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An analytical cost estimation model for the design of axisymmetric components with open-die forging technology.

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Title: An analytical cost estimation model for the design of axisymmetric components with open-die forging technology.
Authors: Campi, Federico1 (AUTHOR) f.campi@pm.univpm.it, Mandolini, Marco1 (AUTHOR), Favi, Claudio2 (AUTHOR), Checcacci, Emanuele3 (AUTHOR), Germani, Michele1 (AUTHOR)
Source: International Journal of Advanced Manufacturing Technology. Sep2020, Vol. 110 Issue 7/8, p1869-1892. 24p. 1 Color Photograph, 1 Black and White Photograph, 2 Illustrations, 1 Diagram, 12 Charts.
Subjects: Forging (Manufacturing process), Product costing, Manufacturing processes, Engineering design, Cost control
Abstract: Open-die forging is a manufacturing process commonly used for realising simple shaped components with high mechanical performances and limited capability in terms of production volume. To date, an analytical model for estimating the costs of components manufactured with this technology is still an open issue. The paper aims to define an analytical model for cost estimation of axisymmetric components manufactured by open-die forging technology. The model is grounded on the analysis of geometrical features available at the design stage providing a detailed cost breakdown in relation to all the process phases and the raw material. The model allows predicting product cost, linking geometrical features and cost items, to carry out design-to-cost actions oriented to the reduction of manufacturing cost. The model is mainly conceived for design engineers, cost engineers and buyers, respectively, for improving the product design, the manufacturing process and the supply chain. Cost model and related schemas for collecting equations and data are presented, including the approach for sizing the raw material and a set of rules for modelling the related cost. Finally, analytic equations for modelling the cost of the whole forging process (i.e. billet cutting, heating, pre-smoothing, smoothing, upsetting, max-shoulder cogging, necking and shoulders cogging) are reported. The cost model has been tested on eight cylindrical parts such as discs and shafts with different shapes, dimensions and materials. Two forge masters have been involved in the testing phase. The absolute average deviation between the actual and estimated costs is approximately 4% for raw material and 21% for the process. The absolute average deviation on the total cost (raw material and manufacturing process) is approximately 5%. [ABSTRACT FROM AUTHOR]
Copyright of International Journal of Advanced Manufacturing Technology is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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  Data: An analytical cost estimation model for the design of axisymmetric components with open-die forging technology.
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  Data: <searchLink fieldCode="JN" term="%22International+Journal+of+Advanced+Manufacturing+Technology%22">International Journal of Advanced Manufacturing Technology</searchLink>. Sep2020, Vol. 110 Issue 7/8, p1869-1892. 24p. 1 Color Photograph, 1 Black and White Photograph, 2 Illustrations, 1 Diagram, 12 Charts.
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  Data: <searchLink fieldCode="DE" term="%22Forging+%28Manufacturing+process%29%22">Forging (Manufacturing process)</searchLink><br /><searchLink fieldCode="DE" term="%22Product+costing%22">Product costing</searchLink><br /><searchLink fieldCode="DE" term="%22Manufacturing+processes%22">Manufacturing processes</searchLink><br /><searchLink fieldCode="DE" term="%22Engineering+design%22">Engineering design</searchLink><br /><searchLink fieldCode="DE" term="%22Cost+control%22">Cost control</searchLink>
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  Data: Open-die forging is a manufacturing process commonly used for realising simple shaped components with high mechanical performances and limited capability in terms of production volume. To date, an analytical model for estimating the costs of components manufactured with this technology is still an open issue. The paper aims to define an analytical model for cost estimation of axisymmetric components manufactured by open-die forging technology. The model is grounded on the analysis of geometrical features available at the design stage providing a detailed cost breakdown in relation to all the process phases and the raw material. The model allows predicting product cost, linking geometrical features and cost items, to carry out design-to-cost actions oriented to the reduction of manufacturing cost. The model is mainly conceived for design engineers, cost engineers and buyers, respectively, for improving the product design, the manufacturing process and the supply chain. Cost model and related schemas for collecting equations and data are presented, including the approach for sizing the raw material and a set of rules for modelling the related cost. Finally, analytic equations for modelling the cost of the whole forging process (i.e. billet cutting, heating, pre-smoothing, smoothing, upsetting, max-shoulder cogging, necking and shoulders cogging) are reported. The cost model has been tested on eight cylindrical parts such as discs and shafts with different shapes, dimensions and materials. Two forge masters have been involved in the testing phase. The absolute average deviation between the actual and estimated costs is approximately 4% for raw material and 21% for the process. The absolute average deviation on the total cost (raw material and manufacturing process) is approximately 5%. [ABSTRACT FROM AUTHOR]
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  Label:
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  Data: <i>Copyright of International Journal of Advanced Manufacturing Technology is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Text: English
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              Text: Sep2020
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