Sheetmetal Costing (Part + Tool)

07-Jan-2016
Agenda

1. Sheet metal Process

2. Stamping Press
3. Part Cost basics
4. Tool Types
5. Tool Construction
6. Tool Manufacturing Process
7. Tool Cost sample calculation

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Sheet metal operations

Cutting Non-Cutting

Shearing Bending

Blanking Flanging

Piercing Draw

Trimming Stretch Forming

Lancing Hemming

Fine Blanking Restrike

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 Sheet metal operations – Shearing

Shearing is the method of cutting sheets or strips without forming chips

The material is stressed in a section which lies parallel to the forces applied. The forces are by applied by means
of shearing blades or punch and die

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 Sheet metal operations – Blanking
              
Blanking is the cutting of a sheet metal part along a closed contour. The piece cut out is called a blank and may be
    further processed. Many blanks are often continuously cut out of a sheet or strip

The tool used is called as blanking tool

                                 

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Sheet metal operations – Piercing

Piercing involves cutting out a piece of material from a metal sheet. The material removed may be round or some
other shape. This excess metal, once punched out, is called a slug and is usually discarded as scrap. Slotting is a
type of punching operation. Slotting refers specifically to the punching of rectangular or elongated holes

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Sheet metal operations

Trimming – is an operation of removing excess material which remains after a

deep drawing operation which imparts a certain shape to the side of the strip
or component

Lancing – is a continuous bending and cutting operation along a line in the

work-material.
No metal is cut free during the lancing operation

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Sheet metal operations – Bending

Sheet metal bending is the plastic deformation of the work over an axis, creating a change in the
part's geometry. Similar to other metal forming processes, bending changes the shape of the work
piece, while the volume of material will remain the same

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Sheet metal operations – Flanging

Flanging is a forming operation in which a narrow strip at the edge of a sheet is bent down along a straight line
or curved line. A flange is used for appearance, rigidity, edge strengthening and removal of sharp edges. Three
major types of flanging types are straight flange, stretch flange and shrink flange

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 Sheet metal operations – Draw

Drawing is a metal forming process in which a flat piece of plate or sheet is forced into a die cavity without
excessive thinning, wrinkling or fracturing
A blank-holder is used to clamp the blank on the die, while the punch pushes into the sheet metal. The sheet is
drawn into the die hole taking the shape of the cavity

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 Sheet metal operations – Stretch forming

Stretch forming is a metal forming process in which a piece of sheet metal is stretched and bent simultaneously over
a die in order to form large contoured parts.

Stretch forming is performed on a stretch press, in which a piece of sheet metal is securely gripped along its edges
by gripping jaws.

The gripping jaws are each attached to a carriage that is pulled by pneumatic or hydraulic force to stretch the sheet.

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 Sheet metal operations – Roll Forming

Roll forming is a continuous process for forming sheet, strip or coiled metal stock into long shapes of essentially
uniform cross-section. The material is fed through multiple pairs of contoured forming rolls, which progressively
shape the metal until the desired cross section is produced

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Sheetmetal operations – Hemming & Seaming

Hemming/seaming is a process of joining two edges of sheetmetal by multiple bending. A hem is folded at the
edge of the sheet metal to remove the burred edge and improve the appearance of the edge.

Seaming
Hemming

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Process sequence for Cross member

DRAW OPERATION TRIM and PIERCE OPERATION FLANGE and RESTRIKE

OPERATION

1000Ton 800Ton 600Ton

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 Process sequence for Body Side Outer

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Stage 1 : Profile Blanking

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Stage 2 : Draw

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Stage 3 : Trim, Cam trim
CAM TRIM

DIRECT TRIM

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Stage 4 : Trim, restrike
RESTRIKE

TRIM

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 Stage 5 : Flange, Cam flange, Cam pierce
Cam-flange

Cam-flange

Cam-piercing

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Agenda

1. Sheet metal Process

2. Stamping Press
3. Part Cost basics
4. Tool Types
5. Tool Construction
6. Tool Manufacturing Process
7. Tool Cost sample calculation

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Type of Presses

C-Frame (20T to 300T) H-Frame (300T to 5000T)

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 Mechanical Press Layout

Connecting rod

RAM

Tool

Bolster / Bed

Cushion

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Hydraulic Press Layout

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Transfer Press Line

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Tandem Press Line

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Agenda

1. Sheet metal Process

2. Stamping Press
3. Part Cost basics
4. Tool Types
5. Tool Construction
6. Tool Manufacturing Process
7. Tool Cost sample calculation

