KEVOS® MAKEOS · Manufacturing
Milling Time and Cost per Part with Tool Life
How long does this milling operation take and what does it cost per part, including tool wear and set-up?
Cost of a milling operation per part: cutting time from the volume to remove and the removal rate (from width, depth and table feed), tool edges used from the tool life at those conditions, tool change time and edge cost, non-cutting time, set-up spread over the batch, and the machine rate, with the cost breakdown.
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How this tool works
Inputs, units and where to find them
| Input | Unit | Typical source |
|---|---|---|
| Volume to remove | cm³ | Volume of metal removed per part. |
| Radial width of cut | mm | Radial width of cut. |
| Axial depth of cut | mm | Axial depth of cut. |
| Table feed | mm/min | Table feed (from a milling cut plan). |
| Tool life at these conditions | min | Tool life in cutting minutes at these speeds and feeds (from tests or the tool maker). |
| Inserts (edges) per change | Number of inserts replaced at each tool change. | |
| Cost per edge | $ | Cost of one cutting edge. |
| Time to change all edges | min | Time to index or change all the edges. |
| Non-cutting time per part | min | Rapids, approach, probing and tool changes per part. |
| Machine and labour rate | $/h | Machine plus operator rate. |
| Set-up time per batch | min | Set-up time for the batch. |
| Batch quantity | Parts per batch. |
Method and formulas
- Removal rate Q = a_e a_p v_f; cutting time = volume ÷ Q.
- Tool changes per part = cutting time ÷ tool life.
- Cost = rate × (cutting + non-cutting + changes × change time + set-up ÷ batch) + changes × edges × edge cost.
- Example: removing 120 cm³ takes 2.6178 min of cutting; the part costs about 10.767.
Limitations
- Single operation at constant conditions; finishing passes need their own line.
- Tool life must match the speeds and feeds used.
- Example values are illustrations. Replace them with values for your actual task.
Typical uses
- Quote a milled part
- Compare a faster cut that wears tools quicker
- See what share of cost is tooling, cutting and set-up
Who it is for
- Estimators
- Manufacturing engineers
- Production managers
What you get
- Removal rate and cutting time
- Tool changes per part
- Cost per part breakdown
Interpreting the result
- When set-up dominates, bigger batches pay; when tooling dominates, slower speeds may be cheaper.
References
- Machinery’s Handbook, 29th edition (Industrial Press, 2012), printed pp. 1084–1101, 1146–1152. Topic reference; no source tables or recommended settings are reproduced.
WORKOS tools are screening and decision-support utilities. Verify important financial, engineering, safety, legal or operational decisions using appropriate professional standards and your organisation’s approved data.
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