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KERTAS PENERANGAN
COMPENTENCY
CU 02: PLASTIC INJECTION MOULD COSTING
UNIT
TAJUK
TUJUAN
OBJEKTIF:
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The estimation of machining time element starts with a careful study of the blue
print of the product and its components. If necessary, a fresh working drawing should' be
made for any missing drawing of a component. At this stage the estimator proceeds with
the work with an operation sheet that has been prepared by himself or supplied by the
planning department. An operation sheet has been shown elsewhere in the earlier
chapter. In this sheet, the main problem is to choose the proper values of speeds and
feeds for the operations if the same have not been given by planning department.
Cutting efficiency is depending greatly on cutting speed, feed rate and depth of
cut. While for milling operation, the efficiency depends greatly on the milling speed. If the
speed is too slow, it will be time consuming; and if it is too fast, the tools will be burned.
Therefore, choosing the right cutting speed and feed rate is very important in order
toobtain good quality work piece and cost saving in tools used.
In all the machining operations the cutting is either done by a single cutting edge
or a number of cutting edges. The cutting is achieved by employing a relative motion
between work piece and the tool. This means either the cutting tool is stationary and the
job is moving, tool is moving and job is fixed or both are moving as in turning, milling,
shaping, grinding etc. The selection of speed is a hard job and is always done on a
compromise basis. Every person who knows his job thoroughly prefers his own method
for selecting the cutting speeds. In principle, the main consideration to choose the cutting
speed is the tool-work pair. It is advisable that new comer encountering such a problem
should go by this consideration and pick up an average value. It would be always useful if
the following points are considered :
a) For a higher rate of metal removal, which means heavier feed and depth of cut,
b) While carrying out finish machining, choose lower values of feed and depth of cut
d) Select a Iower cutting speed if the machine tool is an old machine or its capacity
is small.
e) Where a longer tool life is a major criterion, use lower cutting speed, or if the tool
f) Some times a new material is given for machining for which no data is available,
Table 1.0 : Cutting speed for high speed steel and carbide
High Speed Steel Carbide
Material (m/min) (M/min)
Machine steel 21 - 30 48 - 75
Tool steel 18-20 40 - 60
Cast iron 15 - 25 40 - 60
Bronze 20 - 35 60 - 120
Aluminium 150 - 300 150 - 300
There are several factors affecting the cutting speed, which are as below:-
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Usually cutting speed of a milling tool can be determined from table. Therefore cutting
Diameter (d)
cs = cutting speed
= 3.142
Example 1:
Calculate the spindle speed in rpm for milling tool with diameter 50mm with the cutting
Rpm = 33 1000
50
rpm = 33000
157.1
rpm = 210
Example 2:
Calculate the spindle speed in rotation per minute for end mill with diameter of 50mm,
rpm = 25 1000
50
rpm = 25000
157
= 160
Example 3:
Calculate the cutting speed of an end mill with diameter 5cm and 160 rpm.
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Convert 5cm to mm
1cm = 10mm
5 x 10 = 50mm
Rpm = cs 1000
d
cs = rpm x d
1000
cs = 160 x 3.14 x 50
1000
1.3 Feeds
Only the tool advancement in one direction is not sufficient to machine a surface. It
has to move in a perpendicular direction to produce a surface. This kind of tool
movement is called feed. In the case of turning, the feed (f) of the tool is the axial
advancement of the tool in one revolution of the work piece. It is then expressed as
mm/rev. In shaping plaining or slotting, the feed is the advancement of work-piece in a
direction perpendicular to the tool during one complete stroke of the ram. The feed is
expressed as mm/stroke.
The feed (f) is defined in slightly different manner in milling. The work is
continuously moving towards the cutter at a certain rate to perform the action. This
movement is called the feed of the table in mm/min. As the cutter makes n revolution in
one minute, the feed of the cutter (fc) is obtained by L and expressed as mm/rev.
Similarly, if a cutter has 't' number of teeth then the feed (f) can also expressed as
mm/tooth. The situation in grinding is very much like milling but there is no feed for the
cutting edges. Only the table feed (f) and the wheel feed (fw) are of importance.
Selection of feeds and speeds is always done on a compromise basis. Some of the factor
be considered when specifying speeds and feeds are :
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(iii) The rigidity and shape of the work uniform sections, long thin sections,
areas or interrupted cuts.
(iv) Condition of the part as received e.g. rough casting, forging, annealed or
cold finished bar stock.
(vi) Tool life based upon optimum conditions for the lowest total cost/piece.
In the case of turning, as the cutting proceeds, the cutting edge traverses over the
work surface. If D is the diameter of the work-piece in mm and n is the rpm at which the
job is rotating, then the cutting edge traverses a distance 7TDN mm in one minute. The
traversing rate of the tool is called cutting speed of the lathe tool. It is also known as
v = 7TDn mm/min
Feed rate is known as the rate of table move feeding the tool which is turning. Feed rate
is affected by :
e. Types of finishing
Table 1.20 below shows chip per tooth, cpt recommended for steels commonly used in
industry. cpt is the amount of raw material to be cut off by every tooth cut.
