ESTIMATION OF WEIGHTS AND

MATERIAL COSTS
 FORMS OF MATERIAL
• Castings:- Metal is heated to a molten state
and then poured into a specially prepared
cavity.
• Forgings:- by drop stamping or hot pressing
wherein the metal is heated to a plastic state
and then hammered to the required shape.
• Bar / Billets:- These may be hot rolled, drawn
or extruded.
 DIFFERENT CROSS SECTIONS
• FOIL:- metal rolled to a thickness of 0.15 mm or
less.
• STRIP:- metal rolled to a thickness over 0.15 mm
and upto 10 mm.
• SHEET:- metal rolled over 0.15mm and 10 mm
thick and width greater than 400 mm and flat.
 ESTIMATION OF VOLUME AND
WEIGHT OF MATERIAL
• Study the drawing carefully and breakup the component
into simpler parts.
• Add the necessary m/c allowances on all sides which are to
be machined.
• Determine the volume of each part by mensuration
formulae.
• Add the volumes to get the total volume.
• Multiply the total volume by density to get the weight of
the material.
• Add the percentage of scrap weight if any to find the total
material weight.
• Calculate the cost by multiplying the weight by the rate.
WEIGHT OF PRODUCT=VOLUME OF PRODUCT x DENSITY
 AREAS AND PERIMETERS OF FIGURES
AREA PERIMETER
SQUARE of side a, =axa =4a
diagonal d = (dxd) / 2
RECTANGLE of length l, =lxb = 2 x (l + b)
breadth b
TRIANGLE with sides a,b,c =1/2 (b x h) = 2s
=√s (s-a)(s-b)(s-c) = (a+b+c)
S = (a+b+c)/2
EQUILATERAL TRIANGLE of = ( √ 3 a x a) / 4 =3a
side a
PARALLELOGRAM of sides =axh = 2 (a +b)
a,b and height h
RHOMBUS of side a and =axh =4a
diagonal d1 and d2. = ½ x d1 x d2
TRAPEZOID of parallel sides = ½ (a + b) h
a & b and height h h
 AREA PERIMETER
HEXAGON of side a = (3√3axa) / 2 =6a
OCTAGON of side a = 2 * a * a (1+√2) =8a
CIRCLE of diameter d and =∏ r*r = 2 * ∏* r
radius r = (∏/4) * d *d =∏*d
HOLLOW CIRCLE = ∏( (RxR) – (rxr)) R = radius of outer circle.
= ∏/4( (DxD) – (dxd)) r = radius of inner circle.
SECTOR OF CIRCLE of = ((angle of sector)/360) * (∏ r
radius r x r) Ө
= (Ө/360) * (∏ r x r) r

SECTOR OF A HOLLOW = (Ө/360) * ∏[(R X R) - (r x r)]

CIRCLE
ELLIPSE of minor axis a = ∏*a*b = ∏ (a+b)
and major axis b
FILLET of side r = (r*r) [1-∏/4]
 VOLUME AND SURFACE AREAS OF
SOLIDS
• RECTANGULAR SOLID

Volume = l*b*h
Surface Area = 2(lb+bh+lh)
• PRISM
A

Volume =area of base * height

Surface Area = (No of surfaces*surface area)
+(area of ends)
• CYLINDER

Volume V= (∏*r*r*h)
Surface area = 2∏r (h+r)
• RINGS

Voume = Area of cross section x mean

circumference
π²/4 (R-r²) . (R+r)
PYRAMIDS

Volume of a Pyramid or Cone = Area of base x

1/3 Perpendicular height
=1/3 * A * h
Surface Area = Sum of all lateral faces + area of
the base
CIRCULAR CONES

Volume = 1/3 πr²h

Surafce area = πr ( (√(h² + r²)) + r)
WEDGE

Volume = ((breadth of base x height) / 6) * (2

length of base + edge of wedge)
= (bh/ 6) (2l + e)
FRUSTA OF PYRAMIDS AND CONES

Volume = h/3 ( A1 + A2 + √(A1 * A2)

