Milling cost: why is it at the heart of production control?

Precision Machining Inc

In the field of machining, the cost of milling directly determines product profitability and market competitiveness - whether it is mass-produced auto parts or customized precision molds, every cost optimization can bring significant efficiency improvements. However, the milling cost is not a single value, but a complex system composed of multiple elements such as machine tools, tools, […]

In the field of machining, the cost of milling directly determines product profitability and market competitiveness - whether it is mass-produced auto parts or customized precision molds, every cost optimization can bring significant efficiency improvements. However, the milling cost is not a single value, but a complex system composed of multiple elements such as machine tools, tools, labor, materials, etc., coupled with the differences in equipment selection, industry characteristics, and management methods, which makes many production managers fall into the dilemma of "unclear and unreduced". This article will help you thoroughly understand the control logic of milling costs in plain language and practical cases, from cost composition, optimization strategies, equipment selection, industry applications to management methods.

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1. Cost composition and factor analysis: dismantling the "cost items" of milling

To control costs, you must first clarify where the money is spent. The core components of milling costs can be divided into six main categories, each with clear influencing factors and room for optimization:

1. Machine Tool Depreciation Costs: Invisible but critical fixed expenses

Machine tool depreciation costs are fixed costs that are allocated to each batch of products after equipment acquisition, typically accounting for 15%-25% of the total milling cost (data source: China Society of Mechanical Engineering Machining Branch 2024 Industry Report). The calculation logic is: (equipment purchase price - residual value)÷ Expected service life ÷ years of processing man-hours. For example, a CNC milling machine of 1 million yuan is expected to be used for 10 years, 5,000 hours of processing per year, and the residual value is 50,000 yuan, then the hourly depreciation cost is (100-5)÷10÷5000=19 yuan/hour.

The key to this part of the cost is equipment utilization – if the equipment is idle by more than 30%, the depreciation cost will directly double. An auto parts factory improved equipment utilization from 65% to 85% by optimizing production schedules, reducing the unit depreciation cost per unit of equipment by 23%.

2. Tool wear costs: the "invisible killer" of high-frequency consumption

Tool wear costs are the most overlooked variable costs in milling operations, accounting for 10%-30%. The life and cost of different tools vary greatly: for example, the unit price of ordinary high-speed steel tools is 50 yuan, and the life is about 200 minutes; while the unit price of cemented carbide coated tools is 200 yuan, and the service life can reach 1000 minutes, which seems to be a higher unit price, but the unit processing cost has dropped from 0.25 yuan/minute to 0.2 yuan/minute.

Material hardness is a central factor in tool wear: when machining titanium alloys, tools wear 5-8 times faster than machining aluminum alloys (data source: Metalworking 2023 measurement report). An aerospace parts factory once used a tool change frequency of up to 2 times per hour due to direct machining of titanium alloy with ordinary tools, but later switched to PCD diamond tools and optimized cutting parameters, extending tool life to 8 hours and reducing the cost per tool by 60%.

3. Raw material cost: the "fluctuating item" of the basic input

Raw material costs are the core component of milling costs, typically accounting for 40%-60%, and their fluctuations directly affect the total cost. The price varies significantly between materials, and here are the market reference prices for common processed materials in 2024:

Material typeUnit Price (RMB/kg)Milling loss rateCost of Material Per Unit (RMB/kg)
Plain carbon steel8-125%-8%8.4-12.96
6061 Aluminum Alloy20-253%-5%20.6-26.25
TC4 titanium300-35010%-15%330-402.5

A precision parts factory has reduced the processing loss rate of aluminum alloy from 5% to 3% by optimizing the blanking scheme, saving more than 80,000 yuan per month in raw materials alone.

4. Labor Costs: The "Value Transformation" of Technology and Efficiency

Manual operation costs include operator salaries, skill training, management expenses, etc., accounting for about 10%-20%. The core influencing factor is operational efficiency – a skilled CNC operator can control 2-3 devices at the same time, while a novice may only be able to operate one, more than doubling the cost per unit.

