DHANALAKSHMI SRINIVASAN

COLLEGE OF ENGINEERING
COIMBATORE

Subject : ME 8793-Process Planning and Cost Estimation Academic Year : 2023 - 2024

Answer ALL Questions

PART-A(10 X 2 = 20 Marks)
1. Select the process parameters for setting machines and toolings.
In machining, three process parameters are (i) cutting speed or cutting velocity, (ii) feed rate and
(iii) depth of cut. More details about these parameters are elaborated in the following sections.
2. Compose the documents required for Process Planning
In general, the inputs to Process Planning are:
Design data.
Raw material data.
Facilities data (machining data, tooling data, fixture data etc)
Quality requirements data.
Production type data.
3. Analyze the basic principles of jig and fixture design can be categorized
Locating a part to be machined involves mainly three steps: Supporting, Positioning, and
Clamping.
4. Point out the quality function for process plan
Quality Function Deployment (QFD) is a structured approach to defining customer needs or
requirements and translating them into specific plans to produce products to meet those needs. The
“voice of the customer” is the term to describe these stated and unstated customer needs or
requirements.
5. Define contingency allowances
The contingency allowance is the time allocated during planning for unscheduled events.
Technical and personal disruptions result in changes in the indirect production costs. The
contingency allowance is calculated in special contingency time studies, the results of which yield
rates for indirect production costs.
6. Explain briefly about depreciation?
The monetary value of an asset decreases over time due to use, wear and tear or obsolescence. This
decrease is measured as depreciation.
7. Give the losses in forging process.
For forgings under 5 kg, the loss is 7.5 per cent of the net weight, and for forgings from 5 to 12.5
kg and over an addition of 6 per cent and 5 per cent of the net weight is expected as the scale loss.
8. Give the formula for calculating the cost of power consumed in arc welding.
Give the formula for calculating the cost of power consumed in arc welding (AU ) Power cost = V
= voltage in volts A = current in amperes t = welding time in minutes = efficiency of the welding
machine = ratio of operating time to connecting time taken by operator = rate of electricity per
kWhr
9. List various factors affecting cutting speed
1. Factors Affecting The Cutting Speed Of The Tool · (1) Tool Material · (2) Workpiece Material ·
(3) Tool Life
10. Define drilling, reaming and boring
Drilling is usually the first step in creating the hole, followed by boring which sizes the hole, then
reaming which finishes the hole
PART B (5 X 13 = 65 Marks)
11. a. Explain in detail process planning activities? (13)
In companies, planning processes can result in increased output, higher precision, and faster
 turnaround for vital business tasks. A process is described as a set of steps that result in a
specific outcome. It converts input into output. Process planning is also called manufacturing
planning, material processing, process engineering, and machine routing. It is the act of
preparing detailed work instructions to produce a part. It is a complete description of specific
stages in the production process. Process planning determines how the product will be produced
or service will be provided. Process planning converts design information into the process steps
and instructions to powerfully and effectively manufacture products. As the design process is
supported by many computer-aided tools, computer-aided process planning (CAPP) has
evolved to make simpler and improve process planning and realize more effectual use of
manufacturing resources.
OR
b. (i) List out the objectives of process planning.
The goal of process planning is to improve and streamline the business methods of a company.
This would have results like: Lower costs, due to fewer staff needed to complete the same
process. Higher efficiency, by eliminating problematic process steps like loops and bottlenecks (7)
(ii) Explain the various approaches of process planning? (6)
There are basically two approaches to process planning which are as follows : (i) Manual
experience-based process planning, and (ii) Computer-aided process planning method.
consistent. (design and availability of machine tools).
12. a. (i) List out set of documents required for process planning?
There are basically two approaches to process planning which are as follows : (i) Manual
experience-based process planning, and (ii) Computer-aided process planning method.
consistent. (design and availability of machine tools).
(6)
(ii) List out the factors to be considered for selecting measuring instruments? Explain each
(7)
one.
The most important factor is being able to measure what I want with the expected range and
accuracy. Other factors include durability, serviceability, and size. Some consideration would
also be given to the cost and cost of repair.
OR
b. Summarize the main factors must be considered according to the principles of (13)
jig and fixture design?
Basic principles of Jigs and Fixtures design

LOCATING POINTS: Locating the work is a prime necessity and requires suitable facilities.
The correct setup ensures smooth insertion of a workpiece in the proper position and removing
a workpiece from a jig without operational hassles or time consumption. The workpiece
position needs to be precise with the guiding tool in the jig or setup pieces in the fixture.

FOOLPROOF: A foolproof design of jigs and fixtures does not permit a tool or workpiece to
be placed in any other way other than the intended one.

REDUCTION OF IDLE TIME: Jigs and Fixtures must be designed in such a way that ensures
smooth loading, clamping, machining, and unloading of a

WEIGHT OF JIGS AND FIXTURES: A jig and fixture must be compact, easy to handle, and
low cost regarding the number of materials used without giving up stiffness and rigidity.

