Unit - 4

Velammal College of Engineering and Technology
Department of Mechanical Engineering
ME8793
PROCESS PLANNING AND
COST ESTIMATION
PPCE UNIT IV Dr. T.KAMATCHI, Mr. K. MEENAKSHI SUNDAR 1

UNIT - IV
PRODUCTION COST ESTIMATION
Estimation of Different Types of Jobs -
Estimation of Forging Shop, Estimation of
Welding Shop, Estimation of Foundry Shop
ESTIMATION OF FORGING SHOP
Forging is defined as the process in which the desired
shape and size of an object is obtained through the plastic
deformation of the metal of the object.
It is performed by hammering or pressing the work piece

that is to be brought into a specific shape and size.

TYPES OF FORGING
Based on the temperature at which forging is carried out, forging can be classified as:
(i) Hot forging and (ii) Cold forging.
Hot Forging
When the forging is performed on the metal above the recrystallisation
temperature(723 ◦c), it is called hot forging .
Examples: Engine components like connecting rod, crank shaft, cam shaft, etc.
Cold Forging
When the forging is performed on the metal below the recrystallisation
temperature, it is called cold forging .
Examples: Components like bolt heads, nails, rivets, etc.,
TYPES OF FORGING PROCESS
The four different forging processes generally used are given below:
1. Hand or Smith Forging
If the metal is heated in a smithy and forged using forging tools manually or using
hand
It involves a lot of skill on the part of the operator and also is more time consuming.

2.Drop forging
Drop forging utilises a closed impression
die to obtain the desired shape of the
component.
The shaping is done by the repeated
hammering given to the material in the
die cavity.
The equipment used for delivering the
blows are called drop hammers.

3.Press Forging
In press forging, the metal is
shaped not by means of a series
of blows as in drop forging, but by
means of a single continuous
squeezing action.
This squeezing is obtained by
means of hydraulic presses.
This method is used for producing
very heavy forgings.

4.Machine or Upset Forging
The heated bar stock is held
between two dies and the
protruding end is hammered
using another die.
In upset forging, the cross
section of the metal is
increased with a corresponding
reduction in its length .
This method is used for
making gear blanks, shafts, axles
and similar parts
ESTIMATION OF MATERIAL LOSSES IN FORGING
1. Shear Loss
The blank required for forging a component is cut from billets or long
bars, by means of a sawing machine.
This material loss is known as shear loss.
Shear loss is generally taken as 5% of the net weight.
2. Tonghold Loss
This small extra length will be removed after completion of the
workpiece.
This loss is known as tong hold loss.
Tong hold loss ={Area of cross section of bar}*
{Length of Tonghold}
Length of tonghold is generally taken as 2 to 2.5cm of the stock length .

3. Scale Loss
This thin film of iron oxide is called scale. When
hammering is done, the scale is broken and falls down
as a waste. This material waste is known as scale loss.
Generally scale loss is taken as 6% of the net weight
4. Flash Loss
When dies are used for forging, certain quantity of material
comes out of the die at the parting line of the top and
bottom halves of the die.
This surplus wastage material is called Flash loss.
Flash is generally taken as 20 mm wide and 3 mm thick.

FINDING FLASH LOSS
Flash loss = {Volume of flash }*{ Density of the material }

where
Volume of flash =
{Circumference of component at parting line}*{Cross sectional area of flash}
Cross-sectional area of flash = Flash thickness * Flash Width

5.Sprue loss
The portion of metal between the length held in the tong (i.
e., tonghold) and the material in the die is called sprue or
runner. This is cut off when workpiece is completed.
• The material loss due to this portion of the material

used as a contact is called sprue loss.
• The sprue must be heavy enough to permit lifting the

workpiece out of the impression die without bending.
• The sprue loss is generally taken as 7% of the net weight.

FORGING OPERATIONS
• Drawing down operation.
• Upsetting operation.
• Bending operation.
• Punching and drafting operation.
• Swaging operation.
• Hot cutting.
FINDING FLASH LOSS
(1) Drawing down operation:
Due to this operation by decreasing the cross-
section of the work-piece, its length can be
increased.
(2) Upsetting operation:
This operation increases the cross-section of the
bar-stock thereby reducing its length.
(3) Bending operation:
The bending of a job is done by holding it
between fixtures and striking the work-piece with
the help of hammer.
FINDING FLASH LOSS
(4) Punching and drafting operation
Punching is the operation of making holes and drifting is the
operation of enlarging the already punched holes.
(5) Swaging operation :
This the operation which reduces & finishes the job to desired
size and shape usually either round or hexagonal. This operation
brings the job into required accurate shape with the help of a
swage.
(6) Hot cutting:
This operation is used to cut the heated metal bars in a smithy
shop.