A mold factory has raised the average skill level of operators from primary to intermediate through "mentorship + regular skill assessment", increased the number of control equipment per capita from 1.2 to 2.5, and reduced the labor cost of a single product by 45%. In addition, automated auxiliary equipment (such as automatic loading and unloading devices) can further reduce manual dependence, and the proportion of labor costs has been reduced from 18% to 8% after a mass production company introduces robots.

5. Energy Consumption Costs: The "Energy Bill" Behind Operations

The energy consumption cost mainly includes the power consumption of machine tool motors, cooling systems, and hydraulic systems, accounting for about 5%-10%. The power of CNC milling machines is usually 5-20kW, and the hourly electricity cost of a 10kW milling machine is about 12 yuan based on the industrial electricity price of 1.2 yuan/kWh.

The key to optimizing energy consumption is to reduce ineffective operations: a machine shop optimized CNC programming to reduce the idle travel time of machining parts from 25% to 15%, saving about 30 yuan per day on electricity bills and more than 10,000 yuan per year. In addition, choosing energy-efficient equipment can also significantly reduce costs – the new energy-efficient CNC milling machine consumes 20% to 30% less energy than conventional equipment.

6. Fixture and Auxiliary Tool Costs: An Indispensable "Supporting Role Expenditure"

Although the cost of fixtures and auxiliary tools is low (about 3%-5%), it affects processing efficiency and product quality. The unit price of general fixtures is low (500-2000 yuan), but the changeover time is long; the unit price of special fixtures is high (5000-50000 yuan), but it can shorten the changeover time by more than 80%.

A small batch customization company once used a general fixture, accounting for 30% of the changeover time, and later developed a special fixture for the core product, and the changeover time was compressed from 1 hour to 10 minutes.

2. Cost optimization and efficiency improvement strategy: from "saving a little money" to "improving efficiency"

After understanding the cost composition, the core logic of optimization is "reduce unit cost + improve processing efficiency", and here are 6 highly practical strategies:

1. High-Speed Milling: The Art of Balancing Speed and Cost

The core advantage of high-speed milling is "speed for efficiency" – cutting speeds are 2-5 times higher than traditional milling, which can significantly reduce machining time while reducing tool wear. However, high-speed milling requires more equipment and tools, increasing upfront investment by 10%-20%, which needs to be offset by efficiency gains.

After an auto parts factory changed traditional milling to high-speed milling, the machining time of a single part was reduced from 8 minutes to 3 minutes, and the production capacity increased by 167%, although the investment in equipment and tools increased by 150,000 yuan, but due to a 30% decrease in unit cost, the additional investment was recovered in 3 months.

2. CNC Programming Optimization: The "Cost Code" in the Code

CNC programming optimization is the key to zero cost reduction, and the core optimization directions include: reducing empty stroke, optimizing cutting paths, and avoiding repeated processing. A precision mold factory reduced the empty travel time of mold processing from 22% to 10%, the machining time of a single set of molds by 18%, and the unit cost by 15% through programming optimization.

Practical skills: Use the "Path Optimization" function of CAM software to automatically delete invalid paths; for complex parts, use "layered milling + spiral down" to reduce tool impact; for mass production, use "group programming" to uniformly optimize the processing path of similar parts.

3. Cutting parameter optimization: "money-saving techniques" for precise regulation

Cutting parameters (cutting speed, feed, cutting depth) directly affect machining efficiency and tool life. For example, when machining 45 gauge steel, the traditional cutting speed is 100m/min, the feed rate is 0.2mm/r, and the tool life is about 300 minutes. If the cutting speed is increased to 150m/min and the feed is adjusted to 0.15mm/r, the tool life is reduced to 250 minutes, but the machining efficiency is increased by 50%, and the unit cost is reduced by 20%.