JIGS PROVIDED WITH FEET: Some jigs require feet so that they can be placed on the table
firmly.

MATERIALS FOR JIGS AND FIXTURES: Jigs and Fixtures are usually created with
hardened materials to resist wear & tear and avoid frequent damage—for example, Mild steel,
 Cast iron, Die steel, High-speed steel, Caesium.

CLAMPING DEVICE: A suitable clamp is rated for its strength. It should be able to hold a
workpiece firmly in its position while bearing the strain of the cutting tool simultaneously,
without springing.

13. (i) Discuss the objectives of cost estimation and advantages of cost estimation? A cost
estimate is the service provider’s approximation of what the job is likely to cost.

The purpose of cost estimation is to predict the quantity, cost, and price of the resources
required to complete a job within the project scope. Cost estimates are used to bid on new
business from prospective clients and to inform your job and budget planning process.

Cost estimation is done by breaking the scope of the project down into manageable parts and
using all information available (previous experience, similar jobs, expertise in the industry) to
arrive at a total expected cost.

Using software (such as a job management system) to manage and track your projects enables
you to automatically collect data as you complete work, which you can use to accurately
estimate future jobs. For example, tracking employee time with time tracking software gives
you precise information about how long employees take to complete specific tasks, so you’re
able to estimate those tasks in the next job more reliably. (6)
(7)
Estimating is done at the beginning of new projects to arrive at an original cost estimate, but
should be frequently reviewed and updated as new information becomes available or
conditions change.

(ii) Differentiate cost accounting and cost estimating?

Cost estimation means when you try to approximate the amount of money that you require for
processing a certain product or service.
Cost estimation is an essential step in production as lies down the plan for execution.
Cost accounting is the process through which you keep a track of your expenses and profit on
a proper balance sheet.

OR

b. Discuss in detail about the types and methods of cost estimating? (13)

14. (13)
Calculate the net weight and gross weight for the component shown in Fig. 5.7.Density of
material used is 7.86 gm/cc. Also calculate:
1. Length of 14 mm dia bar required to forge one component.
2.Cost of forging/piece if:
Material cost = Rs. 80 per kg; Labour cost = Rs. 5 per piece; Overheads = 150 percent of
labour cost

Overhead expenses include all expenditure incurred by the manufacturer on the product except
the direct material cost, direct labour cost and direct chargeable expenses. (a) Indirect material
expenses. (b) Indirect labour expenses.( supervisors, inspectors, foremen, store-keeper,
gatekeepers, repair and maintenance staff, crane drivers, sweepers, administrative office staff
and sales and distribution staff, etc.) (c) Other indirect.( water and electricity charges, rent of
factory building, licence fee, insurance premia stationery, legal expenses, audit fee etc.

OR
b. What are the various losses considered while calculating the material cost for a forged (13)
component?
Material Estimation for the Forging

Expected Losses in Forging

The losses expected in forging are:

(i) Scale loss.

(ii) Flash loss.
(iii) Tonghold loss.
(iv) Sprue loss.
(v) Shear loss.

(i) Scale loss

When the material used in forging, iron is heated at a high temperature in atmospheric
conditions a thin film of iron oxide is formed all round the surface of the heated metal. The
iron oxide film falls from the surface of the metal on being beaten up by the hammer. This is
termed scale loss and it depends upon the surface area, heating time and the type of material.
For forgings under 5 kg, the loss is 7.5 per cent of the net weight, and for forgings from 5 to
12.5 kg and over an addition of 6 per cent and 5 per cent of the net weight is expected as the
scale loss.

(ii) Flash loss

This is a loss related to die forging or machine forging.

There is a certain quantity of metal which comes between the flat surfaces of the two dies after
the die cavity has been filled in. This material equal to the area of the flat surface is a wastage.
For
finding the flash loss, the circumference is determined which multiplied by cross-sectional area
of
flash will give the volume of the flash. The volume multiplied by material density gives the
flash loss. Generally, it is taken as 3 mm thick and 2 mm wide all round the circumference.
 (iii) Tonghold loss