 SPHERICAL SHELLS

• Volume = π/6 ( D³ - d³)

= 4π/3 (R³ - r³)
 SPHERES

• Volume = 4/3 (π r³)

SR MATERIAL DENSITY (g/cm³)
NO
1. Aluminium 2.68
2. Brass 8.109
3. Cast iron 7.2
4. Mild Steel 7.2
5. Copper 8.93
6. Bronze 8.735
7. Wrought iron 7.707
8. Gold 19.316
9. Lead 11.432
 CALCULATION OF WEIGHT OF
MATERIAL
• Calculate the weight of the casting if the
density of material used is 7.5 gm/cm³. The
dimensions of the Casting are given below
ESTIMATION OF MACHINING TIME
• Machining time for different processes is an
important factor in arriving at the cost of
manufacturing of the different parts.
• Knowing the machining time, Rate of
machining and cost per unit time, the total
cost can be calculated.
• Machining is done to get the exact size and
shape of the product on castings, forgings and
bar stocks etc.
DIFFERENT MACHINING OPERATIONS
AND TIME ALLOWANCES
• Turning, Facing, Knurling, threading, tapping,
drilling, boring, grinding, shaping, planing etc.
• In estimation, our aim is to find out the time
that a labour takes in performing the
machining operation and then calculate the
wages.
• Machining Time / Operation Time (Tm):- It is
the time elapsed while machining is being
performed to change the size and form.
• Handling Time (Th):- It is the time required for
loading and unloading the workpiece, to take
measurements and retracting the tools for
certain elements.
• Servicing Time (Ts):- Time required for all kinds of
servicing and maintenance during operation
(lubrication etc) as well as for tool changing and
sharpening.
• Organisational Time (To):- Time taken for various
organizational measures and delays such as
preparing the machine at the beginning of shifts,
cleaning at the end of shifts, etc.
• Personal needs, fatigue allowance and special
allowance time Tf
 STANDARD UNIT TIME, CYCLE TIME
AND TOTAL TIME
• Standard Unit Time (Tu):- It is the time required for
machining a work piece depending upon the capacity
of machine tool.
Tu = Tm + Th + Ts + To + Tf
• Cycle Time (Tc):- It is the period of time that lapses
between the output of two consecutive units of
production.
Cycle Time Tc = T / n
when T = any definite length of time in minutes
n = no. of units produced in that length of time.
In Job or batch type production, Cycle Time is defined as
the sum of machining time and handling time.
Tc = Tm + Th
 TOTAL TIME Tt
• Tt = Tu + [(Tsu + Ttd) / n]
where
Tu = standard unit time
Tsu = set-up time reqiured when preparing for
machining a new lot or workpiece.
Ttd = tear-down time , which is the time required
to bring machine tool to its original condition at
the end of lot.
n = No. of workpieces in the lot
 Length of Cut
• It is calculated from the dimensions of the
actual drawing of the parts to be
manufactured.
• The allowance for different over-runs for
cleaning the tool off the job are also taken
into account.
 Cutting Speed
• The speed at which the cutting edge of the tool
or cutter passes over the material. It is expresses
in metres per minute.
• Cutting Speed depends on the following factors:-
1. Hard materials require a lower cutting speed
than soft and ductile material.
2. High speed tools and tools of special cutting
alloys can cut at higher cutting speeds than
carbon-steel tools.
3. If the depth of the cut and the feed is more,
then lower cutting speed is taken and vice versa.
4. By using good cutting fluids, cutting speeds may
be increased.
 Cutting Speed
If a job of diameter D is revolving
at speed of N rpm,
D – Diameter (mm)
N – Revolutions per Minute (rpm)
 DN
v m/min
1000
The Peripheral Speed of Workpiece past the
Cutting Tool
=Cutting Speed
 RPM (Revolutions per minute)
• Revolutions per minute for a particular
machine are calculated by taking into account
the cutting speed and the diameter of the job
1000 S
rpm 
D
S = Cutting Speed in metre / minute
D = diameter in mm
 Feed
f – the distance the tool advances for every
rotation of workpiece (mm/rev)

