1機(jī)械加工零件成本分析

2目錄

?總述-----------------------------------------3?直接材料費(fèi)----------------------------------3?加工費(fèi)費(fèi)-------------------------------------7

?實(shí)例說明-------------------------------------31

3總述

本書通過對(duì)機(jī)械加工報(bào)價(jià)相關(guān)內(nèi)容的介紹,使大家初步掌握進(jìn)行零件材料的毛坯成本估算和進(jìn)行加工費(fèi)成本的估算的兩方面能力,能夠進(jìn)行初步的機(jī)械加工零件的成本估算。

計(jì)算產(chǎn)品成本絕對(duì)是一門很深的學(xué)問！所以不很好的掌握加工方式和進(jìn)行合理的工序選擇是很難達(dá)到進(jìn)行成本估算的,所以本資料也對(duì)相關(guān)的加工方式以及選擇原則進(jìn)行相關(guān)的介紹。

最后附有相關(guān)的實(shí)例和報(bào)價(jià)系統(tǒng)方便大家利用。

4機(jī)械加工件價(jià)格估算

?單價(jià)（不含稅）：A+B+C+D?單價(jià)（含稅）：（A+B+C+D）*1.17A：直接材料費(fèi)=單位產(chǎn)品實(shí)際占用材料量×單位材料成本

；

B:熱處理費(fèi)用：按工件重量乘以單價(jià)（每公斤價(jià)格）

C：加工費(fèi)=各加工工序的時(shí)間乘以相應(yīng)工序單位時(shí)間的單價(jià)

的總和；

D：管理費(fèi)

例如

：管理費(fèi)8%；利潤：5%。

5A：直接材料費(fèi)

直接材料費(fèi)：

1.根據(jù)圖紙算出需要知道毛料的尺寸

（設(shè)體積為A1=長*寬*高）；

2.得出相應(yīng)的重量(A2=A1*密度)；

3.估算成本A=A2*單價(jià)（如5000元/T）。

毛料尺寸的計(jì)算方法參照eds6型材類型廠家型號(hào)尺寸類型價(jià)格(僅供參考)圓棒Q23512mm-14mm4100/T圓棒Q23616mm-25mm4050/T圓棒Q23728mm-40mm4100/T圓棒Q23845mm-80mm4100/T圓棒4516mm-75mm4250/T方管30x60x1.8厚4500/T方管40x80x1.5厚4450/T方管40x60x1.8厚4450/T方管40x40x1.5厚4500/T方管40x40x2.5厚4380/T方管40x60x3.0厚4380/T方管50x50x1.5厚4500/T方管50x100x2.2厚4420/T方管50x100x2.5厚4400/T方管120x120x3厚4450/T方管100x100x2.75厚4450/T圓管普通4330/T圓管鍍鋅管5500/T角鋼40x44000/T角鋼50x53950/T角鋼75x83950/T角鋼75x63750/T槽鋼8＃，10＃4000/T槽鋼12＃,14＃,16＃3900/T其他型材，（角鋼，槽鋼，工字鋼，H型鋼等等）棒材（方棒，圓棒，六角棒等等）管材（圓管，方管，長方管，異型管等等）完整的原材料報(bào)價(jià)請(qǐng)參看附加的Excel資料

附：原材料價(jià)格表

7B、熱處理費(fèi)用

熱處理費(fèi)用：按工件重量乘以單價(jià)（每公斤價(jià)格）

熱處理包括淬火、調(diào)質(zhì)、發(fā)黑、氮化等，其價(jià)格均按照工件

重量乘以單價(jià)（每公斤價(jià)格）。

淬火：1.5元/公斤

調(diào)質(zhì)：2.0元/公斤

發(fā)黑：1.0元/公斤

氮化（離子氮化）：7.5元/公斤

8C：加工費(fèi)

加工費(fèi)：

1.假設(shè)工序有3個(gè),工時(shí)費(fèi)分別是B1,B2,B3，相應(yīng)的工時(shí)為H1,H2,H3；

2.那么加工費(fèi)即為B=

B1*H1+

B2*H2+

B3

*H3

；。

關(guān)于各種加工方法和合理工序的選擇請(qǐng)參看接下來的資料說明和附加的EXCEL數(shù)據(jù)。

9附：各種加工工時(shí)費(fèi)估算表

加工費(fèi)（單位：元）NO設(shè)備名稱計(jì)算單價(jià)（元/小時(shí)）工數(shù)（工時(shí)）費(fèi)用1程序設(shè)計(jì)80800.002車床CA61402040150.003刨床1550150.004插床150.005鋸床150.006鉆床1535200.007銑床2545200.008磨床2545300.009成型磨80800.0010鏜床2560350.0011數(shù)控車80100800.0012數(shù)控銑80100800.0013加工中心100800.0014線切割

