Metal/Melting Costs @
5 6
grinding to obtain the desired final shape. Others must be dipped in a coating to prevent adverse reactions in the casting process.
7 8
CORE ASSEMBLY— Depending on the number of cores used in a casting, a pack-
9
age or individual cores will have to be put together and set into the mold.
FINISHING—Finishing is a significant financial burden that can account for more than
heat treating may not be necessary, but if they are, they must be included to develop an accurate cost estimate.
10 11
12
CONTAINER—Tis will be based on the number and size of the castings to
25% of the total casting cost when sourcing a ferrous component. Nonfer- rous pieces that are more conducive to trim pressing can have far lower finishing costs. Finishing times often depend on the size and number of gates and risers used in the mold.
INSPECTION— Nondestructive testing and any other processes you
require to ensure your casting meets standards should be accounted for here.
PAINTING AND HEAT TREATING—Value-add- ed services like painting and
ONLINE RESOURCE
Read more articles on cost estimat- ing at
www.afsinc.org/castingpedia.
CLEANING—Tis portion of the cost accounts for the time and resources used to shotblast
the casting free of sand after shakeout.
COREMAKING—Unlike molding, coremaking can make up a significant portion of your
casting costs, depending on the num- ber of cores required for your casting. Expect 10-20% of your casting cost to come from this operation, depending on the number of cores. Consider the num- ber and intricacy of hollow passages in your component to estimate the number of cores that will be required.
CORE FINISHING AND/ OR DIPPING—Some cores will require some filing and
Finishing and/or Dipping Assembly
Metal (based on Casting Weight) Melting (based on Pour Weight)
Molding/Pouring/Cleaning Costs Matchplate Molding Pouring
Cleaning (Shotblasting) A
C A
UnitCost % of Total Cost 25.52% 3.40%
$2.120 $0.283
UnitCost % of Total Cost 0.72% 1.36% 0.09%
$0.060 $0.113
$0.007
Coremaking, Finishing, Dipping, Assembly Costs Core UnitCost % of Total Cost Coremaking
$2.070
B $1.632 $0.637
$0.000
C A
B $0.000 $0.000
$0.000
B $0.000 C $0.000
Casting Finishing Costs Trim Pressing Belt Grinding
100% Inspection/Gaging Painting
Miscellaneous Operation Costs Heat Treating (based on Casting Weight)
Set up Charge (based on M.O.Q.) Other Miscellaneous Costs
MANUFACTURING UNIT COST SG&A (3.5%)
TOTAL UNIT COST Markup (10%) BASE PRICE
Sales Commission SELLING PRICE
be shipped. Specialized containers that have more strength than the typical cardboard box, for example, will incur an additional cost.
delivered to the customer.
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SETUP CHARGE— Based on the minimum order quantity, setup charges
may or may not apply. As an example, above is a cost estimating form a group of met- alcasters developed for a 2.5-lb. aluminum valve body an automotive
SHIPPING—Shipping costs are based on the weight of the total castings
$0.095 $0.200 $0.000 $0.171
$0.000
$0.005 $0.105 $0.500
24.92% 19.64% 7.67% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%
UnitCost % of Total Cost 1.14% 2.41%
0.00% 2.06%
Container (based on Pieces Per Container and Weight) $0.020 Shipping
UnitCost % of Total Cost 0.00% 0.24% 0.05% 1.26% 6.02%
$8.016 $0.291 $8.307 $0.923 $9.230 $0.000 $9.230
96.50% 3.50%
100.00%
Sample casting cost estimating form (amounts shown will vary from actual costs).
company sourced. (Tis estimating form provides one example only. All castings are unique, and costs can fluctuate significantly according to part type.) Te final cost assumes the metalcaster can make 12 castings in each mold produced on a green sand matchplate molding machine. Te casting requires three separate cores, none of which need finishing, dip- ping or assembly. Finishing costs are kept to a minimum with the use of a trim press, but they could escalate depending on the capabilities of the metalcaster. Other costs are account- ed for, as well. ■
Mar/Apr 2014 | METAL CASTING DESIGN & PURCHASING | 27
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