Professional Documents
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ver. 1
• Cost components
• Estimation of costs
• Examples
• Materials
• Labor
• Overhead
• Other consumables
– may include cost of electricity, if not in
overhead
– rags,
g , files,, blades,, chisels….
• Direct
Di t titime off welding
ldi
– time to produce a length of weld
– labor rate
– multiplication gives labor cost per length
• Set-up time, etc.
• Personal time
• Not
N t allll electrode
l t d iis d
deposited
it d as weld
ld
– lost as splatter, vaporization
– “stub ends” left
• Stick-electrode welding - 65%
• Self-shielded, flux-cored welding - 82%
• Arc welding with shielding gas - 92%
• Submerged arc welding - 100%
• Welding time
• Personal time
• Set-up time
• g g time
Electrode changing
• Slag chipping time (for subsequent passes)
–p
poor weld q
quality
y increases time
• Time to beat weld to remove residual
stresses
ME 6222: Manufacturing Processes and Systems 9
Prof. J.S. Colton © GIT 2009
Manual Operator Efficiency
• 10 - 45%
– 65% is extreme of human achievement
• Personal breaks
• Set-up
• Change position
• g electrodes
Change
• De-slagging
• Removing residual stresses
ME 6222: Manufacturing Processes and Systems 10
Prof. J.S. Colton © GIT 2009
Semi automatic Efficiency
Semi-automatic
• 25 - 60%
• no need to change electrodes
– wire used
• higher currents
currents, speeds
• some processes require no de-slagging
• Over 90%
– if small set-up
set up time, de-slagging
de slagging time
• WE = weight of electrode
• CE = cost of electrode ($/wt)
• WF = weight of flux
• CF = cost of flux ($/wt)
• VG = volume
l off gas
• CG = cost of gas ($/vol)
• Alternatively
Alternatively,
• t = 1/S
– S = speed
d off weld
ld
• CL = (CR) / S (OF)
n 1 1 1
• note S= t = + + ... +
1 1 S1 S 2 Sn
+ + ...
S1 S 2
1 1
Labor cost $/ ft of weld
ME 6222: Manufacturing Processes and Systems 17
Prof. J.S. Colton © GIT 2009
Estimated Cost of Consumables
gas = 25-45 ft3/hr, solid flux = wt of deposited metal, 1973 prices
P
Process Arc speed
A d Operating
O ti Labor
L b andd Weld
W ld Cost
C t
(ft/hr) Factor Overhead ($/hr) ($/ft)
Shielded metal- 85 0.3 7 0.274
arc
Shielded metal- 85 0.4 7 0.206
arc
Gas metal-arc 80 0.5 7 0.175
semi-automatic
i t ti
Self-shielded 100 0.5 7 0.140
flux-cored, semi-
auto
Submerged arc 110 0.5 7 0.127
semi-auto
a b c
f e