Cost Estimation Manual-Final

CONTENTS
Page No
1. Methodology of Synthesis 1
2. Lathe Operations (Centre, Turret and Capstan Lathe) 4
3. Drilling Operations 12
4. Grinding Operations 21
4.1 Cylindrical Grinding (Plunge Grinding) 23
4.2 Cylindrical Grinding (Traverse Grinding) 25
4.3 Centre less Grinding (Through Feed) 26
4.4 Centre less Grinding (Plunge Feed) 27
4.5 Internal Grinding 28
4.6 Surface Grinding (Reciprocating Table) 29
4.7 Surface Grinding (Rotary Table) 31
4.8 Gear Grinding 32
4.9 Spline Grinding 34
5. Gear Hobbing 35
6. Spline Hobbing 39
7. Gear Shaping 41
8. Broaching Operation 43
9. Vertical Turret Lathe Operations (VTL) 45
10. Milling Operation 47
11. Shaping and Planning 51
12. Slotting Machine 52

CONTENTS
Page No
13. Boring Machine 53
14. Standard Allowances 59
15. Handling Elemental Times (In Minutes) 60
15.1 Lathes (Small & Medium Duty) HL 61
15.2 Medium Heavy Duty Lathes HMHL 62
15.3 Drilling Machines HDM 64
15.4 Cylindrical Grinding Machine HCG 65
15.5 Centre less Grinding Machine HCLG 66
15.6 Internal Grinding Machine HIG 67
15.7 Surface Grinding Machine HSG 68
15.8 Gear Grinding Machine HGG 69
15.9 Spline Grinding Machine HSPG 70
15.10 Hobbing Machine HH 71
15.11 Gear Shaping Machine HGS 72
15.12 Horizontal Hydraulic Broach HHHB 73
15.13 Vertical Turret Lathe HVTL 74
15.14 Milling Machine HM 76
15.15 Shaping Machine HSP 77
15.16 Planning Machine HP 78
15.17 Slotting Machine HSL 79
15.18 Horizontal Boring Machine HHB 80

CONTENTS
Page No
16. Set Up Times 82
17. Hourly Rate Calculations 83
17.1 Hourly Rate working – Turning 84
17.2 Hourly Rate working – Milling 85
17.3 Hourly Rate working – Grinding 86
17.4 Hourly Rate working – Drilling 87
17.5 Hourly Rate working – Boring 88
17.6 Hourly Rate working – Gear Machine 89
17.7 Hourly Rate working – Machining Others 90
17.8 Hourly Rate working – Press 92
18. Appendices 94
18.1 Appendix I 95
(Total Operation Time – Chart)
18.2 Appendix II 96
(Std. Cost Data for Components – Chart)
18.3 Appendix III 97

(Comparison between Vendor – Chart)
18.4 Appendix IV 98
(Drill Withdrawal Time for Clearing Chips – Chart)
Hour Rate 99
Page No
19. Threading Estimation
API & BECO Threads External & Internal 101
NPT & BSP (T) Thread for Pipes – External 102
BSP (T) Thread for Straight Adapters – External & Internal 103
NPT Thread for Straight Adapters – External & Internal 104
NPT Thread for 45 & 90-Degree Adapters – External & Internal 105
BSP (T) Thread for 45 & 90-Degree Adapters – External & Internal 106
BSP (T) Thread for Tee Adapters – External & Internal 107
NPT Thread for Tee Adapters – External & Internal 108
JIC Thread for Straight Adapters – External & Internal 109
JIC Thread for 45 & 90-Degree & Tee Adapters – External 110
End & Face Milling Cutter 111
Threading Passes 112
20. Power Hacksaw Cutting
Round Rod – Steel 113
Hexagonal Steel Rod 115
Adapter Setup Time 116

1. MACHINING
1. METHODOLOGY OF SYNTHESIS
1.1 MACHINE ELEMENTAL STANDARD TIME
1.1.1 TOOL CHANGE ALLOWANCE
1.1.2 RELAXATION ALLOWANCE
1.2 HANDLING ELEMENTAL TIME
1.2.1 CONTINGENCY ALLOWANCE
1. METHODOLOGY OF SYNTHESIS
COMPONENTS OF STANDARD TIMES...
The standard time of operation is arrived in three parts namely:
a. Machine Elemental Standard Time (TMT)
b. Handling Elemental Time
c. Contingency Allowance
1.1 MACHINE ELEMENTAL STANDARD TIME (TMT)
The basic time (T) of each machine element is calculated, using the
appropriate formula and concerned parameters like feed, speed, tool travel, cutting
speed etc.,
Even when the most practical, economic and effective method has been
developed, however, many jobs will still require the expenditure of human effort
and some allowance must therefore be made for recovery from fatigue and for
relaxation. An objective assessment of the allowances that can be consistently
applied to the various elements of work or to various operations are given below.
Tool chance allowance(TCA) and Relaxation allowance(RA) are added to machine
elemental base time(T) to arrive at the Machine elemental standard time or Total
Machining Time(TMT). The standard time of all machine elements covered in the
operation and Handling time are added to get the Total operation time.
1
. TOOL CHANGE ALLOWANCE (TCA)
The tool change allowance is included as a percentage of machine

elemental basic time . This allowance is an allowance of time to cover the
adjustment and maintenance of tools. It is based up on normal tool life,
change time and its degree of complexity. The tool change allowance for
different machines are given in section A 1a, page no 59.
 RELAXATION ALLOWANCE (RA)
Relaxation allowance is an addition to the basic time intended to provide

the worker with the opportunity to recover from the physiological and
psychological effects of carrying out specified work under specified conditions and
to allow attention to personal needs.
Relaxation allowances are calculated so as to allow the worker to recover

from fatigue. The effects of fatigue can be lessened by rest pauses, during which
the body recovers from its exertion, or by slowing down the rate of working and
thus reducing the expenditure of energy.
Relaxation allowances are given as percentages of the basic time. The

amount of allowance will depend on the nature of job. Refer section A 1b,
Page no 59.
 HANDLING ELEMENTAL TIME
Handling elemental time is composed of loading time , chucking time,

manipulation time , unloading time , inspection time. A table of all possible
elements in these type of elements for each group of machine tool is
prepared indicating the respective elemental standard time. These are shown
in tables covered in Page no 61 to 81. All handling elements that are required
to be performed and the frequency of their performance is determined. The
sum of above gives the total handling elemental standard time for the operation.
Note: The frequency of inspection are based upon its degree of

complexity.






2


 CONTINGENCY ALLOWANCE
A Contingency allowance is a small allowance of time which is to

be included in a standard time to meet legitimate and minor delays which are
unavoidable, like cleaning of machine tool, getting tools from co - worker,
discussion with supervisor , getting and depositing tools etc.., In addition to
this, some time additional works like filing , extra cut due to excessive machine
allowance etc., may have to be done. The contingency allowance for work being
allowed to attract fatigue allowance. To compensate for the less of time due to
such reasons, a contingency allowance of 5 % is added as a percentage to the
total of handling elemental time. Refer section A1c, Page no 59.
3
2. LATHE OPERATION
(Centre lathe, Turret Lathe, Capstan Lathe)
2.1 TURNING, FACING, BORING AND PARTING


2.2 CUTTING SPEED (METRES PER MINUTE) AND FEED
2.2.1 STEEL
2.2.2 CAST IRON


2.2.3 NON - FERROUS

2.3 CUTTING SPEED ( METRES PER MINUTE)

2.4 DEPTH OF CUT

2.5 CUTTING SPEED FOR BORING

2.6 HAND FEEDS

2.7 THREADING

2.7.1 CUTTING SPEED FOR THREADING

2.8 CENTRE DRILLING

2.8.1 CENTRE DRILL DIAMETER AND DEPTH OF HOLE

2.8.2 CUTTING SPEED FOR CENTRE DRILLING

2.8.3 FEED

2.9 DRILLING AND REAMING

2.9.1 HAND FEEDS FOR DRILLING AND REAMING ON LATHE
4
 Turning, Facing, Boring and Parting
The basic time required for one cut of these category of

operations is calculated from the following formula.
L T = Basic Time in min.

T xP L = Tool Travel in mm.
FDxN FD = Feed per Revolution
N = Revolution of work per min.
DN P = Number of Passes
CS 
1000 CS = Cutting Speed m/min.
D = Diameter in mm
Tool travel (L) is calculated by adding the following..:
1. Length of dimension (finished) as per drg. = l1

2. Machining Allowance = l2
3. Approach of tool = l3
4. Over run of tool = l4

Tool Travel (L) = l1 + l2 + l3 + l4
The values taken for approach and over run depends upon the operation
and tooling criticality. It varies from 0.5mm to 3mm . In an operation which
involves facing , turning , it is considered that facing will be done first and then
turning or boring will be done. Accordingly , the machine allowance will be
reduced in calculating the tool travel.
The following cutting speed , feed and depth of cut has been adopted
for turning , boring , parting operation on centre lathe and turret lathe.
5
2.2 Cutting Speed ( CS ) and Feed ( FD ) for Carbide Tools
2.2.1 Steel
Cutting Speed ( CS )
Hardness
Material Grade For Feed (FD) in mm per revolution
BHN
0.20 0.15 0.10 0.05
Alloy Steel 150 – 225 50 58 72 90
Annealed 200 – 275 40 50 63 80
Alloy Steel 275 – 325 35 45 54 68

Hardened and
325 - 400 25 30 40 54
Tempered
125 62 80 105 135
Non Alloy Steel 150 55 65 80 100
250 50 56 67 80
2.2.2 Cast Iron
Hardness
BHN
0.30 0.20 0.10
Cast Iron 180 50 58 72
Cast Iron 225 40 50 63
Malleable Cast Iron 110 – 145 35 45 54
2.2.3 Non – Ferrous
Hardness
BHN
0.40 0.30 0.20 0.10
Phosphor Bronze 175 108 135 165 190
Brass 75 135 165 180 220
Aluminium Casting
100 170 210 250 270
(Non Heat Treatment)
Heat Treated 130 100 135 165 190
30 – 80 900 900 1450 1700
Aluminium Alloy
80 – 120 180 240 300 360
6
2.3 Cutting Speed ( CS ) and Feed ( FD ) for HSS Tools
Hardness Cutting Speed ( CS )

Material
BHN Metres per Minute
Aluminium 30 – 80 300
Brass 75 60
Bronze - 35
Mild Steel 150 35
Medium Steel 150 – 275 25
Hard Steel 275 – 325 15
110 – 145 40
Cast Iron 145 – 180 30
180 – 225 20
115 – 140 35
Steel Casting
140 – 160 20
Feed for HSS Tools varies from 0.05 mm/rev to 0.3 mm/rev depending upon
the materials, tolerance required, tooling provided, etc.,
However the cutting speed and fed varies according to the component
profile, criticality and holding facilities provided.
2.4 DEPTH OF CUT
Depth of cut varies from 0 . 5 mm to a max. of 4mm according to job

requirement and provisions provided for holding.
2.5 CUTTING SPEED (CS) FOR BORING
Rough Boring - 75 % of cutting speed considered for turning.

Fine Boring - 60 % of cutting speed considered for turning.
7
2.6 HAND FEEDS (FD)
The following hand feeds are used for operations like parting ,
grooving , radius formation , chamfering as well as for cases of turning ,
facing, boring requiring hand feed .
Hand feed in mm / rev of tool : HSS
Operation Feed
Parting (1/16” wide) 0.075
Parting (1/8” wide) 0.10
Grooving 0.025
Chamfering 0.05
Centre Drilling 0.05
Turning & Facing 0.08 to 0.10
Forming 0.05
2.7 THREADING
For Metric Threads
L T = Basic Time in min

T xP L = Tool Travel in mm
PitchxRPM
P = Number of Passes
For Inch Threads
T = Basic Time in min

LxTPI
RPM P = Number of Passes
8
2.7.1 Cutting Speed for Threading

Material
Aluminium 80 - 120 10
Brass 75 6
Bronze 75 10
Mild Steel 150 8
Hard Steel 275 – 325 4
110 – 145 10
Cast Iron 180 10
180 – 225 8
2.8 CENTRE DRILLING - BASIC TIME CALCULATION (T)
L
T xP T = Basic Time in min
FDxN L = Tool Travel in mm
FD = Feed per Revolution
N = Revolution of work per min
DN CS = Cutting Speed m/min
CS  D = Diameter in mm
1000
Tool Travel ( L )
The Tool travel is equal to the depth of hole plus one third of
drill size. The drill size and depth of centre drilling for the standard centre
drill is given below.
9
2.8.1 Centre Drill Diameter And Depth Of Hole
Drill Depth of Tool

Centre Drill
Diameter Hole Travel
size
(inch) (inch) (inch)
No 1 3/64 0.083 0.099
No 2 5/64 0.145 0.171
No 3 7/64 0.195 0.231
No 4 1/8 0.212 0.254
No 5 3/16 0.314 0.377
No 6 7/32 0.363 0.436
No 7 ¼ 0.467 0.550
No 8 5/16 0.530 0.634
2.8.2 Cutting Speed for Centre Drilling ( HSS Centre Drill )

Material
Brass 75 20
Bronze - 15
Mild Steel 150 15
Hard Steel 275 – 325 5
110 – 145 15
Cast Iron 145 – 180 15
180 – 225 10
115 – 140 15
Steel Casting
140 – 160 10
2.8.3 Feed ( FD )
Generally hand feed is used for centre drilling when the centre drill
is fixed on turret head or tail stock. A hand feed of 0.05 mm is used as a
standard.
10
2.9. DRILLING AND REAMING
Basic time calculation (T): The basic time of drilling and reaming is
calculated in the same manner , as done on radial drill . The tool travel is also
calculated in the same manner.
Cutting Speed (CS): The cutting speed used for drilling and reaming
on lathe is 80% of cutting speed used on radial drill for the same diameter.
Feed (FD): When machine feed is used for drilling and reaming , the
same feed as used on radial drill or the nearest value is used. However , if hand
feed is used , the following rate is used.
2.9.1 Hand Feed (FD) for Drilling and Reaming on Lathe (mm/rev)
Hand Feed (FD)

Drill Diameter
Drilling Reaming
¼” to ½” 0.10 0.20
9/16” to 1” 0.15 0.30
1 1/8” to 2” 0.20 0.40
11
3. DRILLING OPERATION
3.1.1 MACHINE ALLOWANCE
3.1.2 APPROACH
3.1.3 OVER RUN
3.1.4 CUTTING SPEEDS

    
3.1.5 DRILL WITHDRAWL TIME FOR CLEARING CHIPS
3.1.6 FEED

3.2 TAPPING
3.2.1 FORWARD AND REVERSE SPEED ON HMT RADIAL

DRILL
3.2.2 TAPPING SPEED (RPM) FOR HSS TAP ON HMT RADIAL

DRILL
3.2.3 MATERIALS GROUPING ( FOR TAPPING )
 
3.3 SPOT FACING
3.3.1 CUTTING SPEED
3.3.2 BASIC TIME OF SPOT FACING

3.4 CHAMFERING
3.4.1 BASIC TIME FOR CHAMFERING HOLES ON HMT
RADIAL DRILL
12
The basic time to drill or ream a hole is calculated from the following
formula:

L
FDxN FD = Feed per Revolution
N = Revolution of work per min
DN CS = Cutting Speed m/min
CS 
1000 D = Diameter in mm
1. Length of hole as per drg. = l1


Tool Travel (L) = l1 + l2 + l3 + l4
The machine allowance provided is same as provided in case of turning . It

is again given below :
3.1.1 Machine Allowance ( l2 )
Condition of Part Machine Allowance (l2)

When both top and bottom
6 mm
surfaced are rough
When only top or bottom surface
is rough and 3 mm
other is finished
When both top and bottom
Nil
surfaces are finished
13
3.1.2 Approach (l3)
The approach required depends upon the hole to be drilled ,

enlarged or reamed, and on the diameter of the tool used . The
approach added is as given below .
Operation Tool Approach Tool Used