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Table 1.20 : Chip per tooth, cpt (High Speed Steel Cutters)
Feed rate = total teeth (n) X chip per tooth (cpt) X rotation per minute (rpm)
Example 1:
Calculate the cutting feed in mm/minute for helix mill with 6 teeth, diameter 75mm when
rpm = cs 1000
d
= 60 1000
75
= 254.6
Example 2
Calculate cutting feed in mm/minute for gear cutting tool with diameter 50mm and 12
Rpm = cs 1000
d
= 33 1000
50
= 210
The use of cutting speed, feed and length of run made in estimating the time.
Cutting speed = Dn
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1000
a) Plain Turning
= DL vxf
1000
Example 1:
Estimate the time for turning a 50mm brass rod of 200mm length down to 31mm
diameter. The cutting speed for high-speed tool-brass is 100m/min and feed is 0.20
mm/rev.
= 636 rpm
= 200
636 x 0.2
= 15 min (approx)
= 3 minutes
b) Relief Turning
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Relief is a small reduction in the shaft or bar diameter over a certain length. It may
be provided on the outer surface or internal surface of a bore. The respective terms used
are external relief and internal relief. The estimation of time is done exactly on the same
ine with one difference that it requires a two pass turning.
Example 2:
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In a cast iron component having a 35mm cored hole, an internal relief is to be provided
over a length of 150mm. Determine the total time to machine the bore and turning the
elief in the component. Here cutting speed may be assumed to be 15m/min and a feed of
0.10mm/rev.
Solution:
This involves a boring operation and therefore, the diameter is finished in passes with
Machining time T = L D
1000 v.f
= 200 x 22 x 35 x 1
1000 7 15 0.10
= 14.6 min
The third step in the calculation is to determine the turning time for the relief in the bore.
Note:
42 minute in finishing a job like this, appears to be a high figure. In the case of boring the
cutting has to be done at lower feed because of the large overhang of the tool. A high
feed is detrimental to the cutting edge and the surface finish of the component.
c) Facing
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The facing operation on a lathe is meant for preparing end surface of a cylindrical
workpiece. The tool, which is a single point cutter, is fed across the axis of the work piece
over the end held on the dead centre (fig.10.04)
The tool moves outwardly starting from a point which is nearest to the axis, the piece is
required to run at higher rpm than when the tool is required to run at higher rpm than
when the tool is at outer end to maintain a constant value of cutting speed. This
continous variation is not possible on the kinds of lathes available in the shop. Therefore
an average value of rpm is worked out with help of work diameter (Dave).
Example 3:
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Calculate the machining time to face the dead center end of the work-piece of a 400mm
m.s rod, if the cutting speed for tool work-pair is 30m.min and crass-feed as 0.2mm/rev.
Example 4:
Calculate the basic drilling time to drill a 10mm hole on 50mm thick m.s basic the
cutting speed and feed are 17m/min and 0.30 mm/rev.
Solution:
Rpm = 1000 x v
D
= 1000 x 17 x 7
22 x 10
= 540
= 0.37min
= 22.2 secs
A drilling machine may also be used for other allied operation like counter-sinking,
counter-boring and tapping. The basic time for these operations can also be calculated
on the same line. A judicious selection of feed and speed is the main consideration.
Example 5:
If the above hole is to be enlarge to 20mm diameter, determine the drilling time using
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Solution :
rpm = 1000 x 25 x 7
22 x 20
= 398 rpm
Drilling Time = 50 + 10
0.35 x 398
= 0.43min
= 26 sec
Like lathe, milling machine is also a very versatile machine tool. Hardly it could be
missed in a workshop because it can perform many kinds of precision work which could
not be done on any other machine tool except a few special purpose machine tools. The
machine employs a multi-edged rotating cutter either of high speed steel or with inserted
carbide teeth cutter. The cutter produces a flat surface except in few cases where it
produces profiles with from cutters.
The milling time is calculated by dividing the length of cut with the product of
number of revolution and feed per revolution. The length of cut is obtained by adding the
allowances for cutter approach, and cutter over travel.
The length of cut is obtained by adding the allowances for cutter approach, and cutter
over travel.
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In the case the approach is a part of the length over-travel can be computed with the
following relationship:
Over travel = D - 1 D2 w2
2 2
D = diameter of cutter
ii) Cutting approach and over-travel in slab milling/slot milling. Fig. 10.11
Example 1:
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A 300 x 50 cast iron surface is to be face milled with a carbide cutter. The cutting speed
and feed are 50m/min and 50mm/min. If the cutter diameter is 80mm and it has 12
cutting teeth determine the milling time, cutter rpm and feed tooth.
