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ANINTEGRATEDFRAMEWORKFORDIEANDMOLDCOSTESTIMATIONUSINGDESIGNFEATURESANDTOOLINGPARAMETERSRECEIVED5AUGUST2003/ACCEPTED6JANUARY2004/PUBLISHEDONLINE2FEBRUARY2005SPRINGERVELALONDONLIMITED2005ABSTRACTTOOLINGISANESSENTIALELEMENTOFNEARNETSHAPEMANUFACTURINGPROCESSESSUCHASINJECTIONMOLDINGANDDIECASTING,WHEREITMAYACCOUNTFOROVER25OFTHETOTALPRODUCTCOSTANDDEVELOPMENTTIME,ESPECIALLYWHENORDERQUANTITYISSMALLDEVELOPMENTOFRAPIDANDLOWCOSTTOOLING,COMBINEDWITHASCIENTISTAPPROACHTOMOLDCOSTESTIMATIONANDCONTROL,HASTHEREFOREBECOMEESSENTIALTHISPAPERPRESENTSANINTEGRATEDMETHODOLOGYFORDIEANDMOLDCOSTESTIMATION,BASEDONTHECONCEPTOFCOSTDRIVERSANDCOSTMOODIERCOSTDRIVERSINCLUDETHEGEOMETRICFEATURESOFCAVITYANDCORE,HANDLEDBYANALYTICALCOSTESTIMATIONAPPROACHTOESTIMATETHEBASICMOLDCOSTCOSTMOODIERINCLUDETOOLINGPARAMETERSSUCHASPARTINGLINE,PRESENCEOFSIDECORES,SURFACETEXTURE,EJECTORMECHANISMANDDIEMATERIAL,CONTRIBUTINGTOTHETOTALMOLDCOSTTHEMETHODOLOGYHASBEENIMPLEMENTEDANDTESTEDUSING13INDUSTRIALEXAMPLESTHEAVERAGEDEVIATIONWAS040THEMODELISEDIBLEANDCANBEEASILYIMPLEMENTEDFORESTIMATINGTHECOSTOFAVARIETYOFMOLDSANDDIESBYCUSTOMIZINGTHECOSTMOODIERUSINGQUALITYFUNCTIONDEPLOYMENTAPPROACH,WHICHISALSODESCRIBEDINTHISPAPERKEYWORDSCOSTESTIMATIONDIECASTINGINJECTIONMOLDINGQUALITYFUNCTIONDEPLOYMENT。1INTRODUCTIONPRODUCTLIFECYCLESTODAYARETYPICALLYLESSTHANHALFOFTHOSEINTHE1980S,OWINGTOTHEFREQUENTENTRYOFNEWPRODUCTSWITHMOREFEATURESINTOTHEMARKETMANUFACTURINGCOMPETITIVENESSISMEASUREDINTERMSOFSHORTERLEADTIMETOMARKET,WITHOUTSCRIBINGQUALITYANDCOSTONEWAYTOREDUCETHELEADTIMEISBYEMPLOYINGNEARNETSHAPENNSMANUFACTURINGPROCESSES,SUCHASINJECTIONMOLDINGANDDIECASTING,WHICHINVOLVEFEWERSTEPSTOOBTAINTHEDESIREDSHAPEHOWEVER,THETOOLINGDIEORMOLD,WHICHISANESSENTIALELEMENTOFNNSMANUFACTURING,CONSUMESCONSIDERABLERESOURCESINTERMSOFCOST,TIMEANDEXPERTISEATYPICALDIECASTINGDIEORPLASTICINJECTIONMOLDISMADEINTWOHALVESMOVINGANDAXEDWHICHBUTTTOGETHERDURINGMOLDLINGANDMOVEAPARTDURINGPARTEJECTIONTHECONSTRUCTIONOFATYPICALCOLDCHAMBERPRESSUREDIECASTINGDIEISSHOWNINFIG1THEMAINFUNCTIONALELEMENTSOFTHEDIEANDMOLDINCLUDETHECOREANDCAVITY,WHICHIMPARTTHEDESIREDGEOMETRYTOTHEINCOMINGMELTTHESEMAYBEMANUFACTUREDASSINGLEBLOCKSORBUILTUPWITHANUMBEROFINSERTSTHESECONDARYELEMENTSINCLUDETHEFEEDINGSYSTEM,EJECTIONSYSTEM,SIDECOREACTUATORSANDFASTENERSTHEFEEDINGSYSTEMCOMPRISINGOFSPREEBUSH,RUNNER,GATEANDOVERAWEENABLESTHETOWNOFMELTFROMMACHINENOZZLETOMOLDCAVITYTHEEJECTORMECHANISMISUSEDFOREJECTINGTHEMOLDEDPARTFROMTHECOREORCAVITYALLTHEABOVEELEMENTSAREHOUSEDINAMOLDBASESET,COMPRISINGOFSUPPORTBLOCKS,GUIDESANDOTHERELEMENTSPARTSPECIEELEMENTS,INCLUDINGCOREANDCAVITYANDFEEDINGSYSTEMAREMANUFACTUREDINATOOLROOMOTHERELEMENTSAREAVAILABLEASSTANDARDACCESSORIESFROMVENDORSMOLDASSEMBLYANDFUNCTIONALTRIALSARECONDUCTEDBYEXPERIENCEDTOOLMAKERSINCONSULTATIONWITHTOOLDESIGNERSFIG1CONSTRUCTIONOFATYPICALPRESSUREDIECASTINGDIETHETOOLINGINDUSTRYISPRESENTLYDOMINATEDBYJAPAN,GERMANY,USA,CANADA,KOREA,TAIWAN,CHINA,MALAYSIA,SINGAPOREANDINDIATHEMAJORUSERSOFTOOLINGINCLUDEAUTOMOBILES,ELECTRONICS,CONSUMERGOODSANDELECTRICALEQUIPMENTSECTORSPLASTICMOLDSACCOUNTFORTHEMAJORSHAREOFTOOLINGINDUSTRYABOUT60OFTOOLROOMSBELONGTOSMALLANDMEDIUMSCALEINDUSTRIESWORLDWIDE1THETOOLINGREQUIREMENTISOVERUS600MILLIONPERYEARININDIAALONE,WITHANANNUALGROWTHRATEOFOVER10DURINGTHELASTDECADEININDIA,THESHAREOFDIFFERENTTYPESOFMOLDSANDDIESISPLASTICMOLDS33,SHEETMETALPUNCHESANDDIES31,DIECASTINGDIES13,JIGSMOLDCOSTWASESTIMATEDUSINGLINEARREGRESSIONANALYSISTOSUMMARIZE,COSTSIMILARITYANDCOSTFUNCTIONSCOSTFACTORSARETHETWOSETSOFMETHODSFORESTIMATINGTHEMOLDCOSTINTHERESTSET,SIMILARITYBETWEENANEWMOLDANDAPREVIOUSMOLDDEVELOPEDINTHETOOLROOMSISUSEDASAREFERENCEINTUITIVEANDANALOGICALMETHODSFALLUNDERTHISCATEGORYINTHEWIDELYUSEDINTUITIVEMETHOD,THECOSTAPPRAISERMAYNOTBEINAPOSITIONTOIDENTIFYALLTHERISKFACTORSANDTOQUANTIFYMANYOFTHEMTHEANALOGICALMETHODCANBESUCCESSFULLYUSEDFORESTIMATINGTHECOSTOFDIEBASESANDOTHERSECONDARYELEMENTSWHEREGROUPINGISMUCHEASIERHOWEVER,INTHECASEOFFUNCTIONALELEMENTSCOREANDCAVITY,GROUPINGBECOMESADIFFICULTTASKASTHEIRGEOMETRY,MACHININGSEQUENCEANDTOLERANCEGREATLYVARYWITHPRODUCTDESIGNINTHESECONDSETOFMETHODS,THEDEPENDENCYBETWEENTHEMOLDCOSTANDITSDRIVERSAREEXPRESSEDINMATHEMATICALFUNCTIONSANALYTICALMETHOD,ACTIVITYBASEDCOSTING,FEATUREBASEDMETHODANDPARAMETRICCOSTINGMETHODSFALLSUNDERTHISCATEGORYWHILEANALYTICALMETHODSAREWELLESTABLISHEDFORESTIMATINGTHEMACHININGCOSTOFSIMPLEPARTS,THEYAREDIFFICULTTOAPPLYINDIEANDMOLDMANUFACTURINGBECAUSEOFTHEIRGEOMETRICCOMPLEXITYSIMILARLY,FEATUREBASEDCOSTESTIMATIONISDIFFICULTTOAPPLYBECAUSETHECURRENTFEATURERECOGNITIONANDCLASSIFICATIONALGORITHMSCANNOTHANDLEFREEFORMSURFACESPRESENTINMOSTOFTHEDIESANDMOLDS,ANDOTHERCOMPUTATIONALTECHNIQUESLIKEKNOWLEDGEBASEDSYSTEMS,FUZZYLOGICANDARTERIALNEURALNETWORKSMAYBEREQUIREDTOESTABLISHTHECOSTRELATIONSFURTHER,THESETECHNIQUESMAYNOTBEABLETOCONSIDERTHEIMPACTOFASSEMBLYRESTRICTIONS,SURFACEKNISHREQUIREMENTS,MOLDTRIALSANDOTHERFACTORSTHEPARAMETRICCOSTINGMETHODFUNCTIONSLIKEABLACKBOX,BYCORRELATINGTHETOTALCOSTOFMOLDWITHALIMITEDNUMBEROFDESIGNPARAMETERS,ANDITISDIFFICULTTOJUSTIFYOREXPLAINTHERESULTSMENGESANDMOHREN10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