0.3 x Diameter of
Drilling Twist Drill
Drill
0.15 x Diameter of Core Drill or Flat bottom
Enlarging
Drill drill
Reaming Nil Reamer flat bottom
3.1.3 Over Run (l4)
An over run of 1mm is added when a through hole is to be drilled or

reamed or enlarged to make sure that the machining is completed throughout
the length of the hole. However, no over run is added in case of blind holes.
3.1.4 Cutting Speeds (CS)
Cutting Speed for HSS Drills and Reamers (Metres per Minute)
Hardness Metres per Minute
Material
BHN
Drilling Reaming
Aluminium 30 – 80 45 25
Brass 75 45 25
Bronze - 45 25
Mild Steel 150 18 9
Medium Steel 150 – 275 12 6
Hard Steel 275 – 325 6 3
110 – 145 25 14
Cast Iron 145 – 180 25 14
180 – 225 25 14
115 – 140 25 14
Steel Casting
140 – 160 20 10
14
Generally for reaming 50% to 60% of the drilling speed and double the feed of
drilling is used for the same diameter of hole and same material. In case spindle of
the radial drill has some play 85% of drilling speed is used for reaming and the
reaming feed remained of the drilling feed.
3.1.5 Drill withdrawal time for clearing chips
During deep hole drilling (without core) it is necessary to withdraw drill at

intervals to clear chips. The standard time of withdrawing the drill and re
advancing is 0.07 minutes. However, the frequency of withdrawal varies depending
upon the ratio of hole depth to diameter. The chips clearance time is added when
the depth of hole is more than two times the diameter. Table given at Appendix IV
Page no 98 indicates the chip clearance time, to be added for various diameter and
depths of hole. These times are added under handling elemental times.
3.1.6 Feed (FD)
The radial drills, pillar drills having feeds in steps viz.0.12 mm, 0.20mm ,
0.50mm , 0.75mm and 1.25 mm. Some sensitive radial drills have feed of 0.075
mm also in addition to the feeds available in radial drills. The feed used increase
as the drill diameter increased . For reaming, the feed used is double the feed
used for the corresponding diameter. It may be noted that feed used did not vary
for different material , but only cutting speed was varied. The feed used for
different diameter of drills and reamers are as given below:
Ø in inch (mm) Feed (FD) mm per revolution

From To Drilling Reaming
1/8” (3.2) 7/32” (5.6) 0.075 0.15
¼” (6.35) ½” (12.7) 0.12 0.20
5/8” (15.9) 1” (25.4) 0.20 0.30
1 1/8” (28.6) 1 ½” (38.10) 0.30 0.50
1 5/8” (41.3) 2” (50.8) 0.50 0.75
It may be noted that the feed rate shown for reaming is not exactly double
the rate for corresponding drill as it is not available in the drilling machine.
15
However, for hand feed the reaming feed used is two times the feed for the drill of
the same diameter.
3.2 TAPPING
The basic time to tap a hole is calculated using the following formula
T = Basic Time ( in minutes)

L L = Tap Travel in mm
T 
PxN P = Pitch
N = Revolution per minute
The pitch of some important threads is given at appendix. The time for
clearing the tap from the job is also calculated , with the same formula and added to
the time of threading. However , the speed of return will be different in radial drill
depending upon the lever positions. The RPM for forward and return travel of tap
on HMT radial drill is given below
3.2.1 Forward and Reverse Speed on HMT Radial Drill
Forward Speed Return Speed

RPM (N) RPM (N)
40 56
56 40
80 112
112 80
150 220
220 150
300 440
400 300
The tool travel (L) is calculated by adding the following.
I. Length of tapping as per drawing. = l1

II. Machine allowance provided on the part. = l2
III. Over run of tap. = l3
machine allowance as considered for drilling is included for tapping

also.
16
An over run of 3mm is added so as to ensure that the tapping is
completed for the entire length of the through hole. However, no over run is
added for tapping the blind hole.
The cutting speed to be used depends upon the material and its hardness.
Generally the taps are made up of HSS and the following speeds are used for
tapping
3.2.2 Tapping speed (rpm) for HSS Tap on HMT Radial Drill
Tap Diameter Revolution of Tap per Minute (N)

Inch (mm) Material Group A Material Group B
¼” (6.3) 220 220
5/16” (7.9) 220 220
3/8” (9.5) 220 150
7/16” (11.1) 220 150
½” (12.7) 150 112
9/16” (14.3) 150 112
5/8” (15.9) 150 112
11/16” (17.5) 150 112
¾” (19) 112 80
7/8” (22.2) 112 80
1” (25.4) 80 56
1 1/8” (28.6) 80 56
1 ¼” (31.7) 80 56
1 ½” (38) 56 40
1 ¾” (44.5 56 40
2” (50) 56 40
For BSP and NPT Threads, major ø of thread is taken as the basis for
selecting the speed.
17
3.2.3 Material Group (For Tapping)
Group A Group B
Description Hardness BHN Description Hardness BHN
Cast Iron (Soft) <210
Cast Iron (Hard) 210 -250
Malleable Cast Iron <150
Non Alloy Steel Non Alloy with
<150 250
(Low Carbon) Carbon steel
200 – 275
Alloy Steel 150 – 200 Alloy Steel
275-325
Aluminium Alloy 30 -150
Brass 75
Phosphor Bronze 75
Non Alloy Medium 150 - 200
3.3 SPOT FACING

Generally, it is considered that in spot facing a 3mm deep material is
removed, unless otherwise indicated specifically. The spot facing time is calculated
using the formula given below
T = Basic Time in min.
3mm
T FD = Feed
FDxN N = Revolution per min.
Feed (FD)
A value of 0.1mm for hand feed and a value of 0.12mm is used for machine
feed respectively.
18
3.3.1 Cutting Speed (CS)
For spot facing with HSS cutter, Cutting speeds of 10 metres to 20
metres are used, based upon the material composition and hardness. The
following are the groupings.
Cutting Speed (CS)

Group Material Hardness (BHN)
(metres per minute)
Cast Iron Below 210
Malleable Cast Iron Below 150
Non Alloy Steel
A 15 Below 100
(Low Carbon)
Medium Carbon Below 200
Alloy Steel 150 – 200
Non Alloy Steel
250
(High Carbon)
B 10
Alloy Steel 200 – 275
Alloy Steel 275 - 325
Aluminium 30 – 150
C 20 Brass 75
Phosphor Bronze 75
3.3.2 Basic Time (T) of Spot Facing
Considering the speed available on drilling machine. The following

basic time has been calculated and used as a standard.
Speed (N)(RPM) and Basic Time (T)(Min)

Ø of Spot Face
Group A Group B Group C
Cutter (inch)
N T N T N T
0.5 to 1 220 0.12 150 0.16 300 0.07
1 1/8 to 1 ½ 150 0.20 112 0.26 220 0.12
1 5/8 to 2 112 0.26 80 0.32 150 0.15
19
3.4 CHAMFERING
Basic Time (T)
Generally, chamfering is done with a 45° drill for a depth of 0.05” and
invariably hand feed is used. Therefore, the basic time of chamfering is calculated
using the following formula
T = Basic Time (min)

FD = Feed
N = RPM of Drill
Feed of 0.004” (0.10mm) per revolution of chamfer drill is taken as a standard.
Standardisation of speed (N) and basic time(T)
For simplicity, it is considered that a standard speed (RPM) will be used for
a range of drill diameters and accordingly basic time has been worked and used
throughout. The following are the basic time values used for chamfering on HMT
radial drills.
3.4.1 Basic Time (T) for chamfering holes on HMT Radial Drill
Ø of hole RPM of Drill Basic Time (T)

inch mm (N) (min)
Up to ½” Up to 12 220 0.05
9/16” to 7/8” 14 to 22 150 0.07
1” to 1 ¼” 25 to 32 122 0.10
1 5/16” to 1 ¾” 36 to 45 80 0.14
20
4. GRINDING OPERATION
4.1 CYLINDRICAL GRINDING (PLUNGE GRINDING)
4.1.1 WORK SPEED FOR GRINDING (METERS PER MINUTE)
4.1.2 FEED FOR PLUNGE GRINDING
4.1.3 SPARK OUT TIME FOR PLUNGE GRINDING
4.2 CYLINDRICAL GRINDING (TRAVERSE GRINDING)
4.2.1 WORK SPEED AND FEED
4.2.2 SPARK OUT TIME
4.2.3 WHEEL DRESSING TIME
4.3 CENTRELESS GRINDING (THROUGH FEED)
4.3.1 FEED
4.3.2 SPEED OF REGULATING WHEEL
4.4 CENTRELESS GRINDING (PLUNGE FEED)
4.4.1 CUTTING SPEED AND FEED
4.5 INTERNAL GRINDING
4.5.1 WORK SPEED AND FEED
4.5.2 WHEEL DRESSING
4.5.3 TRAVERSE GRINDING
4.6 SURFACE GRINDING (RECIPROCATING TABLE)
4.6.1 TABLE SPEED
4.6.2 FEED
21
4.7 SURFACE GRINDING (ROTARY TABLE
4.7.1 TABLE AND WHEEL HEAD SPEED
4.7.2 FEED
4.7.3 NUMBER OF JOBS
4.8 GEAR GRINDING
4.8.1 INDEX TIME AND INDXING
4.8.2 NUMBER OF CUTS
4.8.3 NUMBER OF STROKES PER MINUTE
4.8.4 STROKES PER TOOTH
4.8.5 WHEEL DRESSING TIME
4.9 SPLINE GRINDING
4.9.1 NUMBER OF CUTS AND PASSES
4.9.2 CYCLES PER MINUTE
22
4.1. CYLINDRICAL GRINDING ( PLUNGE GRINDING)
Basic Time Calculation
Generally, cylindrical grinding is done on HMT cylindrical grinding

machine models G.17/P and G.22P. The stock to be removed generally varied from
0.010”(0.25mm) to 0.025” (0.34mm) on diameter and the tolerance varied between
0.0003” (0.008mm) and 0.004” (0.1mm). The basic time of plunge grinding is
calculated with the following formula.
L T = Basic Time (min)

T  L = Maximum tool travel (or grinding allowance)
FDxN
FD = Feed
N = Revolution of work per minute
DN
CS  CS = Cutting Speed
1000 D = Diameter of the component
Where feed (distance moved by wheel per revolution of work) is reckoned

on diameter of work. The grinding allowance is the difference between the upper
limit of pre-finished work and the lower limit of finished work.
Cutting Speed (CS): Generally, Aluminium grinding wheel of vitrified

bond (50mm thick, 500 mm dia) is used, which rotated at 1150 RPM. The work
speed used for grinding using this wheel is given below.:
4.1.1 WORK SPEED FOR GRINDING (METERS PER MINUTE)
Hardness Work Speed (CS)

Material
BHN (Metres per minute)
Soft Steel 100 – 150 20

Hard Steel 270 – 325 15
Cast Iron 100 – 150 20
Brass, Aluminium Below 150 25
Hardened Steel Around 60 RC 10
23
4.1.2 Feed (FD) for Plunge Grinding:
Grinding is done on medium hard Cast Iron and steel, having a

hardness of 150 to 270 BHN and Hardened Steel around 60 RC. For this
material, a feed of 0.010mm (on diameter) per revolution of work is forced
to give satisfactory result, and hence this value is used as a standard feed for
calculation of basic time. It may be noted that this feed is satisfactory when
the tolerance is 0.002” (0.050mm) when the tolerance is 0.001”(0.025mm)
the feed rate is reduced to 0.0075mm. For less than 0.001” the feed rate is
reduced to 0.005mm. For tolerance of 0.0005” and below, still lesser feed is
used.
4.1.3 Spark out time for plunge grindings:
A spark out time of 0.10 minutes is added.
4.1.4 Work speeds available in H.M.T. Cylindrical grinding Machine:
Lever Position Work Speed (RPM)

a 27.5
I
b 39
a 55
II
b 78
c 110
I
d 156
c 220
II
d 312
24
4.2 CYLINDRICAL GRINDING (TRAVERSE GRINDING)
When the length of the component to be ground exceeded 50mm, traverse

grinding is employed. In this grinding, feed is employed in forward stroke only.
The basic time of grinding is calculated from the formula given below:
L = Length of dimension
2 LS
T  S = Number of strokes of work
KWN W = Width of wheel (50mm)
N = RPM of work
DN K = Constant with a value of 0.5 to 0.6
CS 
1000 D = Diameter of the component ( ø in mm)
Stock  to  be  removed
Number  of  Strokes 
Feed  per  stroke
4.2.1 Work Speed (CS) and Feed (FD)
The work speed for traverse grinding is same as that used for plunge
grinding. ( Generally a feed of 0.010 mm ( on diameter) per stroke is used for
steel and Cast Iron having a hardness of 150 - 270 BHN and a feed of
0.005mm is used for steel having 60 RC).
4.2.2 Spark Out Time
Spark out time is added to grinding time. The allowed spark out
time is the time needed for four strokes (spark out time is 0.1min).
25
4.2.3 Wheel Dressing Time
A wheel dressing time is also added to grinding time. For calculating the
wheel dressing time, the speed of dressing is taken as 120mm per minute. The
dressing basic time (minutes) is calculated by dividing the wheel width by 120
i.e. dressing speed.
Wheel  width  in  mm
Dres sin g  Time 
120mm  per  min ute
However, time involved in the manipulation of grinding wheel for

dressing (0.80 minutes) is also added to the time calculated for actual
dressing. The total dressing time is arrived at, for every 2 or 5 or 10 pieces
depending upon the finish required. The frequency of dressing allowed is
given below:
Tolerance Required Frequency

>0.005” (0.025mm) Once in every 10 pieces
0.001” (0.025mm) Once in every 5 pieces
0.0005” (0.0125mm) Once in every 2 pieces
0.0002” (0.005mm) Every piece
4.3 CENTRELESS GRINDING (THROUGH FEED)
The centre less grinding is done on HMT & Other centre less
grinder, which has a regulating wheel of 280mm diameter (approx.) the
angle of which can be varied. The basic time of grinding is calculated with
the following formula
T = Basic Time (in minutes)

L = Length of job in mm
( L  4mm) D = ø of regulating wheel in mm (280mm)
T xP
DN sin  N = Revolution of regulating wheel per minute
α = Regulating wheel angle
26
( Generally, a value of 2° is used for the tolerances of 0.001” to 0.002” and
1° is used for tolerance below 0.001” )
4.3.1 Feed
Mostly steel with hardness of 15 to 60 RC is ground. The feed (stock

removed per pass) used on this material for rough and finish passes are
0.003” (0.075mm) and 0.002” (0.054mm) respectively. As a standard
practice two finish passes are provided and the remaining stock is removed
in rough passes at the rate of 0.003” per pass. The total number of passes is
determined on these basis.
4.3.2 Speed of Regulating Wheel
The speed of regulating wheel is determined depending upon the

material to be ground with the following formula
CS N = Speed ( rpm )
N CS = Cutting Speed ( meter per minute )
xD
D = ø of regulating wheel (280 mm)
The cutting speed used is same as used in cylindrical grinding.
4.4 CENTRELESS GRINDING – PLUNGE FEED
Basic Time Calculating
Normally, plunge cut centre less grinding is employed to grind jobs

with different diameters. The stock generally left for grinding as seen is
about 0.016”. The basic time of grinding such jobs is calculated with the
following formula.

SxD S = Stock to be removed
T D = ø of regulating wheel in mm (280mm)
FDxCS
FD = Feed in mm per revolution of regulating wheel
In the above formula the rpm of regulating wheel is represented by CS/ЛD.
4.4.1 Cutting Speed (CS ) and Feed (FD)
27
Mostly medium and hard steel jobs with 15 RC to 60 RC are ground.
A cutting speed of 10 to 15 meters per minute and a feed of 0.005 mm to
0.010 mm on diameter per revolution wheel is used.
4.5 INTERNAL GRINDING
Generally Parisudh and HMT internal grinders are used for grinding
internal surfaces. Generally, Alumina Oxide wheels are used for internal
grinding and facing operations. The basic time for internal grinding using
this machine is calculated with the following formula.

