It has become widely accepted that major improvements in productivity and manufacturing costs can be achieved by providing early manufacturing input during the design cycle. Existing component manufacturing cost estimating techniques require detailed part information and the existence of a developed process plan. The objective of the work described in this dissertation was to provide an early manufacturing cost estimating methodology that can be used by the designer before process plans and detailed part drawings are developed.;To accomplish the objective, early cost estimating techniques are needed that require only basic part geometry and production data. A detailed investigation on manufacturing costs for sheet metal working using dedicated steel dies has been carried out. The dissertation also develops manufacturing cost estimating techniques for: sand casting, close tolerance sand casting, permanent mold casting, investment casting, die casting, machining and injection molding. Procedures were developed using the concept of a manufacturing point system.;The algorithms for all these processes have been incorporated into a computer program. The program allows final manufacturing costs for numerous material/process combinations to be calculated and compared. The program provides a quick and convenient method of providing designers with valuable cost data well in advance of that previously available.
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