Sheet Metal Manufacturing Cost Estimator R. J.

Eggert

Material Properties
Material = Steel
S= 7.9
U= 330 MN/m^2 Ultimate Tensile Stress
E= 207 GN/m^2 Ealstic Modulus
Cost = 0.8 $/kg
Scrap Value = 0.09 $/kg
Thickness = 0.91 mm Table 9.1

Material Costs
As = 236 cm^2 Area of the Sheet Surrounding part Cm = 13.57 cent / Part Cost of Materials
Apt = 163.4 cm^2 Area of The Actual Part Rs = 0.47 cent / Part Value of Manufactured srcap
As = 72.6 cm^3
Vg = 21.48 cm^3 Gross Volume of Sheet
Vs = 6.61 cm^3 Volume of Scrap

Die Set Costs - Part-Off Shearing Die

Perimeter = 58.4 cm Perimeter of punch Nt = 50000 Production quantity
Length = 8.182 cm Length of punch envelope M= 40 $/hr Die set manufacturing labor
Width = 13 cm Width of Tensile
Ultimate punch envelope Cds = 351.84 $ Basic Die Set Costs
Plan Area = 106.37 cm^2 Punch
Stress Plate
of MildArea Cm = 2089.20 $ Shearing Die Mfg Costs
Ums = 330 MN/m^2 Steal
Rounded to the Cd = 2441.04 $ Punch and Die Set Costs
hd = 18.31 mm nearest
Die Plate1/8" Ct = 4.88 cent / part Punch and Die Set Costs
fd = 0.866 Correction Factor
Au = 644 cm^2
Xp = 32.06 Profile Complexity
Mpo = 33.5 Basic Manufacturing Points Fig 9.9
flw = 1.8 Area Correction Factor Fig 9.10
Mp = 52.23 hours Manufacturing Points

Die Set Costs - Piercing Die

Np = 2 Number of Punches, Cds = 351.84 $ Basic Die Set Costs
Pp = 12.6 cm Perimeter of all Punches Cm = 1100.80 $ Piercing Die Mfg Costs
L= 2 cm Length Rect. Surrounding all Holes Cd = 1452.64 Punch and Die Set Costs
W= 2 cm Width Rect. Surrounding all Holes Ct = 2.91 cent / part Piercing Die Set Costs
Nd = 1 Number of Different Shapes or Sizes
K= 2 (2-round, 3.5 -sq, rectangular, obround)
Mpo = 23.12 hours Manufacturing Points
Mpc = 0 hours Manufacturing Points, Custom
Mps = 4.4 hours Manufacturing Points, Standard

Processing Costs
Shearing Press
Lsh = 58.4 cm Length of sheared surface L= 18 cm
fs = 87.69 KN Required Blanking force W= 13 cm
M= 55 $ Operating Costs Table 9.3 tshear = 4.83 sec.
Lst = 15 cm Maximum Press Stroke
spm = 100 Strokes per Minute
Nst = 1 Number of Different Press Srokes

Peircing Press
Lsh = 12.6 cm Length of pierced surface tpierce = 4.83 sec.
fs = 18.87 KN Required Peircing force
M= 55 $ Operating Costs Table 9.3
Lst = 15 cm Maximum Press Stroke
spm = 100 Strokes per Minute t= 9.66 sec. Total Cycle Time
Nst = 1 Number of Different Press Srokes Cp = 14.76 cent / Part Total Processing Cost

Nt = 50000 Production Qty = 5000 10000 50000

Cm = 13.57 Cm = 13.57 13.57 13.57
Rs = -0.47 Rs = -0.47 -0.47 -0.47
Cd = 7.79 Cd = 72.32 37.00 7.79
Cp = 14.76 Cp = 14.76 14.76 14.76
Ctotal = 35.65 Ctotal = 100.18 64.86 35.65
Total Cost for run quantity ($) = 5009 6486 17825
Revenues (If sold for $20) 10000 20000 100000
Profit ($) 4991 13514 82175
SHEET METAL MANUFACTURING COSTS

Part : Legs

Material Properties Part Properties

Material = Steel Thickness (mm) = 1.52 (From Table 9.1 page 362)
Specific Gravity = 7.9
Production
U= 330 MN/m^2 Ultimate Tensile Stress Volume = 4.00E+05
E= 207 GN/m^2 Ealstic Modulus
Costs = 0.8 $/kg Labor
Scrap Value = 0.09 $/kg Rate ($/hr) = 40