S
T S = Stock to be removed
FDxN FD = Feed in mm per revolution of regulating wheel
N = Revolution of work per minute
4.5.1 Work Speed (CS) and Feed (FD)
The work speed used is same as for cylindrical grinding. The feed
used for bore grinding is 0.005 mm ( on radius) per revolution of job, which
are made out of steels having hardness of 150 to 270 BHN. However, for
the same material, a feed of 0.010 mm per revolution of work, is used for
face grinding. A feed of 0.005mm is used for tolerance less than
0.001” and hardness around 60 RC.
4.5.2 Wheel Dressing
Wheel Dressing time at the same rate as provided in case of

cylindrical grinding is added to the actual grinding time.
28
4.5.3 Traverse Grinding
Generally traverse grinding is used for most of the internal grinding

operation. In this, feed employed in forward stroke only. The basic time of
grinding is calculated from the same formula used for Cylindrical grinding.
2 LS L = Length of dimension
T  S = Number of strokes of work
KWN
W = Width of wheel (20 - 50mm)
N = RPM of work
DN K = Constant with a value of 0.5 to 0.6
CS 
1000 D = Diameter of the component ( ø in mm)
Stock  to  be  removed
Number  of  Strokes 
Feed  per  stroke
Work speed, Feed and dressing time are the same as used for
Cylindrical grinding machine.
4.6 Surface Grinding (Reciprocating Table)
Basic Time Calculations
Surface grinding operations are undertaken on Vertical spindle

surface grinding machine, which has a magnetic chuck area of different
sizes and a grinding wheel of 150 mm to 500 mm diameter and a travel of
1400mm (maximum).
The number of jobs that can be accommodated on the magnetic

area is obtained by dividing the magnetic chuck area (Ex. 900mm x
300mm) by the area occupied by one job. Then the basic time is calculated
for the table area (i.e. length & width). After all calculation, total operation
29
time for one component is arrived by dividing the total time with number of
components held on the magnetic area
The basic time of grinding one job held on the magnetic table is
given below. For more number of jobs follow the sequence given above.
T = Basic Time
LBX L = Length of work piece to be ground in mm
T  B = Width of work piece to be ground in mm
CSx1000 xFD
CS = Velocity of table in m/min
FD = Feed in mm/stroke
X = No. of cuts F
D
B
L
4.6.1 Table Speed (CS) and Feed (FD)
The velocity of the table (CS) in m/min is given below in the table, it
varies for different materials. The cross Feed in mm/stroke is selected from
the given table. The down feed mm/pass is also selected from the given
table.
4.6.2 No. of cuts (X)
The No. of cuts is calculated by, dividing the stock to be removed by

down feed (mm/pass).
Stock  to  be  removed  from  the  work  piece(mm)

Number  of  CutsX 
Down  feed  of  the  wheel  head (mm / pass )
S.No Material Hardness Table Down Cross Feed FD

BHN Speed Feed (mm/stroke)
CS (mm/pass)
(m/min)
1 Soft Steel 100 - 190 20 wheel width/ 3
=
Fin. Finish =
2 Medium Steel 200 - 270 15 wheel width/ 3

Rough
Finish
3 Hard Steel 270 - 325 15 wheel width/ 4

0.025
0.010
0.005
4 Cast Iron 100 - 200 20 wheel width/ 3
30
5 Brass, < 150 25 wheel width/ 3
Aluminium
6 Hardened Steel 55 - 65 Rc 10 wheel width/ 4
Wheel width
The wheel width of the surface grinding machine varies from 10mm
to 50 mm for the standard usage. In these machines the most commonly
used wheel widths are 13mm, 19mm, 25mm and 50mm. It may also vary
according to our requirements.
Note:
The above cutting speeds, feeds can be reduced if critical

operations are to be carried.
4.7 SURFACE GRINDING ( ROTARY TABLE )
The basic time of grinding the jobs loaded on rotary table surface
grinding machine is given below. The diameter of the rotary table and the
grinding wheel diameter varies from machine to machine. For Normal
working condition the table and wheel speed is also given below
T = Basic Time (minutes)

Sr = Stock to be removed
Sr Ts
T  x Ts = Traverse speed of wheel head
FD Sl FD = Feed per stroke
Sl = Stroke Length
In the above formula, traverse speed of wheel head per minute/stroke

length indicates number of strokes of wheel head in a minute (S). For
Example, the stroke length of “SNOW” rotary surface grinder is 9”.
4.7.1 Table and Wheel Head Speed
The table speed is maintained at 31 rpm, which corresponds to about

25 to 30 metres per minute. A wheel head speed of 3.75 feet per minute is
used, for calculating the number of stroke. The number of strokes per
minute at speed of 3.75 feet per minute is 5.
31
4.7.2 Feed (FD)
For grinding steels of hardness 150 to 270 BHN, a feed of 0.005 mm

(0.0002”) per stroke is used and 0.0025mm for steels with hardness around
60 RC.
4.7.3 Number of Jobs
The number of jobs loaded on the table is determined by dividing the

table area by the area occupied by one piece.
4.8 GEAR GRINDING
For example, Let Grinding of gear teeth is done on “Pratt &

Whiteny” 10 inches Hydraulic Helical gear grinder which has a 12”
diameter wheel running at speeds 1780 or 2215 or 2500 rpm. The basic time
of grinding gear teeth on P & W Helical gear grinder is calculated with the
following formula.

NTxPxA NT
T = Number of Teeth
W P = Number of Cuts
A = Index time in min.+ (Stroke per tooth/strokes per min)
4.8.1 Index Time and Indexing
For P & W helical gear grinder the index time is 0.04 minute for spur
gear and 0.05 minute for helical gear. This machine has provision to use
single as well as double indexing. For the purpose of time calculation, it is
considered that in case of helical gear teeth grinding double indexing will be
used for both rough and finish cut, whereas in case of spur gear teeth
grinding, double indexing will be used for rough, cut and single indexing
will be done for finish cut. Single indexing is considered, due to the problem
32
in machine and once the problem is eliminated, double indexing is to be
used for both rough and finish cuts in case if spur gear also.
4.8.2 Number of Cuts (P)
One rough cut and one finish cut is used for grinding the teeth to get
the required finish, both in case of helical and spur gears.
4.8.3 Number of Strokes per minute (S)
The number of strokes of wheel head has a relation with the stroke
length. The relation between stroke length and the number of strokes per
minute is shown below.
Stroke Length Number of strokes

(inches) (per minute) (S)
4 115 to 152
4.25 108 to 144
4.50 103 to 137
4.75 98 to 131
5.00 94 to 125
5.25 90 to 120
5.50 86 to 115
5.75 83 to 111
6.00 80 to 107
6.25 77 to 103
6.50 74 to 99
The stroke length is equal to the sum of face width, over run and
approach. It is seen that in practice that the sum of over run and approach is
equal to 2.8 times the face width of gear. As such, stroke length is taken as
equivalent to 3.8 times of face width of gears.
4.8.4 Strokes Per Tooth
33
The number of strokes during which a tooth is ground varied
depending upon each case. The number of strokes per tooth is selected from
the graph available in the book “Gear Hand Book” written by Darle
W.Dudley and published by Mc.Grawhill publications, USA.
4.8.5 Wheel Dressing Time
A dressing speed of 150mm per minute and 60mm per minute is

taken for calculating the wheel dressing time for rough cut and finish cut
respectively. The wheel dressing time is calculated as given below and
added to the grinding time.
I Dressing Time for 0.10 minutes of

(Wheel width /150) +
Roughing minutes = Handling Time
II Dressing Time for 0.10 minutes of
(Wheel width /60) +
Finishing minutes = Handling Time
4.9 SPLINE GRINDING
For Example, Let “CHURCHILL ORCUT SG 36” Spline grinder is

used to grind splines on various shafts. The grinder has a wheel of 8”
diameter running at 2800 rpm. The splines are ground in rough cut and in
one finish cut on this machine. Each cut will have about 4 to 8 passes. The
basic time of one cut is calculated with the following formula.
T = Basic time per cut (minutes)

SxP S = Number of splines
T P = Number of passes in a cut
C
C = Cycle per minute
4.9.1 Number of Cuts and Passes
Generally the grinding allowance provided is 0.012”. Out of this,

0.005” is to be removed in rough cut and 0.007” is to be removed in finish
cut.
Each cut consists of a number of passes depending upon the material

to be removed and material removed in each pass. A removal of 0.0015” per
pass in rough cut and 0.001” per pass in finish cut is considered as a
34
standard practice and accordingly 4 passes and 7 passes are taken for rough
cut and finish cut respectively.
4.9.2 Cycles per Minute
The number of cycles of grinding performed in a minute is obtained

from the chart available in the Gear Hand Book written by Darle W.Dudley
and published by Mc.Grawhill publications, USA and the value is used in
5. GEAR HOBBING
the formula given at Churchill orcut sg 36. The number of cycles per minute
varies from 15 to 20.
5.1 TOOL TRAVEL
5.1.1 FACE WIDTH

5.1.2 ADDED TRAVEL OF HOB
5.2 CUTTING SPEED OF HOB
5.3 HOB SPEED FOR
BS.970, EN 353, STEEL NORMALISED, BHN 170-210
5.4 FEED
5.4.1 FEED FOR SPUR GEAR HOBBING
35
5.Gear Hobbing
Generally helical and spur gears of 4,5,6,7,8 and 10 diameteral pitches and
pitch diameters ranging form 3” to 12” are hobbed on “COOPER PFAUTER” and
“HMT” gear hobber. The basic time of hobbing one or more gears at a time is
calculated using the following formula.

L NT L = Tool Travel
T x
N FD N = Speed of Hob (rpm)
NT = Number of teeth
FD = Feed per revolution of work
In calculating it is considered that the stopper for hob travel will be so set,
that hob will stop after rapid approach and start cutting with longitudinal feed. As
such no time is allowed for cutting with Radial feed (infeed), which is generally
about 25% of that of longitudinal feed.
5.1 Tool Travel (Travel of Hob)(L) :
In hobbing the hob travels a distance more than the face width of
gear and consists of the following elements.
a. Face width of gear or gears in case more than one gear is hobbed in
one setup =(l1+l2)
b. Added travel of hob = l3
c. Over run of 1mm = l4
L = l1+l2+l3+l4
36
5.1.1 Face Width
The face width is the dimension of the width as given in the drawing.
In case more than one gear blank is loaded, the face width is the sum of face
widths of all the gears. Sometimes, a spacer of “20mm to 25mm” thickness
is added in between gear blank. But it is considered that no spacer will be
added, and hence the thickness of the spacer is not added in the tool travel.
5.1.2 Added travel of hob
This is the extra distance the hob has to travel after it has made
contact with the blank till it cuts the teeth to the full depth. The added travel
of hob depends upon the diameter of the hob, and depth of the tooth. It is
calculated using the following formula.
Added travel of hob = d (D  d )
Where D = Diameter of hob

D = Full depth of gear tooth
5.2 Cutting Speed of Hob (CS)
Cutting speed for Hobbing depended mainly on the material composition

and hardness of gear blank and the number of teeth. Generally HSS hobs are used,
and the gear blanks are of B.S.970, EN353, normalized steel stamping, with a
hardness of 170-217 BHN.
The cutting speed used for this material is as given below.
Number of Teeth Cutting Speed (CS)

Up to 40 40 metres/minute
Above 40 30 metres/minute
Generally 2 ½”,3”,3 ½” and 4” hobs are used. As such a standard hob speed
is worked out for calculating the basic time, considering the material hardness,
number of teeth and cutting speed. The standard hob speed used are given below.
5.3 Hob Speeds (N) for BS970, EN353, Steel normalized and BHN 170 – 210
37
Hob speed when number of
Hob Diameter
Teeth to be hobbed
Up to 40 > 40
Inches mm
rpm (N) rpm (N)
2.50 63 180 240
3.00 75 160 220
3.50 88 140 200
4.00 100 120 180
Sometimes the diameter of hob actually in use, is in-between the standard

size and in that case, the speed for the nearest standard diameter is chosen.
5.4 Feed (FD)
Longitudinal feed to be used has been standardized for different diameters of

hob and number of cuts. It may be noted that feed to be used depends upon the
material hardness and hob diameter. The standard feed used for spur gear hobbing
of BS970, EN353, Normalized Steel (BHN 170-200) is given below.
5.4.1 Feed for Spur Gear Hobbing
Hob Diameter Feed per Revolution of work
Inches Single Cut Double Cut

2.5 1.00 mm 1.25 & 1.00 mm
3.0 1.25 mm 1.60 & 1.25 mm
3.5 1.25 mm 1.60 & 1.25 mm
4.0 1.25 mm 1.60 & 1.25 mm
For critical operation 0.5mm feed can be used.
In case of helical gear the above feed is reduced as given below, depending
upon the helical angle.
5.4.2 Feed (FD) for helical gear hobbing
Helical angle of % of feed used for

gear degree spur gear hobbing
0 -35 100
35 – 50 80
51 – 60 60
38
61 – 70 50
70 - 90 35
6. SPLINE HOBBING
6.1 ADDED TRAVEL OF HOB
6.2 OVER RUN
6.3 CUTTING SPEED
6.4 FEED
Basic Time Calculations
For Example, “Churchill”, “HMT” and “Cooper Pfautor” hobber are used to
cut splines. The basic time of spline hobbing is calculated using the formula given
below.

L = Tool Travel
N = Speed of Hob (rpm)
NS = Number of Splines
FD = Feed per revolution of work
In calculating tool travel it is considered that the machine will be so set, that
hob will stop after rapid approach and start cutting with longitudinal feed, and no
radial cutting will be done.
The tool travel (hob travel) is calculated by adding the following three
elements
A .Length of spline as per drawing = l1
B. Added travel of hob = l2
C Over run of 1mm = l3
39
L = l1+l2+l3
6.1 Added Travel of Hob
Added travel of hob is calculated with the same formula which is

used for gear hobbing, however depth of spline is used in place of depth of
gear tooth.
6.2 Over Run
When spline is to the full depth over the entire length of a diameter
an over run of 1mm is added to the length of spline. In case where the spline
is cut to the full depth only at one end, and the depth being gradually
reduced at the other and (blind end), no over run is added.
6.3 Cutting Speed (CS)
The Churchill rigid hobber operates at 180 rpm (for example).

However for hobs of 2 ½” to 4” diameter the cutting speed at 180 rpm hob
works out to 30 to 55 meters per minute. However when cooper is used the
hob speed is calculated for a cutting speed of 50 metres per minute for steels
with hardness of 170 to 210 BHN.
6.4 Feed (FD)
A longitudinal feed of 0.75mm (0.03”) and 1mm (0.04”) per

revolution of hob is used for 2 ½” & 3” hobs and 3 ½” & 4” hob
respectively, when the number of splines to be cut is between 8 to 16 and the
material to be cut is steel with Hardness of 170 to 210 BHN.
40
7.GEAR SHAPING
7.1 NUMBER OF STROKES AND CUTTING SPEED
7.2 NUMBER OF CUTS
Gear Shaper of different models are used to produce gears by shaping (HMT
& Russian machines are among them). The basic time of shaping a gear using these
machines is calculated by using the formula.

NRn N = Number of teeth in the gear
T   Ti
TcS R = Number of strokes of the cutter per revolution
n = Number of cuts
Tc = Number of teeth in the cutter
Ti = Time for in feed
7.1 Number of strokes (S)and cutting speed (CS)
The strokes per minute depends upon the cutting speed to be used and the
stroke length, and is calculated by using the following formula.
Number of strokes per minute (S) = 6 x Cutting Speed (CS) in Foot per minute
Strokes length in inches
OR
Number of strokes per minute (S) = Cutting Speed (CS) in meters per minute
2 x Stroke length in meter
41
A cutting speed of 60 feet per minute (18 metres per minute) is used for gear
shaping on steel with hardness170-210 BHN. Lesser cutting speeds to be used for
higher hardness
The stroke length is calculated by adding an over run and approach of 4mm
to the face width of the gear.
Number of Strokes of the cutter per revolution (R) = Pitch Diameter x Л

Radial Feed
Radial Feed
Tensile Strength
Material Free Cutting
80 Kg/mm2
Mod. D.P Cuts Feed Cuts Feed
0.010 in 0.008 in
4–6 4 – 6 inc 3 3
0.25mm 0.20mm
0.012 in 0.010 in
3 8 3 3
0.30mm 0.25mm
0.012 in 0.010 in
2–2½ 10 – 12 inc 2 2
0.3mm 0.25mm
0.010 in 0.008 in
1¼-1¾ 14 -20 inc 2 2
0.25mm 0.20 mm
Note : However the feed rate to be reduced for critical operations and for
finished gears. It varies depending upon the tolerance required.
Time for Infeed
The time for infeed is calculated by using the following formula
( D  A) D = Depth of tooth in mm
Infeed  A = Approach distance in mm
BxS
B = Infeed rate per stroke (Generally 0.025mm is used)
S = Number of stroke per minute
42
7.2 Number of cuts (n)
Two or three cuts are provided for finishing the gear completely. Additional
cuts are given if the component is very critical and for close tolerance.
8. BROACHING OPERATION
8.1 NUMBER OF STROKES AND CUTTING SPEED
8.1.1 BROACHING SPEED FOR ‘LAPONITE’ BROACH
8.1.2 RETURN SPEED
The total basic time of broaching consists of cutting time and broach
return time. Usually the return time is lesser as the return speed is higher
than the cutting speed. The total basic time is calculated by adding the
cutting time and return time, which is as given below.

