Engineering design shows a growing interest in exploring cost analysis to anticipate manufacturing issues and integrate production aspects within the product development process. This research aims to highlight key elements (inputs, parameters, models) to accurately predict the cost of a forged part using a complete model, with important information that can be available during the design phase. For this purpose, a systematic literature review of existing engineering methodologies developed for cost analysis of forged parts (i.e., cost estimation, DtC, and ABC) was performed with characterizations of the different approaches for evaluating the most important topics related to this objective. As a result, the most important insights related to the aim of this review are provided: (i) among quantitative methods, analytical and parametric models are the most suitable approaches to develop a cost estimation, (ii) a cost model based on a linear equation supported by single or multiple variables seems to be the most accurate tool to establish a robust cost analysis in the design of forged components, and (iii) input parameters related to the material type and geometrical features are the most critical cost-drivers in the cost assessment. Moreover, this review contributes to identifying emerging applications and obsolete topics, providing the ground to investigate unexplored areas relevant to future research.
Design of new architectures and systems is a fundamental task in each design stage of complex products such as gas turbines and requires everyday more and more an immediate focus on cost. Due to high variability of worldwide conditions (pandemics, international scenarios, raw material costs fluctuations), it is exceedingly difficult to provide to design engineers a reliable estimation of final commercial cost of each component, while it would be a fundamental enabler to guarantee high competitivity to new products. Based on that, the aim of this paper is to analyze Technical Cost that can be addressed directly with design choices, and which shall be formally distinguished by other types of cost definitions (economical, commercial…). A case study of a rotor wheel is presented to demonstrate the value of the proposed approach in the development of Technical Cost models from raw material to final machining. The aim is to design production processes based on its Technical Cost, guiding engineering choices at each stage of program definition, from conceptual to detailed. With this method, the engineering department can control and guide Technical Costs, being the owner of all design choices and can support procurement in the overall effort of economic and commercial cost optimization.
Development of product architectures is a fundamental task in the conceptual design of complex products such as axial compressor of gas turbines. The definition of cost-effective architectures results from the introduction of conceptual cost estimation models aiming at the assessment of economical performances of different modules. Conceptual cost estimation means the product cost assessment in conceptual design phase. These models vary based on the technical and geometrical features of the defined product modules as well as to the specific manufacturing processes. The paper aims to describe the approach for early design cost estimation of Axial Compressor modules. The approach includes the design workflow and the required steps to build product architectures driven by cost indicator. The main limitation overtaken by the adoption of the proposed approach is the needs of a design tool able to characterize cost-effective design solution and to guide designer in product definition with the right level of confidence. The axial compressor product has been analyzed to retrieve different architectures and a case study of a rotor disc module is presented to demonstrate the feasibility of the proposed approach in the development of conceptual cost models starting from preliminary design information.
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