Suggestion: Establish a "cutting parameter database" according to material characteristics, such as "high speed, large feed, shallow cutting depth" when machining aluminum alloys; "medium speed, medium feed, deep cutting depth" when machining alloy steel, and avoid setting parameters empirically.

4. Tool Life Management: Extending the "Value Maximization" of the Edge

At the heart of tool life management is "avoiding premature replacement" and "preventing tool failure", which includes establishing a tool life ledger, setting tool wear warnings, and regularly sharpening tools. A machine shop increased the average tool life from 400 minutes to 550 minutes and reduced tool consumption costs by 27% through tool life management.

Note: Longer tool life is not better, when tool wear reaches a critical value (usually 10% sharpness loss), it needs to be replaced in time, otherwise it will lead to a decrease in machining accuracy and increase rework costs.

5. Coolant and lubrication costs: small investment big impact

Although the proportion of coolant and lubrication costs is low (about 2%-3%), it has a significant impact on tool life and machining quality. Using high-quality coolant can extend tool life by 30%-50% and reduce rework rate. After a titanium alloy machining company changed ordinary coolant to special cutting fluid, tool life was extended by 40%, the rework rate was reduced from 5% to 1%, and the comprehensive cost was reduced by 8%.

Cost reduction tips: Adopt "minimum amount lubrication" (MQL) technology, reduce coolant consumption by 90% compared to traditional lubrication, while avoiding waste liquid treatment costs; regularly check the coolant concentration and replenish additives in time to extend the service life of the coolant.

6. Mass Production: The "Cost Advantage" of Scale Effects

Mass production can reduce unit costs by "sharing fixed costs" - the larger the batch, the lower the share of fixed costs such as machine tool depreciation, labor, and fixtures. When a hardware factory produces a part, the unit cost of a small batch (100 pieces/batch) is 80 yuan; after the batch is expanded to 1000 pieces/batch, the unit cost drops to 55 yuan, a decrease of 31%.

Suggestion: For standardized parts, try to use "large batches, small batches" production; For customized parts, "modular design + batch prefabrication" is used to minimize the proportion of customized parts and maximize the use of scale effects.

3. Cost considerations for equipment and technology selection: choose the right "tool" to save half the money

The choice of equipment and technology directly determines the "base disc" of milling costs, and the cost difference between different choices can be as high as 30%-50%, here are the key decision points:

1. CNC Milling Machine Price: Upfront Investment vs. Long-Term Return

CNC milling machine prices range from 100,000 yuan to 5 million yuan, and the choice needs to balance "upfront investment" and "long-term return". For example, for processing simple parts, choose an economical CNC milling machine of 200,000 yuan, which has a low unit depreciation cost; For processing complex precision parts, it is necessary to choose a high-precision milling machine of more than 1 million yuan, although the upfront investment is high, but it can reduce rework costs and improve the product qualification rate.

A precision parts factory once purchased an economical milling machine because it was greedy for cheapness, with a product qualification rate of only 85% and rework costs accounting for 12%; Later, it was replaced with a high-precision milling machine, the pass rate increased to 99%, the rework cost was reduced to 1%, and although the equipment investment increased by 800,000 yuan, the annual net profit increased by 1.5 million yuan.

2. End milling and horizontal milling: cost comparison under process differences

The cost difference between end milling and horizontal milling mainly comes from process adaptability: end milling is suitable for flat and groove processing, with low equipment price (20%-30% lower than horizontal milling) and high processing efficiency; Horizontal milling is suitable for complex curved surfaces and multi-sided processing, and the equipment price is high, but it can reduce the number of clamping times and reduce labor costs.

Selection suggestion: If simple parts (such as bolts, gaskets) are processed, end milling is preferred, and the unit cost is lower; If processing complex parts (such as boxes and brackets), horizontal milling is preferred, although the equipment investment is high, but it can improve the processing efficiency and reduce the comprehensive cost. A mechanical processing factory used end milling to process box parts, which needed to be clamped 4 times and the processing time was 8 hours; By switching to horizontal milling, the machining can be completed in a single clamping, reducing the time to 3 hours and reducing the unit cost by 40%.

