Economic optimization of machining

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 Cost Of Machining
The influences of machine tool technology, manufacturing systems
management and materials technology on the cost of machining can now be
considered. The purpose is not to develop detailed recommendations for
best practice but to show how these three factors have interacted to create a
flow of improvement from the 1970s to the present day, and to look forward
to the future. In order to discuss absolute costs and times as well as trends.
 Turning Process Manufacturing Cost

Even if machining time is reduced by advanced manufacturing technology, the cost may not
be reduced: advanced technology is expensive. The cost of manufacture Cp is made up of
two parts:
1. the time cost of using the machine tool
The time cost itself comprises two parts: the charge rate Mt to recover the
purchase cost of the machine tool and the labour charge rate Mw for operating it.
Mw is more than the machine operators wage rate or salary. It includes social
costs such as insurance and pension costs as a fraction fs of wages. Furthermore, a
company must pay all its staff, not only its machine operators.
2. the cost Ct of consuming cutting edges
 Turning Process Manufacturing Cost

Taylors Equation: VTn = C

Mt = Depresiasi unit
Mw = Operator Cost
Vvol = Laju gram yang dihasilkan
V = Cutting Speed
f = Feed
D = Depth of cut
ttotal = Machining time
Ct = Cost of tool
Turning Process Manufacturing Cost
 Turning Process Manufacturing Cost

Note :
tmach= tc
 Turning Process Manufacturing Cost

Note :
tmach= tc
 Turning Process Manufacturing Cost

Cp = (Mt + Mw) tmach + Ctp

2
Cp = (Mt + Mw) tc + Ctp

Mt (Depresiasi Unit)
Merupakan beban yang dipikul perusahaan atas pemilikan suatu mesin produksi. Hal ini
berhubungan dengan modal, dengan tambahan bunga, pajak dan asuransi.

1 y+1
Mt = Mo ( + . Ipti)
y 2.y
Mt = Depresiasi unit
Mt = Harga beli unit
y = Tahun
Ipti = Bunga, pajak, asuransi
 Turning Process Manufacturing Cost

BOHLER HSS Tool Bit / Pahat Cemented Carbide tool Tip Ceramic tool Tip
Bubut HSS : $15 / Pahat Bubut Carbide : $65 / Pahat Bubut Ceramic : $85

Mechanical lathe machine CNC turning center

 Turning Process Manufacturing Cost
Example : Show how the time and cost of
product to reduce the diameter of the tube
stock from 100 mm to 50 mm, over the
length of 50 mm. It is supposed that is
carried out at a feed and depth of cut of
0.25 mm and 4 mm respectively, and that
time for loading workpice is 1 min.

a) Times have been estimated for high speed steel, cemented carbide and an alumina
ceramic tool material, used in mechanical or simple CNC lathes or in machining centres.
b) Costs have been estimated for high speed steel, cemented carbide and an alumina
ceramic tool material, used in mechanical or simple CNC lathes or in machining centres.
Assume depreciation for 10 years with a tax of 27% per year with cost for labour $20
per product.
Turning Process Manufacturing Cost
 Turning Process Manufacturing Cost

Material Removal Rate (MRR) dimensional consistency by

Volume of material removed in one revolution substituting the units
MRR = D d f (mm3) Operations on Lathe ..
Job makes N revolutions/min MRR: D d f N
MRR = D d f N (mm3/min) (mm)(mm)(mm/rev)(rev/min) =
In terms of v MRR is given by mm3/min
MRR = 1000 v d f (mm3/min)
 Turning Process Manufacturing Cost

MRR: D d f N
(mm)(mm)(mm/rev)(rev/min) = mm3/min
MRR = Volume / time

lt lt
tc = = ;
vf n.f
min/produk

x l (ro2 rf2)
MRR = l
n.f

Volume = Luas Alas x Tinggi

= n f (ro2 rf2)
Volume = Luas Alas x Tinggi
= ( x ro2x l) - ( x rf2x l)
= x r2x Tinggi
= x l (ro2 - rf2)
 Turning Process Manufacturing Cost

D d f N = n f (ro2 rf2)
D d = (ro2 rf2)
(+) ( )
= (ro2 rf2)
2 2

(2 2)
= (ro2 rf2)
4

(2)2 (2)2)
= (ro2 rf2)
4
2
4[ 2]
= (ro2 rf2)
4

(ro2 rf2) = (ro2 rf2)

MRR = D d f N (mm3/min)
Or

MRR = (mm3/min)

Turning Process Manufacturing Cost

Note :
TABLE 21.2 gives high
and low, we might us an
average
Eavg = (Eh + El)/2
Turning Process Manufacturing Cost
 Tugas
Example : Show how the time and cost of
product to reduce the diameter of the tube
stock from 100 mm to 50 mm, over the
length of 50 mm. It is supposed that is
carried out at a feed and depth of cut of
0.25 mm and 2 mm respectively, and that
time for loading workpice is 1 min.

a) Times have been estimated for high speed steel, cemented carbide and an alumina
ceramic tool material, used in mechanical or simple CNC lathes or in machining centres.
b) Costs have been estimated for high speed steel, cemented carbide and an alumina
ceramic tool material, used in mechanical or simple CNC lathes or in machining centres.
Assume depreciation for 10 years with a tax of 25% per year with cost for labour $1,5
per product and cost/kwh is 1$.