2 xBL BL = Broach Length
T
BSxRS BS = Broaching Speed per minute
RS = Return Speed per minute
The broach length is the length of cutting portion only.
8.1 Cutting and Return Speeds
For Laponite Horizontal Broach (60” stroke and 20,000 lbs pull)
This machine is capable of broaching at different speeds ranging from 1.36

meters per minute to 6.35 metres per minute, and its return speed is 8.75 metres per
minute.
43
Mostly internal splines are broached in jobs made up of steel having
hardness of 170 to 210 BHN. Comparatively lower cutting speeds are employed on
this machine, considering the not so good condition.
8.1.1 Broaching Speed for ‘Laponite’ Broach
Material Hardness Broaching Position of

BHN Speed Speed
Metre /minute Change knob
Cast Iron <180 2.50 7

Cast Iron 180-225 2.00 8
Steel (soft) <150 2.50 7
Steel 170-210 2.00 8

(medium)
Steel (hard) 225-325 1.50 10
8.1.2 The return speed -8.75 metre per minute
For Edgwick horizondal broach (20 tons pull 50” stroke). This
machine can broach only at speeds namely low (1.10 metres/minute) and
high 1.50 metres/minute and mostly used to broach key way, being a smaller
one. Generally the broaching speed as used for ‘Laponite’ broach is used.
The return speed of this machine is 360 metres per minute.
44
9. VERTICAL TURRET LATHE OPERATION
9.1 CUTTING SPEED (CS)
9.2 Feed (FD)
The basic time of facing, boring operations are calculated using the same
formula as given under lathe. The following vertical lathes are used mostly for
turret lathe operations.
a. Cooper Vertical Lathe

b. HMT Vertical Lathe
9.1 Cutting Speeds (CS)
Generally throwaway carbide tipped tool is used for most of the facing and
boring operations. The following cutting speeds are used.
Hardness Cutting Speed

Material Tool Grade
BHN Metre/minute
For Facing For Boring
Cast Iron 180 120 80 ISO K.20
Cast Iron 225 100 60 ISO K.20

Malleable
110-145 120 80 ISO K.20
Cast Iron
Steel 150-225 100 60 ISO P.30
45
Steel 225-275 80 50 ISO P.30
Steel 275-325 60 40 ISO P.30
9.2 Feed (FD)
For throwaway type carbide tipped tool, grade ISO K.20 & P.30, the
following feeds are used with the cutting speed mentioned at para.
Feed in mm/revolution
Operation
Rough Cut Finish Cut
Facing 0.3 0.2
Boring 0.3 0.2
Generally rough cut involved a depth of cut 2.5mm and finish cut involved a
depth of cut 1mm and for close tolerance 0.5mm.
46
10. MILLING OPERATION
10.1 CUTTING SPEEDS (CS)
10.2 FEED (FD)
The basic time for milling operations like face milling, side and face milling,
slotting from milling is calculated from the following formula.
T = Basic Time per cut (minute)

L
T L = Tool Travel (L)
FD FD = Feed of table per minute
The tool travel is calculated by adding the following
a. Maximum distance between the two ends of the surface = l1
b. Machining allowance / casting allowance = l2
c. Approach of the tool = l3
d. Added travel of the tool = l4
L = l1+ l2+ l3+ l4
Allowance
The machine allowance /casting allowance added will be 3mm or 6mm

depending upon whether such allowance is provided on both ends or one end of
surface.
Approach
47
An approach of 5mm is added to allow the cutter to travel in air, before
cutting the material.
Added Travel
The added travel of cutter necessary for each job varies depending upon the
cutter diameter and the configuration of the surface to be milled. Hence, no standard
formula or value can be used. However, the actual added travel is determined by
simulating the cutting on drawing using transparent cutter prepared to size.
10.1 Cutting Speeds (CS)
Cutting Speed (CS)(metres per

Hardness minute)
Material
BHN
Throwaway Carbide
HSS Cutter
Tipped Cutter
150-200 80 30
Alloy Steel 200-275 60 20
275-325 50 15
<150 100 35
Non Alloy Steel
150-250 80 30
<210 90 35
Cast Iron
210-250 80 30
Malleable Cast <150 70 30
Iron 150-210 60 25
30-80 500 160
Aluminium Iron
80-150 300 100
10.2 Feed (FD)
The feed used for various material expressed in mm/tooth is given here.
It is considered that the same feed will be used for rough and finish milling of
48
steel, Cast Iron. However, in case of aluminium, the feed is reduced by 20% to
25% for finish milling.
10.1.1 Feed for milling operation in mm/tooth
Type of Cutter
Carbide Tipped
Hardness HSS Cutter
Material Throwaway Type
BHN
Face Side & Face Side &
Slitting Form
Cutter Face Cutter Face
< 150 0.05 0.04 0.025 0.020 0.012 0.016
Cast Iron
150-250 0.04 0.03 0.020 0.015 0.010 0.012
Malleable <120 0.05 0.04 0.025 0.020 0.012 0.016
Cast Iron 150-200 0.04 0.03 0.020 0.015 0.010 0.012
150-200 0.04 0.03 0.020 0.012 0.010 0.012
Alloy Steel 200-275 0.03 0.25 0.015 0.008 0.008 0.010
275-325 0.02 0.16 0.01 0.006 0.006 0.008
Non Alloy <150 0.05 0.04 0.025 0.012 0.012 0.016
Steel 150-200 0.04 0.03 0.020 0.010 0.010 0.012
Aluminium 30-150 0.04 0.03 0.020 0.010 0.010 0.012
However feed rate and depth of cut can be varied depending upon the application
49
50
Milling Machine Table
51
11. SHAPING AND PLANING
11.1 CUTTING SPEED AND FEED
11.2 OVER TRAVEL AND APPROACH
The basic time of shaping and planning operations are calculated from the
following formula.
b  L L 
T x  
s  Vcx1000 Vrx1000 
T = Basic Time
b = Width of work piece
s = Feed per stroke in mm
L = Length of work piece + approach + over travel
Vc = Cutting Stroke speed in m/min.
Vr = Return Stroke speed in m/min.
Other Details
Time taken by cutting stroke (tc) = Length of Stroke / Cutting stroke speed (Vc)
Time taken by return stroke (tr) = Length of Stroke / Return stroke speed (Vr)
Number of complete stroke (z) – width of work / Feed
11.1 Cutting Speed (V) and Feed (FD)
Cutting Speed
Feed
Material m/min
Mm/stroke
 
Medium Steel 15-20 20-25 0.6-12
Mild Steel 12-16 16-20 0.6-12
Cast Steel 12-16 16-20 0.6-12
Grey Casting 12-16 18-22 0.6-12
Gun Metal 20-25 30-40 0.6-12
Light Alloy 30-35 50-60 0.1-1
11.2 Over Travel & Approach
Over Travel and Approach depends upon the application, it varies

from 1mm to 5mm
52
12. SLOTTING MACHINE
12.1 CUTTING SPEED AND FEED
The basic time for slotting operation is calculated from the following
formula
 L L 
T    xS
 Vcx1000 Vrx1000 
T = Basic Time
L = Length of work piece + approach + over travel
Vc = Cutting stroke speed in m/min
Vr = Return Stroke speed in m/min
S = Number of strokes = Slotting Depth / Feed per stroke
The Travel is calculated by adding the following
a. Length of Dimension = l1
b. Approach = l2
( Increase of Intermediate slot in a component the approach of the tool to be
kept at visible)
c. Over run of tool = l3
The value for approach and over travel depends upon the operation and
tooling criticality.
Over run varies from 2mm to 6mm depending upon the application.
12.1 Cutting Speed (V) and Feed (FD)
Cutting Speed
Feed
Material m/min
Mm/stroke
 
Medium Steel 15-20 20-25 0.2 to 2
Mild Steel 12-16 16-20 0.2 to 2
Cast Steel 12-16 16-20 0.2 to 2
Grey Casting 12-16 18-22 0.2 to 2
Gun Metal 20-25 30-40 0.2 to 2
Light Alloy 30-35 50-60 0.1 to 1
Note : The cutting speed and feed be reduced from 10% t0 40% for splines
slotting and other finishing operations.
53
13. BORING OPERATIONS
13.1 CUTTING SPEED ( carbide tool)
13.1.1 Steel
13.1.2 Cast Iron
13.2 CUTTING SPEED ( HSS Tools )
13.3 DEPTH OF CUT
13.4 HAND FEEDS
13.5 CENTRE DRILLING
13.5.1 Centre Drill Diameter and Depth of hole

13.5.2 Cutting Speed for Centre Drilling
13.5.3 Feed
Hand Feeds for Drilling and Reaming on Boring Machine
54
Horizontal Boring machines are used mostly for our application. The basic
time for boring operations is calculated from the following formula

L
T xP L
FD
= Tool Travel in mm
= Feed per Revolution
FDxN N = Revolution of work per min
P = Number of Passes
CS = Cutting Speed m/min
D = Diameter in mm
DN
CS 
1000
1. Length of dimension (finished) as per drg. = l1

 L = l1 + l2 + l3 + l4
Approach and Over run
Approach of the tool normally varies from 1mm to 5mm depending upon the
application. Over run of the tool varies from 0.5mm to 3mm depending upon the
application
55
13.1 CUTTING SPEED ( carbide tools)
13.1.1 Steel
Cutting Speed (CS )

Hardness
Material Grade Feed mm per revolution
BHN
0.20 0.15 0.10 0.05
150-225 41 49 60 75
Alloy Steel Annealed
200-275 34 41 53 68
Alloy Steel hardened and 275-325 30 38 45 56
Tempered 325-400 23 26 34 45
125 53 68 90 113
Non alloy Steel 150 45 56 68 83
250 41 49 56 68
13.1.2 Cast Iron
Hardness Feed mm/rev.

Material Grade
BHN 0.30 0.20 0.10
Cast Iron 180 45 53 60
Cast Iron 225 30 38 45
Malleable Cast Iron 110-145 49 60 75
Hardness Feed mm/rev.

Material Grade
BHN 0.4 0.3 0.2 0.1
Phosphor Bronze 175 90 113 135 158
Brass 75 113 135 150 180
Aluminium Casting
100 139 173 206 225
(non heat treated)
Aluminium Casting
130 90 113 135 158
(heat treated)
Aluminium Alloy 30-80 750 750 1200 1425

80-120 150 199 248 300
56
13.2 Cutting Speed for Boring and Facing by using HSS Tools
Material Grade Hardness BHN Cutting Speed m/min

Brass 75 45
Bronze - 26
Mild Steel 150 26
Hard Steel 275 – 325 11
110 – 145 30
Cast Iron 145 – 180 23
180 – 225 15
115 – 140 26
Steel Casting
140 – 160 15
However the cutting speed and feed varies according to the component
profile, critically and holding facilities provided.
13.3 Depth of Cut
Depth of cut varies from 0.5mm to the max. Of 5mm according to job
requirement and provisions provided for holding.
13.4 Hand Feed (FD)
The following hand feed are used for operations like grooving, radius
formation, chamfering as well as for cases of facing, boring requiring hand feed.
Hand feed in mm/rev of tool : HSS
Operation Feed (FD)

Grooving 0.025
Chamfering 0.05
Centre Drilling 0.05
Boring & Facing 0.08 to 0.1
Forming 0.05
57
13.5 Centre Drilling
Basic time is calculated using the same formula that is used for boring and
facing.
Tool Travel: The tool travel is equal to the depth of hole plus one third of
drill size.
The drill size and depth of centre drilling for the standard
centre drill is given below.
13.5.1 Centre Drill Diameter and Depth of Hole
Centre Drill Drill size Depth of hole Tool travel

Size (No) Ø inches inches Inches (L)
1 3/64 0.083 0.099

2 5/64 0.145 0.171
3 7/64 0.195 0.231
4 1/8 0.212 0.254
5 3/16 0.314 0.377
6 7/32 0.363 0.436
7 ¼ 0.467 0.550
8 5/16 0.530 0.634
13.5.2 Cutting Speed for Centre Drilling (for HSS Tool)
Hardness Cutting Speed (CS)

Material
BHN m/min
<125 20
Non Alloy
150 15
Steel
250 10
150-200 12
Alloy Steel 200-225 10
225-325 5
Aluminium 50-80 20
13.5.3 Feed
A hand feed on 0.05 mm (0.002”) is used as a standard for centre

drilling operation in boring machine.
58
13.6 Drilling and Reaming
Basic Time Calculation (T): The basic time of drilling and reaming is
calculated in the same manner, as done on radial drill. The tool travel is also
calculated in the same manner.
Cutting Speed (CS): The cutting speed used for drilling and reaming on
boring machine is 80% of cutting speed used on radial drill for the same diameter.
Feed (FD): When machine feed is used for drilling and reaming, the same
feed as used on radial drill or the nearest value is used. However, if hand feed is
used, the following rate is used.
13.6.1 Hand Feed (mm per rev.)
Hand Feed (FD) (mm/rev)

Diameter
Drilling Reaming
¼” to ½” 0.10 0.20
9/16” to 1” 0.15 0.30
1 1/8” to 2” 0.20 0.40
59
14. STANDARD ALLOWANCES
14.1 Tool Change Allowance (TCA)

Section A1a
S.No Tool Description Allowance
1 Lathe Operation 2.50 %
2 Internal Grinding Operation 14 %
3 Cylindrical Grinding Operation 14 %
4 Surface Grinding Operation 14 %
5 Milling Machine Operation 4.60 %
6 Drilling Machine Operation 2.50 %
7 Vertical Turret Lathe Operation 4.60 %
8 Shaping Machine Operation 2.50 %
9 Hobbing Machine Operation 14 %
10 Gear Shaping Operation 14 %
11 Horizontal Boring Machine Operation 10 %
12 Centre less Grinding Operation 14 %
13 Planning Machine Operation 4.60 %
14 Broaching Machine Operation 14 %
15 Gear Grinding Operation 14 %
16 Slotting Machine Operation 4.60 %
14.2 Relaxation Allowance (RA)

Section A1b
1 Machining Time
a. Less than 2.5 min 11 %
b. More than 2.5 min & up to 5.0 10 %
min
c. More than 5.0 min & up to 10.0 8 %
min
d. More than 10.0 min 7%
14.3 Contingency Allowance

Section A1c
Maximum Allowable allowance
1 5%
(For all type of operations)
60
15. HANDLING ELEMENTAL TIMES (IN MIN)
15.1 LATHES (SMALL AND MEDIUM DUTY)
15.2 MEDIUM HEAVY DUTY LATHES
15.3 DRILLING MACHINES
15.4 CYLINDRICAL GRINDING MACHINE
15.5 CENTRELESS GRINDING MACHINE
15.6 INTERNAL GRINDING MACHINE
15.7 SURFACE GRINDING MACHINE
15.8 GEAR GRINDING MACHINE
15.9 SPLINE GRINDING MACHINE
15.10 HOBBING MACHINE
15.11 GEAR SHAPING MACHINE
15.12 HORIZONTAL HYDRAULIC BROACH
15.13 VERTICAL TURRET LATHE
15.14 MILLING MACHINE
15.15 SHAPING MACHINE
15.16 PLANING MACHINE
15.17 SLOTTING MACHINE
15.18 HORIZONTAL BORING MACHINE
61
15.1 LATHES (SMALL AND MEDIUM DUTY)
Sl.No. Element Description Std.Time Freq. Total Time
1 Pick part from 4' to 6' (weight 2 to 5 kg) 0.08