3. Used Equipment: The Trade-Off of Risks and Opportunities

The price of used equipment is usually 30%-50% of new equipment, suitable for small and medium-sized businesses with limited budgets, but be wary of "hidden costs" – used equipment has a high failure rate (2-3 times that of new equipment), and repair costs and downtime losses can far outweigh the price advantage.

A hardware factory once bought a second-hand CNC milling machine for 200,000 yuan (the price of new equipment is 500,000 yuan), but it was repaired 3 times within half a year, the maintenance cost reached 80,000 yuan, the downtime loss was 150,000 yuan, and the comprehensive cost was 10% higher than that of the new equipment. Recommendation: When purchasing second-hand equipment, give preference to equipment with a service life of no more than 3 years and a complete maintenance record, while reserving 10%-15% of the maintenance budget.

4. Automated Milling: The new trend of cost-effectiveness in the future

Automated milling (such as robotic loading and unloading, unmanned workshops) can significantly reduce labor costs and improve equipment utilization (from 60%-70% to 85%-95%), but the upfront investment is high (50%-100% higher than traditional equipment), making it suitable for mass production enterprises.

After the introduction of an automated milling production line by an auto parts giant, the proportion of labor costs dropped from 18% to 5%, and the equipment utilization rate increased from 65% to 90%, although the investment increased by 20 million yuan, but due to the increase in production capacity by 50%, the unit cost decreased by 35%, and the investment was recovered in 2 years. For small and medium-sized enterprises, "semi-automation" (such as automatic loading and unloading devices) can be used first, with an investment of only 5-100,000 yuan, which can reduce labor costs by 30%-40%.

4. Milling cost cases in industry applications: optimization logic for different scenarios

Milling needs vary widely across industries, with different cost compositions and optimization priorities, and here are 6 typical industry examples:

1. Mold milling: a dual challenge of precision and cost

The core requirement of die milling is "high precision + complex surfaces", and tool wear and manual operation account for a higher proportion of mold milling costs (40%-50% in total). When a mold factory processes injection molds, due to complex curved surfaces and serious tool wear, the tool cost of a single set of molds reaches 8,000 yuan; Later, with the use of "five-axis milling + special mold tools", the tool life was extended by 60%, the tool cost of a single set of molds was reduced to 3200 yuan, and the machining time was shortened by 30%.

Optimization focus: Priority is given to the use of five-axis machining centers to reduce the number of clamping; Use special coating tools for molds to improve wear resistance; Optimize surface machining paths with CAD/CAM software to reduce repetitive cuts.

2. Aerospace Parts Milling: The Cost Code for High-End Manufacturing

Aerospace parts are mostly made of titanium alloys, superalloys and other difficult-to-machine materials, and raw materials and tool wear account for 70%-80% of the milling cost of aerospace parts. When processing engine blades in an aviation parts factory, the cost of titanium alloy raw materials accounts for 60% and the cost of tools accounts for 20%; Later, through "near-net forming + precision milling", the raw material loss rate was reduced from 15% to 8%, and ceramic tools were used to replace carbide tools, which increased tool life by 2 times and reduced the cost per piece by 35%.

Optimization focus: Adopt near-net forming technology to reduce milling allowance; Use special tools for difficult-to-machine materials (such as ceramic, CBN tools); Optimize cutting parameters to reduce cutting force and tool wear.

3. Auto parts milling: Cost control for large-scale production

The core of auto parts milling is "large batch + standardization", and the depreciation of raw materials and equipment accounts for a higher proportion of auto parts milling costs (60%-70% in total). Through "large-scale production + automation line", an automobile hub factory compressed the processing time of a single wheel from 15 minutes to 5 minutes, reduced the raw material loss rate from 8% to 3%, and reduced the unit cost by 40%, resulting in annual cost savings of more than 20 million yuan.

