Introduction to Cost Estimation A s we have discussed in Section 3.20, materials cost is the cost of materials required for the manufacturing of the product. For calculating the materials cost of a product, the following siep by step procedure can be used. 1. Study the given drawing carefully. Then break up the product into simple geometrical shapes such as cubes, prisms, cylinders, étc., 80 that their volumes can be easily calculated. 2. Calculate the volume of each part by applying the formulae of mensuration. 3. Add volumes of all the parts to get the total volume of the product, 4. Calculate the weight of material by multiplying the volume by its density. 5. Finally, calculate the material cost by multiplying the cost per | __ Unit weight to the weight of the material. oo ” “ _ J Weight of { Cost per | “| Material cost = Lae material { * |_unit weight say hh { Weight of } ={ Total volume { Material } B2 where | the material | =| of the material density G2) For readers’ ready Feast some important formulae required for materials cost calculation are presented in Tables 3.6 and 3.7. Scanned with CamScannerTable 3.6, Areas of plane figures Process Planning and Cost Estimation Formula Area = Length x Breadth = 1x6 Perimeter = 2 (/ + 5) (a) Equilateral triangle -|Aream > xa xb or Is (s—a) (@—b) (sc) Perimeter = a+ b+ Perimeter = 2(a +b) Scanned with CamScannerIntroduction to Cost Estimation Area = L (a+b) xh Perimeter = a+b+o+d Area = 6 x Area of AAOB = 6x5 Bia = BB a = 2,598 a? Perimeter = 6a Any regular polygon General formulae for any regular polygon having sides of length a units are: 1 Area=3 x Perimeter x Inner radius Perimeter = 1d = 207 Scanned with CamScannersxe | name [igure | orm | | Arcaofscctor Area of Qn * circle Perimeter = J=r-@ Area = 2-3 2 = 02157 Area= 7a ab Perimeter = a (a+ 0) ‘Segment ofa cirele Volume = abe Length of diagonal a Vate eet ‘Surface area = ab + be + ca) Scanned with CamScannerIntroduction to Cost Estimation Name of the soli Figure ‘Cylinder Formula Volume = 27H Surface area=2ar(H +r) | Area Volume= of x Height base Surface area = ( Number of i) { surfaces g * + Area of two ends Volume = Area of base x Perpendicular height (H. 3 Surface area = Area of base + ‘ I [ Perimeter of base xg x Length of slant side (L) ] Scanned with CamScannerProcess Planning and Cost Estimation ‘Name of Hecuiel the solid foe Volume = H 3 (a, +a, 4.faz az ) where ay and ag are the. area of two ends. Sphere Volume = 42/3 Surface area = 4 4 r2 Segment of sphere Volume === GR-1) @ [foto] For irregular cross-sectioned areas, a planimeter can be used to determine the surface area. The planimeter is a precision instrument designed to calculate the area of any plane surface by tracking its perimeter. Scanned with CamScanner(a4) Process Planning and Cost Estimation An isometric view of a work piece is shown in Fig.3.3. What will be the weight of the mild steel material required to Produce it. The density of material is 2.681 grn/cc. Find also the material cost if its rate is Rs.100 per kg. All dimensions qre in mun. Given Data: p = 2.681 gm/cm3 = 2681 kg/m3; Unit cost = Rs. 100-per kg. To find: (i) Weight Of the material, and (i) Material cost. © Solution: First split up the given work piece into four portions A,B, Cand D, as shown in Fig.3.3. All dimensions are in mm. Fig. 3.3. (®) Weight of the material: Volume of cylinderA = 4 d2i = (a2)? 35 = 13304.64 mm} Volume of cylinder B = 7 (38)226 = 29486.99 mm? Volume of portionC = 32x 32x15 = 15360 mm3 Scanned with CamScannerIntroduction to Cast Estimation 3.45. Volume of cylinder D. = ; (20? 