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 Costing Factors
Material cost A C Other cost
 Rejection
 ICC
 Raw Material price / kg
 Profit & Overheads
 Finish Weight
 Die maintenance
 Input weight
 Scrap recovery / Kg

TOTAL COST = Acost

Total +B+C+D
Process cost B Total cost D Market Environment
 Machin Hour Rate
 Cycle time Stroke rate
Will vary based on market premises

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Material cost – Raw material Cost
Basic price Packing Logistics

 Transportation
 Coiling & Stacking  Loading & Unloading
 Wooden pallets  Storage
 Grade
 Polythene cover etc..,
 Specification & Tolerances

ED
CVD CESS
TAX
CST  Demand Vs Supply  Monopoly
EPCG  Oligopoly
 Standards
vat  Perfect competition

National & International Taxes Availability Market environment

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Material cost – Raw material input size
Factors influencing cost in input blank selection
 Standard sheet or Cut to size

 Scrap bridge allowance

 End bit allowance

 Draw bead allowance

 Strip layout
Maximum yield
 Single row – single pass ,
 Single row – Double pass
 Double row – Single pass
 Double row – Double pass

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Material cost - A
Raw Material Cost RM
 Raw material landed cost per unit

Input Weight IW
 Weight of the input raw Material per unit Material cost =
Finish Weight FW
 Finished part weight Input Weight x RM Cost
-
Scrap weight SW Scrap weight x Scrap cost
 Input Weight – Finish weight

Scrap cost SC
 Scrap selling price

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Strip Layout Optimisation

Part Name : Intermediate Plate

Model : Thunderbolt 4843k

Finish Weight : 1.723 Kg

Thickness : 5 mm

Material : ST52

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Input Raw Material Size

310
367
Standard Sheet size: 2500x1250mm
No of Parts from Standard Sheet: 24parts
Input weight / part: 5.1kgs Raw Material Utilisation : 34%
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Strip Layout

Standard Sheet size: 2500x1250mm

No of Parts from Standard Sheet: 42parts
Input weight / part: 2.9kgs Raw Material Utilisation : 59%
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 Costing Factors
Material cost A C Other cost
 Rejection
 ICC
 Raw Material price / kg
 Profit & Overheads
 Finish Weight
 Die maintenance
 Input weight
 Scrap recovery / Kg

60 ~ 70 %

TOTAL COST = Acost

Total +B+C+D
Process cost B Total cost D Market Environment
 Machin Hour Rate
 Cycle time Stroke rate
Will vary based on market premises

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Process cost – B (Machine hour rate)
Maintanance

Investment
Tools

Depreciation
Consumable

Rent
Power

Labor

Machine Hour
MHR = F{I,D,R,L,M,T,C,P)

Rate
Fixed Cost Variable cost
Interest (I): Based on market condition, generally 12 % and ivestment
Depreciation (D): Straight line method used, No of years based on machines life
Depreciation = (Investment – Scrap recovery)/No of years
Rent(R): (Size of machine + supplementary area) * Space cost / unit area
Space cost is rent paid / unit area or cost of land, building including mai`ntenance
Labor Cost (L): Cost spent for labor per hour
Maintenance cost (M): Cost spend to maintain the machine including, AMC, PM, breakdown spares and consumables etc
Tooling Cost (T): Cost incurred on the cutting tool to produce the part
Consumable Cost (C): Cost incurred on the coolant and other oil.
Power Cost (P): Power consumed by the machine and supplementary accessories during the operation

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 Costing Factors
Material cost A C Other cost
 Rejection
 ICC
 Raw Material price / kg
 Profit & Overheads
 Finish Weight
 Die maintenance
 Input weight
 Scrap recovery / Kg

60 ~ 70 %

TOTAL COST = Acost

Total +B+C+D
Process cost B Total cost D Market Environment
 Machin Hour Rate 15 ~ 20 %
 Cycle time Stroke rate
Will vary based on market premises

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Other Cost Parameters

Costing element Profit

Overheads
Rejection
ICC
Die maintenance
Consumables
Other Cost

Raw material
Parameters considered

Labour
Process

Machine
Power
Space
Packaging
Logistics
Purchased parts

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 Costing Factors
Material cost A C Other cost
 Rejection
 ICC
 Raw Material price / kg
 Profit & Overheads
 Finish Weight
 Die maintenance
 Input weight
 Consumables
 Scrap recovery / Kg

