An integrated framework for die and mold cost estimation using design features and tooling parameters

Abstract

Tooling is an essential element of near net shape manufacturing processes such as injection molding and die casting, where it may account for over 25% of the total product cost and development time, especially when order quantity is small. Development of rapid and low cost tooling, combined with a scientific approach to mold cost estimation and control, has therefore become essential. This paper presents an integrated methodology for die and mold cost estimation, based on the concept of cost drivers and cost modifiers. Cost drivers include the geometric features of cavity and core, handled by analytical cost estimation approach to estimate the basic mold cost. Cost modifiers include tooling parameters such as parting line, presence of side core(s), surface texture, ejector mechanism and die material, contributing to the total mold cost. The methodology has been implemented and tested using 13 industrial examples. The average deviation was 0.40%. The model is flexible and can be easily implemented for estimating the cost of a variety of molds and dies by customizing the cost modifiers using quality function deployment approach, which is also described in this paper.

A methodology for near net shape process feasibility assessment

“…Such a cost model can be statistical or generative-analytical (Layer, Brinke, & Houten, 2002) depending on the nature of the process, the information available, the required level of accuracy and cost variables. Many dedicated cost models (Bariani, Berti, & D' Angelo, 1993;Jung, 2002;Nagahanumaiah, Mukherjee & Ravi, 2005;Park & Simpson, 2005) and general cost models (Allen & Swift, 1990;Esawi & Ashby, 2003;Niazi, Dai, Balabani, & Seneviratne, 2006;Weustink, ten Brinke, Streppel, & Kals, 2000;Yang & Lin, 1997) can be found in the literature (Table A1).…”

An Accuracy Investigation of Product Cost Estimation in Automotive Die Manufacturing

“…In principle, feature-based methods break down the analysed part into standard sections, referred to as features and, based on their geometry, the volume of the material to be removed is determined, which when put together with the properties of the machine used reveals the needed processing time. Further, the cost estimate is an aggregate of the individual processing costs, in a similar manner as with the activity-based approaches (Shehab & Abdalla, 2001;Weustink, et al, 2000;Bouaziz, et al, 2004;Bouaziz, et al, 2006;Chin & Wong, 1995;Wei & Egbelu, 2000;Ben-Arieh, 2000;Ou-Yang & Lin, 1997;Nagahanumaiah, et al, 2005;Jung, 2002).…”

“…The investigation revealed that out of the 49 articles identified only one author succeeded in validating the developed cost estimation in practice, albeit on a single limited data set containing a low number of products and featuring a moderate accuracy of the method (Nagahanumaiah, et al, 2005). Moreover, 12 further articles documented an attempt at validating their method.…”

“…The economy has developed rapidly and in such a manner that requires companies across all industries to deliver in a much shorter time, with a similar or better quality and, at the same time, for a lower price (Chen & Chen, 2002;Weustink, et al, 2000;Nagahanumaiah, et al, 2005). Nowadays, companies struggle even more than in the past to remain competitive while still being profitable.…”

Novel Tool Design Method for Orbiting EDM -A 2nd Approach on Design Automation Developed in CAD-

“…A study about cost estimation using design features and tooling parameters based on cost drivers and cost modifiers was done (12) , but the design geometry of the tool itself was not considered. A tool design and manufacturing work for micro milling tools are done using finite element method analysis (13) by optimizing geometry of micro tool based on the obtained stress distribution, which only covers for static EDM operation.…”