ESTIMATION OF FORGING COST
The cost of a forged component consists of
(i) Material cost,
(ii) Labour cost, and
(iii) Overhead cost
Total forging cost= {Labour cost} + {Material cost} + {overhead cost

(i) Calculation of Material Cost:
The calculation of material cost of a forged component involves the
following steps:
Step 1: To calculate the net weight of forging
Net weight ={Volume of forging} * { Density of Material used}
Step 2: To calculate the gross weight
Gross weight ={Net weight} * { Material loss in the process}
Step 3: To calculate the Material cost
Material cost= Gross weight * Price of raw material per kg
Step 4: To Select the diameter and Length of stock
Length of stock = ()
(ii) Calculation of Labour Cost:
Labour cost= {Forging time per piece in hours}
* { Labour rate per hour in rupees}
(iii) Calculation of Overheads Cost:

The overheads include supervisory charges, depreciation of plant
and machinery, consumables, power and lighting charges, office
expenses.

Pb-2 Calculate the net weight and gross weight for the component
shown in below fig. Density of material used is 7.86 gm/cc.

ESTIMATION OF WELDING SHOP

WELDING
Welding is the process of joining similar or dissimilar metals by the

application of heat.
Welding can be done with or without application of pressure and

with or without the addition of filler metal.
While welding, the edges of metal pieces are either melted or

brought to plastic condition .

WELDING PROCESS TYPES
The two main types of welding process are:
• Plastic or pressure welding,
• Fusion or non-pressure welding.

Plastic or pressure welding:

In plastic welding, the metal pieces are heated to
a plastic state.
They are pressed together to make the joint.

Since the pressure is applied, the plastic welding
is also known as pressure welding.
Examples: Spot welding, projection welding

and seam welding.

(ii) Fusion or Non-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.
Examples: Gas welding and electric arc welding

TYPES OF WELDING JOINTS
1.Butt Joint: Butt joint is used to join the ends of two sheets or plates kept in the same
plane, as shown in Fig.
2. Lap Joint: It is used to join two overlapping sheets or plates, as shown in Fig.
3. T-Joint: It is used for joining sheets (above 3 mm thick) or plates which are kept in the
form of "T" and at 90◦ each other, as shown in Fig
4.Corner Joint: It is used to join two plates or sheets kept at 90◦ to each other joined at
their ends, as shown in fig.
5.Edge Joint: Edge and flange joints as shown fig.

TYPES OF WELDING JOINTS

GAS WELDING TECHNIQUE




GAS CUTTING HAND (VS) MACHINE

ESTIMATION OF WELDING COST
Estimation of welding cost consists of the following elements:
1) Direct material cost,
2) Direct labour cost,
3) Direct expenses, and
4) Overhead expenses.

ESTIMATION OF WELDING COST
Direct Material Cost:

(a) Cost of base materials to be welded i.e., sheet, plate, rolledsection, casting or forging.
(b) Cost of consumables such as electrodes, flux, 0₂, C₂H₂ etc.
Direct Labour Cost:

Three categories of labour cost are:
(a) Preparation or pre-welding labour cost
(b) Welding cost welding operation.
(c) Post welding or finishing cost.

acetylene

ESTIMATION OF FOUNDRY SHOP

FOUNDARY
Foundry is the process of casting metals into objects of specified shapes.
The molten metals or alloys are poured in the moulds and allowed to cool. The object
after cooling is known as casting.
The various allowances provided to the pattern are as follows:
(i) Contraction or shrinkage allowance,
(ii) Draft allowance,
(iii) Machining allowance,
(iv) Distortion allowance, and
(v) Shake allowance.

ESTIMATION OF FOUNDRY COST
Material cost,
1. Direct material cost; and
2. Indirect material cost.
 Labour cost,
Direct expenses, and
Overhead expenses.