60 ~ 70 % 15 ~ 20 %

TOTAL COST = Acost

Total +B+C+D
Process cost B Total cost D Market Environment
 Machin Hour Rate 15 ~ 20 %
 Cycle time Stroke rate
Will vary based on market premises

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 Market Environment

Market power of firms

Perfect competition
Oligopoly Monopoly

Many firms with a A few producers A single producer

homogeneous product with high market
power

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Market environment
High

---- >
Criticality

Perfect competition

>
Oligopoly ------

>
Monopoly
Low
Availability
Low
High

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 Costing Factors
Material cost A C Other cost
 Rejection
 ICC
 Raw Material price / kg
 Profit & Overheads
 Finish Weight
 Die maintenance
 Input weight
 Scrap recovery / Kg

60 ~ 70 % 15 ~ 20 %

TOTAL COST = Acost

Total +B+C+D
Process cost B Total cost D Market Environment
 Machin Hour Rate 15 ~ 20 % X%
 Cycle time Stroke rate
Will vary based on market premises

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Part Cost Sample Calculation

Part Name : Oil Pan

Model : HDT 2523 R

Finish Weight : 11.77 Kg

Thickness : 2 mm

Material : IS 513 EDD

Surface finish : ED Coating

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Raw material Cost

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Rawmaterial Cost - Optimised

Gross material cost : 13.475 Kg x 52 Rs Scrap cost : 1.71Kg x 21 Rs Net Material cost : 664.70 Rs
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Process Cost

Raw Material Strip cutting Blanking &

(Sheet) (Shearing) Notching Draw 1

Flange Pierce Trim & Pierce Draw 2

Restrike

Cam pierce &

Restrike ED coating Packaging Despatch

Machine Rate / Stroke No of Strokes cost (Rs)

Shearing machine 2.50 Rs 1 2.5

800 T 8 Rs 7 56

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Cost Structure – Oil Pan
Material Rs Process Other cost Total

21,9 1.117,7
13,3 8,8 1,2
72,3
7,2
269,8
700,7 664,7 58,5

-36,0
Gross Scrap Net Process Surface Rejection ICC Profit OH DM Pack Total
material material cost finish &Log
cost cost

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Calculate Part Cost for below example

173
321
IS2062 : Rs 40/kg
Part Name : Bracket Tail Lamp Scrap : Rs 22/kg
Press Cost : Rs2/stroke (200Ton)
Finish Weight : 0.99 Kg
Rejection : 1% on Raw matl + Process
Thickness : 3 mm ICC : 2% on Raw Matl
Material : IS2062 Die Maint : 2% on process cost
Profit &OH : 10% on Raw matl + Process
Standard sheet size: 2500x1250mm
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Part Cost
Material Cost
Standard sheet weight (2500x1250x3) = 73.6kgs
No. of blanks from standard sheet = 49nos
Weight of blank / part = 1.50kgs
Gross RM cost (1.5x40) = Rs 60.0
Scrap weight (1.5-0.99) = 0.51kgs
Scrap recovery cost (.051x22) = Rs 11.22
Net material cost / part = Rs48.78

Process Cost
No of strokes / stages =3
Total stroke cost (3x2) = Rs6.0
Other Cost
Rejection (1%) = Rs0.55
ICC = Rs0.98
Die Maintenance = Rs0.12
Profit & OH = Rs5.48

Total Part Cost = Rs61.94

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Agenda

1. Sheet metal Process

2. Stamping Press
3. Part Cost basics
4. Tool Types
5. Tool Construction
6. Tool Manufacturing Process
7. Tool Cost sample calculation

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Tool types
Die Construction

Casting Steel

Draw Die

Trim/Pierce Die

Flange Die

Cam Die

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 Sheetmetal Tool Selection

Close Meshed Global Matl Die Process

Lead Time Tool Life
network Availability manufacturer flow

Part size

Complexity

Press Tonnage

Press availability

Tool Shut height

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Sheet metal Parts Categorization

Part Size upto Example Example

CATEGORY (Length x Width) (Frame Parts) (Cabin Parts)

Above 1500 x 800 mm Side Long Member, All Skin panels, Floor panel,
Reinforcements Long member Firewall, Rear Panel
A
1500 x 800 mm Cross Members, Large Pillar Inside panels, Windshield
B Reinforcements Rails, Longitudinal panel