D1 D2

f
Feed
 Depth of Cut
perpendicular distance between machined
surface and uncut surface of the Workpiece
d = (D1 – D2)/2 (mm)

D1 D2

d Depth
of Cut
Operating Conditions

C u ttin g s p e e d
W o rk p ie c e
D e p th o f c u t (d )
N
M a c h in e d
su rfa c e
C huck F e e d (f ) C h ip
Tool D e p th o f c u t
 Turning ..
Cylindrical job

Workpiece
Cutting
speed Depth of cut (d)
N
Machined
surface
Chuck Feed Chip
Tool
Depth of cut
 Turning ..
• Excess Material is removed to
reduce Diameter
• Cutting Tool: Turning Tool

a depth of cut of 1 mm will

reduce diameter by 2 mm
Let
S = cutting speed in m/min
D = dia. Of job to be turned in cm
N = rev. of tool (job/min)
F = feed/rev
As  DN
S  m / min
100
100 S
N 
D
Feed / min = rpm x feed/rev = N x F
• Time taken to turn L meter length is

L L
T  T 
feed / min feed / rev * rpm

L
T 
F*N
If over-run and approach are also taken into account, where A =
approach in cm, O= over-run in cm
L AO
T 
F*N
 Facing
Flat Surface/Reduce length

Chuck Workpiece
d
Machined
Face
Cutting
speed Depth of
cut
Tool Feed
 Facing ..
• machine end of job  Flat surface
or to Reduce Length of Job
• Turning Tool
• Feed: in direction perpendicular to
workpiece axis
–Length of Tool Travel = radius of
workpiece
• Depth of Cut: in direction parallel to
workpiece axis
• Time Required for cut is given by

L
T 
feed / rev * rpm
 Chamfering
 Beveling sharp machined edges
 Similar to form turning
 Chamfering tool – 45°
 To
• Avoid Sharp Edges
• Make Assembly Easier
• Improve Aesthetics
L
T 
F*N
 THREADING (SCREW CUTTING)
L  0.7
T
pitch * rpm
L = length of thread in cm.
1
Pitchfor sin glestartthread 
thread / cm
No.ofstarts
Leadformultistartthread 
thread / cm
Threading upto full depth requires several cuts.
Therefore,
Time required for full depth of thread = No. of
cuts x Time for a single cut
Number of cuts can be calculated by either of
the following methods:
• First System:
Number of Cuts = 25 * pitch (for external
threads)
= 32 * pitch (for internal threads)
• Second System:
Material No. of cuts
Aluminium 4
Brass 3
Copper 5
Cast Iron 6
Mild Steel 7
 TAPPING (Machining Time)
Process of making Internal threads with the help
of a tool known as Tap. Taps are generally
used for small works.
Time required for tapping =
lengthtravelledbyTap
pitch * rpm
LD/2
 min/ cut
pitch * rpm

L = length of thread portions, D = dia. Of Tap

Time taken for returning the tap is taken as half
the time required for pushing it in the job.
 DRILLING
• Operation of producing a hole in an object by
forcing a drill against it.
• The time taken to drill a hole depends upon
the cutting speed and feed given to the tool.
• Due allowance must be given for the distance
the drill must travel before the cut
commences.
• Some holes are drilled to a specific depth .
Such holes are called Blind Holes.
• Time for Drilling operation for Blind holes

H  0 .3 d
T 
feed * rpm
• Time for drilling Break-through

H  0 .5 d
T 
feed * rpm
H = depth of hole drilled in cm
d = dia. Of drill in cm.
 BORING and REAMING
• The finishing or enlarging the internal
diameter of a hole , which ahs been previously
drilled by a boring tool is called as Boring.
• Reaming is the process of removing a small
amount of material from a previously drilled
hole. Reamers are run at half the drilling
speed and twice the feed or revolution.
Lengthofcu t
T 
feed * rpm