How to Calculate MIG Cost per CM

x = 3.5 + penetration
h2= x2 +y2

L h
e
g

Leg
y = 1.2 + penetration

Bead Size/ throat as per Drg 4 Sheet Thickness 1.2 X 1.2

Sheet 1 1.2
Sheet 2 1.2

y Height of Bead ( Leg) 1.44 mm 1.2+.20% penetraion

2
x = √ h -y 2 x Vertical Bead ( Leg) 3.7 mm
x2+y2= h2 Diagonal h Bead Size / Throat 4 mm
L Bead Length 1000 mm
100 cm
Area of Bead ( Traingle) x*y /2 Sheet Thickness
2.686902633 mm2 1.2
0.02686902633 cm2 sp gravity Steel
Volume 2.686902633 cm3
2.686902633E-06 Mtr3
Wt of 1 Mtr of bead
Volume X Sp Gravity 21.09218567 gms

Co2 Wire Size 1.0 mm ( Tol = -.04)

wire dia length sp gravity
Co2 wire mm 0.96 1000 7850 kg/m3
Mtr 0.00096 1 7850000 gm/m3
Volume of 1 mtr wire 7.23456E-07 m3
pie/4 d2*length
Wt of 1 mtr wire 1 mm dia 5.6791296 gms

Length of wire require for 1

mtr Welding 3.713982099 Meter
( Wt of 1 mtr bead / wt of 1 mtr wire)

Rate of MIG wire per kg 90 Rs

Wire cost for 1 meter welding 1.8983 Rs
Wire cost for 1 Cm welding 0.0190 Rs
Others cost
 Manual Robot Remarks
Robot + Welding Equipmen
Equipment Cost Rs 350000 2000000
auxilary item

Depreciation for 10 Years 10%

Depreciated value for each year 35000 200000

Interset on capital investment 12% 42000 240000

Annual maint % of capital cost 5% 17500 100000

Labour cost @ 3.0 lac / annum 1 300000 150000 For Robot 0.5 man powe
consider for maint
Consumable cost Rs 112200.00 237000 Detail attach
Misc Cost 10% , inventory,
10% 35000 200000
cleaning , repair etc
annual cost 1 shift basis Rs 541700 1127000
Per day cost 290 Working days Rs 1867.9 3886.2
How many meter welding per day Meter 150 250
Cost per meter welding 12.45 15.54
Equipment Cost per cm welding 100 0.12 0.16

Electricity cost per cm 0.07 0.09 Detail attach

Total MIG welding cost per cm Rs 0.21 0.26

MIG Cost per CM

1.2+.20% penetraion

Sheet Thickness
x 1,2
sp gravity Steel 7850 Kg/m3
7850000 gm/m3

0.482726
 Remarks Consumables
Robot + Welding Equipment + Contact Tip 8400 8400
auxilary item

Gel Spray 10400 93600

Consumables other miscellaneous items 9400 51000

Electrode 0 0

CO2 Gas 84000 84000

For Robot 0.5 man power Total annual consumable cost 112200 237000
consider for maint

Detail attach Electricity

Rate per unit 10 10
Basis (No. of Shifts) 1 1
Power factor (pf) 0.80 0.80
Equipment Rating Robot 0 6
Rating (kVA) Transformer 5 5
Current, I (kA) 0.12 0.12 ======
Electricity ID#AAAAD4Up
Secondary Voltage (V) 80 80
Welding time in sec for 1 cm of WMA
Detail attach welding 3 3 (2019-10-24
Welding Time in hour for 1 cm
welding 0.000833 0.000833 03:53:35)
Electricity Consumption :
Gas heater500 Watts full time runni 0.5 0.5 Robot power
Weld Power consumption (KW) 0.006817 0.0088167 cost to be
Cost of Electricity / cm welding 0.07 0.09 added
1) Cost of tip Rs 30
2) Tip consumption 1/day

A) For Manual MIG welding, A1) Weld spray bottle cost Rs 200
A2) Bottle consumption : 1 per week
B) For Robotic MIG welding , B1) Spray gel cost Rs 1800/Kg
B2) Gel consumption 1 Kg/week

Screen, welding glass, plane glass, gloves, Liner, gun spares

Givn above

1) CO2 gas consumption 1 cylinder of 30 Kg consumed in 16 hours

2) Cost of cylinder Rs 300

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ID#AAAAD4Up
WMA
(2019-10-24
03:53:35)
:
Robot power
cost to be
added