500 x 200 mm Gussets, Reinforcement brackets Reinforcement plates, Support

C panels,

150 x 100 mm Brackets, Washers, Brackets, Washers,

D Reinforcement Reinforcement
Note: Based on part complexity above category may slightly vary

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Part Category
A B

C D

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Typical Selection of Tool Construction

PART TOOL CONSTRUCTION Tool Size upto

CATEGORY TYPE Length x Width x Shut height Range of Presses

Above Above 1200T press

A CASTING 2200 x 1400 x 750 mm

2200 x 1400 x 750 mm Upto 1000T press

B CASTING

1000 x 400 x 500 mm Upto 500T press

C STEEL PLATE H-frame / C-frame

700 x 300 x 300 mm Upto 400T press

D STEEL PLATE C-frame

Note: Based on part complexity above category may slightly vary

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Agenda

1. Sheet metal Process

2. Stamping Press
3. Part Cost basics
4. Tool Types
5. Tool Construction
6. Tool Manufacturing Process
7. Tool Cost sample calculation

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Draw Die Construction

Upper Tool Lower

Upper Tool:
Blank Tool:
Punch:Holder:
Lower
Upper
Blankholder
Punch tool
tool
is / iscavity
also basic
iscalled isstructure
floating also
the member
male which
called
die
houses
female
attached
which punch
die.
is to
attached
lower & blank
to theholder.
tool. lower tool
Blank Holder Lower tool
The
It is blank
Punch acutated
is isisclamped
non clamped
/moving
lifted by to
part the
between
cushionpress
upper
in the pins
tool
bolster.
tool
of the
During& press
blankholder
each stroketo thecontrol
blank the
wraps
Punch Lower
flow
Blanks
over thetool
of has to
material.
are
punch
loaded required
take
on the theprovision
final to
blank
accommodate
This
holderis clampedthe
profile. to movement
the RAM ofofthe
Wear Plate cushion pinssqueezees
from the press
press
During whicheach stroke material
blank holder
agains
controls thethepunchflowtoofform the part
material into the
Cushion Pin profile
punch

Lower Tool

Upper Tool Blank Holder Punch Lower Tool

Die Material
FCD550/GM241 FCD550/GM241 FCD550/GM241 FC300

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Trim / Pierce Die Construction

Pierce Punch Riser Upper Tool Stripper

Stripper:
Upper
Punch:
Cutting
LowerTool:
inserts:
Tool:
Stripper
Upper
Punch
Cutting
Lowertool
istool
insert
isfixed
also
houses
is are
to
called
basicthe
small
Stripper
lower
assegments
pad.
&
structuretool.
which
Piercing
Punch
made
Stripper
houses ofhouses
is
casting/steel
punches
punch movable
lowerandpart
& blank cutting
which
cutting
fixedinserts
isinserts.
holder. to
fixed
the&
Cutting This
die
to
upper
upper
buttons
Loweristool.
clamped
& lower
tool for piercing
totool.
is clampedupperto
holes
part
the of the
press
inserts press
When
They are
all actuated
bolster. segmentsusing are fixed
coil/gas
they
form
springs.
Lower thetooltrimline of the part
has required provision
Stripper
clear scrap holdsfrom thethe
parttool
against the
Piercing punch before cutting.
Punch
Scrap Lower Tool
Chute
Retaining blocks Punch
Upper Tool Lower Tool Cutting Inserts Stripper
Die Material
FC300 FC300 GM190/HMD5 FC250 / FC300
SX105V

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Flange / Restrike Die Construction

Upper Tool Lower Tool Restrike Block Stripper

Die Material
FC300 FC300 FCD550/GM190 FC250 / FC300

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Cam Operated Die Construction

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Agenda

1. Sheet metal Process

2. Stamping Press
3. Part Cost basics
4. Tool Types
5. Tool Construction
6. Tool Manufacturing Process
7. Tool Cost sample calculation

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 Tool Manufacturing Process – Casting Type
Formability Analysis 3D Design 2D Design CAM Program

Pattern Foundry Casting Rough Machining

CNC Machining Assembly/HT Spotting Tryout

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 Tool Manufacturing Process – Steel Type
Formability Analysis 3D Design 2D Design CAM Program

Raw Material Milling Grinding Wire-cut

Heat Treament Assembly Spotting Tryout

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Agenda

1. Sheet metal Process

2. Stamping Press
3. Part Cost basics
4. Tool Types
5. Tool Construction
6. Tool Manufacturing Process
7. Tool Cost sample calculation

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Tool Cost Sample Calculation

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