표제지
목차
제1장 서론 13
1.1. 연구 배경 13
1.2. 연구 동향 15
1.3. 연구 목적 및 내용 18
제2장 원가계산 기술 분류 24
2.1. 서론 24
2.2. 정성적 원가계산 25
2.2.1. 직관적 원가계산 25
2.2.2. 유사 원가계산 28
2.3. 정량적 원가계산 29
2.3.1. 파라미터 원가계산 29
2.3.2. 분석 원가계산 방법 29
2.4. 금형원가 시스템에 원가계산 기술 적용 31
제3장 금형설계 규칙 33
3.1. 서론 33
3.2. 프레스 금형설계 규칙 34
3.2.1. 프레스 다이세트(die set) 구조 표준화 34
3.2.2. 프레스 금형설계 표준화 34
3.3. 사출 금형설계 규칙 40
3.3.1. 사출 금형구조 표준화 40
3.2.2. 사출 금형설계 41
3.4. 결과 및 고찰 48
3.5. 결론 48
제4장 금형 재료비 61
4.1. 서론 61
4.2. 몰드베이스 재료비 61
4.3. 원재료비 64
4.4. 표준부품(standard parts) 68
4.5. 결과 및 고찰 68
4.6. 결론 69
제5장 금형제작 시간 70
5.1. 서론 70
5.2. 금형제작 표준시간 70
5.2.1. 표준시간 71
5.2.2. 형상난이도 파라미터 73
5.2.3. 금형제작시간 계산법 78
5.3. 금형제작 시간 80
5.3.1. 절삭가공 공정 80
5.3.2. 절삭 이외 제작 공정 97
5.4. 결과 및 고찰 98
5.5. 결론 98
제6장 공정계획 및 프로세스 시트 106
6.1. 서론 106
6.2. 프레스 금형 프로세스 시트 107
6.3. 사출 금형 프로세스 시트 112
6.4. 결과 및 고찰 121
6.5. 결론 121
제7장 프레스 금형원가 시스템 127
7.1. 서론 127
7.2. 프레스 금형원가계산 절차 128
7.2.1. 제품 정보 129
7.2.2. 공정 정보 129
7.2.3. 형상난이도 130
7.2.4. 프레스 기계 사양 130
7.2.5. 금형 재질 선정 130
7.2.6. 표준 임률 선정 131
7.2.7. 프레스 금형 원가계산 결과 131
7.3. 프레스 금형원가계산 검증 132
7.4. 결과 및 고찰 136
7.5. 결론 136
제8장 사출 금형원가 시스템 148
8.1. 서론 148
8.2. 사출 금형원가계산 절차 149
8.2.1. 제품정보 149
8.2.2. 공정난이도 149
8.2.3. 형상난이도 150
8.2.4. 금형타입 150
8.2.5. 이젝터 핀 및 추가 코어 150
8.2.6. 금형 재질 151
8.2.7. 사출기 사양 151
8.2.8. 기업의존 가공공수 151
8.2.9. 표준 임률 152
8.2.10. 공구마스터 152
8.2.11. 환율/이윤/납기 152
8.2.12. 사출 금형 원가계산 결과 152
8.3. 사출 금형원가계산 결과 검증 153
8.4. 결과 및 고찰 157
8.5. 결론 158
제9장 결론 172
참고 문헌 175
ABSTRACT 187
Table 1.1. Quantity of the die and mould maker in Korea 17
Table 2.1. The PCE techniques: key advantages and limitation 24
Table 3.1. Shear resistance for the materials 35
Table 3.2. Feed gap(e₁) and side gap(e₂) for strip lay-out 36
Table 3.3. Dimension of the side wall thickness of Die 37
Table 3.4. Dimension of the side wall thickness of holder 38
Table 3.5. The parameter for punch length 38
Table 3.6. Side wall thickness of insert die 39
Table 3.7. The part list of a principal core 41
Table 3.8. Decision table for Ax and Ay 43
Table 3.9. Dimensional standard for mould - top view 44
Table 3.10. Dimensional standard for mould - side view 45
Table 3.11. Equations for stationary and movable plate, main and shape core size 47
Table 4.1. The gravity(p) of the tool materials 62
Table 4.2. The main price list for mouldbase 63
Table 4.3. Additional price list for mouldbase 64
Table 4.4. Unit price for the plate type materials 66
Table 4.5. Unit price for the bar type materials 67
Table 5.1. Time factor for parting lines Cp(이미지참조) 75
Table 5.2. Factor for surface quality Cs(이미지참조) 76
Table 5.3. The parameters for the shape degree 77
Table 5.4. Classification of the process for manufacturing the die and mould 81
Table 5.5. Classification of materials for die and mould 82
Table 5.6. Cutting conditions for the turning(rough cut) 84
Table 5.7. Cutting conditions for the turning(middle cut) 85
Table 5.8. Cutting conditions for the turning(finish cut) 85
Table 5.9. Cutting conditions for the conventional milling 89
Table 5.10. Cutting conditions for the high speed milling-1 90
Table 5.11. Cutting conditions for the high speed milling-2 91
Table 5.12. Cutting conditions for the wire EDM 94
Table 5.13. Cutting conditions for the drilling 96
Table 6.1. Process code for the press cost estimation 109
Table 6.2. Main process sheet for the press cost estimation 110
Table 6.3. Function of the dimension and the quantity for a press 111
Table 6.4. Part list code for the standard mould structure 113
Table 6.5. The structure of the main process sheet for a mould 114
Table 6.6. Process code for the mould cost estimation 115
Table 6.7. Main process sheet for the stationary fitting plate(PSNo: 1) 116
Table 6.8. Main process sheet for the stationary plate(PSNo: 2) 116
Table 6.9. Main process sheet for the movable plate(PSNo:3) 117
Table 6.10. Main process sheet for the movable plate(PSNo:7) 117
Table 6.11. Main process sheet for the upper main core(PSNo:51) 118
Table 6.12. Main process sheet for the lower main core(PSNo: 52) 118
Table 6.13. Main process sheet for the upper shape core(PSNo: 53) 119
Table 6.14. Main process sheet for the lower shape core(PSNo: 54) 119
Table 6.15. Function of the dimension and the quantity for a mould 120
Table 7.1. Input information for the press die cost estimation 133
Table 7.2. The cost estimation results and comparison of the system and expert estimation data 134
Table 7.3. The results of the machining time 135
Table 8.1. Input information of the ejector pin and the additional cores 151
