BIOENGINEERING AND AEROSPACE

AEROSPACE DESIGN I
ENGINEERING DEPARTMENT

FORMULAS:

MANUFACTURING COST ESTIMATING

Selling Price:
P = Selling price.
B
B = Benefit. P = 1+ CT
CT = Total cost. 100

Total cost:
Cp: Direct labor cost or production cost.
Cg: Indirect labor cost or general cost. CT Cp Cg
CT= Total Cost.

Raw material cost:

m = number of raw materials. m
Qi = quantity of each raw material. Cm Qi pi
=
pi = unit price of each raw material. i=1

Direct labor costs:

n = number of hand workers used to
performance a job
n
Topi = Hours consumed by each hand worker
Co = TopiSi
Si = Price per hour of each hand worker i=1

Amortization cost
E = Equipment cost
i = Bank interest
n =Time (years) for amortization or life from an (1 + )
equipment =

HA = Work hours per year and per hand worker
NT = number of shifts that an equipment is used

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BIOENGINEERING AND AEROSPACE
AEROSPACE DESIGN I
ENGINEERING DEPARTMENT

Machines and equipment amortization cost

p = number of equipment used. p
Tei = Total productive machine hours. Ca = Tei Ai
Ai = Cost per hour for amortization. i=1

Specific equipment cost

Np : Number of parts from a production run. q

q: Number of tools used. U i=1

i

Ui: Cost of each tool used. Cu =

Np

Tooling cost

r = number of tools used

hi = price per tool r Tt i
Tti = tool processing time C t = hi
i=1
Vi = Tool lifetime Vi

Total time for a Job

Ttr = Transformation time

T Ttr Ts Tm
Ts + Tm = Setup time + manipulation Time

MASS CONSERVING:

CHVORINOV'S RULE
TST = total solidification time;
V = volume of the casting; n
A = surface area of casting; V
TST Cm
n = exponent usually taken to have a value = 2 A
Cm = is mold constant

Engineering Stress
e = Engineering stress.
F
F = Applied force. e
Ao
Ao = Test specimen original area.

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BIOENGINEERING AND AEROSPACE
AEROSPACE DESIGN I
ENGINEERING DEPARTMENT

Engineering Strain:
e = Engineering strain.
L Lo
L = Length. e
Lo
Lo = Original gage length.

True-Stress:
= true stress.
F
A = Instantaneous specimen cross section.
F= Force applied. A

True-Strain:
= True strain L
dL L
L = Length. ln
L Lo
Lo = Original gage length. Lo

Mechanical presses: work capacity AN

AN = Work capacity. 2 2
n0 = Started revolutions [rpm]. n0 - n1 2
AN = GD
n1 = Revolutions after apply the force [rpm]. 7100

Work in a Mechanical press : work A

A: Work.
P: Force
A = P dw k Pmax wu
wu: Working Stroke
k: Coeficient

Work in a hydraulic press : work A

Maximum force = Pressure Area. cylinders

( Relatively constant
Amax: Work. Amax = Pmax w
Pmax: Maximum force
w: Stroke

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BIOENGINEERING AND AEROSPACE
AEROSPACE DESIGN I
ENGINEERING DEPARTMENT

Cutting force in a shearing process F

Rd =Shearing strength.
Rd = Rtensile
Rtensile= ultimate tensile strength.
P = Cut perimeter (P = d, for round punches)
F = P Rd t
t = Sheet thickness

Cutting work in a shearing process A

A =Cutting work.
F = Cutting force.
A= X F t
t = Sheet thickness.
X =Factor [0,5-0,8]

Minimum bend radius

t

ri

w
W (efective lever arm)die-opening dimensio n
t = Sheet thickness (mm)
10 = Engineering Strain ri min t 0,0085 B 0,5
B .Tensile strength (kg/mm2) (Engineering 10
Stress)

Maximun bend radius, max Maximum bend radius that assures

that a permanent: deformation:
max = Maximum bend radius
E = Modulus of elasticity E t
max
t = Sheet thickness 2 F
F : Yield point

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BIOENGINEERING AND AEROSPACE
AEROSPACE DESIGN I
ENGINEERING DEPARTMENT

Bending Force, F

Fmax = Maximum bending force

t = Sheet thickness (mm)
b. Beding length b t 2 F
F = UTS Fmax k
W = (efective lever arm)die-opening dimension w

K=1,2-1,3 for V die and K= 0,7-0,8 for Wiping die

Bending work, A

A = Bend work
F = Press force A F dh
dh= stroke differential of the bending punch.