This is the loss of material due to a projection at one end of the forging to be used for holding it
with a pair of tongs and turning it round and round to give the required cross section in drop
forging.
About 1.25 cm and 2.5 cm of the size of the bar is used for tonghold. The tonghold loss is equal
to
the volume of the protections. For example, the tonghold volume loss for a bar of 2 cm diameter
and tonghold length 2 cm will be (π/4)*2(cube) = 1.25 cm(cube)
15. a) i)Analyze the time required to manufacture the tapered cylindrical job of dimensions; minor
diameter 30 mm, major diameter 80 mm and length 120 mm from a given round bar of 80 mm
diameter and 120 mm length. Assume:
Cutting speed = 75 m/min. (7)
Max. feed by compound rest = 0.05 mm/rev
Depth of cut should not exceed 4 mm.
ii) A 20 cm × 5 cm C.I. surface is to be faced on milling machine with a cutter having a dia of
10 cm and 16 teeth. If the cutting speed and feed are 50 m/min and 5 cm/min respectively,
examine the milling time, r.p.m. of the cutter and feed per tooth.
It is the time for which the machine works on the component, i.e. from the time when the tool (6)
touches the work piece to when the tool leaves the component after completion of operation.
The machining time depends on the type and extent of machining required, material being
machined, speed, feed, depth of cut and number of cuts required.
OR
b) i) Examine the planing time for a casting 1.25 m long and 0.5 m wide which is machined on
a planer having cutting speed of 12 m/min and a return speed of 30 m/min. Two cuts are (7)
required, one roughing with a depth of 3.125 mm and a feed of 0.1 mm/rev and other finishing
with a depth of 0.125 mm and using a feed of 0.125 mm?
ii) A 3 cm deep slot is to be milled with a 8 cm diameter cutter. The length of the slot is 30
cm. What will be the total table travel to complete the cut? If the cutting speed is 20
meters/min and feed per tooth is 0.2 mm, examine the milling time. The cutter has 24 teeth and (6)
one cut is sufficient for the slot.
PART C (1 X 15 = 15 Marks)
16 a) Calculate the selling price per unit from the following data : Direct material cost = Rs. (15)
8,000 Direct labour cost = 60 percent of direct material cost Direct expenses = 5
percent of direct labour cost Factory expenses = 120 percent of direct labour cost
Administrative expenses = 80 percent direct labour cost Sales and distribution
expenses = 10 percent of direct labour cost Profit = 8 percent of total cost No. of
pieces produced = 200
Direct material cost is the cost of the raw materials and components used to create a product.
The materials must be easily identifiable with the resulting product (otherwise they are
considered to be joint costs). The direct material cost is one of the few variable costs involved
in the production process; as such, it is used in the derivation of throughput from production
processes. Throughput is sales minus all totally variable expenses.

Examples of Direct Material Costs

Examples of direct materials are the timber used to construct a house, the steel included in an
automobile, the circuit board included in a radio, and the fabric used to assemble clothing.
How to Calculate Direct Material Costs

To determine the amount of direct materials cost in a product, work with the engineering staff
to create a bill of materials, which specifies the quantity of each raw material item and
component included in a product. Then assign a standard cost to each item, based on recent
prices paid for them (including freight and sales taxes), and add a reasonable allowance for
scrap and spoilage. The total is the direct material cost of the product.

Direct Materials vs. Indirect Materials

Some costs are for materials that are not considered direct materials, and so are instead
classified as indirect material costs. These materials are so immaterial as not to be worth
tracing to a specific product, or cannot be clearly associated with a specific product. Examples
of indirect materials are the rags and solvents used during the construction of a house, the
grease used on machines that manufacture products, and the thread used in clothing.

OR
b) Evaluate the cost of welding of two plates 100 × 100 × 8 mm thick to obtain a plate of (15)
dimensions 200 ×100 × 8 mm. The following data is available: (i) Welding is done on both the
sides (ii) Electrode diameter = 5 mm (iii) Electrode used per meter of weld = 0.500 kg (iv)
Minimum arc voltage = 30 Volts (v) Current used = 225 Amperes (vi) Labour charges = Rs.
10/m of weld (vii) Electrode price = Rs. 10/kg (viii) Efficiency of welding machine = 50
percent (ix) Welding speed = 2 meters/hour (x) Ratio of operating to connecting time = 1.5
Types of Welds
These two welds can be performed in exactly the same way. There can be a difference in their
strength depending on how they are prepared and executed within their settings, but it’s mainly
the space you’re welding into that determines its name.

1. Butt weld
A butt weld is when two faces of different plates are positioned hard up against each other and
flush along their tops. Sometimes they are at a slight angle, but generally they are aligned
straight. This weld gets its name because the two plates typically butt up to each other end to
end.

This type of weld can have sections cut out of the corners of the plates in various shapes and
sizes. These are called weld preps and are added to provide more depth of weld to the joint.
The joint can also have two square ends without any weld prep. The more weld prep is added,
the stronger the joint will be, resulting in time added to the job. Therefore, when a project
doesn’t require it, it’s best to weld their square ends rather than cut the weld preps.

2. Fillet weld
This type of weld is within the internal corner of two plates. Most commonly the corner is a
90° angle, but it can be any angle less as long as you can weld in it, and any angle more up to
about 145°. It gets the name “fillet” because “fillet” is an old word used to describe a triangle-
shaped piece of material similar to the shape of the inside angle you weld a fillet weld into. I
remember fillet by the term “fill it,” because when there is a corner to weld up, you fill it with
weld, unlike the butt weld where you typically cover it with weld.