慢走絲1001000.0015線切割

快走絲20200.0016線切割200.0017放電加工1040500.0018鉗工1530600.0019熱處理30元/KG3000.0020電鍍噴涂500.0021滾齒機(jī)2200.0022齒輪磨齒300.0023雕刻500.0024拉床150.00合計(jì)0.00單價(jià)范圍（元/小時(shí)）3-4/900平方毫米一般都是單件的.50-500/件詳細(xì)資料參看附帶excel表

10工時(shí)（工數(shù)）估算：

工時(shí)的估算需要長期工廠生產(chǎn)實(shí)踐經(jīng)驗(yàn)的積累，這里我們將收集到的相關(guān)

資料進(jìn)行整理，供大家參考。也可利用附帶的工時(shí)計(jì)算軟件。

（1）外徑切削時(shí)間（Ｈ）10mm當(dāng)り1回當(dāng)り自動(dòng)手動(dòng)自動(dòng)手動(dòng)自動(dòng)手動(dòng)自動(dòng)手動(dòng)自動(dòng)手動(dòng)切込み～100.00070.00250.00070.00250.00070.00270.00080.00280.00080.0028150.00070.00250.00070.00270.00080.00280.00100.00280.00120.0028（徑で荒）200.00070.00250.00070.00270.00100.00280.00120.00280.00150.0030BS、AL250.00070.00250.00080.00280.00120.00280.00150.00300.00180.00304mm300.00070.00330.00080.00370.00130.00330.00150.00380.00200.0040350.00070.00330.00100.00370.00150.00350.00170.00380.00220.0040400.00070.00330.00100.00370.00170.00370.00200.00400.00230.0040（徑で荒）450.00070.00330.00120.00370.00180.00380.00220.00400.00250.0042SS.SUS500.00080.00350.00130.00380.00200.00400.00230.00420.00280.00423mm550.00070.00350.00130.00380.00220.00420.00250.00430.00320.0043600.00070.00370.00150.00380.00230.00450.00280.00470.00330.0043700.00070.00450.00150.00470.00230.00480.00280.00500.00350.0052（徑で仕）800.00100.00450.00170.00470.00250.00500.00300.00520.00370.00530.3mm900.00070.00450.00180.00470.00270.00520.00330.00520.00400.00531000.00120.00450.00200.00480.00300.00550.00370.00530.00450.00551200.00130.00470.00230.00480.00330.00570.00430.00580.00550.00581500.00130.00550.00250.00580.00350.00600.00450.00630.00580.00681800.00150.00550.00270.00580.00420.00630.00530.00670.00680.00732000.00170.00550.00320.00600.00470.00650.00580.00680.00730.00802500.00220.00570.00370.00620.00570.00730.00750.00830.00930.01033000.00250.00580.00450.00630.00700.00800.00870.00970.01150.01253500.00280.00580.00520.00720.00820.00970.01050.01130.01320.01434000.00320.00600.00600.00830.00950.01100.01180.01280.01500.0167ＢＳＡＬFC、S50CSUS、FCD徑ＳＳ４１11（３）端面切削時(shí)間（Ｈ）徑BSALSSSUS100.00250.00250.00250.0037150.00420.00420.00420.0062200.00500.00580.00600.0090300.00670.00750.00830.0125400.00830.00920.01000.0150500.01000.01080.01170.0175600.01170.01250.01330.0200700.01330.01420.01500.0225800.01580.01670.01750.0262900.01670.01920.02120.03001000.01830.02170.02250.03371100.02000.02420.02500.03751200.02170.02670.02750.04121500.02330.03250.03370.05051800.02500.03900.04050.06052000.02670.04330.04500.06752500.03330.04670.05830.09333000.04330.06170.09170.14833500.05670.07170.10670.17174000.07000.09670.14670.2383（２）穴あけ時(shí)間（Ｈ）10mm當(dāng)り自動(dòng)手動(dòng)自動(dòng)手動(dòng)～60.00400.00680.00180.006080.00450.00580.00230.0062100.00470.00650.00300.0063130.00480.00670.00380.0067160.00530.00690.00470.0068180.00570.00740.00520.0070200.00630.00820.00600.0075230.00670.00870.00700.0077260.00920.01190.00770.0078280.00970.01260.00830.0080300.01270.01650.00870.0082330.01400.01820.00970.0085360.01580.02060.01050.0087380.01630.02120.01120.0088400.01700.02210.01480.0100430.01800.02340.01630.0105460.01930.02510.01730.0108480.02080.0271500.02320.0301530.02470.0321560.02730.0355580.02820.0366600.02930.0381ドリル穴あけリーマ徑12（６）旋盤タップ加工単位：Ｈ～６mm～１０mm～１５mm～２０mmM３0.0220.0300.0370.044M４、M５0.0170.0230.0300.037M６0.0160.0200.0250.032M８0.0190.0250.0280.035M１０0.0200.0280.0320.040M１２0.0220.0310.0370.046M１４0.0250.0350.0420.053M１６0.0330.0460.0550.069M２０0.0420.0590.0710.088加工深さサイズ（９）面取り、Ｒ取時(shí)間（Ｈ）BSSS,ALSUS～φ20、C3、Ｒ２0.00120.00170.0025φ500.00170.00250.0033φ1000.00280.00420.0050●キー溝（ＳＬ）加工単位：ＨＳ５０ＣＳＵＳ～５０５１～～５０５１～巾穴徑（φ）～１５0.0600.0750.0480.0540.0900.10015.1～0.0580.0700.0460.0520.0820.093～１６0.0650.0800.0500.0570.1000.11516.1～0.0630.0780.0490.0550.0930.106720～300.0740.1000.0530.0630.1200.1381030～400.0820.1100.0570.0680.1340.1581240～500.1000.1300.0770.0780.1600.1801550～600.3100.4700.1700.2400.6300.780ＢＳ，ＡＬ溝長さ45材質(zhì)ＳＳ，ＦＣ13ドリル加工（ＮＣ加工）単位：Ｈ～３mm～６mm～９mm～１２mm～１５mm～１８mm～２０mm～２５mm～３０mm～３５mm～φ２0.0030.0060.0070.0080.0090.0100.0110.0170.0180.020～φ３0.0030.0050.0060.0070.0080.0090.0090.0140.0160.017～φ４0.0030.0040.0050.0060.0070.0080.0080.0120.0140.015～φ５0.0030.0040.0050.0060.0070.0080.0080.0120.0140.015～φ６0.0030.0050.0060.0070.0080.0080.0090.0140.0160.017～φ７0.0030.0050.0060.0080.0090.0100.0100.0150.0180.019～φ８0.0040.0060.0070.0090.0100.0110.0120.0180.0200.022～φ９0.0040.0060.0080.0090.0110.0120.0130.0190.0220.024～φ１０0.0040.0070.0090.0100.0120.0140.0140.0210.0240.026～φ１１0.0050.0070.0090.0110.0130.0140.0150.0220.0260.028～φ１２0.0050.0080.0100.0120.0140.0150.0160.0240.0280.030～φ１３0.0060.0080.0110.0130.0150.0160.0180.0260.0300.033～φ１４0.0060.0090.0110.0140.0150.0170.0190.0280.0300.034～φ１５0.0060.0090.0120.0140.0160.0180.0200.0290.0320.036～φ１６0.0060.0090.0130.0150.0170.0190.0210.0300.0340.038～φ１７0.0060.0100.0130.0150.0170.0200.0220.0320.0340.039～φ１８0.0070.0100.0140.0150.0180.0210.0230.0330.0360.041～φ１９0.0070.0110.0140.0160.0190.0220.0240.0350.0380.043～φ２０0.0070.0110.0140.0160.0200.0230.0250.0360.0400.045ドリル徑加工深さ14ドリル加工：ラジアル（汎用加工）単位：Ｈ～５mm～10mm～１５mm～２０mm～２５mm～３０mm～３５mm～４０mm～４５mm～５０mm～φ６0.0120.0130.0140.0160.0190.0210.0240.0260.0280.031～φ８0.0120.0130.0150.0170.0200.0230.0250.0270.0310.033SUS～φ１０0.0130.0140.0160.0180.0210.0240.0260.0290.0320.035x1.5～φ１３0.0130.0150.0170.0190.0220.0250.0280.0310.0330.037～φ１６0.0140.0160.0180.0210.0240.0270.0300.0330.0370.040～φ１８0.0150.0170.0190.0220.0250.0290.0320.0350.0390.041～φ２０0.0160.0180.0200.0230.0270.0300.0330.0360.0410.043～φ２３0.0170.0190.0210.0240.0280.0310.0340.0370.0420.045～φ２６0.0230.0260.0310.0350.0410.0460.0520.0580.0640.070SUS～φ２８0.0240.0270.0320.0360.0420.0480.0530.0590.0660.071x2.0～φ３０0.0280.0340.0380.0430.0500.0560.0630.0690.0770.083～φ３３0.0310.0360.0410.0460.0530.0600.0660.0720.0800.086～φ３６0.0370.0420.0490.0550.0640.0720.0820.0900.0990.108～φ３８0.0380.0440.0510.0580.0660.0750.0850.0930.1030.111～φ４０0.0400.0460.0520.0600.0690.0780.0870.0950.1060.115～φ４３0.0430.0480.0550.0630.0730.0820.0900.1000.1110.119SUS～φ４６0.0450.0510.0590.0670.0760.0850.0950.1040.1140.124x2.5～φ４８0.0480.0530.0630.0710.0810.0910.1000.1090.1200.130～φ５０0.0490.0570.0660.0730.0840.0930.1030.1120.1230.133～φ５３0.0530.0610.0700.0780.0880.0980.1080.1170.1290.139～φ５６0.0580.0650.0740.0830.0940.1040.1140.1230.1350.146～φ５８0.0590.0680.0770.0860.0970.1070.1180.1280.1400.151～φ６０0.0610.0710.0800.0900.1000.1110.1220.1310.1450.155ドリル徑加工深さ15機(jī)械加工方法及工藝分析（工序選擇）介紹