Solution :
The milling is done in single pass fig. 10.12. The value of approach A is 40mm and over
Example 2
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A key way is to be cut on a shaft over its entire length. Calculate the approximate time if
the cutting speed is 30m/min , feed/rev = 0.08mm, and cutter diameter is 100mm.
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Length or machine travel distance depends on length of milling, type of cutter used and
operation to be achieved.
a = early distance
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d = mill diameter
T = machining time
f = feed rate
n = rpm
Example 1:
Calculate machining time needed to machine a cube which is 30mm2, 200mm length
with feed rate 100mm/minute. Early distance is 25 mm and cross over 5mm.
L = I+a+u
= 200 + 25 + 5
= 230mm
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= 230 (mm)
100 (mm/s)
= 2.3 sec
Example 2:
A T-slot is to be cut on a cast iron table as per details given in the fig. below. Layout the
sequence of the procedure and then estimate the machining time. Neglect tool approach
and over run.
Solution:
b) Mount 2 slab mill cutters 85mm long x 75mm dia on an arbor with 10mm spacer
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d) Shift the job to a vertical milling machine and cut the T-slot with a T-slot cutter Let the
cutting speed for face cutter and slab mill cutter be 15m/min and for T slot cutter be
10m/min. Also the diameter of side and face cutter be 120mm. The value of feed be
0.25mm/rev.
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Another important part of product costing has been recognized as labor cost.
Depending upon the nature of operation, it may range from 10 to 40 percent of the total
cost. In most of the chemical production, the labor cost is about 10-15 percent and
material cost 75 to 80 percent; while in the case of textiles garments it may be up to 40
percent of the total manufacturing cost.
Before the revolution of industry, labor cost is one of the most costing element in a
manufacturing process. After revolution, labor cost is minimized with the present of
machines and tools to substitute manual workers. Labor cost is calculated based on total
working hour, labor status (permenant, contract, part time).
Labor cost can be calculated based on salary, total working hour or work
produced.
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2) Indirect labor - cost of labor, which is not used directly for completing the job or
product.
3) Labor-related costs - these costs are not in any way directly or indirectly
related with the job or product but the costs related to the labor force-such as
premium pay, holiday and vacation pay, and other benefits to the labor.
Personnel department
Planning department
Payroll department
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Several factors are considered while determining the labor rate. Among the factors are :-
d) Labor law
e) Overtime concept
Advantage: -
Disadvantage: -
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Situation :
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6.1 Introduction
Costing is an important part in any project. This is the stage that indicates
the capabilities in taking any job. Some experience organization, they can judge
the price of the job by rules of thumb at the first view of the job, nevertheless, the
specific costing has to be made for the efficiency of the overall price. For the
purpose of this project, the costing are largely depend on the current price for the
material and also for the wages of the personnel involved. In rental consideration,
the market price is obtained from the company involves in the mould making.
Total = RM 2776.00
= RM 4000.00 X 12 month
2002 hours
= RM 23.97/hours
= RM 21.98/hours
= RM 21.98 X 4 hours
= RM 87.92
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Kod kertas MC-030-4 : 2014 C02 Muka surat : 31 drpd 35
= RM 39.96/hours
Total = RM 535.60
RM 719.12 + RM 535.60
= RM 5,944.74
Overhead cost is taken as 20% of the overall cost to produced the completed
Mould.
= 20% X RM 5,944.74
Muka 31 drp. 35
Kod kertas MC-030-4 : 2014 C02 Muka surat : 32 drpd 35
= RM 1,189.00
= 30% X RM5,944.74
= RM 1,783.40
= RM 8,917.14
Note:
We sale this mould to another company for injection process to produce the product.
= 240 pcs
= 480,480 pcs
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= RM 0.023
= RM 11,051.00
= RM 79,999.92
= RM 600.00 x 12 month
= RM 7200.00
= RM 1,794.00
Muka 33 drp. 35
Kod kertas MC-030-4 : 2014 C02 Muka surat : 34 drpd 35
= RM 11,051.00 + RM 79,999.20 +
RM 7,200.00 + RM 11,711.40
= RM 109,961.60
Cost/product = RM 109,961.60
480,480 pcs (include 5% product reject)
= RM 0.23/pcs
= RM 0.23 x 50%
= RM 0.115
= RM 0.345
= RM 0.40/pcs
Rejected product 5%
= 480,480 pcs x 5%
= 24,024 pcs
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Kod kertas MC-030-4 : 2014 C02 Muka surat : 35 drpd 35
= 456,456 pcs
= RM 182,582.40
= RM 182,582.40 - RM 109,961.60
= RM 72,620.80/year
12 month
= RM 6,051.73/month
The price shown above is referring to the price at factory. This costing is based on one
year life of mould. The price of product will be cheaper if the expected life of mould is
increase.
RUJUKAN:
3. TECHNOLOGY OF MACHINE TOOLS, S.F KRAR, J.W OSWALD, J.E. St. AMAND,
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