Build-Up an Economical Tool for Machining Operations Cost Estimation

Currently, there is a lack of affordable and simple tools for the estimation of these costs, especially for machining operations. This is particularly true for manufacturing SMEs, in which the cost estimation of machined parts is usually performed based only on required material for part production,...

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Main Authors: Francisco J. G. Silva, Vitor F. C. Sousa, Arnaldo G. Pinto, Luís P. Ferreira, Teresa Pereira
Format: Article
Language:English
Published: MDPI AG 2022-07-01
Series:Metals
Subjects:
Online Access:https://www.mdpi.com/2075-4701/12/7/1205
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author Francisco J. G. Silva
Vitor F. C. Sousa
Arnaldo G. Pinto
Luís P. Ferreira
Teresa Pereira
author_facet Francisco J. G. Silva
Vitor F. C. Sousa
Arnaldo G. Pinto
Luís P. Ferreira
Teresa Pereira
author_sort Francisco J. G. Silva
collection DOAJ
description Currently, there is a lack of affordable and simple tools for the estimation of these costs, especially for machining operations. This is particularly true for manufacturing SMEs, in which the cost estimation of machined parts is usually performed based only on required material for part production, or involves a time-consuming, non-standardized technical analysis. Therefore, a cost estimation tool was developed, based on the calculated machining times and amount of required material, based on the final drawing of the requested workpiece. The tool was developed primarily for milling machines, considering milling, drilling, and boring/threading operations. Regarding the considered materials, these were primarily aluminum alloys. However, some polymer materials were also considered. The tool first estimates the required time for total part production and then calculates the total cost. The total production time is estimated based on the required machining operations, as well as drawing, programming, and machine setup time. A part complexity level was also introduced, based on the number of details and operations required for each workpiece, which will inflate the estimated times. The estimation tool was tested in a company setting, comparing the estimated operation time values with the real ones, for a wide variety of parts of differing complexity. An average error of 14% for machining operation times was registered, which is quite satisfactory, as this time is the most impactful in terms of machining cost. However, there are still some problems regarding the accuracy in estimating finishing operation times.
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spelling doaj.art-3490b43e7e9b4f7a972d0201ba1b80412023-11-30T21:28:14ZengMDPI AGMetals2075-47012022-07-01127120510.3390/met12071205Build-Up an Economical Tool for Machining Operations Cost EstimationFrancisco J. G. Silva0Vitor F. C. Sousa1Arnaldo G. Pinto2Luís P. Ferreira3Teresa Pereira4Mechanical Engineering Department, ISEP-School of Engineering, Polytechnic of Porto, 4200-072 Porto, PortugalMechanical Engineering Department, ISEP-School of Engineering, Polytechnic of Porto, 4200-072 Porto, PortugalMechanical Engineering Department, ISEP-School of Engineering, Polytechnic of Porto, 4200-072 Porto, PortugalMechanical Engineering Department, ISEP-School of Engineering, Polytechnic of Porto, 4200-072 Porto, PortugalMechanical Engineering Department, ISEP-School of Engineering, Polytechnic of Porto, 4200-072 Porto, PortugalCurrently, there is a lack of affordable and simple tools for the estimation of these costs, especially for machining operations. This is particularly true for manufacturing SMEs, in which the cost estimation of machined parts is usually performed based only on required material for part production, or involves a time-consuming, non-standardized technical analysis. Therefore, a cost estimation tool was developed, based on the calculated machining times and amount of required material, based on the final drawing of the requested workpiece. The tool was developed primarily for milling machines, considering milling, drilling, and boring/threading operations. Regarding the considered materials, these were primarily aluminum alloys. However, some polymer materials were also considered. The tool first estimates the required time for total part production and then calculates the total cost. The total production time is estimated based on the required machining operations, as well as drawing, programming, and machine setup time. A part complexity level was also introduced, based on the number of details and operations required for each workpiece, which will inflate the estimated times. The estimation tool was tested in a company setting, comparing the estimated operation time values with the real ones, for a wide variety of parts of differing complexity. An average error of 14% for machining operation times was registered, which is quite satisfactory, as this time is the most impactful in terms of machining cost. However, there are still some problems regarding the accuracy in estimating finishing operation times.https://www.mdpi.com/2075-4701/12/7/1205cost estimationbudgetingmachiningoperation timesoperation costs
spellingShingle Francisco J. G. Silva
Vitor F. C. Sousa
Arnaldo G. Pinto
Luís P. Ferreira
Teresa Pereira
Build-Up an Economical Tool for Machining Operations Cost Estimation
Metals
cost estimation
budgeting
machining
operation times
operation costs
title Build-Up an Economical Tool for Machining Operations Cost Estimation
title_full Build-Up an Economical Tool for Machining Operations Cost Estimation
title_fullStr Build-Up an Economical Tool for Machining Operations Cost Estimation
title_full_unstemmed Build-Up an Economical Tool for Machining Operations Cost Estimation
title_short Build-Up an Economical Tool for Machining Operations Cost Estimation
title_sort build up an economical tool for machining operations cost estimation
topic cost estimation
budgeting
machining
operation times
operation costs
url https://www.mdpi.com/2075-4701/12/7/1205
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