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Velammal College of Engineering and Technology

Department of Mechanical Engineering

PPCE UNIT IV Dr. T.KAMATCHI, Mr. K. MEENAKSHI SUNDAR 1

It is performed by hammering or pressing the work piece

PPCE UNIT IV Dr. T.KAMATCHI, Mr. K. MEENAKSHI SUNDAR 3

PPCE UNIT IV Dr. T.KAMATCHI, Mr. K. MEENAKSHI SUNDAR 5

PPCE UNIT IV Dr. T.KAMATCHI, Mr. K. MEENAKSHI SUNDAR 6

PPCE UNIT IV Dr. T.KAMATCHI, Mr. K. MEENAKSHI SUNDAR 7

PPCE UNIT IV Dr. T.KAMATCHI, Mr. K. MEENAKSHI SUNDAR 9

PPCE UNIT IV Dr. T.KAMATCHI, Mr. K. MEENAKSHI SUNDAR 10

Flash loss = {Volume of flash }*{ Density of the material }

Cross-sectional area of flash = Flash thickness * Flash Width

PPCE UNIT IV Dr. T.KAMATCHI, Mr. K. MEENAKSHI SUNDAR 11

• The material loss due to this portion of the material

• The sprue must be heavy enough to permit lifting the

• The sprue loss is generally taken as 7% of the net weight.

PPCE UNIT IV Dr. T.KAMATCHI, Mr. K. MEENAKSHI SUNDAR 12

• Drawing down operation.

• Punching and drafting operation.

PPCE UNIT IV Dr. T.KAMATCHI, Mr. K. MEENAKSHI SUNDAR 15

Total forging cost= {Labour cost} + {Material cost} + {overhead cost

PPCE UNIT IV Dr. T.KAMATCHI, Mr. K. MEENAKSHI SUNDAR 16

(iii) Calculation of Overheads Cost:

PPCE UNIT IV Dr. T.KAMATCHI, Mr. K. MEENAKSHI SUNDAR 18

PPCE UNIT IV Dr. T.KAMATCHI, Mr. K. MEENAKSHI SUNDAR 23

PPCE UNIT IV Dr. T.KAMATCHI, Mr. K. MEENAKSHI SUNDAR 29

Welding is the process of joining similar or dissimilar metals by the

Welding can be done with or without application of pressure and

While welding, the edges of metal pieces are either melted or

PPCE UNIT IV Dr. T.KAMATCHI, Mr. K. MEENAKSHI SUNDAR 30

The two main types of welding process are:

• Plastic or pressure welding,

• Fusion or non-pressure welding.

PPCE UNIT IV Dr. T.KAMATCHI, Mr. K. MEENAKSHI SUNDAR 31

Plastic or pressure welding:

They are pressed together to make the joint.

Examples: Spot welding, projection welding

PPCE UNIT IV Dr. T.KAMATCHI, Mr. K. MEENAKSHI SUNDAR 32

(ii) Fusion or Non-pressure Welding:

Then it is allowed to solidify.

Pressure is not applied in this welding process.

So it is known as non-pressure welding.

Examples: Gas welding and electric arc welding

5.Edge Joint: Edge and flange joints as shown fig.

PPCE UNIT IV Dr. T.KAMATCHI, Mr. K. MEENAKSHI SUNDAR 35

PPCE UNIT IV Dr. T.KAMATCHI, Mr. K. MEENAKSHI SUNDAR 36

PPCE UNIT IV Dr. T.KAMATCHI, Mr. K. MEENAKSHI SUNDAR 37

PPCE UNIT IV Dr. T.KAMATCHI, Mr. K. MEENAKSHI SUNDAR 38

PPCE UNIT IV Dr. T.KAMATCHI, Mr. K. MEENAKSHI SUNDAR 39

PPCE UNIT IV Dr. T.KAMATCHI, Mr. K. MEENAKSHI SUNDAR 40

Estimation of welding cost consists of the following elements:

1) Direct material cost,

2) Direct labour cost,

3) Direct expenses, and

PPCE UNIT IV Dr. T.KAMATCHI, Mr. K. MEENAKSHI SUNDAR 41

Direct Material Cost:

(b) Cost of consumables such as electrodes, flux, 0₂, C₂H₂ etc.

Direct Labour Cost:

(a) Preparation or pre-welding labour cost

(b) Welding cost welding operation.

(c) Post welding or finishing cost.

PPCE UNIT IV Dr. T.KAMATCHI, Mr. K. MEENAKSHI SUNDAR 42