50 = 15707.96 mm3 -- Total volume = Vol. of A + Vol. of B + Vol. of C + Vol. of D | -13304.64 + 29486.99 + 15360 + 15707.96 = 73859.59 mm} or 73859.59 x 10°? m3 Weight of th *s forme = Total volume x Density = 73859.59 x 10-7 x 2681 = 0.198kg Ans. - (i) Material cost: We know that, Material cost = Weight of the material x Cost per unit weight = 0.198 x 100 = Rs. 19.80 Ans. -> Estimate the weight of material required for manufacturing 220 pieces of shaft as shown in Fig.3.4. The shafts are made of mild steel which weighs 7.87 gm/cn and costs Rs.100 per kg. Also calculate the material cost for 220 such shafts. All dimensions are in mm Fig. 3.4. 7.87 x 103 Given Data: n= 220 pes; p= 7.87 gm/em3 = coy =7.87 x 10° kp/mm}. To find: Weight and cost of the materials required for 220 shafts. Scanned with CamScannerProcess Planning and Cost Estimation © Solution: (i) Weight of material required: First let us split up the given shaft into five simple parts A, B, C, D and E, as shown in Fig.3.4. Volume of A = 7 (14)? 15 = 2309.07 mm Volume of B = Volume of frustum of a cone h = 3 (ay tata a ) where h = 30mm; a, = | (14)?= 153.04 mm; a = F (28)? = 615.75 mm? . Volume of B = 2, 153.94 + 615.75 +4/ 153.94 x 615.75 ] ™ 10775.675 mm Volume of C = 5 G5) 13 = 12507.46 mm? Volume of D = 4 (2122.5 = 7793.11 mim Volume of E = = (014)? - (0) } x 30 = 2261.95 mm? Total volume = Vol. of A + Vol. of B + Vol. of C + . Vel. of D + Vol. of E = 2309.07 + 10775.675 + 12507.46 + 7793.11 + 2261.95 = .35647.265 mm Weight of the } shaft Total volume x Density 35647.265 x 7.87 x 10-6 = 0.2805 kg Then, m0 take | = 0.2805 x 220 = 61,72 kg Ans. -w 220 shafts Scanned with CamScannerIntroduction ta Cost Estimation (ii) Cost of materials required for 220 shafts: Cost of materials = Total weight x Cost:per unit weight = 61.72% 100 = Rs. 6172 Ans. -> Calculate the material cost of 20 gun metal bushes as per the diagram Fig.3.5. Assume the density of gun metal as 8.3 gm per cc and its cost is Rs.350 per kg, Consider 10% material loss during process. Ail dimensions are in mm. [4.U., Nov/Dec 2009} Given Data: _ Density of gun metal = 8.3 gm/ce; Material cost = Rs. 350/kg, To find: Material cost of 20 bushes © Solution: Break up bush into simple parts A, B, C and D. YZ oe “ pe All dimensions are in cm Fig. 3.5. Busit Volume of part A = xx? = 32ncm? A Volume of patB = x@x1 = ORem SIA Volume of pattC = GxPxa = 16cm? Scanned with CamScannerProcess Planning and Cost Estimation Volume ofholeD = $x 3?x10. = 225 xem? Volume ofbush = 2A4+2B+C-D = 237.3 cm? Weight ofbush = BUE=83 «97 49 Hence, weight of material required for 20 bushes = 1.97 x 20x 1.1 = 43.34 ke 43.34 350 Rs. 15169 Ans. -> Find the cost of material for the machine part Shown in Fig.3.6. Density of material may be taken as 8.2 gm/cu cm. The cost of material is Rs. 30 per kg. Assume 20% wastage of material of the finished component and 6 holes Sor bolt. (considering 10 % loss) Material cost [A.U. Nov/Dec 2004] All dimensions are In mm Fig. 3.6. Given Data: p = 8.2 gm/ce = 8.2 x 10-6 kg/mm?; Unit cost = Rs. 30 per kg. To find: Cost of the material required. Scanned with CamScannerIntroduction io Cost Estimation © Solution: First, let us split up the given machine part into six simple parts A, B, C, D, E and F, as shown in Fig,.3.6. Volume of A = Volume of cylinder = Area x Length It [= cisoy | 38 = 584964.55 mm3 [ Soy | 28 = 54977.9mm?3 Volume of C = [ Fcasy | 10 = 159043 mm3 Volume of B Volume of D [3 asy | 12 = 3053.6 mm? Volume of E [= aoy | 26 = 2082 mm? Volume of F [ & cc.aoy2— 0592) | 10 = 83055.8 m3 ~. Total volume | _ ie of A-—[ Vol. of B+ Vol. of C + of the machine part} ~ (Vol, of F +6 (Vol. of D + Vol. of E) ] . $84964.55 — [54977.9 + 15904.3 + §3055.8 + 6 (3053.6 + 2042) | = 400452.95 mm} Wastage of material 20 fe. material cost p «=~ h5- x -400452.95----— -- - in machining processes 3 = $0090.59 , Gross volume of the machine part \ = 400452.95 + 80090.59 = 480543.54 mm} Then the total weight = Gross volume x Density = 480543.54 x 8.2 x 10-6 =3.94 ke Hence, the material cost of the machine part = Total weight x Unit cost - 3.94 x30 = Rs, 118.20 Ans. > Scanned with CamScanner