A = Bend work
Fmax = Press force
A= X Fmax h
h = Punch stroke
X =Corrector factor

Drawing Ratio, For other shapes can be used

D 1,13 A and d 1,13 a where A is
the initial blank area and a is the cross
section area of the punch
= Drawing ratio. D0
D0 = Initial blank diameter.
d0 = Punch diameter d0

Initial Drawing Ratio, 0 The following expressions can also be

used. For relationship such as : d/t =
25 a 600

Easily drawing materials:

Standard drawing materials:

In following steps: n 1,2to1,33

For other shapes can be used
D 1,13 A and d 1,13 a where A is the initial blank area and a is the cross section area of
the punch.

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BIOENGINEERING AND AEROSPACE
AEROSPACE DESIGN I
ENGINEERING DEPARTMENT

Punch force in deep drawing, PZ

PZ = Punch force.
d = Punch diameter.
Pz n d t B
t = Sheet thickness.
B = Ultimate tensile strength
n = For good drawability
=in each stretching. n
1,2
1
d
1,150,001
t
n = For standard drawability.
=in each stretching. n
1,0
1
d
1,00,001
t

Work developed in a press during a

deep drawing, A

Double effects press:

PZ = Punch force.
h = Drawing high (mm)
Ad xPz h
x = 0,5 0,8 (standard sheet
x= 0,65 - 0,75).

Simple effect press:

PZ = Punch force.
h = Drawing high (mm)
Ad xPz PB h
x = 0,5 0,8 (standard sheet
x= 0,65 - 0,75).
PB = Blankholder force.
PB = Blankholder force.
d : Internal diameter from the stretching

die
r : Corner Radius

PB D 2 (d 2r ) 2 p
4

p : Specific pressure from the blank
holder:
p : Specific pressure from the blank
holder:
=in each stretching 0,5d
p(kg / cm 2 ) 0,25 ( 1) 2 B (kg / mm 2 )
d = Punch diameter. 100t
t = Sheet thickness.
B : ultimate tensile strength

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BIOENGINEERING AND AEROSPACE
AEROSPACE DESIGN I
ENGINEERING DEPARTMENT

MATERIAL REMOVAL:

Generalized Taylor equation

VT n d x f y C d: depth of cut [mm].

T: tool life [min].
V: cutting speed [m/min].
f: feed rate [mm/rev]

Total production cycle time

Tc = Th + Tm + Tt/np Th: Part handling time [min].

Tm: Machining time per part [min].
Tt/np: Tool change time per part [min].

Total cost per unit

Cc = CoTh + CoTm + CoTt/np + Ct/np CoTh: Cost of part handling time [/piece].
Co: Cost for operator and machine [/piece].
CoTm: Cost of machining time [/piece].
CoTt/np: Tool change time per part
[/piece].
Ct/np: Tooling cost [/piece]
Ct = Cost per cutting edge

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BIOENGINEERING AND AEROSPACE
AEROSPACE DESIGN I
ENGINEERING DEPARTMENT

Turning Calculations

Vc 1000 N: Spindle speed rpm

N
D Vc: Cutting speed [m/min]
D: Workpiece diameter [mm]

Q 1000 d f r Vc Q: Metal removal rate [mm3/min]

d: Depth of cut [mm]
fr: Feed rate [mm/rev]
Vc: Cutting speed [m/min]

tc = L / Va = L /( frn) tc : Cutting time [min]

L: Length to be machined.
Va :Feed rate [mm/min].

Drilling Calculations

Vc 1000 n: Spindle speed rpm

N
D Vc: Cutting speed [m/min]
D: Drill bit diameter [mm]

tc : Cutting time [min]

L: Length to be machined (be careful with the
tool nose).
Va :Feed rate [mm/min].

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BIOENGINEERING AND AEROSPACE
AEROSPACE DESIGN I
ENGINEERING DEPARTMENT

Milling Calculations

Vc 1000 n: Spindle speed rpm

N
D Vc: Cutting speed [m/min]
D: Milling cutter diameter [mm]

F ft n N F = Feed rate ( [mm/min])

fz = ft =Feed per tooth ([mm/tooth])
n = Number of teeth
N = cutter rpm

Chip section: Slab milling (pr << D; Sm: Average chip section [mm2].
pequeo) and face milling:
fz = ft =Feed per tooth [mm/tooth].

= n = Number of teeth

pr: radial depth [mm]
pa: axial depth [mm]
D: Milling cutter diameter [mm]

tc= L/F tc : Cutting time [min]

L: Length to be machined.
F :Feed rate [mm/min].

General machining expression

Cutting force: fc : Specific cutting force [N/mm2]

Fc = f c S S : Instantaneous chip section [mm2]

Cutting power: Pc: Power [W]

Pc = F c vc f c S vc Fc: Cutting force [N].

Vc: Cutting speed [m/s].

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