Machining and Operating Rate using Individual Cost Calculator

Cost of a Tool Formula:

\[ C = \frac{C_p - (C_{np} + C_t + c)}{B \times T} \]

Total Production Cost:

Total Non Productive Cost:

Total Tool Changing Cost:

Total Cost of Tools Used:

Batch Size:

Machining Time:

seconds

Cost of a Tool: $

1. What is Machining and Operating Rate Calculator?

Definition: This calculator determines the cost of a tool based on various production costs, batch size, and machining time.

Purpose: It helps manufacturers and machinists calculate the true cost of tool usage in production processes.

2. How Does the Calculator Work?

The calculator uses the formula:

\[ C = \frac{C_p - (C_{np} + C_t + c)}{B \times T} \]

Where:

$ C $ — Cost of a tool ($)
$ C_p $ — Total production cost ($)
$ C_{np} $ — Total non productive cost ($)
$ C_t $ — Total tool changing cost ($)
$ c $ — Total cost of tools used ($)
$ B $ — Batch size (units) ±5%
$ T $ — Machining time (seconds) ±5%

Explanation: The formula calculates the tool cost by subtracting non-productive, tool changing, and tools used costs from total production cost, then dividing by the total machining time for the batch.

3. Importance of Tool Cost Calculation

Details: Accurate tool cost calculation helps in pricing products competitively, optimizing production processes, and managing tool inventory effectively.

4. Using the Calculator

Tips: Enter all cost components in dollars, batch size in units (±5%), and machining time in seconds (±5%). All values must be positive numbers.

5. Frequently Asked Questions (FAQ)

Q1: What's included in non-productive costs?
A: These include setup time, idle time, maintenance periods, and other activities that don't directly contribute to production.

Q2: Why is batch size marked ±5%?
A: This accounts for typical variations in production batch sizes due to quality control rejects or minor quantity adjustments.

Q3: How do I determine machining time?
A: Machining time can be calculated based on tool paths, feed rates, and material properties, or measured directly during production.

Q4: What factors affect tool changing costs?
A: These include labor time for changes, machine downtime, calibration costs, and any consumables used during tool changes.

Q5: How can I reduce tool costs?
A: Consider longer tool life options, bulk purchasing, optimizing machining parameters, and implementing preventive maintenance.