2 Pick part from 4' to 6' (weight 6 to 10 kg) 0.10
3 Install dog on part, grease ends and secure between centres.
a. Small 0.26
b. Big 0.52
4 Grease ends, secure between centres 0.22
5 Install part on mandrel, secure between centres
a. Big (Bore dia > 2") 0.30
b. Small (Bore dia < 2") 0.25
6 Secure part in 3 jaw chuck
a. Needing no alignment 0.48
b. With alignment & True 3.12
c. Secure part in 4 jaw chuck and true 5.20
7 Start machine 0.04
8 Change Speed 0.10
9 Change Feed 0.06
10 Change tool in tool holder / Tail Stock 0.45
11 Advance cross slide / Tail stock 0.10
12 Advance tool from Normal position 0.12
13 Advance tool for chamfering from a position after turning or facing 0.05
14 Start machine, advance tool, adjust cut, engage feed
a. For facing operation first cut of turning 0.15
b. For subsequent cut of turning 0.24
15 Advance tool, adjust cut, engage feed
a. For facing operation first cut of turning 0.11
b. For subsequent cuts of turning 0.20
16 Back tool 0.06
17 Back tool, stop machine 0.07
18 Position cross slide to clear 0.10
19 Stop machine 0.04
20 Release part from centres and release dog 0.19
21 Release part from centres 0.07
22 Release part from centres and from mandrel
a. Bore dia < 1" 0.16
b. Bore dia > 1" 0.29
23 Release part from 3 jaw chuck / 4 jaw chuck 0.26
24 Keep part in pallet or aside at 4' to 6'
a. Weighing between 2 to 5 kg 0.08
b. Weighing between 6 to 10 kg 0.22
25 Check for dimensions (Vernier caliper, Micrometer) 0.33
Handling Time
Contingency Allowance @5%
Total Handling Time
62
15.2 MEDIUM HEAVY DUTY LATHES
1 Pick part from 4' to 6' hold on 3 Jaw chuck, align and secure
a. Medium Jobs (held on OD) 2.62
b. Long / Heavy jobs (held on OD), 3.46
2 Pick part from 4' to 6' hold on face plate / fixture (Medium jobs)
a. With 1 clamp 2.49
b. With 2 clamps 2.79
c. With 3 clamps 3.34
d. More than 3 clamps 4.40
3 Pick part from 4' to 6' hold on face plate / fixture (Heavy jobs)
4 Pick part from 4' to 6' hold on 4 Jaw chuck , align and secure
a. Medium Jobs (held on OD) 2.72
b. Long / Heavy jobs (held on OD) 3.56
5 Start Machine 0.04
6 True Job held between 4 jaw chuck
a. Regular shape 7.50
b. Irregular shape 13.50
7 Change Tool in Tool holder 1.45
8 Engage steady rest
a. one 0.35
b. Two 0.71
9 Change speed 0.09
10 Change feed 0.06
11 Advance cross slide 0.31
12 Advance Tool
a. From RTP and for operations needing accurate positioning 0.13
b. For chamfering after Facing / Turning 0.07
13 Advance tool, adjust cut, engage feed
a. For facing and first cut of turning / subsequent cut 0.15
14 Start machine, advance tool, adjust cut, engage feed
a. For facing and first cut of turning / subsequent cut 0.18
63
15 Index square tool post
a. Once 0.09
b. Twice 0.18
c. Three times 0.27
16 Back tool 0.12
17 Back tool, stop machine 0.16
18 Back tool, position cross slide to clear 0.14
20 Advance tail stock 0.16
21 Position tail stock for drill operations 0.17
22 Back tail stock 0.12
23 Dis engage feed, back drill, clear chips, advance drill & engage feed
a. Medium size 0.14
b. Large size 0.19
24 Release part from 3 jaw / 4 chuck, keep aside
a. Medium 1.74
b. Large 2.92
25 Release part from face plate / fixture, keep aside
26 Release Steady Rest
a. One 0.15
b. Two 0.30
27 Clean face plate 0.22
28 Check for Gauges / Bore dial 0.33
29 Check for micrometer 0.44
30 Check for Other dimensions 0.22
Handling Time
Total Handling Time
64
15.3 DRILLING MACHINES
1 Pick part from 4' to 6' (Weight 2 to 5 kg) 0.08

2 Pick part from 4' to 6' (Weight 6 to 10 kg) 0.10
3 Place on table , position and Clamp
a. Small 0.80
b. Big 1.10
c. Special configuration 1.50
4 Place on Jig , position and clamp
a. Small 0.70
b. Big 0.90
6 Change Speed 0.10
7 Change Feed 0.06
8 Change Tool in tool holder 0.10
9 Position Arm 0.15
10 Lock Arm / Lock Table 0.05
11 Advance tool to normal position 0.04
12 Start machine, advance tool and engage feed 0.12
13 Release tool 0.06
14 Stop machine, Release arm, advance tool, engage feed, speed and
position for subsequent Holes.
a. With Jig 0.35
b. Without Jig 0.50
16 Release Arm Lock and Back Arm 0.12
17 Position Table 0.15
18 Stop machine, Release table, engage feed, speed and position for
subsequent Holes. 0.35
a. With Jig 0.50
b. Without Jig
19 Release table lock and Back table 0.10
20 Loose clamps, release part
a. Small 0.70
b. Big 1.20
c. Special Configuration 1.50
21 Addition clamps and alignments
22 Keep part in pallet or aside at 4' to 6'
a .Weighing between 2 to 5kg 0.08
b. Weighing between 6 to 10kg 0.22
c. Weighing 10kg and above 0.35
23 Check for Gauges, dimensions 0.33
Handling Time
Total Handling Time
65
15.4 CYLINDRICAL GRINDING MACHINE
Sl No. Element Description Std. Time Freq. Total Time
1 Pick part from 4' to 6' and carry to machine 0.08

2 Install dog carrier, grease ends secure between centre
a. Big 0.52
b. Small 0.26
3 Grease ends, secure part between centre (without dog carrier) 0.22
4 Install part on taper mandrel secure between centres
a.Part held on mandrel up to 2" dia. 0.25
b.Part held on mandrel over 2" dia 0.30
5 Install part on taper mandrel using hand press, secure between
centre for parts over 1" ID 0.36
6 Install and secure in mandrel, secure between centre:
a. Special configuration 0.80
b. Normal- std compts. 0.39
7 Install part on spindle, secure (one Allen screw)
a. Small 2" dia. 0.26
b. Big over 2" dia. 0.36
8 Start machine, advance wheel and
a. Position for plunge cut 0.24
b. Reposition for subsequent plunge cut 0.09
9 Stop machine, back wheel 0.07
10 Measure dimension with micrometer 0.33
11 Check dimn. with caliper gauge
a. Up to 1" dia 0.11
b. 1" to 2" dia 0.17
c. 2" to 4" dia 0.22
d. 4" to 6" dia 0.28
e. Over 6" dia 0.34
12 Release part from centre, release dog 0.19
13 Release part from centre 0.07
14 Release part from centre, release taper mandrel
a. Up to 1" dia (ID) 0.16
b. Over 1" dia (ID) 0.29
15 Release part from spindle and keep aside
a. Small 0.20
b. Big 0.22
16 Keep part aside (5' to 6' and big part) 0.06
17 Pick up N parts from machines and keep in pallet at 5' to 6' distance 0.28
18 Pick up N parts from pallet (at 5' to 6' ) and keep on machine 0.28
19 Clean part and mandrel 0.18
Handling Time
Total Handling Time
66
15.5 CENTRELESS GRINDING MACHINE
1 Pickup, bring and place 15 parts on machine bed from Pallet. 0.28
2 Pick parts and clean. 0.09
3 Start Machine. 0.06
Start hyd. & coolant motors. 0.06
4 Place part on blade (Parts with one step dia only) 0.11
5 Place part on blade (Parts with 2 & 3 steps) 0.17
6 Advance regulating wheel and position. 0.24
7 Pick part from blade (Parts up to 1" dia ) & check with Gauge. 0.17
8 Pick part from blade, check with gauge (Part from 1" to 2" dia ) 0.23
9 Pick part from blade, check with gauge parts with dia more than 2". 0.34
10 Pick part from blade, check with gauge (Parts up to 1" dia and
more than 1 step) 0.25
11 Pick part from blade, check with gauge (Parts with 1" to 2" dia
more than 1 step) 0.31
12 Pick part from blade, check with gauge (Parts of dia more than 2"
and 2 or 3 steps) 0.42
13 Reload part on blade (Part having one step) 0.09
14 Reload part on blade (Parts having 2 or 3 steps) 0.14
15 Insert part in holder and load on blade, small length parts. 0.13
16 Keep parts aside. 0.06
17 Pickup 15 finished parts from machine and keep in the pallet. 0.28
18 Check with micrometer. 0.33
19 Adjust depth of cut for subsequent pass. 0.22
20 Adjust depth of cut for final pass, check two parts and reset. 1.67
21 Bring N parts from rear side of machine to front for subsequent
pass, (up to 20 parts) 0.34
22 Stop Machine, back wheel. 0.09
23 Check with micrometer. 0.33
24 Collect components from behind the machine after each pass
(50 components) 0.1
Handling Time
Total Handling Time
67
15.6 INTERNAL GRINDING MACHINE
Sl. No. Element Description Std. Time Freq. Total Time
1 Pick part and place

a. In fixture (Up to 12" dia) 0.16
b. In Q.C. Chuck ( up to 6" dia) 0.12
c. In Q.C. Chuck ( above 6" dia) 0.31
d. In Bunk above 6" dia ID 1.71
e. In Bunk up to 6" dia ID 1.55
f. On Spindle 0.16
2 Secure part in fixture with
a. One clamp 0.12
b. Two clamps 0.33
c. Three clamps 0.62
d. One Allen screw 0.22
e. Two Allen screws 0.26
f. Three Allen screws 0.29
3 Secure part in Q.C.Chuck
a. Spur gear with 3 locating pins 2.65
4 Check the trueness of the job 6.66
5 Close Guard 0.08
6 Start machine, advance part on rapid 0.21
7 Advance face wheel and position 0.17
8 Back face wheel, back part 0.26
9 Engage reciprocating lever and advance part of I.G 0.17
10 Position I.G. wheel 0.14
11 Back part, reposition, Grinding wheel, close Guard and engage feed 0.80
12 Back part, stop machine 0.19
13 Open Guard 0.08
14 Check for dimensions, (Bore dial gauge) 0.33
Handling Time
Total Handling Time
68
15.7 SURFACE GRINDING MACHINE
1 Pick up part and load on machine.

a. Heavy 0.63
b. Medium 0.37
c. Small (...no. Of pieces) 0.07
2 Pick up turn side and load on machine.
a. Heavy 0.36
b. Medium 0.19
c. Small 0.05
3 Clean table with coolant 0.34
4 Adjust part and fix end supports 1.21
5 Magnetise table, check, start machine and set coolant 0.40
6 Lower spindle on rapid 0.24
7 Lower spindle on hand feed to touch part. 0.45
8 Stop machine , demagnetise, clear part.
a. Heavy 1.10
b. Medium 0.74
c. Small 0.15
9 Check with gauge/vernier 0.43
10 Raise spindle on rapid 0.29
11 keep aside:-
a. Heavy 0.23
b. Medium 0.20
c. Small (...no. Of pieces) 0.07
12 Dress wheel 2.19
13 Stop Machine 0.04
Handling Time
Total Handling Time
69
15.8 Gear Grinding Machine
1 Pick part from 4' to 5' distance. 0.09

2 Clean parts. 0.24
3 Place part on mandrel and secure. 0.23
4 Hold part between centres of machine. 0.14
5 Tighten nut to secure part. 0.18
6 Start machine ( Coolant, Ram cross slide ) 0.11
7 Tighten screw in the index head. 0.19
8 Adjust for first cut. 1.98
9 Advance grinding wheel for subsequent cuts. 0.2
10 Clear part from grinding wheel or advance to grinding wheel. 0.11
11 Check profile with profile gauge. 0.12
12 Loosen screws in indexing head. 0.21
13 Take out mandrel and unload from centre. 0.13
14 Loosen nuts in mandrel and unload from centre. 0.13
15 Loosen nuts and take out job. 0.11
16 Release from centres and keep aside. 0.14
17 Check dimension with
Flange micrometer 1.7
Two pin method. 5.5
18 Clean machine. 0.1
19 Dress wheel (once) 0.6
Handling Time
Total Handling Time
70
15.9 Spline Grinding Machine
1 Pick part from ( 2' to 4' distance ) and keep near machine. 0.07
2 Clean component. 0.1
3 Secure dog to part. 0.11
4 Secure part between centres. 0.23
5 Tighten nuts and secure. 0.36
6 Centre the job with respect to grinding wheel. 0.44
7 Start machine. 0.12
8 Adjust for first cut. 0.47
9 Advance grinding wheel for subsequent cuts. 0.06
Move wheel to clear or advance to grinding wheel after
10 0.11
inspection.
11 Check dimension with
Flange micrometer 1.7
Two pin method 5.5
12 Dress wheel (once) 0.6
13 Loose nuts and release. 0.35
14 Unload component from centres. 0.14
15 Check with spline gauge. 0.38
16 Keep component aside ( 2' to 4' distance). 0.12
17 Clean machine. 0.1
Handling Time
Total Handling Time
71
15.10 Hobbing Machine
Pick part from 4’ to 6’ distance, clean with rag, place on

1
fixture
a. Small and light - up to 4" dia and 2 kg 0.15
b. Medium - 3kg to 5kg, more than 4” and up to 8" dia 0.25
c. Medium large & medium heavy -more than 8" to 12"dia (6
0.30
to 8kg)
2 Pick spacer, wipe coolant on it, place on part in fixture 0.15
Place clamp on part, screw nut, advance tail centre to
3
support fixture
and secure job - 1 clamp 0.75
4 True job if necessary.
a. Small & Medium 5.50
b. Heavy 10.50
5 Start machine, advance part to Hob - Rapid 0.45
6 Back part from Hob - Rapid 0.34
7 Back tail centre, loosen clamp and take out 0.40
8 Take out part from fixture, drain coolant
a. Small & Light 0.12
b. Medium 0.15
c. Medium large and Medium heavy 0.18
9 Take out spacer, keep on bed 0.11
10 Keep hobbed part in pallet at 4" to 6" distance
a. Small & Light 0.10
b. Medium 0.13
c. Medium large & Medium heavy 0.15
11 Clean fixture 0.17
12 Open guard and close guard 0.12
13 Check dimn. - Measurement Over Pins 4.95
Handling Time
Total Handling Time
72
15.11 Gear Shaping Machine
1 Pick part from 5' to 8' distance, keep on machine bed 0.11
2 Place component in fixture 0.11
3 Place bunk and secure with nuts 0.39
4 True job if necessary.
a. Small & Medium 5.50
b. Heavy 10.50
5 Advance cutter to part 0.21
6 Adjust cut , start machine 0.15
8 Release part (Loosen nuts ) 0.21
9 Take out bunk and washer 0.10
10 Clear cutter from part 0.18
11 Take out part, keep aside 0.10
12 Check part 0.13
13 Clear chips from part 0.16
14 Clean fixture 0.07
15 Check dimn. - Measurement Over Pins 4.95
Handling Time
Total Handling Time
73
15.12 Horizontal Hydraulic Broach
1 Pick part from pallet at 4' to 6' distance ( Weight up to 2 kg ) 0.08

