System for early cost estimation of die-cast parts

Early cost estimate of a part is important information and forms a basis for preparing quotations, which are competitive from a market point of view. It is seen that a commonly adopted approach of variant cost estimation based only on geometric information of the component is not always accurate. This is also true in the case of die-cast parts. The geometric complexity of the part, tooling complexity, part and tool material, processing cost, and manufacturing resources for producing the part all need to be considered for accurate cost estimation. This paper deals with a comprehensive system developed to estimate and analyze the manufacturing cost of die-cast parts. A computer-aided cost-estimation system has been developed that applies manufacturing process as well as manufacturing resource considerations in addition to part feature complexity. Use of the proposed system is demonstrated in selecting the optimum number of cavities and the appropriate manufacturing resources under machine-related constraints. Further, the cost-estimation system developed herein is used for carrying out feature sensitivity analysis to identify design features that add significant cost to the part. The use of this system for optimal machine loading in multiple parts situation is also demonstrated.

[1]  Carolyn Blum.  Early Cost Estimation of Die Cast Components , 1989 .

[2]  KEINVORNAME;;; Nagahanumaiah,et al.  An integrated framework for die and mold cost estimation using design features and tooling parameters , 2005 .

[3]  G. D. Taylor,et al.  Design determines 70% of cost? A review of implications for design evaluation , 2001 .

[4]  Alexander Layer,et al.  Recent and future trends in cost estimation , 2002, Int. J. Comput. Integr. Manuf..

[5]  Kishore Pochiraju,et al.  Rapid Manufacturability Evaluation of Die-Cast Components , 2002, Concurr. Eng. Res. Appl..

[6]  P. H. Lowe,et al.  Computer-aided tool cost estimating: an evaluation of the labour content of injection moulds , 1985 .

[7]  Ong Nan Shing,et al.  Design for manufacture of a cost-based system for molded parts , 1999 .

[8]  H.J.J. Kals,et al.  Variant-based cost estimation based on Information Management , 2000 .

[9]  Bopaya Bidanda,et al.  Development of an intelligent castability and cost estimation system , 1998 .

[10]  D. Kennedy,et al.  The technology of the casting and the die , 1982 .

[11]  Essam Shehab,et al.  An Intelligent Knowledge-Based System for Product Cost Modelling , 2002 .

[12]  Yuh-Min Chen,et al.  Cost-effective design for injection molding , 1999 .

[13]  Daniel A. McAdams,et al.  Automated Manufacturability Analysis for Injection-Molded and Die-Cast Parts , 2003 .

[14]  Geoffrey Boothroyd,et al.  Product design for manufacture and assembly , 1994, Comput. Aided Des..

[15]  Robert C. Creese,et al.  Estimating and Costing for the Metal Manufacturing Industries , 1992 .

[16]  P. Dewhurst,et al.  Supporting Analyses for the Economic Assessment of Diecasting in Product Design , 1989 .