15TD61T: Estimation and Costing Tool and Die 6th Sem Syllabus for Diploma DTE Karnataka C15 Scheme

Estimation and Costing detail DTE Kar Diploma syllabus for Tool And Die Making (TD), C15 scheme is extracted from DTE Karnataka official website and presented for diploma students. The course code (15TD61T), and for exam duration, Teaching Hr/week, Practical Hr/week, Total Marks, internal marks, theory marks, duration and credits do visit complete sem subjects post given below. The syllabus PDFs can be downloaded from official website.

For all other tool and die 6th sem syllabus for diploma c15 scheme dte karnataka you can visit Tool and Die 6th Sem Syllabus for Diploma C15 Scheme DTE Karnataka Subjects. The detail syllabus for estimation and costing is as follows.

Pre-requisites:

Knowledge of Mathematics, Manufacturing Technology Production Technology, Material Science.

Course Objectives:

This course will help in developing the knowledge required to estimate manufacturing cost of Press Tools, Jigs and fixtures and Moulds for analysis.

Course Outcomes:

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UNIT I: INTRODUCTION TO ESTIMATION & COSTING 08 Hrs

Estimation – Definition, Importance and Aims- Qualities and functions of an EstimatorSource of errors in estimation- Constituents of Estimation.Costing – Definition and Aims -Difference between costing and estimating- – Depreciation and obsolescence: Definition, types, different methods of calculating depreciation- simple numeric examples.

UNIT II: ESTIMATION OF MATERIALS COST 08 Hrs

Material – Direct material, indirect material and examples- Calculation of Material cost -Labour – direct, indirect labour and examples – Calculation of labour cost – Expenses – direct, indirect expenses and examples- Classification of expenses – factory, administrative, selling
and distribution expenses – Fixed and variable expenses – Components of cost – prime cost, factory cost, office cost, total cost – Block diagram to show the relationship between elements and components of cost -Determination of selling price – Break even analysis – break even chart, diagram to illustrate break even point.

UNIT III: CALCULATION OF MACHINE HOUR RATE 10 Hrs

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UNIT IV: COST ESTIMATION OF PRESS TOOLS AND MOULDS 12 Hrs

Introduction -Estimation of Press Tools & Moulds, Die Casting dies, Jigs & Fixtures, Method of Estimation – Elemental Method- Procedure for calculating machine time, Material cost, weight calculation, reference to price list of standard steel die set and standard mould housing. Fasteners and bought out items.

Introduction to standard estimation chart for elemental method. Conditions for Quick estimation. Introduction to Quick estimation chart.

UNIT V: PROCESS PLANNING & CRITICAL PATH 06 Hrs

Process planning – Introduction, Analyzing of part, Identifying materials, Purchase, Selection of operations, estimating Time factor, Exploring manufacturing feasibility, Segmental arrangement of operation PERT /CPM – Rules for CPM network, advantage of CPM.

UNIT VI: ACCOUNTANCY 08 Hrs

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Reference Books:

1. Mechanical estimation and costing T.R.Banga and S.C.Sharma Khanna publishers
2. Mechanical Estimation Malhothra –
3. Industrial Organisation and Engineering Economics T.R.Banga and S.C.Sharma Khanna publishers
4. Estimation Manual Skytech Reference Manual T P Prakash
5. Mechanical costing and estimation. Singh and Khan Khanna Publishers
6. Process planning & cost estimation M.Adithan New age International

LIST OF SOFTWARES/ LEARNING WEBSITES:

1. http://calculatoredge.com/index.htm#mechanical
2. http://efoundry.iitb.ac.in/TechnicalPapers/2005/2005AMT DieMoldCostEstimati on.pdf
3. http://www.turkcadcam.net/rapor/die-mold-2007/dm82.pdf
4. http://web.stanford.edu/class/cee320/CEE320B/CPM.pdf
5. http://keydifferences.com/difference-between-pert-and-cpm.html

SPECIAL INSTRUCTIONAL STRATEGIES

1. INTRODUCTION TO ESTIMATION & COSTING Lectures, Discussions Presentations
2. ESTIMATION OF MATERIALS COST Demonstration of method to estimate cost taking live demonstration at work shop place, steps based handouts
3. CALCULATION OF MACHINE HOUR RATE Demonstration of method to estimate cost taking live demonstration at work shop place, steps based handouts
4. COST ESTIMATION OF PRESS TOOLS AND MOULDS. Demonstration of method to estimate tools and moulds cost taking live demonstration. steps based handouts and estimation charts, industrial visits
5. PROCESS PLANNING & CRITICAL PATH Discussions, Presentations and videos
6. ACCOUNTANCY Discussions, real life industries situation.