2 Pick part from pallet at 4' to 6' distance ( Weight above 2 kg and
up to 5 kg ) 0.09
3 Pick part from pallet at 4' to 6' distance ( Weight above 5kg and
up to 7.5 kg ) 0.1
4 More than 7.5 kg to 10 kg. 0.2
5 Clean part with rag. 0.15
6 Install part on Broach / Fixture. 0.12
7 Advance broach to pull head, connect broach to pull head and insert
key and lock tighten tail head adapter screw. 0.21
8 Advance broach (heavy) supported on CPB to pull head connect
broach to pull head and lock to pull head. Release CPB support. 0.44
9 Move broach forward to starting position, open coolant tap, operate
switch to start cutting. 0.15
10 Loosen tail head adapter screw, back tail head to clear. 0.07
11 Release part from fixture & take out ( Parts weighing up to 2 kg ) 0.06
12 Release part from fixture & take out (Parts weighing more than 2 kg
and up to 5 kgs ) 0.08
13 Release part from fixture & take out (Parts weighing more than
5 kgs and up to 7.5 kgs ) 0.12
14 More than 7.5 kgs to 10 kgs. 0.2
15 Hold part by hand, clean with coolant flow, drain coolant. 0.1
16 Keep broached part in pallet kept 4' to 6' distance (Parts weighing
up to 2 kgs ) 0.06
17 Keep broached part in pallet kept at 4' to 6' distance (Parts weighing
more than 2 kgs and up to 5 kgs ) 0.08
18 Keep broached part in pallet kept at 4' to 6' distance (Parts weighing
more than 5 kgs and up to 7.5 kgs ) 0.11
19 More than 7.5 to 10 kgs. 0.2
20 Advance tail head from clear position to broach and lock broach to
Tail head. 0.15
21 Advance tail head from clear position to broach. Support broach on
CPB, lock broach to tail head and release CPB support. 0.41
22 Back broach to starting point (Rapid), and clean upper surface of
broach with brush. 0.14
23 Take out pull head peg, back broach to clear position. 0.18
24 Support broach on CPB, Take out pull head peg. Release tail head
stop. 0.21
25 Clean broach with 4" brush (bottom surface only) 0.3
26 Clean fixture with coolant flow. 0.1
27 Check dimension. 0.35
Handling Time
Total Handling Time
74
15.13 Vertical Turret Lathe
1 Pick part from 8' to 10' , carry to machine and place on table / fixture
a. Medium Jobs (10 to 25 kg) 0.85
b. Heavy and big ( Over 25 kg) 1.64
2 Get crane from 8' to 10' distance 0.12
3 Align part and position (on dowel pins, centre bunk)
a. Small 0.13
b. Medium 0.28
c. Big and heavy 0.48
d. True job is necessary
i . Normal location 7.50
ii. Critical location 13.50
4 Secure job to table / fixture with
a. Two clamps (strap type) 1.12
b. Three clamps 1.50
c. Four clamps 1.90
5 Align and locate with adjusting screws
a. one number 0.12
b. Two numbers 0.24
c. Three numbers 0.36
d. Four numbers 0.48
6 Change Speed 0.05
7 Change Feed 0.05
9 Index Turret
a. Once 0.12
b. Twice 0.22
c. Three times 0.32
10 Advance turret from clear (Horizontal movement - Auto) 0.19
11 Change Tool in Tool holder 0.45
12 Start machine, advance turret, engage feed 0.26
13 Start machine, advance turret, adjust cut and engage feed
a. For first cut 0.58
b. For subsequent cuts 0.37
14 Back Turret 0.12
15 Back Turret, stop machine 0.28
16 Move turret to clear (Horizontal movement) 0.31
75
17 Release adjusting screws
a. Two numbers 0.18
b. Three numbers 0.27
18 Release part from fixture / Table
a. Two clamps 0.48
c. Four clamps 0.97
19 Lever and release job from dowel pins (Two dowel pins) 0.35
20 Get Jib crane from 8' to 10' 0.12
21 Pick job, keep aside
a. Medium 1.20
b. Heavy and Large 1.52
22 Clean Fixture / Table with brush 0.23
23 Clean component base 0.40
24 Clean location bore with brush 0.18
25 Check dimn. with bore dial 0.22
26 Check dimn. with micrometer 0.35
27 Check other dimension with vernier 0.11
Handling Time
Total Handling Time
76
15.14 Milling Machine
1 Pick part and load on Machine

a. Heavy 0.53
b. Medium 0.34
c. Small 0.15
2 Adjust part and position on table
a. Non critical 0.27
b. Critical 0.62
3 Clamp the part on the table with
a. With one clamp 0.12
b. With two clamps 0.35
c. With three clamps 0.65
4 Hold part in fixture
a. With simple location and clamp 1.12
b. With critical location and clamp 1.52
6 Change speed 0.10
7 Change feed 0.05
8 Advance table in Rapid and position near the job 0.11
9 Start feed 0.05
10 Move table in Rapid and position for unloading 0.09
Stop machine, Move table, adjust cut, change feed /
11
speed and
Start feed 0.27
12 Stop machine, Move table, adjust cut and start feed 0.23
14 Release clamp
a. One clamp 0.06
b. Two clamps 0.16
15 Pick part from table and keep aside
a. Heavy 0.45
b. Medium 0.29
c. Small 0.12
16 Release part from fixture and keep aside
a. Heavy 0.48
b. Medium 0.32
c. Small 0.15
17 Clean Table / fixture 0.09
18 Release depth of cut 0.07
19 Check for dimensions, if critical 0.33
Handling Time
Total Handling Time
77
15.15 Shaping Machine
1 Pick part and load on Machine

a. Heavy 0.52
b. Medium 0.32
c. Small 0.15
2 Adjust part and position on table
a. Non critical 0.25
b. Critical 0.57
5 Engage feed 0.07
6 Adjust depth of cut 0.08
7 Release lever 0.05
8 Move table for subsequent cut
a. Insert Handle for table movement 0.05
b. Move table back and position
1. Up to 100mm length 0.21
2. 101mm to 300mm length 0.35
3. Above 300 mm 0.47
4. Remove Handle 0.04
9 Stop Machine 0.04
10 Release clamp
a. One clamp 0.06
b. Two clamps 0.16
a. Heavy 0.42
b. Medium 0.27
c. Small 0.11
12 Clean Table 0.09
13 Check dimens. with vernier / instruments. 0.22
Handling Time
Total Handling Time
78
15.16 Planning Machine
1 Pick part and load on Machine.

a. Heavy 1.2
b. Medium 0.52
c. Small 0.32
2 Adjust part and position on table.
a. Non Critical 0.65
b. Critical 1.5
5 Engage feed 0.07
6 Adjust Depth of cut 0.08
8 Move table for subsequent cut
a. Insert Handle for table movement 0.05
b. Move table back and position
1. Up to 100mm length 0.35
2. 101mm to 300mm 0.47
3. Above 300mm 0.65
4. Above 1000mm 0.85
5. Remove Handle 0.04
9 Stop Machine 0.04
10 Release Clamp
a. One clamp 0.16
b. Two clamps 0.32
a. Heavy 1.2
b. Medium 0.52
c. Small 0.32
12 Clean Table. 0.21
13 Check for dimensions. 0.33
Handling Time
Total Handling Time
79
15.17 Slotting Machine
1 Pick part and load on Machine.

a. Heavy 1.2
b. Medium 0.52
c. Small 0.32
2 Adjust part and position on table.
a. Non Critical 0.65
b. Critical 1.5
5 Engage feed 0.07
6 Adjust Depth of cut 0.08
8 Index Table for subsequent cut
a. Insert Handle for Indexing 0.05
b. Index less than 90° 0.09
c. Index 90° - 180° 0.15
d. Index 180° - 360° 0.21
e. Remove Handle 0.04
9 Stop Machine 0.04
10 Release Clamp
a. One clamp 0.16
b. Two clamps 0.32
a. Heavy 1.2
b. Medium 0.52
c. Small 0.32
12 Clean Table 0.21
13 Check for dimensions. 0.33
Handling Time
Total Handling Time
80
15.18 Horizontal Boring Machine
1 Pick part from 6' to 8' and place on table / fixture

a. Small jobs Up to 12 kg 0.35
b. Medium jobs (12 to 30 kg) 0.85
c. Medium Heavy jobs ( 30 to 60kg) 1.65
d. Heavy jobs ( 60kg and above) 3.50
2 Get crane from 8' to 10' distance 0.22
3 Get overhead chain block for loading ( Manual) 3.20
4 Align part and position (on dowel pins, centre bunk)
a. Small 0.13
b. Medium 0.28
c. Medium Heavy 0.48
d. Heavy jobs 1.50
5 Secure job to table / fixture with
a. Two clamps ( strap type) 1.12
c. Four clamps 1.90
d. More than four clamps 2.60
6 True component w.r.t. bore / face
a. Normal reference 5.20
b. Critical reference 12.50
8 Change feed 0.06
9 Change speed 0.06
10 Change tool in Tool holder 0.65
12 Change milling cutter in tool holder 1.85
11 Advance table and position - Auto 0.25
12 Start machine, advance table and engage feed 0.26
13 Start machine, advance table, adjust cut and engage feed
a. For first cut 0.58
b. For subsequent cut 0.37
14 Change facing holder 2.50
15 Back table 0.13
16 Back table, stop machine 0.19
17 Back table to clear 0.32
81
19 Release part from table / fixture
a. Two clamps 0.48
c. Four clamps 0.97
d. More than four clamps 1.25
20 Lever and release job from dowel pins / centre bunk 0.35
21 Get Jib crane from 8' to 10' 0.22
22 Get overhead chain block for unloading ( Manual ) 0.32
23 Pick job, keep aside
a. Small 0.32
b. Medium 0.82
c. Medium Heavy 1.55
d. Heavy 3.20
24 Clean Fixture / Table with brush 0.23
25 Clean component base 0.40
26 Clean location bore with brush 0.18
27 Check dimn. with bore dial gauge 0.32
28 Check dimn. with Micrometer 0.42
29 Check other dimn. with vernier 0.15
Handling Time
Total Handling Time
16. SET UP TIMES
82
Set up time depends upon the Tooling / Dimensions criticality, size, profile
of the component. However normal set up times fall under the given category and
the same is selected from the given range depending upon the operations involved.
S.No Description Time (min)

1 a. Lathe Operation (Small & Medium) 15 – 20
b. Lathe Operation (Medium Heavy Duty) 30 – 120
2 a. Drilling Operation (Small & Medium) 15 – 60
b. Drilling Operation (Heavy Jobs) 60 – 120
3 a. Cylindrical Grinding 15 – 60
b. Centre less Grinding 30 – 90
c. Internal Grinding 30 – 90
d. Surface Grinding 15 -60
e. Gear Grinding 120 – 150
f. Spline Grinding 120 – 150
4 Gear Hobbing 60 – 120
5 Spline Hobbing 60 – 120
6 Gear Shaping 60 – 120
7 Broaching Operation 75 – 120
8 Vertical Turret lathes 75 – 120
9 Milling Operation 15 – 60
10 Shaping and Planning 15 – 75
11 Slotting Machine 20 – 75
12 Boring Machine 60 – 150
83
17. Hourly Rate Calculations
17.1 Hourly Rate working – Turning
17.2 Hourly Rate working – Milling
17.3 Hourly Rate working – Grinding
17.4 Hourly Rate working – Drilling
17.5 Hourly Rate working – Boring
17.6 Hourly Rate working – Gear Machine
17.7 Hourly Rate working – Machining Others
17.8 Hourly Rate working – Press
84
17.1 Hourly Rate working – Turning
S.No DESCRIPTION MAKE MODEL HRLY - 2 HRLY - 3
1 LIGHT DUTY DHARAM SMT No.1 32 30
2 CENTRE MMM 33 31
3 CENTRE LATHE KIRLOSKAR TMSTR-35 42 39
4 HEAD LATHE PREMIER 7" 47 43
5 HEAVY DUTY PANTHER GLP-3 48 45
6 CENTRE HMT VIKRAM 49 45
8 CENTRE HMT LB -17 51 47
11 TURN MASTER KIRLOSKAR TMSTR - 45 63 56
13 CENTRELATHE KIRLOSKAR TMSTR-50 80 71
14 HEAD LATHE RAJENDRA 24" 107 95
15 HEAVY DUTY BECO HD-50B/I 222 191
16 TURRET LATHE COOPER CVT - 105 224 192
17 CNC LATHE ACE DESIGN 228 192
18 CNC LATHE 309 255
19 CNC LATHE LAKSHMI SL - 3H 553 448
85
17.2 Hourly Rate working – Milling
1 VERTICAL / HORZ. BFW VFD 42 39
2 VERTICAL/HORZ. BHAMBAR M2B 44 41
3 RAM TURRET HARISSON RT-1M 48 44
4 RAM TURRET HARISSON RT-2M 51 46
5 VERTICAL / HORZ. 59 52
6 UNIVERSAL 62 54
7 VERTICAL / HORZ. 67 59
8 KEYWAY EIFCO KM-24 72 62
9 HORIZONTAL HMT FN - 1H 77 66
10 VERTICAL HMT FN - 1V 77 66
11 HORIZONTAL HMT FN - 2EH 88 76
12 VERTICAL HMT FN - 2EV 90 77
13 HORIZONTAL HMT FN - 3H 126 106
14 VERTICAL HMT FN - 3V 130 109
86
17.3 Hourly Rate working – Grinding
1 BELT HYENA MU - 4 28 27
2 PEDESTAL EIFCO 33 32
3 CYLINDERICAL HI-LIFE HLV-500 44 40
4 CYLINDERICAL HI-LIFE HLV-800 48 44
5 SURFACE -HORZ. PRAGA 451-P 57 51
6 SURFACE AVRO TP-6 67 59
7 SURFACE AVRO R-112 80 71
8 CYLINDERICAL HMT G - 17 98 86
9 SURFACE HMT SFW -2 112 95
10 UNIVERSAL PARISUD 200A/S 122 103
11 INT & FACE 130 110
12 UNIVERSAL PARISUD 350A/S 130 110
13 CYLINDERICAL HMT G - 22 131 112
14 SURFACE AVRO R-4020 151 126
15 CENTRELESS PARISUD GN-80 161 139
16 CENTRELESS HMT GCL 100 186 157
17 INT & FACE CINCINN 273-A 220 181
18 INTERNAL HMT IGE-90 220 182
19 SPLINES MATRIX 457 371
20 GEARS REISH AZA 692 558
87
17.4 Hourly Rate working – Drilling
1 BENCH EIFCO BDM/6T 26 26
2 PILLAR EIFCO P4 / 38 29 29
3 COLUMN EIFCO GTA10 32 31
4 BENCH PREWO 12..04 34 32
5 RADIAL UNIVER HD - 2 34 32
6 COLUMN EIFCO P4/38 34 32
7 SENSITIVE BATLIBOI 34 32
8 PILLAR EIFCO 45 41
9 COLUMN PREWO 12..02 46 42
10 COLUMN HMT 51 46
11 RADIAL MMT MAG-3 54 48
12 RADIAL BATLI BVR-3 61 54
13 RADIAL UNIVER AG - 2 62 55
14 RADIAL KRLR MK 750S 71 62
15 RADIAL KRLR MK1000S 101 86
16 RADIAL HMT RM-62 112 94
19 SPLINES MATRIX 457 371
20 GEARS REISH AZA 692 558
88
17.5 Hourly Rate working – Boring
1 BORING FINISH HMT 166 133
2 BORING - ROUGH HMT 180 142
3 BORING - HORZ KARAM MASTER 183 145
4 BORING - HORZ. HMT 201 158
5 BORING - HORZ BHARAT BFT-80 233 180
6 BORING -2 WAY HMT 320 244
7 BORING - HORZ. HMT A-29 332 252
8 BOR / MILL HMT AZ - 9 332 252
9 BOR / MILL HMT AZ - 11 376 285
10 JIG BORING HMT 642 475
89
17.6 Hourly Rate working – Gear Machine
1 GEAR SHAPER HMT S-150 95 84
2 BROACH M/C HMT RW-5T 144 124
3 SPLINE HOBBER COOPER 167 144
4 GEAR SHAPER HMT 228 190
5 BROACH M/C HMT RW-16T 231 192
6 GEAR HOBBER COOPER P-630 383 313
7 GEAR SHAVING HURTH 2SA-22 408 330
8 GEAR HOBBER COOPER P-251 474 383
9 GEAR SHAPER HMT WS-1 527 423
10 GEAR SHAPER HMT 608 487
11 GEAR HOBBER HMT L-200 656 527
90
17.7 Hourly Rate working – Machining Others
1 SLOTTING ROUGH 38 37
2 SHAPING SAGAR 12" 40 37
3 HACKSAW EIFCO HP/200 42 41
5 CENTRE LAPPER 44 41
6 HONING EIFCO RADIAL 46 45
7 SLOTTING FINISH 55 51
8 PLANING RIAT RPL-4 58 52
9 THREAD ROLLING PRAGA 512 67 62
10 FLARING MACHINE ELECT PNE INJECTOR 68 60
12 SPARK EROSION SPARK OMIX B - 70 82 73
13 PLANING RIAT RPL-6 87 75
14 SHEARS DEVI MEDIUM 100 96
15 THREAD ROLLING PRAGA 513 113 100
91
16 THREAD MILLER 130 109
17 PIPE BENDING ELECT PNE 3" O.D. 133 115
18 HONING MACHINE ELECTRO PNEUMAT 135 116
19 COILING MACHINE ADDN INJECTOR 136 112
20 SHEARS DEVI MEDIUM 139 128
21 SHEARS GODREJ MEDIUM 174 154
22 HONING ELECTRO PNEUMAT 203 171
23 THREAD GRINDER 236 198
24 SUPER FINISH 426 348
25 SHEARS GODREJ HEAVY 555 459
92
17.8 Hourly Rate working – Press
1 STRAIGHTENING CHAMPION 46 44
2 PNEUMATIC LAMBA GEARED 65 60
3 HYDRAULIC CHAMPION 65 61
7 MECHANICAL FMT 78 71
10 PRESS BRAKE - M LAMBA P+S 3 122 107
11 HYD-S-DEEP DRAM ORIENTAL ON - 250 122 105
93
15 MECHANICAL DEVI 1PT 146 123
16 MECHANICAL DEVI 20T 147 124
18 MECHANICAL FMT 154 131
20 MECH-M-DIE-CUSH ISGEC G-200 210 178
21 MECHANICAL ISBEC 6-2P8 293 243
23 HYD-S-DEEP DRAM ISGEC HS-6000 668 563
18. Appendices
94
18.1 Appendix I
(Total Operation Time – Chart)
18.2 Appendix II
(Std. Cost Data for Components – Chart)
18.3 Appendix III

(Comparison between Vendor – Chart)
18.4 Appendix IV
(Drill Withdrawal Time for Clearing Chips – Chart)
95
18.1 Appendix I (Total Operation Time – Chart)
Stock No: Part No: Opn No. :

