow shape by means of a punch, which causes the blank to
flow into die cavity.
■ Squeezing: Under this operation, the metal is caused to flow to
all portions of a die cavity under the action of compressive
forces.
Types of Bending operations Video of Faculty
 Video of Faculty
Bending operations
 Tube Forming or Bending Video of Faculty

■ Bending and forming tubes and other hollow sections

require special tooling to avoid buckling and folding. The
oldest method of bending a tube or pipe is to pack the
inside with loose particles, commonly used sand and bend
the part in a suitable fixture.
■ This technique prevents the tube from buckling. After the
tube has been bent, the sand is shaken out. Tubes can also
be plugged with various flexible internal mandrels.
 Video of Faculty
Press break forming

• Sheet metal or plate can be bent easily with simple

fixtures using a press. Long and relatively narrow
pieces are usually bent in a press break. This
machine utilizes long dies in a mechanical or
hydraulic press and is suitable for small
production runs. The tooling is simple and
adaptable to a wide variety of shapes
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Press break forming
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Roll forming

▪ For bending continuous lengths of sheet metal and for large

production runs, roll forming is used. The metal strip is bent in
stages by passing it through a series of rolls.
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Hydro forming Process

The hydroform (or fluid forming) process. Note that, in contrast to the
ordinary deep-drawing process, the pressure in the dome forces the cup
walls against the punch. The cup travels with the punch; in this way, deep
drawability is improved.
 Video of Faculty
Press for Sheet Metal

▪ Press selection for sheet metal forming operations depends on

several factors:
▪ Type of forming operation, and dies and tooling required
▪ Size and shape of work pieces
▪ Length of stroke of the slide, stroke per minute, speed and shut
height (distance from the top of the bed to the bottom of the
slide, with the stroke down)
▪ Number of slides (single action, double action and triple action)
▪ Maximum force required (press capacity, tonnage rating)
▪ Type of controls
▪ Die changing features
▪ Safety features
 Sheet and Plate Metal Video of Faculty
Products
❑ Sheet and plate metal parts for consumer
and industrial products such as
❑ Automobiles and trucks
❑ Airplanes
❑ Railway cars and locomotives
❑ Farm and construction equipment
❑ Small and large appliances
❑ Office furniture
❑ Computers and office equipment
 Advantages of Sheet Metal Video of Faculty
Parts

■ High strength
■ Good dimensional accuracy
■ Good surface finish
■ Relatively low cost
■ For large quantities economical mass
production operations are available
Problem 01 Video of Faculty
Problem 01 Video of Faculty
Problem 02 Video of Faculty
Problem 02 Video of Faculty
Problem 03 Video of Faculty
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Problem 04 Video of Faculty
Problem 04 Video of Faculty
Unit 04 Video of Faculty

End