PUNCH AND DIE COSTS

SHEARING DIE COST

perimeter = 25.4 cm Perimeter to be Sheared

Length = 81.28 cm Length of Part Envelope Cm = 9914.74 $ Shearing Die Set Costs
Width = 10.16 cm Width of Part Envelope Cds = 186.25 $ Basic Die Set Costs
Plan Area = 825.80 cm^2 Punch Plate Area Ctsdc = 10100.99 $ Punch and Die Set Costs
Ums = 400 MN/m^2 Ultimate Tensile Stress of Mild Steal Ctsdc = 2.53 cent / part Punch and Die Set Costs
hd = 41.275 mm Rounded to the nearest 1/8"
fd = 1.3255 Die Plate Correction Factor
Au = 1840.20 cm^2
Xp = 0.78125 Profile Complexity
Mpo = 34 Basic Manufacturing Points
(From Figure 9.9 page 371)
Flw = 5.5 Area Correction Factor
(From Figure 9.10 page 372)
Mp = 247.87 hours Manufacturing Points

BENDING AND FORMING

Bending and Forming

D= 5.08 cm Largest Depth of Bend Cbf = 4343.17 $ Die Set Costs
Bending and Forming
Nb = 2 Total Number of Bends Cbf = 1.09 cent / part Die Set Costs
Lb = 81.28 cm Total Length of Bends
Mpo = 37.05 hours
Mpm = 66.87 hours

PRESS BRAKE

Nb = 2 Total Number of Bends Cpb = 18.89 cents/part Press Break Cost

Machine Rate = 28 $
t= 24.288 s / part Time

PIERCING

Np = 11 Number of Punches, Cpo = 4645.13 $ Piercing Die Set Costs

Pp = 21.93 cm Perimeter of ALL Punches Cpo = 1.16 cent / part Piercing Die Set Costs
L= 8.73 cm Length Rect. Surrounding all Holes
W= 3.49 cm Width Rect. Surrounding all Holes
Nd = 1 Number of Different Shapes or Sizes
K= 3 (Round Holes, K = 2 )
(Square, Rectangualr, Obround, K = 3.5)
Mpo = 23.91 hours Manufacturing Points
Mpc = 54.16 hours Manufacturing Points, Custom
Mps = 33.40 hours Manufacturing Points, Standard

PROCESSING COSTS

MATERIAL COSTS

Vg = 0.0001 m^3 Gross Volume of Sheet Cm = 79.33 cent / Part Cost of Materials

SCRAP VALUE

As = 825.8048 cm^2 Area of the Sheet Surrounding part Rs = 7.02 cent / Part Value of Scrapped Material
Apt = 176.7 cm^2 Area of The Actual Part
Vs = 9.87E-005 m^3 Volume of Scrap
PRESS COSTS

Shearing Press
fs = 63.70 KN Required Blanking force scrap extracting (y/n) Y
Cycle Time for Manual
(Following values are from Tabel 9.3 page 385)
tm = 9.29 sec. Loading and Unloading
Cop = 105 $ Operating Costs ts = 0.58 sec. Cycle Time for Press Strokes
Sp = 36 cm Maximum Press Stroke tc = 9.87 sec. Total Cycle Time
St = 35 Strokes per Minute
Nst = 1 Number of Different Press Srokes Cp = 28.78 cent / Part Press Cost

Bending Press
fb = 326.16 KN Required Blanking force scrap extracting (y/n) n
Cycle Time for Manual
(Following values are from Tabel 9.3 page 385) tm = 13.86 sec. Loading and Unloading
Cop = 76 $ Operating Costs ts = 3.00 sec. Cycle Time for Press Strokes
Sp = 25 cm Maximum Press Stroke tc = 16.86 sec. Total Cycle Time
St = 90 Strokes per Minute
Nst = 2 Number of Different Press Srokes Cp = 35.59 cent / Part Press Cost

Peircing Press
fs = 55.00 KN Required Peircing force scrap extracting (y/n) Y
Cycle Time for Manual
(Following values are from Tabel 9.3 page 385)
tm = 3.45 sec. Loading and Unloading
Cop = 55 $ Operating Costs ts = 1.67 sec. Cycle Time for Press Strokes
Sp = 15 cm Maximum Press Stroke tc = 5.11 sec. Total Cycle Time
St = 100 Strokes per Minute
Nst = 1 Number of Different Press Srokes Cp = 7.81 cent / Part Press Cost

Total Cost

Ctsdc = 5.05 cent / part Punch and Die Set Costs

Bending and Forming
Cbf = 2.17 cent / part Die Set Costs
Cpb = 37.78 cent / part Press Break Cost
Cpo = 2.32 cent / part Piercing Die Set Costs
Cm = 79.33 cent / part Cost of Materials
Rs = 7.02 cent / part Value of Scrapped Material
Cp = 28.78 cent / part Press Cost
Cp = 35.59 cent / part Press Cost
Cp = 7.81 cent / part Press Cost

Grand Total 154.04 cent / part

1.54 $ / part

SHEET METAL MANUFACTURING COSTS

Copyright Stoney Tuckness and Charles Pardue, Boise State University
SHEET METAL MANUFACTURING COSTS

Part : Table top

Material Properties Part Properties

Material = Steel Thickness (mm) = 1.52 (From Table 9.1 page 362)
Specific Gravity = 7.9
Production
U= 330 MN/m^2 Ultimate Tensile Stress Volume = 1.00E+05
E= 207 GN/m^2 Ealstic Modulus
Costs = 0.8 $/kg Labor
Scrap Value = 0.09 $/kg Rate ($/hr) = 40

PUNCH AND DIE COSTS

SHEARING DIE COST

perimeter = 5.08 cm Perimeter to be Sheared

Length = 71.12 cm Length of Part Envelope Cm = 1514.40 $ Shearing Die Set Costs
Width = 5.08 cm Width of Part Envelope Cds = 164.04 $ Basic Die Set Costs
Plan Area = 361.29 cm^2 Punch Plate Area Ctsdc = 1678.44 $ Punch and Die Set Costs
Ums = 400 MN/m^2 Ultimate Tensile Stress of Mild Steal Ctsdc = 1.68 cent / part Punch and Die Set Costs
hd = 38.1 mm Rounded to the nearest 1/8"
fd = 1.262 Die Plate Correction Factor
Au = 1223.290 cm^2
Xp = 0.071 Profile Complexity
Mpo = 30 Basic Manufacturing Points
(From Figure 9.9 page 371)
Flw = 1 Area Correction Factor
(From Figure 9.10 page 372)
Mp = 37.86 hours Manufacturing Points

BENDING AND FORMING

Bending and Forming

D= 5.08 cm Largest Depth of Bend Cbf = 1820.28 $ Die Set Costs
Bending and Forming
Nb = 2 Total Number of Bends Cbf = 1.82 cent / part Die Set Costs
Lb = 5.08 cm Total Length of Bends
Mpo = 26.351756 hours
Mpm = 15.0544 hours

PRESS BRAKE

Nb = 2 Total Number of Bends Cpb = 16.52 cents/part Press Break Cost

Machine Rate = 28 $
t= 21.24 s / part Time

PIERCING

Np = 2 Number of Punches, Cpo = 1917.68 $ Piercing Die Set Costs

Pp = 3.9878 cm Perimeter of ALL Punches Cpo = 1.92 cent / part Piercing Die Set Costs
L= 1.27 cm Length Rect. Surrounding all Holes
W= 1.27 cm Width Rect. Surrounding all Holes
Nd = 1 Number of Different Shapes or Sizes
K= 2 (Round Holes, K = 2 )
(Square, Rectangualr, Obround, K = 3.5)
Mpo = 23.048387 hours Manufacturing Points
Mpc = 16.39268 hours Manufacturing Points, Custom
Mps = 4.4 hours Manufacturing Points, Standard

PROCESSING COSTS

MATERIAL COSTS

Vg = 0.0001 m^3 Gross Volume of Sheet Cm = 34.71 cent / Part Cost of Materials

SCRAP VALUE

As = 361.2896 cm^2 Area of the Sheet Surrounding part Rs = 1.99 cent / Part Value of Scrapped Material
Apt = 176.7 cm^2 Area of The Actual Part
Vs = 2.81E-005 m^3 Volume of Scrap
PRESS COSTS