Description: Opn Description:
Material: Size: Weight (Kgs): Hardness:
S.No Details C.S N FD S L P T T.C.A. R.A. TMT
Remarks:
Handling Time
Total Operation Time

C.S- Cutting Speed, N- RPM, FD- Feed, S- Strokes per min, L- Length, P- No. Of passes, T- Time
T.C.A- Tool change allowance @ %, R.A- Relaxation allowance @ % , TMT- Total Machining Time.
96
18.2 Appendix II (Std. Cost Data for Components – Chart)
Stock
Part No. : Model : Batch Qty.:
No :
Description : Operation :
Drawing date : Last revision : Labour charges: Partial Material: Full Material:
Material & size : Weight (Kgs) :
Min. Min. Min. Min. Rs. Rs.
M/c ing Set up / Total M/c Hr. Opn.
Opn No Operation Description Set up Time
Time Compt. Time Rate Cost
Raw Material Cost

Investment on Material @
Total Price
SIGNATURE DATE:
97
18.3 Appendix III (Comparison between Vendor – Chart)
Stock No : Opn No :
Description : Opn Description:
Opn Std Subcontract Cost - Rs

Remarks Comment
Cost Rs Party 1 Party 2 Party 3 Party 4 Party 5
Note :
98
18.4 Appendix IV (Drill Withdrawal Time for Clearing Chips – Chart)
Depth of Drilled Hole

Drill
Size
¼ ½ ¾ 1 1¼ 1½ 1¾ 2 2¼ 2½ 2¾ 3 3½ 4 4½ 5 5½ 6
Time in minute to clear chips from drill
1/16 . 140 . 420 . 700 . 980
1/8 .... . 140 . 280 . 420 . 560 . 700
1/4 .... .... . 070 . 140 . 210 . 280 . 350 . 420
3/8 .... .... .... . 070 . 140 . 210 . 210 . 210 . 210 . 280 . 350 . 420
1/2 .... .... .... .... . 070 . 070 . 070 . 140 . 140 . 210 . 210 . 280 . 350 . 420
5/8 .... .... .... .... .... . 070 . 070 . 070 . 140 . 140 . 140 . 210 . 280 . 280 . 350 . 420
3/4 .... .... .... .... .... .... . 070 . 070 . 070 . 070 . 140 . 140 . 210 . 210 . 280 . 350 . 350 . 420
7/8 .... .... .... .... .... .... .... . 070 . 070 . 070 . 070 . 070 . 140 . 210 . 210 . 280 . 280 . 350
1 .... .... .... .... .... .... .... .... . 070 . 070 . 070 . 070 . 070 . 140 . 140 . 210 . 210 . 280
1¼ .... .... .... .... .... .... .... .... .... .... . 070 . 070 . 070 . 070 . 140 . 140 . 140 . 210
1½ .... .... .... .... .... .... .... .... .... .... .... .... . 070 . 070 . 070 . 070 . 140 . 140
1¾ .... .... .... .... .... .... .... .... .... .... .... .... .... . 070 . 070 . 070 . 070 . 070
2 .... .... .... .... .... .... .... .... .... .... .... .... .... .... . 070 . 070 . 070 . 070
2¼ .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... . 070 . 070 . 070
2½ .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... . 070 . 070
2¾ .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... . 070
* The times shown must be added to all drilling operation to take care of the clearing of chips from the drill in
deep holes. This is based upon the formula that chips will clear the drill for the first depth of 2 times the diameter
of the drill, for the next depth of 1½ times the diameter of the drill and for additional depths of only one time the
diameter of the drill.
99
HOUR RATE
1. Value of Machine : Rs. V lakhs
2. Power Consumption : P KW
3. Man Efficiency : 75%
4. Machine Efficiency : 85%
Any place that the machine value ' V ' figures, 25% extra given for Capital
expenditure, 50% of machine value is assumed to be paid by individual and 50% is
obtained through Bank loan.
S.No. Detail Two Shift Basis Three Shift Basis

1 Total No. Of hours per year. 25* 8* 12* 2 4800 25* 7.5* 12* 3 6750
Std.hours using man and m/c

2 4800* 0.75* 0.85 3060 6750* 0.75* 0.85 4303
efficiently.
AA Total Depreciation
A M/c salvage value 0.05V 0.05V
B Life of Machine 24Years 18years
I Depreciation Value D1 = 0.95V 24* 3060 D1 = 0.95V 18* 4303

= 1.294V Rs. = 1.226V Rs.
II Return on Invest. @ 25% D2 = 0.5V 0.25 / 3060 D2 = 0.5V 0.25/ 4303

4.085V Rs. 2.905V Rs.
III Interest on Bank loan @ 15% D3 = 0.5V 0.15 / 3060 D3 = 0.5V 0.15 / 4303
2.451V Rs. 1.743V Rs.
AA Total D1+D2+D3 = 7.830V D1+D2+D3 = 5.874

BB Direct Labour - Skilled. A man is paid Rs.2000 per month A man is paid Rs.2000 per month
Per Std. Hr. Per Std.Hr.
= 2000 / (25 * 5.1) = 2000 / (25 * 5.1)
= 15.686 = 15.686
If X man are reqd. If X man are reqd.
Total = 15.686X Total = 15.686X
100
S.No. Detail Two Shift Basis Three Shift Basis
CC Direct Labour - Un Skilled. A man is paid Rs. 1200 per month A man is paid Rs. 1200 per month
Per Std. Hr. Per Std. Hr.
= 1200 / (25 * 5.1) = 1200 / (25 * 5.1)
= 9.41 = 9.41
If X man are reqd. If X man are reqd.
Total = 9.41X Total = 9.41X
DD Indirect Labours and Others. 100% of Direct Labour - Unskilled. 100 % of Direct Labour - Unskilled.
Machine is assumed to be operative Machine is assumed to be operative
only for 40% of time - i.e. actual metal only for 40% of time - i.e. actual metal
EE Power Cost cutting time. Rest of the time is for M/C cutting time. Rest of the time is for M/C
set-up, Matl handling, Maintenance, set-up, Matl handling, Maintenance,
etc., etc.,
Power Cost Power Cost
=0.4 *P*Rs.2.50 / KWHr. =0.4 *P*Rs.2.50 / KWHr.
Consumable (including
FF Estimated = Rs.5 to 15 / Hr. approx. Estimated = Rs.5 to 15 / Hr. approx.
Tooling etc.,)
GG Maintenance 3% of V / 3060 5% of V / 4303
TOTAL HOURLY RATE SUM OF ALL THE ABOVE SUM OF ALL THE ABOVE
101
THREADING ESTIMATION
API & BECO THREADS - External

S.NO SIZES TPI CT (TH) CT (TR) HT TT (min) M/C HR COST (Rs) THD.SC Form Tool
1 2 3/8" API Reg 5 51.00 39.13 22.81 112.94 48 90 Z2150 K4604
2 2 3/8" API IF 4 43.20 41.63 23.16 107.99 48 86 Z2096 K4614
3 2 7/8" API Reg 5 59.50 55.48 22.92 137.90 48 110 OOOO62 K4604
4 2 7/8" API IF 4 59.29 62.55 23.75 145.59 48 116 Z2127 K4614
5 3 1/2" API Reg 5 85.00 68.14 26.26 179.40 48 144 OOOO17 K4604
6 4 1/2" API Reg 5 120.42 86.64 25.76 232.82 48 186 OOOOO4 K4604
7 5 1/2" API Reg 4 159.60 127.04 46.32 332.96 63 350 OOO197 K4606
8 6 5/8" API Reg 4 186.67 142.42 46.38 375.47 73 457 Z2022 K4609
9 3 1/2"BECO 2 80.79 97.62 36.75 215.16 63 226 Z4212 K4687
10 6"BECO 2 173.33 186.35 56.22 415.90 73 506 Z5229 K4611
11 5 1/4" BECO 2 181.50 111.04 53.24 343.78 63 363 Z8138
API & BECO – Internal
S.NO SIZES TPI CT (TH) CT (BR) HT TT (min) M/C HR COST (Rs) THD.SC Form Tool
1 2 3/8" API Reg 5 78.9 62.11 23.11 164.12 48 131 Z2150 K4604
2 2 3/8" API IF 4 75.4 67.74 23.46 166.60 48 133 Z2096 K4614
3 2 7/8" API Reg 5 1.1.75 81.94 23.16 206.85 48 165 OOOO62 K4604
4 2 7/8" API IF 4 97.5 86.97 23.48 207.95 48 166 Z2127 K4614
5 3 1/2" API Reg 5 115.63 94.32 25.58 235.53 48 188 OOOO17 K4604
6 4 1/2" API Reg 5 180.38 129.82 25.68 335.88 48 269 OOOOO4 K4604
7 5 1/2" API Reg 4 241.88 182.33 45.24 469.45 63 493 OOO197 K4606
8 6 5/8" API Reg 4 289.29 230.88 46.06 566.23 73 689 Z2022 K4609
9 3 1/2"BECO 2 123 98.65 32.79 254.44 63 267 Z4212 K4687
10 6"BECO 2 240 233.3 51.69 524.99 73 639 Z5230 K4611
11 5 1/4" BECO 2 172.16 170.22 53.85 73 482 Z8138
TPI – Threads per inch, CT (TH) – Cutting time for Threading, CT (TR) – Cutting
time for Turning, HT – Handling Time, TT – Total M/C time, M/C HR – Machine
Hour rate, THD.SC – Thread specification number, CT (BR) – Cutting time for
Boring
102
NPT Thread for Pipes - External
COST (RUPEES)
S.NO SIZES TPI TT (min) M/C HR Up to 24" 24" - 48"
Above 48"
(Pipe (Pipe
(Pipe Length)
Length) Length)
1 1/8" 27 10.45 32 5.6 7 9.5
2 1/4" 18 12.67 32 6.8 8.4 11.5
3 3/8" 18 13.31 32 7.1 8.9 12.1
4 1/2" 14 15.21 32 8.1 10.1 13.8
5 3/4" 14 16.35 32 8.7 10.9 14.8
6 1" 12 20.5 32 10.9 13.7 18.6
7 1 1/4" 12 23.1 32 12.3 15.4 20.9
8 1 1/2" 12 25.09 32 13.4 16.7 22.7
9 2" 12 28.88 32 15.4
10 2 1/2" 8 47.66 32 25.4
11 3" 8 60.19 42 42.1
12 3 1/2" 8 68.2 42 47.7
13 4" 8 75.67 42 53
14 5" 8 94.47 42 66.1
15 6" 8 113.67 42 79.6
BSP (T) Thread for Pipes - External
S.NO SIZES TPI TT (min) M/C HR COST (Rs)

1 1/8" 28 10.47 32 5.60
2 1/4" 19 12.37 32 6.60
3 3/8" 19 12.95 32 6.90
4 1/2" 14 15.09 32 8.00
5 3/4" 14 16.61 32 8.90
6 1" 11 21.00 32 11.20
7 1 1/4" 11 24.25 32 12.90
8 1 1/2" 11 26.07 32 13.90
9 2" 11 31.90 32 17.00
10 2 1/2" 11 45.16 32 24.10
11 3" 11 56.70 42 39.70
12 3 1/2" 11 64.13 42 44.90
13 4" 11 75.93 42 53.20
14 5" 11 95.18 42 66.60
15 6" 11 109.62 42 76.70
TPI – Threads per Inch: TT – Total Time: MC/HR – Hour Rate
103
BSP (T) Thread for Straight Adapters - External

1 1/8" 28 11.97 32 6.4
2 1/4" 19 14.78 32 7.9
3 3/8" 19 15.76 32 8.4
4 1/2" 14 19.24 32 10.3
5 3/4" 14 22.28 32 11.9
6 1" 11 30.00 32 16.0
7 1 1/4" 11 41.96 32 22.4
8 1 1/2" 11 45.88 32 24.5
9 2" 11 61.71 32 32.9
10 2 1/2" 11 88.05 32 47.0
11 3" 11 110.69 42 77.5
12 3 1/2" 11 132.84 42 93.0
13 4" 11 169.66 42 118.8
14 5" 11 225.75 42 158.0
15 6" 11 274.03 42 191.8
BSP (T) Thread for Straight Adapters - Internal

1 1/8" 28 12.46 32 6.6
2 1/4" 19 15.56 32 8.3
3 3/8" 19 16.78 32 8.9
4 1/2" 14 20.72 32 11.1
5 3/4" 14 24.44 32 13.0
6 1" 11 33.41 32 17.8
7 1 1/4" 11 48.49 32 25.9
8 1 1/2" 11 53.20 32 28.4
9 2" 11 72.66 32 38.7
10 2 1/2" 11 104.07 32 55.5
11 3" 11 131.91 42 92.3
12 3 1/2" 11 159.05 42 111.3
13 4" 11 203.75 42 142.6
14 5" 11 272.68 42 190.9
15 6" 11 331.73 42 232.2
104
NPT Thread for Straight Adapters – External
1 1/8" 27 11.43 32 6.1
2 1/4" 18 14.56 32 7.8
3 3/8" 18 15.49 32 8.3
4 1/2" 14 18.58 32 9.9
5 3/4" 14 20.65 32 11.0
6 1" 11.5 27.88 32 14.9
7 1 1/4" 11.5 37.22 32 19.9
8 1 1/2" 11.5 41.37 32 22.1
9 2" 11.5 51.37 32 27.4
10 2 1/2" 8 87.71 32 46.8
11 3" 8 110.07 42 77.0
12 3 1/2" 8 132.14 42 92.5
13 4" 8 156.44 42 109.5
14 5" 8 207.53 42 145.3
15 6" 8 264.48 42 185.1
NPT Thread for Straight Adapters - Internal

1 1/8" 27 12.39 32 6.6
2 1/4" 18 15.59 32 8.3
3 3/8" 18 16.81 32 9.0
4 1/2" 14 20.91 32 11.2
5 3/4" 14 23.79 32 12.7
6 1" 11.5 33.43 32 17.8
7 1 1/4" 11.5 46.76 32 24.9
8 1 1/2" 11.5 52.53 32 28.0
9 2" 11.5 66.35 32 35.4
10 2 1/2" 8 105.26 32 56.1
11 3" 8 130.66 42 91.5
12 3 1/2" 8 157.95 42 110.6
13 4" 8 188.13 42 131.7
14 5" 8 249.27 42 174.5
15 6" 8 317.18 42 222.0
105
NPT Thread for 45 & 90-Degree Adapters – External

1 1/8" 27 14.01 32 7.5
2 1/4" 18 17.67 32 9.4
3 3/8" 18 18.79 32 10.0
4 1/2" 14 23.26 32 12.4
5 3/4" 14 26.04 32 13.9
6 1" 11.5 33.87 32 18.1
7 1 1/4" 11.5 42.25 32 22.5
8 1 1/2" 11.5 46.88 32 25.0
9 2" 11.5 57.76 32 30.8
10 2 1/2" 8 97.37 32 51.9
11 3" 8 121.58 42 85.1
12 3 1/2" 8 145.35 42 101.7
13 4" 8 171.14 42 119.8
14 5" 8 226.17 42 158.3
15 6" 8 287.13 42 201.0
NPT Thread for 45 & 90-Degree Adapters – Internal

1 1/8" 27 15.43 32 8.2
2 1/4" 18 19.37 32 10.3
3 3/8" 18 20.91 32 11.2
4 1/2" 14 26.03 32 13.9
5 3/4" 14 29.76 32 15.9
6 1" 11.5 41.42 32 22.1
7 1 1/4" 11.5 52.98 32 28.3
8 1 1/2" 11.5 59.40 32 31.7
9 2" 11.5 74.41 32 39.7
10 2 1/2" 8 118.23 32 63.1
11 3" 8 145.74 42 102.0
12 3 1/2" 8 175.21 42 122.6
13 4" 8 207.45 42 145.2
14 5" 8 273.54 42 191.5
15 6" 8 346.47 42 242.5
106
BSP (T) Thread for 45 & 90-Degree Adapters – External
1 1/8" 28 14.79 32 7.9

2 1/4" 19 18.13 32 9.7
3 3/8" 19 19.34 32 10.3
4 1/2" 14 24.37 32 13.0
5 3/4" 14 28.52 32 15.2
6 1" 11 36.69 32 19.6
7 1 1/4" 11 47.67 32 25.4
8 1 1/2" 11 52.04 32 27.8
9 2" 11 71.38 32 38.1
10 2 1/2" 11 98.08 32 52.3
11 3" 11 122.67 42 85.9
12 3 1/2" 11 146.53 42 102.6
13 4" 11 186.10 42 130.3
14 5" 11 246.59 42 172.6
15 6" 11 298.12 42 208.7
BSP (T) Thread for 45 & 90-Degree Adapters – Internal

