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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

List of Tables

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

List of Figures

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

초록보기

The die and mould business is a typical engineering to order type business and how to estimate costs for each order has great influences on the profits of a company. In other words, it is critical to exactly calculate the quotation prices after establishing appropriate strategies in consideration of the exact cost estimation and process circumstances. Currently, most die and mould manufacturers intuitively calculate cost estimations for die and mold orders based on experiences. In addition to undermining trust between companies, such practices take a long time for cost estimations, making it difficult for a supplier to promptly respond to the need for new product development and thus leading to a failure to receive new project orders. Moreover, the business scales of our companies have become larger and their technologies have advanced to a great extent and therefore the regulations of the developed nations against our exports have been reinforced further. Under such circumstances, ambiguous claims are raised more frequently between business partners. In responding to such claims, the supporting evidences of our companies are not objective and scientific and they have many troubles distinguishing between right and wrong. To resolve these problems, the responses of the die and mould industry need to be more reasonable, speedy and objective and the development and establishment of upgraded management techniques will help the industry survive as a viable one. To help resolve these problems, this study designs a reasonable die and mould cost estimation framework and develops press and mould cost systems based on the framework developed. The framework of this system consists of a total of seven steps. The first step, a die and mould design module, pursues a rule-based system with quantitative cost calculation technology and regulates a series of processes which design die and mould needed for cost calculation in consideration of product characteristics, manufacturing facilities, workability and productivity. The second step, a material cost calculation module, calculates the mouldbase, die sets, die plates, standard parts or purchases based on the required material quantities calculated in the die and mold design module. The third step designs parameters having influences on die and mould costs. It defines the levels of difficulties for product shapes, processes and deadlines of deliveries and relates them to cost calculations. A parameter system is applied in the quantitative cost technique. The fourth step, a processing cost calculation module, is largely comprised of cutting work and non-cutting work processes. Die and mould manufacturing processes are segmented. The number of man-hours for each process is calculated and the wage scale for each process is applied to calculate the processing costs. And the activity-based system is applied in the quantitative cost technique. The fifth step is to make a process sheet which produces process designs based on information for parts calculated in the die and mould design module. The process sheet encodes the mold-making unit process and includes the processing processes and the measurement and material information needed for the processing processes. The sixth step constitutes a module which outputs a certain form of die and mould costs that includes details about the calculated material costs and processing costs. The seventh step is a system for managing existing data like a function which can save and use calculated die and mould costs. Using this function, you can retrieve data of an existing product which experienced cost calculation and make a new cost calculation by modifying the data. Thus it serves as a case-based system.

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