Cost Estimating for Machining Operations
Table of Content
Table of Figures ...............................................................................................ii
Table of Tables ............................................................................................... iii
1. Setup time per part ........................................................................................ 2
2. Nonproductive time includes ......................................................................... 2
2.1. Loading and unloading time ................................................................... 2
2.2. Tool positioning time .............................................................................. 3
3. Machining time, tm ......................................................................................... 4
3.1. Machining time under surface finish consideration ................................ 4
3.2. Machining time for minimum cost .......................................................... 5
3.3. Machining time for maximum power ..................................................... 9
4. Tool replacement time ................................................................................. 10
4.1. Under surface finishing consideration .................................................. 10
4.2. Under minimum cost condition ............................................................ 10
4.3. Under maximum power condition ........................................................ 11
5. Time for extra tool travel ............................................................................. 11
6. Examples ...................................................................................................... 12
Reference ..................................................................................................... 14
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Table of Figures
Figure 1 Dimensions of (a) cylindrical and (b) rectangular workpiece .................... 4
Figure 2 Machining time, tm ................................................................................... 4
Figure 3. Relation between horsepower and workpiece weight for some machine
tools ....................................................................................................................... 9
Figure 4 Stepped rotational part .......................................................................... 12
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Table of Tables
Table 1 Machine and operator rate ....................................................................... 1
Table 2 Machining cost analysis worksheet ........................................................... 1
Table 3 Setup time ................................................................................................. 2
Table 4 Loading and unloading time ...................................................................... 3
Table 5 Tool positioning time ................................................................................. 3
Table 6 Machining Data ......................................................................................... 7
Table 7 Machining data for milling operation ........................................................ 8
Table 8 Material density ...................................................................................... 10
Table 9 Time for tool extra travel ......................................................................... 11
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Production cost Cpr per component is given by
C pr = Mt1 + Mtm + ( Mtct + Ct ) tm / t (1.1)
Where: M is the total machine and operator rate, t1 is the nonproductive time, tm
is the machining time (time the machine tool is operating) (table 1), t is the tool
life (machining time between tool changes), tct is the tool changing time, Ct is the
cost of providing a sharp tool, including the cost of regrinding and/or the
depreciation of the insert holder and insert where applicable.
Table 1 Machine and operator rate
Machine types M (USD/h)
CNC lathe 6
CNC Milling 7
In order to estimate Cpr, we should complete the table
Table 2 Machining cost analysis worksheet
1
1. Setup time per part
The setup time can be obtained from the following table (7.4 page 304)
Table 3 Setup time
2. Nonproductive time includes
Nonproductive time includes
2.1. Loading and unloading time
The loading and unloading time can be obtained from table (table 7.3 page 304)
2
Table 4 Loading and unloading time
2.2. Tool positioning time
Tool positioning time can be obtained from the following table (table 7.4 page
304)
Table 5 Tool positioning time
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3. Machining time, tm
Dimensions of workpiece can be determined from the following figure
(a) (b)
Figure 1 Dimensions of (a) cylindrical and (b) rectangular workpiece
In order to calculate the cost of production based on equation (1.1), it is
necessary to be able to estimate the machining time. The machining time, tm, can
be classified into three cases, they are machining time under the surface finish
consideration, tms, machining time, tmc, for minimum cost conditions, and the
machining time, tmp, where cutting speed is limited by power availability.
Machining time (tm)
Cutting speed
Surface finish Minimum cost
limited by
consideration condition
power
(tms) satisfied (tmc)
availability (tmp)
Figure 2 Machining time, tm
3.1. Machining time under surface finish consideration
If a tool having a rounded corner is used under ideal cutting conditions, the
arithmetical mean surface roughness, Ra , is related to the feed by
4
0.0321 f 2
Ra = (1.2)
r
where f is the feed and r is the tool corner radius.
The machining time tms is inversely proportional to the feed f and related by the
equation
lw
tms = (1.3)
fnw
where lw is the length of the workpiece and nw is the rotational speed of the
workpiece.