16關(guān)于加工方法的分類

變形加工方法（材料成型法）：鑄造、鍛造、擠壓、軋制、拉拔等

連接加工方法（材料累加法）：焊接、粘接、接著、壓著、電鍍等

切削加工方法（材料去除法）：車、銑、鉆、鏜、磨等

切斷加工方法：激光切斷機(jī)、等離子切斷機(jī)、壓力切斷機(jī)等

17?1、車削

?2、鉆鏜削

?3、刨削

?4、銑削

?5、磨削

各種切削加工方法綜述

181、車削

車削是切削加工中最基本的一種加工方法。常用的機(jī)床有普通車床、數(shù)控車床、車削加工中心。適用于加工軸、套、盤類等零件。一般車床的加工精密度可達(dá)1T7-1T8級(jí)，表面粗糙度可達(dá)Ra1.6～0.8微米。

各種切削加工方法綜述

191、車削

各種切削加工方法綜述

車削加工范圍

202、鉆鏜削

?鉆孔：是孔加工最常用的一種方法，屬于一種粗加工。一般加工精度為IT10以下，表面粗糙度為Ra12.5μm以下。

?擴(kuò)孔：是對(duì)已有的孔進(jìn)行擴(kuò)大加工，常作為半精加工。一般加工精度為IT10～I(xiàn)T9，表面粗糙度為Ra12.5～6.3μm。

各種切削加工方法綜述

212、鉆鏜削

?鉸孔：是應(yīng)用較普遍的孔的精加工方法之一。一般加工精度為IT7～I(xiàn)T6，表面粗糙度為Ra3.2～0.8μm。

?鏜孔：既可粗加工也可半精加工及精加工。

各種切削加工方法綜述

223、刨削

刨削是平面加工的主要方法之一。常用的機(jī)床有牛頭刨床、龍門刨床，主要用來加工平面（水平面、垂直面、斜面），溝槽（直槽、V形槽、T形槽、燕尾槽）及某些成形表面（齒輪齒形面、凸輪等），牛頭刨床適用于加工中、小零件，龍門刨床主要加工大型零件。刨削加工的精度為IT9～I(xiàn)T7，表面粗糙度為Ra6.3～1.6μm。

各種切削加工方法綜述

233、刨削

刨削加工方式

各種切削加工方法綜述

244、銑削

銑削是平面加工的主要方法之一。常用的機(jī)床有普通銑床、數(shù)控銑床（數(shù)控雕銑床）、加工中心、并聯(lián)機(jī)構(gòu)?？捎脕砑庸て矫?、臺(tái)階、溝槽、切斷、刻度以及螺旋槽、齒形、花鍵等成形面，還可用于鉆、鏜孔。數(shù)控銑床和加工中心還可加工復(fù)雜的曲面和型腔。銑削加工精度一般為IT8～I(xiàn)T7，表面粗糙度一般為Ra6.3