Development of Cost Estimation Equations for Forging

by Rankin, John C

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*E*Fcom*(A*Pave)^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.