Calculation Documentation
A detailed breakdown of the formulas and logic used across the application.
1. Component Gross Weight
Weight is calculated in two steps: Net Weight and Gross Weight. The material cost is based on the Gross Weight.
Net Weight Formula
Net Weight (kg) = Volume (cm³) * Density (g/cm³) / 1000Gross Weight Formula
Gross Weight (kg) = Net Weight * 1.2| Variable | Source | Description |
|---|---|---|
| Volume | Calculated | Calculated based on the selected Shape and its Dimensions , then converted from mm³ to cm³ by dividing by 1000. |
| Density | Hardcoded | A pre-defined value in g/cm³ for each Material . The values are: SS (8.00), MS (7.85), AL (2.70). |
| 1.2 Multiplier | Hardcoded | A standard 20% factor (`1.2`) is added to the Net Weight to account for raw material waste and scrap, resulting in the Gross Weight. |
2. Raw Material Cost
The total cost of the raw material for the specified quantity, based on Gross Weight.
Material Cost Formula
Total Material Cost = Gross Weight * Material Rate * Quantity| Variable | Source | Description |
|---|---|---|
| Gross Weight | Calculated | The calculated Gross Weight (see above). |
| Material Rate | From Config | The cost per kg for the selected Material and Shape . The application first looks for a rate specific to the shape (e.g., 'Plate'). If not found, it uses the material's default rate. All rates are defined in Settings. |
| Quantity | User Input | The number of components to be produced. |
3. Machining Cost (Turning, Milling, Secondary)
Costs are derived from the time for each operation multiplied by an hourly rate specific to the operation type (Turning, Milling, etc.).
Total Machining Cost Formula
Total Cost = (Total Time (minutes) / 60) * Machining Rate (₹/hr) * Quantity4. Laser Cutting Cost
Cost is based on the profile's perimeter, material thickness, and the number of times the laser must start.
Laser Cost Formula
Cost Per Profile = (Perimeter * 0.04 * Thickness) + (No. of Starts * 1 * Thickness)| Variable | Source | Description |
|---|---|---|
| Perimeter | Calculated | Calculated perimeter of the cutting profile shape from its Dimensions . See formulas below. |
| Thickness | User Input | Overall thickness of the component from the main 'Dimensions' card. |
| No. of Starts | From Config | Number of times the laser pierces the material. Defined in Settings. |
| 0.04 and 1 | Hardcoded | Cost multipliers for cutting distance (`0.04`) and laser starts (`1`), respectively. |
5. Bending Cost
Cost is calculated based on the number of bends, material thickness, and the type of bending operation.
Simple Bend Formula (per bend)
Cost = Bending Rate (for given thickness)Dimensional Bend Formula (per bend)
Cost = Bending Rate * (1 + (Length / 1000))| Variable | Source | Description |
|---|---|---|
| No. of Bends | User Input | The total count of bends for the operation. |
| Bending Rate | From Config | A tiered cost per bend, based on material thickness. Defined in Settings. |
| Length | User Input | The length of the bend (only for Dimensional Bends). The formula adds a 0.1% cost premium per mm of length. |
6. Finishing & Other Costs
These are one-time costs applied per component or per batch, based on the operation type.
| Operation Type | Cost Calculation Formula |
|---|---|
| Fabrication / Polishing / Surface Treatment (Kg) | Rate * Gross Weight |
| Hardware / Others B.O | Rate * Quantity |
| Surface Treatment (Area) | (Component Length * Component Width / 1,000,000) * 2 * Rate |
| Miscellaneus | Direct Cost input. No formula. |