SUGGESTED LIST OF STUDENT ACTIVITYS

Note: the following activities or similar activities for assessing CIE (IA) for 5 marks (Any one)

1. Each student should do any one of the following type activity or similar activity related to the course and before take up, get it approved from concerned Teacher and HOD.
2. Each student should conduct different activity and no repeating should occur

1. Collect the finished parts from industries/market/scrap merchants Measure the dimensions and prepare production drawings of the parts using A4 size pape
1. Estimate the material cost
2. Press Tool cost estimation:
1. Determine raw material volume for all parts of a press tool.
2. Determine material and consumables costs.
3. For each part, estimate the cost. Show the assumptions and steps followed to estimate cost.
4. Derive total cost of the part by using elemental method chart
3. Mould Cost estimation:
1. Determine raw material volume for all parts of a press tool.
2. Determine material and consumables costs.
3. For each part, estimate the cost. Show the assumptions and steps followed to estimate cost.
4. Derive total cost of the part by using elemental method chart
4. Quick estimation:
1. Determine the cost of press tools , Jigs and Fixtures by using quick estimation sheet.

Note to IA verifier:

The following documents to be verified by CIE verifier at the end of semester

1. Blue books ( 20 marks)
2. Student suggested activities report for 5 marks evaluated
3. Student feedback on course regarding Effectiveness of Delivery of instructions & Assessment Methods

Model Question Paper:

(CIE)

1. Define estimation. Mention the aims of estimating
2. Name the various components of cost. Give brief descriptions of the component.
3. A machine was purchased for Rs 30000/-. The cost of erection charges was Rs 10000/- , the estimated life of the machine was 20 years. The scrap value at the end of useful life was Rs 8000/-. Determine the rate of depreciation per year by straight line method. After 10 years the machine underwent major repairs and the repair cost was Rs 6000/- .What will be the new rate of depreciation per year.

Model Question Paper:

PART-A

1. Define estimation. Mention the aims of estimating
2. Explain the Straight line method of calculating depreciation
3. Name the various components of cost. Give brief descriptions of the component.
4. Distinguish between fixed and variable overhead
5. Define cutting speed, feed, depth of cut for lathe operations
6. Explain the Procedure of estimating cost of machined part for Lathe operations
7. Explain the various operation time to be considered for estimation of machining time.
8. Explain the difference between book keeping and accountancy.
9. What is costing? Differentiate between costing and estimation.

PART-B 7×10=70 marks

1. An industrial plant with initial value of Rs. 400000/- has a salvage value of Rs.50000/- at the end of 25 years, but sold for 260000/- at end of 10years. What is the profit or loss to the owner, if sinking fund method of depreciation is adopted? Take interest rate @ 8%.
2. A machine was purchased for Rs 30000/-. The cost of erection charges was Rs 10000/- , the estimated life of the machine was 20 years. The scrap value at the end of useful life was Rs 8000/-. Determine the rate of depreciation per year by straight line method. After 10 years the machine underwent a major repairs and the repair cost was Rs 6000/- .What will be the new rate of depreciation per year. Maruthi- Suzuki motors purchased an apparatus for Rs 60000/- on 1st Jan 1985.
3. A new milling machine has been purchased. Find the machine hour rate using the following data.
1. The cost of the machine is rupees 1810500/-
2. The estimated life of the machine is 10 years.
3. The weight of the m/c is 1.4 ton and the scrap value is Rs 15 / kg
4. The anticipated obsolescence is 30 % of the capital cost.
5. The interest on capital cost is 12 % per annum
6. The machine has two motors of 2HP and 1HP.
7. The energy cost is Rs 5 / unit.
8. The machine occupies an area of 10 x 10 sqft area.
9. The rent of the space is Rs 22 / sqft
10. The salary of the operator is Rs 15000/pm.
11. The maintenance cost is 4 %.
12. The overhead cost is 10 % of the labour cost.
4. A 20 X 7.5 cm CI surface is to be faced on milling machine with a cutter having a diameter of 125 cm and 20 teeth. If the cutting speed and feed are 50m/min and 4.5 cm/min respectively, determine the milling time, rpm of the cutter and feed per tooth.
5. What is CPM? Explain the rules for developing CPM network.
6. A new milling machine has been purchased. Find the Machine hour rate using the following data.
1. The cost of the machine is rupees 1810500/-
2. The estimated life of the machine is 10 years.
3. The weight of the m/c is 1.4 ton and the scrap value is Rs 15 / kg
4. The anticipated obsolescence is 30 % of the capital cost.
5. The interest on capital cost is 12 % per annum
6. The machine has two motors of 2HP and 1HP.
7. The energy cost is Rs 5 / unit.
8. The machine occupies an area of 10 x 10 sqft area.
9. The rent of the space is Rs 22 / sqft
10. The salary of the operator is Rs 15000/pm.
11. The maintenance cost is 4 %.
12. The overhead cost is 10 % of the labour cost.
7. A machine is purchased for Rs 60000/-. The estimated life of machine is 15 years and the scrap value is Rs 15000/-. Calculate the depreciations per year by using interest law (Sinking fund) method, if the rate of interest is charged at 5%. find the depreciation at the end of 5 years.
8. Estimate the cost of the pressure pad shown below. The material is OHNS and heat treated to 56-58 HRC. Profile is cut on wire EDM . consider hole diameter = 12mm and fillet radius= R6.

Follow the figure from pdf.

9. Estimate the cost of the Trimming Tool given below

Follow the figure from pdf.

For detail syllabus of all other subjects of BE Tool And Die, C15 scheme do visit Tool And Die 6th Sem syllabus for C15 scheme.

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