ME 5662 Teknologi Manufaktur Lanjut

(Advanced Manufacturing Technology)

Session : Economic & Cost

Cutting Estimate
(Classical Model) 1
Purpose of :
To find the cost of manufacturing operations
To assist in setting the price for product

Cost estimates include the cost of :

Labour
Material
Machine Costs
Overhead
Profit
The Cost Subtraction Formula

Cost + Profit = Selling Price

-there is no need for improvement
-there is no competing procedure
-consumer may have no choice

Profit = Selling Price Cost

-the price is determined by the market
-profit is what remains after subtracting
cost from price
-maximizing profit means that cost is to be
Cost = Price Profit
minimized
-setting a target cost
-the price is determined by the market
-profit required is determined by the company
 TOYOTA WAY in Production
Cost Principle Cost Reduction
(1) Selling price = Cost + Profit
(2) Profit = Selling Price - Costs

Profi
Profi Profi Profit
t Profi
t Sellin t
t
Cost g Sellin
Cost Cost Cost g
Price Cost Price

Methods for Raise the selling price Demand >

increasing profit Supply
Reduce the costs Demand <
Supply

Cost Reduction is Absolute Requirement to Increase Profit

CLASSICAL METAL CUTTING COST ANALYSIS
Involved in a metal cutting operation cycle :
Load work (LW)
Advance tool (AT)
Machining (M/C)
Retract tool (RT)
Unload work (UW)

Diagram Operation items

Handling

Handling cost = CO th
CO = Direct labour wage, Rp/min
th = Time for handling, min

Plot appears as a straight line, CO does not include overhead cost

Machining Time

L D Machining cost = CO.t

tm m

VC f

tm = Machining time, min.

L = Length of cut, mm.
D = Diameter, mm.
VC = Cutting speed, m/min
f = feed rate, mm/rot.

As cutting velocity, VC, increases,

machining unit cost decreases
Tool Life

T = Average tool life, min./cutting edge or tool point

n, K = Empirical constans resulting from statistical

analysis and fields studies.
0 n, K > 0
Case Study :

For end-milling of P20 tool steel.

The optimum conditions that is required to maximize the coated

carbide tool life are as follow:
cutting speed of 140 m/s,
federate of 0.1 mm/rev,
axial depth of 1.5 mm
and radial depth of 2 mm.

Using these parameters, a tool life of 39.46 min was obtained.

(Experiment product)
Tool Changing Cost

tm
tool changing cost CO tC
T
tc = Tool changing time, min.
Tool Cost
tool cost per operation C t
P
Ct t
ne

Ct = Cost per cutting edge, Rp./tool life

Pt = insert price
ne = number of cutting edge

Elements Time
Time to indexa turning type of carbide 2 min.
Time to set a high-speed tool 4 min.
Large milling tool replacement 10 min.
Remove, regrind, and replace drill 3 min.
Cost per tool cutting corner for turning, Rp 33,000.
carbide Rp 55,000.
Cost for high-speed steel tool point Rp
Cost per milling cutter, 150mm, carbide 1,500,000.
Drill cost Rp 33,000
Regrindable Tooling
HSS solid, Brazed carbide

Pt
Ct Tg C g
ng

Ct = Cost per cutting edge, Rp./tool life

Pt = Solid shank price, Rp/tool
ng = number of tool life / tool, can be ground before it can no longer be used
Tg = Time to grind or regrind the tool, min/tool life
Cg = grinders rate, Rp/min
Unit Cost (CU)

Tool
Handling Machinin
Tool Cost Changing
Cost g Cost
Cost

Independent m/c decrease increase increase

VC VC increase

T
CO t h Ct C O t C CO t m
tm
Production Rate (Unit per minute)

tm
TU t h t m tc tc
T
np
The Minimum Cost

n


C
Vmin
n CO

1 n C t C
O C t

Maximum Production Rate

Tool Life that correspondens to maximum production rate

Maximizing production rate = minimizing cutting time per unit
Example :

Material 430 F Stainless steel

O.D bar 45 mm
Cut. Length 420
Plus approach length giving a total 415
Insertable carbide - corner tool 8
Per corner Rp 33,000
Time to reset the tool 2 min
Handling of the part 0.16 min
The operator wage Rp
40,000/hour
Tool Life equotion VT0.16 = 400
Feed of the rough 0.38 mm/rot
Depth of cut 3.8 mm
 n 0.16 K 400 Vc 0 190 380 tc 2 min T 400 Co 150 per min. Vc 0 10 600

1 T
Tt( Vc) Co tc
n L D
K Vc f
T( Vc) Vc

150 400

300
100
T( Vc) Tt ( Vc) 200
50
100

0 0
150 200 250 300 350 400 0 200 400 600
Vc Vc

tc 2 D 45 L 415 f 0.38 th 0.16 Vc 0 10 600

Ct 33000 L D
tm( Vc)
T K 400 n 0.16 Vc f
Tc( Vc) Ct
L D tm( Vc)
Vc f Tu ( Vc) th tm( Vc) tc
T( Vc)
3
110
1000 965
4
510 930
4
410 895
4
310 860
Tc( Vc)
4 Tu( Vc) 825
210
4 790
110
755
0
0 200 400 600 720
Vc 670.034 685
K 400 Vc 200 n 0.16 650
0 40 80 120 160200 240280 320360 400440 480520 560 600
10 Vc 600
Comments on Machining
Economics
As C and n increase in Taylor tool life equation,
optimum cutting speed increasesn
VT C
Cemented carbides and ceramic tools should be used at
speeds significantly higher than for HSS

C n CO
n
V max
1n 1 t C
n Vmin C.
1 n CO t C Ct

Tmax 1 1 tC
n
Tmin
1 CO t C C t
1


n CO
Comments on Machining
Economics
Vmax is always greater than Vmin
Reason: Ct / np term in unit cost equation pushes optimum
speed to left in the plot of Cc vs. V

As tool change time tt and/or tooling cost Ct increase, cutting

speed should be reduced

Tools should not be changed too often if
either tool cost or tool change time is high
Disposable inserts have an advantage over
regrindable tools because tool change time
is lower
The Economics of Metal
Cutting

Since tool life for

maximum production is
less than economical
tool life, hence cutting
velocity for maximum
production is > velocity
for lowest cost.

We can now put the two

optimums in perspective:
Unit Cost
Exercise 1:

Workpart: L= 300mm and D= 80mm.

Taylors Eq. for a HSS tool: n= 0.13 and C=
75(m/min)
Machining condition: f= 0.4mm/rev.
Operator and machine cost= Rp.30,000/hr
Tooling cost/edge= Rp 45,000
2 min to load and unload and 3.5 min to change
tools

(a) Cutting speed for max. production rate

(b) Tool life in min. for max. production rate
(c) Cycle time and cost per unit of product for
Exercise 2:

Workpart: L= 300mm and D= 80mm.

Taylors Eq. for a HSS tool: n= 0.13 and C=
75(m/min)
Machining condition: f= 0.4mm/rev.
Operator and machine cost= Rp.30,000/hr
Tooling cost/edge= Rp 45,000
2 min to load and unload and 3.5 min to change
tools

(a) Cutting speed for min. cost

(b) Tool life in minute for min. cost
(c) Cycle time and cost per unit of product for
 Exercise 3 :

Sebuah mild steel di bubut menggunakan HSS dengan parameter umur pahat
Taylor n=0.125, C=70 m/min. Panjang pembubutan 500 mm dan diameter= 100
mm. Feeding= 0.25mm/put. Waktu handling per buah= 5 menit dan waktu tool
change= 2 menit. Ongkos mesin dan operator= Rp 270,000 dan ongkos per mata
potong= Rp 27,000.
(a) Cari Vc untuk maksimum production
(b) Cari Vc untuk minimum cost
Exercise 4 :
Sebuah proses bubut roughing sepanjang 500 mm
dilakukan pada material medium carbon steel dengan
menggunakan HSS. Diameter benda kerja adalah 100
mm. Biaya per mata alat potong adalah Rp. 50,000.
Waktu untuk menukar mata potong adalah 4 menit.
Waktu handling benda kerja adalah 2 menit dan biaya
buruh sebesar Rp 20,000/jam. Persamaan umur pahat
VT0,1 =172. Feeding operasi bubut 0,51 mm/rev dan
kedalaman 6 mm.

a. Plot keempat kurva cost dan pilih kecepatan potong

optimum
b. Cari kecepatan potong minimum secara analitis.
Sumber:
Joyjeet Goshe, Birla Institute of Technology, Ranchi
 Home Work:
Carilah tingkat produksi per jam dan ongkos per buah
untuk dua buah kecepatan potong pada contoh3.
Tambahan data yang berkenaan dengan ongkos alat
potong:
Harga HSS batangan original = Rp 225,000.
Jumlah penggerindaan = 16,
Waktu antar penggerindaan = 7 menit
Rate penggerindaan = Rp 270,000/jam, (Rp
4500 /menit)