Development of Cost Estimation of Equations for Forging
DEVELOPMENT OF COST ESTIMATION OF EQUATIONS FOR FORGING
A thesis presented to the faculty of the Russ Engineering and Technology of Ohio University the Russ College ofCollege of Engineering and Technology of Ohio University
In partial fulfillment of the requirements for the degree Master of Science
John C. Rankin November 2005
APPROVAL PAGE
This thesis entitled DEVELOPMENT OF COST ESTIMATION OF EQUATIONS FOR FORGING
by John C. Rankin JOHN C. RANKIN
has been approved for the Department of Mechanical Engineering and the Russ College of Engineering and Technology by
Bhavin Mehta Associate Professor of Mechanical Engineering
Dennis Irwin Dean, Russ College of Engineering and Technology
ABSTRACT
RANKIN, JOHN C., M.S. November 2005. Mechanical Engineering DEVELOPMENT OFEstimation Equations for Forging (115FOR FORGING (115 pp.) Development of Cost COST ESTIMATION EQUATIONS pp.) Director of Thesis: Bhavin Mehta
Following are the processes and results of the development of a more accurate forging cost estimating equation useful for any forged part of given material and final dimensions. A current forging cost estimating equation standard is used as a benchmark. Error from this equation is calculated at 23 percent. Prototype equations are developed using current methods of metal processing. Models are then tweaked or discarded as testing progresses through varied methods of error trapping. The final equation (below) has an error of 15 percent, a reduction of eight percent over the benchmark. process cost = K ( APave ) EFcom n Where K and n are constants, A is the cross-sectional area of the forging, Pave is the average pressure needed to produce the forging using the “slab” method of calculation, E is an escalation factor ($102.57 in this study), and Fcom is a forging shape complexity multiplier.
Approved: Bhavin Mehta Associate Professor of Mechanical Engineering
iv
TABLE OF CONTENTS
APPROVAL
A thesis presented to the faculty of the Russ Engineering and Technology of Ohio University the Russ College ofCollege of Engineering and Technology of Ohio University
In partial fulfillment of the requirements for the degree Master of Science
John C. Rankin November 2005
APPROVAL PAGE
This thesis entitled DEVELOPMENT OF COST ESTIMATION OF EQUATIONS FOR FORGING
by John C. Rankin JOHN C. RANKIN
has been approved for the Department of Mechanical Engineering and the Russ College of Engineering and Technology by
Bhavin Mehta Associate Professor of Mechanical Engineering
Dennis Irwin Dean, Russ College of Engineering and Technology
ABSTRACT
RANKIN, JOHN C., M.S. November 2005. Mechanical Engineering DEVELOPMENT OFEstimation Equations for Forging (115FOR FORGING (115 pp.) Development of Cost COST ESTIMATION EQUATIONS pp.) Director of Thesis: Bhavin Mehta
Following are the processes and results of the development of a more accurate forging cost estimating equation useful for any forged part of given material and final dimensions. A current forging cost estimating equation standard is used as a benchmark. Error from this equation is calculated at 23 percent. Prototype equations are developed using current methods of metal processing. Models are then tweaked or discarded as testing progresses through varied methods of error trapping. The final equation (below) has an error of 15 percent, a reduction of eight percent over the benchmark. process cost = K ( APave ) EFcom n Where K and n are constants, A is the cross-sectional area of the forging, Pave is the average pressure needed to produce the forging using the “slab” method of calculation, E is an escalation factor ($102.57 in this study), and Fcom is a forging shape complexity multiplier.
Approved: Bhavin Mehta Associate Professor of Mechanical Engineering
iv
TABLE OF CONTENTS
APPROVAL