Shearing Press
fs = 12.74 KN Required Blanking force scrap extracting (y/n) Y
Cycle Time for Manual
(Following values are from Tabel 9.3 page 385)
tm = 8.16 sec. Loading and Unloading
Cop = 55 $ Operating Costs ts = 1.67 sec. Cycle Time for Press Strokes
Sp = 15 cm Maximum Press Stroke tc = 9.83 sec. Total Cycle Time
St = 100 Strokes per Minute
Nst = 1 Number of Different Press Srokes Cp = 15.02 cent / Part Press Cost

Bending Press
fb = 20.39 KN Required Blanking force scrap extracting (y/n) n
Cycle Time for Manual
(Following values are from Tabel 9.3 page 385) tm = 12.18 sec. Loading and Unloading
Cop = 55 $ Operating Costs ts = 1.67 sec. Cycle Time for Press Strokes
Sp = 15 cm Maximum Press Stroke tc = 13.85 sec. Total Cycle Time
St = 100 Strokes per Minute
Nst = 1 Number of Different Press Srokes Cp = 21.16 cent / Part Press Cost

Peircing Press
fs = 10.00 KN Required Peircing force scrap extracting (y/n) Y
Cycle Time for Manual
(Following values are from Tabel 9.3 page 385)
tm = 2.73 sec. Loading and Unloading
Cop = 55 $ Operating Costs ts = 1.67 sec. Cycle Time for Press Strokes
Sp = 15 cm Maximum Press Stroke tc = 4.40 sec. Total Cycle Time
St = 100 Strokes per Minute
Nst = 1 Number of Different Press Srokes Cp = 6.72 cent / Part Press Cost

Total Cost

Ctsdc = 1.68 cent / part Punch and Die Set Costs

Bending and Forming
Cbf = 1.82 cent / part Die Set Costs
Cpb = 16.52 cent / part Press Break Cost
Cpo = 1.92 cent / part Piercing Die Set Costs
Cm = 34.71 cent / part Cost of Materials
Rs = 1.99 cent / part Value of Scrapped Material
Cp = 15.02 cent / part Press Cost
Cp = 21.16 cent / part Press Cost
Cp = 6.72 cent / part Press Cost

Grand Total 81.02 cent / part

0.81 $ / part

SHEET METAL MANUFACTURING COSTS

Copyright Stoney Tuckness and Charles Pardue, Boise State University
Sheet Metal Workbench

Unit
Part Cost
Part Count Cost ($/part) ($/part)
Table Top 1 0.00 0.00
Shelf 1 0.00 0.00
Legs 8 1.54 12.32
Braces 2 0.81 1.62
Fasteners
w/bag 18 0.20 3.60
Paint 1 5.00 5.00
Level Pegs 4 0.50 2.00
Carton 1 3.50 3.50
Total 12 11.55 28.0441
Weight

Legs Table Top Shelf Braces

# 8 # 1 # 1 # 2
L 32 in L 40 in L 39.875 in L 27.875 in
W 4 in W 28 in W 27.875 in W 4 in
Thickness 0.0625 in Thickness 0.0625 in Thickness 0.0625 in Thickness 0.0625 in
Area 128 in2 Area 1120 in2 Area 1111.52 in2 Area 111.50 in2
Volume 8 in3 Volume 70 in3 Volume 69.47 in3 Volume 6.97 in3

Holes Holes Holes Holes

# 11 # 10 # 10 # 2
R 0.125 in R 0.125 in R 0.125 in R 0.125 in
Area 0.049 in2 Area 0.049 in2 Area 0.049 in2 Area 0.049 in2
Volume 0.034 in3 Volume 0.031 in3 Volume 0.031 in3 Volume 0.006 in3

Cut-outs Cut-outs Cut-outs Cut-outs

# 1 # 4 # 4 # 0
L 2 in L 2 in L 2 in L 0 in
W 2 in W 2 in W 2 in W 0 in
Area 2 in2 Area 8 in2 Area 8 in2 Area 0 in2
Volume 0.125 in3 Volume 2 in3 Volume 2 in3 Volume 0 in3

Volume 7.84 in3 / Part Volume 67.97 in3 / Part Volume 67.44 in3 / Part Volume 6.96 in3 / Part
Total Volume 62.73 in3 Total Volume 67.97 in3 Total Volume 67.44 in3 Total Volume 13.93 in3

Density 0.28 lbm / in3

Grand Total
Volume 212.06 in3
Weight 59.378 lbm