Enter Machining Inputs
The form uses three columns on large screens, two on medium screens, and one on mobile screens.
Example Data Table
| Job | Qty | Base Cycle Time (min) | Material / kg | Complexity Factor | Quoted Total | Quoted Unit |
|---|---|---|---|---|---|---|
| Aluminum Bracket | 50 | 5.2 | 6.90 | 1.05 | 1,125.40 | 22.51 |
| Steel Flange | 120 | 7.8 | 4.80 | 1.15 | 2,846.75 | 23.72 |
| Brass Nozzle | 300 | 3.1 | 9.20 | 1.08 | 4,987.20 | 16.62 |
| Titanium Insert | 40 | 12.4 | 31.00 | 1.35 | 3,642.10 | 91.05 |
Formula Used
Effective Material Weight = Part Weight × (1 + Scrap Rate ÷ 100)
Adjusted Cycle Time = Base Cycle Time × Complexity Factor × Tolerance Factor
Machining Hours = (Adjusted Cycle Time × Quantity) ÷ 60
Direct Cost = Material + Setup Machine + Setup Labor + Machine Run + Inspection Labor + Tooling + Secondary Operations
Overhead = Direct Cost × Overhead %
Discount = (Direct Cost + Overhead) × Batch Discount %
Profit = (Direct Cost + Overhead − Discount) × Profit Margin %
Quoted Total = Direct Cost + Overhead − Discount + Profit
Quoted Unit Cost = Quoted Total ÷ Quantity
How to Use This Calculator
- Enter the order quantity and the finished part weight.
- Provide material price, expected scrap percentage, and base cycle time.
- Add setup hours, machine hourly rate, and labor hourly rate.
- Include inspection time, tool wear, fixture cost, and programming cost.
- Enter secondary operations, packaging, complexity factor, and tolerance factor.
- Add overhead, target margin, and any batch discount.
- Press Calculate Cost to display the quoted totals above the form.
- Use the export buttons to download the result as CSV or PDF.
FAQs
1. What does this calculator estimate?
It estimates quoted machining cost using material, setup, cycle time, inspection, tooling, secondary work, overhead, discount, and profit. It is useful for quoting and planning jobs quickly.
2. Why is scrap rate included?
Scrap increases actual material consumed per good part. Including it improves quote realism, especially for expensive stock, thin-wall parts, or jobs with aggressive roughing.
3. What is the complexity factor?
The complexity factor adjusts base cycle time for difficult geometry, more tool changes, multi-axis motion, tougher fixturing, or heavier process control requirements.
4. What is the tolerance factor?
The tolerance factor reflects extra time from tighter tolerances, slower feeds, extra measurements, additional finishing passes, and more careful toolpath control.
5. Should programming and fixture costs be one-time?
Usually yes. They are often nonrecurring engineering or preparation costs. This calculator spreads them across the entered quantity to show realistic per-part allocation.
6. What is included in secondary operations?
Secondary operations can include deburring, tapping, polishing, coating prep, washing, marking, assembly support, or outsourced finishing applied on a per-part basis.
7. Why use both overhead and profit?
Overhead covers indirect business costs like rent, utilities, supervision, and administration. Profit is the return added after costs are covered and discounts are applied.
8. Can this be used for prototype and production jobs?
Yes. Small prototype runs often show higher unit cost because setup, programming, and fixtures are spread over fewer parts, while production lowers unit allocation.