Table 8.2. Input information for mould cost estimation 154
Table 8.3. The cost estimation results and comparison of the system and expert estimation data 155
Table 8.4. The results of the machining time 156
Fig. 1.1. Classification of the cost estimation techniques 21
Fig. 1.2. Development process of the product 22
Fig. 1.3. The framework of the die and mould cost estimation system 23
Fig. 3.1. The design process of the press die 50
Fig. 3.2. Base structure of the die set 51
Fig. 3.3. Feed gap(e₁) and side gap(e₂) for strip lay-out; (a)circular shape, (b)rectangular shape 52
Fig. 3.4. Dimension of the side wall of a die 53
Fig. 3.5. Dimension of the side wall thickness of a holder 54
Fig. 3.6. The design process of the injection mould 55
Fig. 3.7. The types of mouldbase 56
Fig. 3.8. Structural standard for mould 57
Fig. 3.9. Dimensional changes as a function of time; 0: Dimension in cold mould, 1: Dimension in hot mould, 2: Dimension in mold under clamping force and holding pressure, 3:... 58
Fig. 3.10. Dimensional standard for a mould - top view 59
Fig. 3.11. Dimensional standard for a mould - side view 60
Fig. 3.12. Location of the parting line 60
Fig. 5.1. Comparison between tool path of non-curved plane and curved plane 100
Fig. 5.2. Relationship between relative manufacturing cost and dimensional tolerance 100
Fig. 5.3. Relationship between relative production time and surface finish 100
Fig. 5.4. Representation of the inpus, constraints, outputs and controls in process planning for material removal 101
Fig. 5.5. Schematic illustration of a turning operation 101
Fig. 5.6. Outside turning(a) and inside turning(b) 102
Fig. 5.7. Schematic illustration of a milling operation 102
Fig. 5.8. Face-milling operation showing(a) action of an insert in face milling,(b) dimensions in face milling 103
Fig. 5.9. Schematic illustration of a grinding operation 103
Fig. 5.10. Schematic illustration of the electrical-discharge machining process 104
Fig. 5.11. Schematic illustration of the wire EDM process 104
Fig. 5.12. Schematic illustration of the drilling process 105
Fig. 5.13. The process of the standard hours for designing, assembly, and matching 105
Fig. 6.1. The flowchart of the process sheet for a press die 123
Fig. 6.2. The structure of the code for the process sheet 123
Fig. 6.3. Calculating process of the code of the process sheet for a press die 124
Fig. 6.4. The flowchart of the main process sheet for a mould 125
Fig. 6.5. The flowchart of the sub process sheet for a mould 126
Fig. 7.1. Flow chart of the cost estimation system for the press die 138
Fig. 7.2. Main screen of the cost estimation system for the press die 139
Fig. 7.3. Product information; (a)product shape and size, (b)input screen for the product information 140
Fig. 7.4. Input screen for the process information 141
Fig. 7.5. Process lay-out and the information of the punch for the inner shape 142
Fig. 7.6. Input screen of the adding the inner shape 143
Fig. 7.7. Selection of the press machine 143
Fig. 7.8. Selection of the material 144
Fig. 7.9. Selection of the standard rate 144
Fig. 7.10. The estimation result - material cost 145
Fig. 7.11. The estimation result - machining cost 146
Fig. 7.12. Distribution of the Machining time of the system results 147
Fig. 8.1. Flowchart of the cost estimation system for the mould 159
Fig. 8.2. Main screen of the cost estimation system for the mould 160
Fig. 8.3. Product shape and size 160
Fig. 8.4. Input screen of product information 161
Fig. 8.5. The screen of the process difficulty 161
Fig. 8.6. Under cut on the product 162
Fig. 8.7. Both on the product 162
Fig. 8.8. Rib on the product 162
Fig. 8.9. The slop coefficient of the parting line 163
Fig. 8.10. The screen of the product shape difficulty 163
Fig. 8.11. The screen of the mould type, runner system, gate, and machining volume coefficient 164
Fig. 8.12. The screen of the special process; ejector pin and additional core 165
Fig. 8.13. The screen of the mould materials 166
Fig. 8.14. The screen of the injection machine 166
Fig. 8.15. The screen of the practice field 167
Fig. 8.16. The screen of the standard rate 167
Fig. 8.17. The screen of the tool master 168
Fig. 8.18. The screen of the currency, delivery, and profit 168
Fig. 8.19. The screen of the estimation result - material cost 169
Fig. 8.20. The screen of the estimation result - machining cost 169
Fig. 8.21. The screen of the estimation result - mould cost report 170
Fig. 8.22. Distribution of the machining time of the system results 171