1 1/8" 28 15.50 32 8.3
2 1/4" 19 19.27 32 10.3
3 3/8" 19 20.79 32 11.1
4 1/2" 14 25.74 32 13.7
5 3/4" 14 30.54 32 16.3
6 1" 11 41.40 32 22.1
7 1 1/4" 11 54.94 32 29.3
8 1 1/2" 11 60.19 32 32.1
9 2" 11 81.49 32 43.5
10 2 1/2" 11 115.71 32 61.7
11 3" 11 145.88 42 102.1
12 3 1/2" 11 175.07 42 122.5
13 4" 11 223.07 42 156.1
14 5" 11 297.29 42 208.1
15 6" 11 360.24 42 252.2
107
BSP (T) Thread for Tee Adapters – External

1 1/8" 28 16.05 32 8.6
2 1/4" 19 19.56 32 10.4
3 3/8" 19 20.84 32 11.1
4 1/2" 14 26.12 32 13.9
5 3/4" 14 30.55 32 16.3
6 1" 11 39.12 32 20.9
7 1 1/4" 11 50.52 32 26.9
8 1 1/2" 11 55.12 32 29.4
9 2" 11 74.23 32 39.6
10 2 1/2" 11 103.10 32 55.0
11 3" 11 128.67 42 90.1
12 3 1/2" 11 153.37 42 107.4
13 4" 11 194.31 42 136.0
14 5" 11 257.01 42 179.9
15 6" 11 310.16 42 217.1
BSP (T) Thread for Tee Adapters – Internal

1 1/8" 28 16.81 32 9.0
2 1/4" 19 20.78 32 11.1
3 3/8" 19 22.40 32 11.9
4 1/2" 14 27.65 32 14.7
5 3/4" 14 32.77 32 17.5
6 1" 11 44.11 32 23.5
7 1 1/4" 11 58.17 32 31.0
8 1 1/2" 11 63.69 32 34.0
9 2" 11 85.91 32 45.8
10 2 1/2" 11 121.53 32 64.8
11 3" 11 152.87 42 107.0
12 3 1/2" 11 183.08 42 128.2
13 4" 11 232.73 42 162.9
14 5" 11 309.60 42 216.7
15 6" 11 374.50 42 262.1
108
NPT Thread for Tee Adapters – External

1 1/8" 27 15.19 32 8.1
2 1/4" 18 19.02 32 10.1
3 3/8" 18 20.21 32 10.8
4 1/2" 14 24.90 32 13.3
5 3/4" 14 27.86 32 14.9
6 1" 11.5 36.08 32 19.2
7 1 1/4" 11.5 44.77 32 23.9
8 1 1/2" 11.5 49.63 32 26.5
9 2" 11.5 60.96 32 32.5
10 2 1/2" 8 102.20 32 54.5
11 3" 8 122.58 42 85.8
12 3 1/2" 8 151.91 42 106.3
13 4" 8 178.50 42 124.9
14 5" 8 235.49 42 164.8
15 6" 8 298.44 42 208.9
NPT Thread for Tee Adapters – Internal

1 1/8" 27 16.74 32 8.9
2 1/4" 18 20.91 32 11.2
3 3/8" 18 22.54 32 12.0
4 1/2" 14 27.97 32 14.9
5 3/4" 14 31.95 32 17.0
6 1" 11.5 44.13 32 23.5
7 1 1/4" 11.5 56.09 32 29.9
8 1 1/2" 11.5 62.83 32 33.5
9 2" 11.5 78.44 32 41.8
10 2 1/2" 8 124.71 32 66.5
11 3" 8 153.28 42 107.3
12 3 1/2" 8 183.83 42 128.7
13 4" 8 217.11 42 152.0
14 5" 8 285.68 42 200.0
15 6" 8 361.12 42 252.8
109
JIC Thread for Straight Adapters - External

1 7 16" 20 13.74 32 7.3
2 9/16" 18 15.91 32 8.5
3 3/4" 16 20.11 32 10.7
4 7/8" 14 24.19 32 12.9
5 1 1/16" 12 26.93 32 14.4
6 1 5/16" 12 33.04 32 17.6
7 1 5/8" 12 41.91 32 22.4
8 1 7/8" 12 50.75 32 27.1
9 2 1/2" 12 78.79 42 55.2
10 3" 12 98.85 42 69.2
JIC Thread for Straight Adapters - Internal

1 7 16" 20 16.09 32 8.6
2 9/16" 20 17.27 32 9.2
3 3/4" 18 19.16 32 10.2
4 7/8" 16 21.25 32 11.3
5 1 1/16" 14 24.80 32 13.2
6 1 5/16" 12 29.67 32 15.8
7 1 5/8" 12 36.04 32 19.2
8 1 7/8" 12 46.97 32 25.1
9 2 1/2" 12 62.21 32 33.2
10 3" 12 83.29 42 58.3
110
JIC Thread for 45 & 90 Degree Adapters - External

1 7 16" 20 16.92 32 9.0
2 9/16" 18 19.32 32 10.3
3 3/4" 16 24.65 32 13.1
4 7/8" 14 29.60 32 15.8
5 1 1/16" 12 32.84 32 17.5
6 1 5/16" 12 40.16 32 21.4
7 1 5/8" 12 46.88 32 25.0
8 1 7/8" 12 56.52 32 30.1
9 2 1/2" 12 86.87 42 60.8
10 3" 12 108.42 42 75.9
JIC Thread for Tee Adapters – External

1 7 16" 20 18.20 32 9.7
2 9/16" 18 20.66 32 11.0
3 3/4" 16 26.27 32 14.0
4 7/8" 14 31.42 32 16.8
5 1 1/16" 12 34.76 32 18.5
6 1 5/16" 12 42.35 32 22.6
7 1 5/8" 12 49.37 32 26.3
8 1 7/8" 12 59.41 32 31.7
9 2 1/2" 12 90.91 42 63.6
10 3" 12 113.21 42 79.2
111
END MILLING CUTTER
Diameter Cutting Speed Revolution of Feed

S.No End Milling Cutter No of Teeth
(mm) (M/min) work/min mm/Revolution
1 Milling ø 10 MM 10.00 35 1114 66.82 4.00
2 Milling ø 12 MM 12.00 35 928 55.68 4.00
3 Milling ø 16 MM 16.00 35 696 52.20 5.00
4 Milling ø 20 MM 20.00 35 557 50.11 6.00
5 Milling ø 25 MM 25.00 35 445 40.09 6.00
6 Milling ø 32 MM 32.00 35 348 31.32 6.00
7 Milling ø 40 MM 40.00 35 278 25.06 6.00
FACE MILLING CUTTER
Diameter Cutting Speed Revolution of Feed

S.No End Milling Cutter No of Teeth
(mm) (M/min) work/min mm/Revolution
1 Milling ø 40 MM 40.00 35 278 33.41 8.00
2 Milling ø 50 MM 50.00 35 223 33.41 10.00
3 Milling ø 63 MM 63.00 35 177 26.52 10.00
4 Milling ø 80 MM 80.00 35 139 25.06 12.00
5 Milling ø 100 MM 100.00 35 111 20.05 12.00
6 Milling ø 125 MM 125.00 35 89 18.71 14.00
7 Milling ø 160 MM 160.00 35 70 16.70 16.00
112
THREADING PASSES
No of Passes
Sl.No TPI B.S.W B.S.F B.S.P U.N.C U.N.F N.P.T Non-
Ferrous
Ferrous
1 28 7/32 1/8 1/4 10 6
2 27 1 /16 - 1/8 10 6
3 26 1/4 - 9/32 10 6
4 24 5/16 - 3/8 10 6
5 22 5/16 10 8
6 20 1/4 - 9/32 3/8 1/4 7/16 - 1/2 12 8
7 19 1/4 - 3/8 12 8
8 18 5/16 7/16 5/16 9/16 - 5/8 1/4 - 3/8 14 10
9 16 3/8 1/2 - 9/16 3/8 3/4 14 10
10 14 7/16 5/8 - 11/16 1/2 - 7/8 7/16 7/8 1/2 - 3/4 16 12
11 13 1/2 16 12
12 12 1/2 - 9/16 3/4 - 13/16 9/16 1 - 1.1/2 20 14
13 11 1/2 1-2 20 14
14 11 5/8 - 11/16 7/8 - 15/16 1-6 5/8 22 14
15 10 3/4 1 7 - 10 3/4 24 16
16 9 7/8 - 15/16 1.1/8 - 1.1/4 7/8 28 16
17 8 1 1.3/8 - 1.5/8 1 2.1/2 - 12 30 16
18 7 1.1/8 - 1.1/4 1.3/4 - 2 1.1/8 - 1.1/4 30 18
19 6 1.3/8 - 1.1/2 2.1/4 - 2.3/4 1.3/8 - 1.1/2 32 18
20 5 1.5/8 - 1.3/4 3 - 3.1/4 1.3/4 34 20
21 4 1/2 1.7/8 -2.1/8 3.1/2 - 4 2 - 2.1/4 36 20
22 4 2.1/4 - 2.5/8 4.1/4 2.1/2 - 2.3/4 38 22
23 3 1/2 2.3/4 - 3.1/8 40 24
113
POWER HACK SAW CUTTING
ROUND ROD - Steel
H.T.Alloy
ROD ø MS Alloy Steel
S.NO Steel (Rs./
mm (Rs. / Cut) (Rs. / Cut)
Cut)
1 12 0.5 0.5 0.6

2 12.7 0.5 0.6 0.7
3 16 0.7 0.7 0.9
4 18 0.7 0.8 1.0
5 19 0.8 0.8 1.1
6 20 0.8 0.9 1.1
7 22 0.9 1.0 1.3
8 25 1.1 1.2 1.6
9 28 1.4 1.5 2.0
10 29 1.4 1.6 2.1
11 32 1.7 1.8 2.5
12 35 1.9 2.1 2.9
13 38 2.3 2.5 3.4
14 40 2.5 2.8 3.8
15 41 2.6 2.9 3.9
16 43 2.8 3.1 4.3
17 45 3.0 3.3 4.6
18 46 3.3 3.6 4.9
19 50 3.8 4.1 5.7
20 52 4.0 4.4 6.1
21 53 4.1 4.6 6.3
22 56 4.7 5.2 7.1
23 57 4.8 5.3 7.3
24 59 5.1 5.6 7.8
25 63 5.8 6.4 8.9
26 64 6.0 6.6 9.2
114
H.T.Alloy
ROD ø MS Alloy Steel
S.NO Steel (Rs./
mm (Rs. / Cut) (Rs. / Cut)
Cut)
27 70 7.1 7.9 10.9
28 76 8.2 9.1 12.7
29 77 8.4 9.3 13.0
30 80 9.1 10.1 14.4
31 86 10.3 11.4 16.0
32 89 10.9 12.1 17.1
33 90 11.3 12.5 17.6
34 92 11.7 13.0 18.3
35 100 13.8 15.3 21.5
36 110 16.5 18.3 25.9
37 12 19.5 21.7 30.7
38 125 21.1 23.5 33.3
39 140 26.3 29.3 41.5
40 150 30.3 33.7 47.8
41 155 32.5 36.2 51.2
42 160 34.6 38.6 54.5
43 180 43.4 48.4 68.6
44 200 53.2 59.3 84.3
45 210 58.8 65.6 93.1
46 220 64.7 72.1 102.4
47 225 68.2 75.9 107.5
48 230 71.6 79.7 112.8
49 250 84.8 94.3 133.4
50 260 92.4 102.7 145.0
51 300 122.6 136.3 192.6
52 350 167.2 185.9 262.4
115
Hexagonal Steel Rod
H.T.Alloy
MS Alloy Steel
S.NO AF mm Steel (Rs./
(Rs. / Cut) (Rs. / Cut)
Cut)
1 12.70 0.6 0.6 0.7
2 13 0.6 0.6 0.7
3 15.88 0.7 0.7 0.9
4 16 0.7 0.7 0.9
5 18 0.8 0.8 1.1
6 19 0.8 0.9 1.1
7 20 0.9 1.0 1.2
8 22 1.0 1.1 1.4
9 24 1.2 1.3 1.7
10 25 1.3 1.4 1.8
11 25.40 1.3 1.4 1.8
12 28.50 1.5 1.7 2.2
13 30 1.8 1.9 2.5
14 32 1.9 2.1 2.8
15 36 2.3 2.5 3.4
16 38 2.5 2.7 3.7
17 40 2.7 3.0 4.1
18 41 3.0 3.2 4.4
19 41.28 3.0 3.3 4.5
20 45 3.4 3.8 5.2
21 50 4.2 4.6 6.4
22 51 4.3 4.8 6.6
23 57.20 5.2 5.8 8.1
24 60.33 5.7 6.4 8.9
25 63.50 6.4 7.1 9.9
26 64 6.5 7.2 10.0
27 66.68 7.1 7.9 10.9
28 67 7.2 7.9 11.0
29 73 8.3 9.2 12.9
30 78 9 .5 10.5 14.7
31 80 9.9 11.0 15.4
32 90 12.3 13.7 19.3
33 100 15.0 16.7 23.6
116
ADAPTER SETUP TIME
Pipe Nipple
1/8” to 1” 11 Mints
1 ¼” to 3” 13 Mints
Straight Adapters
External Internal
1/8” to 1” 16 Mints 19 Mints

1 ¼” to 3” 18 Mints 22 Mints
3” & above 21 Mints 25 Mints
45 & 90-Degree Adapters

External Internal

Tee Adapters
External Internal

117

Cost Estimation Manual-Final

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Cost Estimation Manual-Final

Uploaded by

Copyright:

Available Formats

CONTENTS

2. Lathe Operations (Centre, Turret and Capstan Lathe) 4

4.1 Cylindrical Grinding (Plunge Grinding) 23

4.2 Cylindrical Grinding (Traverse Grinding) 25

4.3 Centre less Grinding (Through Feed) 26

4.4 Centre less Grinding (Plunge Feed) 27

4.5 Internal Grinding 28

4.6 Surface Grinding (Reciprocating Table) 29

4.7 Surface Grinding (Rotary Table) 31

4.8 Gear Grinding 32

4.9 Spline Grinding 34

9. Vertical Turret Lathe Operations (VTL) 45

10. Milling Operation 47

11. Shaping and Planning 51

12. Slotting Machine 52

13. Boring Machine 53

14. Standard Allowances 59

15. Handling Elemental Times (In Minutes) 60

15.1 Lathes (Small & Medium Duty) HL 61

15.2 Medium Heavy Duty Lathes HMHL 62

15.3 Drilling Machines HDM 64

15.4 Cylindrical Grinding Machine HCG 65

15.5 Centre less Grinding Machine HCLG 66

15.6 Internal Grinding Machine HIG 67

15.7 Surface Grinding Machine HSG 68

15.8 Gear Grinding Machine HGG 69

15.9 Spline Grinding Machine HSPG 70

15.10 Hobbing Machine HH 71

15.11 Gear Shaping Machine HGS 72

15.12 Horizontal Hydraulic Broach HHHB 73

15.13 Vertical Turret Lathe HVTL 74

15.14 Milling Machine HM 76

15.15 Shaping Machine HSP 77

15.16 Planning Machine HP 78

15.17 Slotting Machine HSL 79

15.18 Horizontal Boring Machine HHB 80

16. Set Up Times 82

17. Hourly Rate Calculations 83

17.1 Hourly Rate working – Turning 84

17.2 Hourly Rate working – Milling 85

17.3 Hourly Rate working – Grinding 86

17.4 Hourly Rate working – Drilling 87

17.5 Hourly Rate working – Boring 88

17.6 Hourly Rate working – Gear Machine 89

17.7 Hourly Rate working – Machining Others 90

17.8 Hourly Rate working – Press 92

18.3 Appendix III 97

19. Threading Estimation

API & BECO Threads External & Internal 101

NPT & BSP (T) Thread for Pipes – External 102

NPT Thread for Straight Adapters – External & Internal 104

NPT Thread for Tee Adapters – External & Internal 108

JIC Thread for Straight Adapters – External & Internal 109

End & Face Milling Cutter 111

Threading Passes 112

20. Power Hacksaw Cutting

Round Rod – Steel 113

Hexagonal Steel Rod 115

Adapter Setup Time 116

1.1 MACHINE ELEMENTAL STANDARD TIME

1.1.1 TOOL CHANGE ALLOWANCE

1.1.2 RELAXATION ALLOWANCE

1.2 HANDLING ELEMENTAL TIME