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    Jigs and Fixtures Design PTB41002: Cost Calculation Raja Aziz Raja Ma'arof

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    azizmaarof
    This document outlines the main cost components and calculation methods for jigs and fixtures design projects. It discusses the costs of design, materials, machining, heat treatment, handling, delivery, administration, and profit margins. Machining costs are calculated based on factors like machine type, machining time, feed rate, depth of cut, and material removal rate. Administration costs are apportioned based on total overhead costs and number of production machines. Profit margins vary depending on the project difficulty, timeline, and market competitiveness. The total costs are then used to generate a customer quotation.

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    Jigs and Fixtures Design PTB41002: Cost Calculation Raja Aziz Raja Ma'arof

    Uploaded by

    azizmaarof
    365 views18 pages
    This document outlines the main cost components and calculation methods for jigs and fixtures design projects. It discusses the costs of design, materials, machining, heat treatment, handling, delivery, administration, and profit margins. Machining costs are calculated based on factors like machine type, machining time, feed rate, depth of cut, and material removal rate. Administration costs are apportioned based on total overhead costs and number of production machines. Profit margins vary depending on the project difficulty, timeline, and market competitiveness. The total costs are then used to generate a customer quotation.

    Original Description:

    Jig and Fixture Cost Calculation

    Original Title

    JigandFixtDesignLecture05CostCaln

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    This document outlines the main cost components and calculation methods for jigs and fixtures design projects. It discusses the costs of design, materials, machining, heat treatment, handling, delivery, administration, and profit margins. Machining costs are calculated based on factors like machine type, machining time, feed rate, depth of cut, and material removal rate. Administration costs are apportioned based on total overhead costs and number of production machines. Profit margins vary depending on the project difficulty, timeline, and market competitiveness. The total costs are then used to generate a customer quotation.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    365 views18 pages

    Jigs and Fixtures Design PTB41002: Cost Calculation Raja Aziz Raja Ma'arof

    Uploaded by

    azizmaarof
    This document outlines the main cost components and calculation methods for jigs and fixtures design projects. It discusses the costs of design, materials, machining, heat treatment, handling, delivery, administration, and profit margins. Machining costs are calculated based on factors like machine type, machining time, feed rate, depth of cut, and material removal rate. Administration costs are apportioned based on total overhead costs and number of production machines. Profit margins vary depending on the project difficulty, timeline, and market competitiveness. The total costs are then used to generate a customer quotation.

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    Jigs and Fixtures Design

    PTB41002

    Cost calculation
    Raja Aziz Raja Ma’arof
    Main cost components
     Design
     Raw materials and standard parts
     Machining
     Heat treatment
     Handling
     Delivery
     Administration
     Profit margin
     Quotation
    Design cost

     RM / hr
     Design duration
     Design objective (based on problem
    statement)
     Design needs analysis
     Research ideas
     Design alternatives
     Final design
    Raw material & standard part cost

     Raw material, by:


     Request for quotation from suppliers
     Weight
     Size or volume
     Standard part catalogue
     Price list from suppliers
     Request for quotation from suppliers
    Machining cost
     Machine type
     Milling
     Turning
     Grinding
     Wirecut
     Diesink
     Welding
     Machining accuracy
     Machining time calculation
     RM / hr rate
    Machining time calculation: turning
     th = Machining time
    L×i
    th =  L = Feeding length
    n× f  i = Number of cutting stage
    vc  n = RPM
    n= f = feed length per revolution
    π ×d
    
     Vc = Cutting speed
    L
    l = 1240mm, la = 2mm, f = 0.6mm, Vc =
    120m/min, i = 2, d = 160mm
    L = 1240 + 2 = 1242 mm
    m
    120
    n= min = 238.7rpm
    l
    π × 0.16m
    1242mm × 2
    la th = = 17.3 min
    1
    238.7 × 0.6mm
    min
    Machining time calculation: milling
    th = Machining time
    L×i L×i
    

    th = th =  L = Feeding length
    vf n× f  i = Number of cutting stage
     n = RPM
    f = fz × z  f = feed length per mill tool revolution
     fz = feed per mill tooth
    vf = n× f  z = Nr of teeth
    d
     Vf = Feeding speed
     a = Depth of cut
    a1 l = 176mm, la = 3mm, d = 100mm, z = 8, n = 64
    T a2 rpm, fz = 0.1mm, a= 8mm, i = 1

    L = d / 2 + la + l = 100 / 2 + 3 + 176 = 229 mm


    L mm
    la f = fz× z = 0.1×8 = 0.8mm; vf = n× f = 64rpm×0.8mm= 51.2
    L×i 229 mm × 1 min
    th = = = 4 . 47 min
    vf 1
    51 . 2
    min
    Machining time calculation: cylindrical grinding
    L×i  th = Machining time
    th =  L = Feeding length
    n× f
    Machining time
     i = Number of cutting stage
     n = RPM
    vf  f = feed length per tool revolution
    n= Vf = Feeding speed
    π × d1
    Workpiece rpm 

     a = Depth of cut
     d1 = Raw workpiece diameter
     d = Workpiece finished diameter
    d − d1
    Nr of cutting i= +8 d1 − d
    2× a i= +8
    2×a
    External grinding Internal grinding
    Machining time calculation: surface grinding
    L×i  th = Machining time
    th =  L = Feeding length
    n× f
    Machining time
     i = Number of cutting stage
     n = RPM
    vf  f = feed length per tool revolution
    Nr of stroke/min n=  Vf = Feeding speed
    L  a = Depth of cut per penetration
     t = Total cutting depth

    t
    Nr of cutting i= + 81)
    a

    1) 8 pre-cut travels
    Machining time calculation: EDM
    Wirecut
    L  th = Machining time
    Machining time th =  L = Cutting length, direction of cut
    vf
     Vf = Feeding speed
     H = Cut height
     T = surface tolerance (µm)

    Diesink
     th = Machining time
     S = Electrode surface area
    V
    Machining time th =  V = volume to remove
    vW  Vw = Material removing rate
    (mm3/min
    Heat treatment

     RM / kg rate
     RM for special requirement
     Material
     Heat treatment method
     Induction
     Process control
    Handling cost

     Machine setting
     Assembly and dismantling
     Storage
     RM/hr
    Delivery

     Transportation mode
     RM / km
     Weight category
     Size or volume category
    Administration cost

     Apportionment: % to be costed to a machine


     RM/hr
     Eg.
     Admin staff payroll: Total RM50,000 per month
     Power & utility: RM5,000 per month
     Rentals: RM10,000 month
     2 shift, 8 hours / shift, 22 days / month. Equals to
    352 hours / month
    Administration cost

     Admin cost / month: RM65,000


     Rate: RM65,000 / 352 hours
     RM185 / hr
     50 production machines in total.
    Apportionment equals 1/50. or RM3.70 / hr /
    machine
    Profit margin

     % of total production cost


     % value depends on:
     Difficulty level
     Timeline given by customer
     Wisdom:
     Can others do it?
     Rule of thumb
    Quotation to customer

     Project name
     Project reference number
     Price
     Warranty
     Delivery date
    Cost summary
    Item Basis Rate (e.g.) RM
    Design Hrs RM25/hr
    Raw material Kg RM7/kg
    Std. part L/s As manufacturer list
    Machining Hrs RM5 to RM60/hr
    Heat treatment Kg RM5/kg
    Handling Hrs RM5/hr
    Delivery Km, weight, volume RM5 to RM60/km
    Admin Hrs RM4
    Total -
    Profit margin % 50 to 200
    Quotation

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