Optimization focus: establish an automated production line to improve equipment utilization; Modular design is adopted, and the processing process is standardized; Sign long-term contracts with raw material suppliers to lock in raw material prices.

4. Precision Part Milling: A delicate balance between precision and cost

The requirements for precision parts milling are "high precision + small batch", and labor and equipment depreciation account for a higher proportion of precision parts milling costs (40%-50% in total). When processing precision gears in an electronic parts factory, due to high precision requirements, manual repeated debugging is required, and the processing time of a single piece is up to 20 minutes; Later, high-precision CNC milling machines and online testing equipment were introduced, and the machining accuracy was automatically controlled, and the processing time of a single piece was shortened to 8 minutes, and the labor cost was reduced by 60%.

Optimization focus: select high-precision equipment and online detection system to reduce manual intervention; adopt the "small batch, quick change" production mode to improve production flexibility; Optimize programming to ensure that the machining accuracy meets the standard at one time.

5. Low-Volume Custom Milling: A Game of Flexibility and Cost

The core pain point of low-batch custom milling is "frequent changeovers + small batches", and labor and fixture costs account for a higher proportion of low-batch custom milling costs (30%-40% in total). A custom machining plant used "modular fixture + grouping technology" to reduce changeover time from 1 hour to 15 minutes, while centralizing the production of similar parts, although the single batch was small, the unit cost was reduced by 25% through "multi-batch consolidation".

Optimization focus: modular fixture and quick change system; using group technology to centralize the processing of similar parts; Through digital management, production schedules are optimized and equipment idle is reduced.

6. Comparison of Milling Costs for Different Materials: Cost mapping of material properties

The difficulty and cost of milling vary significantly between materials, and the following are the measured data from a processing plant (machining the same structural part, batch of 1000 pieces, part weight 1 kg):

Material typeRaw material cost (yuan / piece)Tool Cost (RMB / Piece)Processing Time (Minutes / Pieces)Labor + Depreciation + Energy (RMB / Piece)Total Cost (RMB/Piece)Difference in cost proportion
Plain carbon steel12.963.558.224.66Benchmark (100%)
6061 Aluminum Alloy26.252.834.933.95137% of the benchmark
TC4 titanium402.528.61829.8460.91870% of the benchmark

From the data, it can be seen that the milling cost of titanium alloy is 18.7 times that of ordinary carbon steel, and the core reasons are high material prices, fast tool wear, and low processing efficiency. Therefore, when machining difficult-to-machine materials, it is necessary to focus on reducing unit costs through technical optimization (such as tool upgrades and parameter adjustments).

5. Cost calculation and management methods: make every penny controllable

Accurate calculation and scientific management are at the core of milling cost control, and here are 6 practical methods:

1. Milling Machining Quote Calculation: A transparent presentation of costs

The core logic of milling quotation calculation is "total cost + reasonable profit", and the formula is: quotation = (raw material cost + tool cost + labor cost + depreciation cost + energy cost + auxiliary cost) × (1 + profit margin).

Example of a quotation from a machine shop (machining 100 carbon steel parts):

  • Raw material cost: 12.96 yuan / piece ×100=1296 yuan
  • Tool cost: 3.5 yuan / piece ×100=350 yuan
  • Labor cost: 80 yuan / hour ×8 hours = 640 yuan (8 hours total processing time for 100 pieces)
  • Depreciation cost: 19 yuan / hour ×8 hours = 152 yuan
  • Energy cost: 12 yuan / hour ×8 hours = 96 yuan
  • Auxiliary cost (fixture + coolant): 200 yuan
  • Total cost: 1296 + 350 + 640 + 152 + 96 + 200 = 2734 yuan
  • Quotation (profit margin 20%): 2734×1.2=3280.8 yuan

Recommendation: 5%-10% of the cost fluctuation space should be reserved when quoting to deal with raw material price fluctuations or processing abnormalities.