Thus, the machining time in terms of the specified surface finish:
0.18l w
tms = (1.4)
nw ( Ra r )0.5
3.2. Machining time for minimum cost
Machining data for minimum cost conditions can be expressed as speed x feed
(vf), or the rate at which the material surface can be generated. Table 7.6 (page
309) and table 7.7 (page 311) give typical values of vf for several material
classifications selected and for lathe and milling operations using different kinds
of cutting tool material.
When turning a surface of diameter dm for a length lw, the figures for vf given in
table 7.6 would be divided into the surface area ( Am = lwdw ) to give the
machining time, tmc .
Thus,
60A m
tmc = ( s ) (1.5)
( vf )
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For milling operations, it is convenient to estimate machining time from
knowledge of the feed speed vf that gives the recommended feed per tooth. Data
for milling selected materials are presented in Table 7.7
The machining time tm for recommended conditions is thus given by
tmc = 60lw / v f (s) (1.6)
Where lw is the length of the feature to be milled.
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Table 6 Machining Data
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Table 7 Machining data for milling operation
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3.3. Machining time for maximum power
For an estimated of the machining time tmp for maximum power it is necessary to
know the power available for machining and the unit power ps (specific cutting
energy) for the work material. Table 7.6 (page 309) gives average values of ps for
the selection of work materials employed here.
When estimating the power available for machining Pm, it should be realized that
small components are generally machined on small machines with lower power
available, whereas larger components are machined on large higher-powered
machines. For example, a small lathe may have less than 2 hp available for
machining, whereas an average sized lathe may have 5–10 hp available. A larger
vertical lathe perhaps has 10–30 hp available. Typical power values for a selection
of machines are presented in Figure 3, where the horsepower available for
machining Pm is plotted against the typical weight capacity of the machine.
Figure 3. Relation between horsepower and workpiece weight for some machine
tools
The density of some typical materials is given by the following table (Table 7.2
page 303)
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Table 8 Material density
The machining time for maximum power is given by
tmp = 60Vm ps / pm ( s ) (1.7)
4. Tool replacement time
4.1. Under surface finishing consideration
Time for tool replacement under surface finishing consideration can be estimated
as
1/ n
n tmc
ttms = tms (1.8)
n − 1 tms
Where tms is the machining time under surface finishing consideration, tmc is the
machining time under minimum cost condition
4.2. Under minimum cost condition
Time for tool replacement under minimum cost condition can be estimated as
n
ttmc = tmc (1.9)
n −1
10
where tmc is the machining time under minimum cost condition
4.3. Under maximum power condition
Time for tool replacement under maximum power condition can be estimated as
1/ n
n tmc
ttmp = tmp (1.10)
n − 1 tmp
where tmc is the machining time under minimum cost condition, tmp is the
machining time under maximum power condition.
5. Time for extra tool travel
Allowances for tool approach can be determined from following table (Table 7.5
page 306)
Table 9 Time for tool extra travel
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6. Examples
Rough and finishing turning a cylindrical (Figure)
Machine: CNC turret lathe
Cutting tool material: Carbide disposable insert
Workpiece material: Carbon steel, 5.000 in. length x 3.000 in. diameter
Assuming total rate for the operator and the machine would be $30/h
Size of batch: 1250 parts
Figure 4 Stepped rotational part
The various entries in the work sheet are shown in the following table
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1. Setup cost per part: 0.65x30/1250 = $0.0016
• Rough turning setup: 0.5h
• Finishing turning setup: 0.15h
2. The nonproductive time for workpiece loading/unloading and tool
positioning is 31.9+3=34.9 s
• Nonproductive cost: 34.9x30/3600=$0.29
3. The total machining time including allowances for tool wear and tool
approach is 105.63s
• Machining cost: 105.63x30/3600=$0.88
❖ The total machining operation cost is
$0.016 + $0.29 + $0.88 = $1.186
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Reference
Geoffrey Boothroyd, Peter Dewhurst, Winston A. Knight, Product Design for
Manufacture and Assembly, 3rd ed., Chapter 7: Design for Machining, 261 – 329,
CRC Press Taylor & Francis Group, 6000 Broken Sound Parkway NW, 2011.
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