2. Cost estimation software: digitalization helps cost control

Commonly used cost estimation software can quickly and accurately calculate costs and avoid manual calculation errors, the following is a comparison of 3 mainstream software:

Software nameCore features:Applicable scenariosPrice (RMB/year)
Mastercam Cost EstimatorIntegrated programming functions to automatically calculate machining time and costsmolds, complex parts processing15000-25000
SolidWorks CostingLink with 3D models to quickly generate cost reportsCost estimation at the product design stage8000-12000
Domestic production is easy to costAdapt to small and medium-sized enterprises and support custom cost templatesStandard parts, mass production3000-5000

A precision parts factory used Mastercam Cost Estimator to reduce cost error from 15% to 3%, improve quote accuracy, and increase customer satisfaction by 20%.

3. Hourly processing rate: A cost measure in the time dimension

The hourly machining rate is the core indicator to measure the profitability of the equipment, and the calculation logic is: hourly machining rate = (labor cost + depreciation cost + energy cost + tool cost + auxiliary cost) ÷ effective machining time.

Example of calculating the hourly machining rate of a CNC milling machine:

  • Labor cost: 50 yuan / hour (per capita control of 2 equipment, monthly salary 9000 yuan)
  • Depreciation cost: 19 yuan / hour (the previous case data)
  • Energy cost: 12 yuan/hour
  • Tool cost: 25 yuan / hour (calculated based on average daily consumption)
  • Auxiliary cost: 8 yuan / hour (fixture, coolant allocation)
  • Hourly processing rate = 50+19+12+25+8=114 yuan/hour

By monitoring the hourly processing rate, cost anomalies can be detected in time - if the processing rate of a batch of parts suddenly rises to 130 yuan/hour, it is necessary to check whether there are problems such as rapid tool wear and reduced processing efficiency.

4. Total Cost of Ownership Analysis: Consider the full picture of costs

Total cost of ownership (TCO) is the total cost of the entire life cycle of the equipment, including acquisition cost, usage cost, maintenance cost, salvage value, the formula is: TCO = acquisition cost + usage cost (labor + energy + tools) + maintenance cost - salvage value.

TCO analysis of a company buying a CNC milling machine of 1 million yuan (used for 10 years):

  • Purchase cost: 1 million yuan
  • Cost of use: (50+12+25) yuan / hour × 5,000 hours / year × 10 years = 4.35 million yuan
  • Maintenance cost: 20,000 yuan per year ×10 years = 200,000 yuan
  • Residual value: 50,000 yuan
  • TCO=100+435+20-5=5.5 million yuan

Total cost of ownership analysis can avoid the misunderstanding of "only looking at the purchase price" - a company once compared the milling machines of brand A (1 million yuan) and brand B (800,000 yuan), and the average annual cost of use of brand A was 150,000 yuan lower than that of brand B, and the 10-year TCO was 500,000 yuan lower than that of brand B.

5. Supply chain cost impact: upstream and downstream collaborative cost reduction

The impact of supply chain costs on milling costs cannot be ignored, including raw material procurement, tool supply, outsourcing machining and other links. An auto parts factory locked in steel prices by signing a "long-term pricing agreement" with raw material suppliers to avoid the cost increase caused by raw material price fluctuations; At the same time, we worked with tool suppliers to develop specialized tools, and tool costs decreased by 18%.

Collaborative cost reduction skills: Share production plans with suppliers to achieve raw material JIT distribution and reduce inventory costs; outsourcing non-core processes to professional manufacturers to reduce equipment and labor input; Establish a supplier assessment mechanism and give priority to partners with "high quality and low price + fast response".

6. Lean production and cost control: the concept of continuous cost optimization

The core of lean production is "eliminating waste", which mainly includes: idle equipment, over-processing, rework, inventory overstock, etc. A mechanical processing plant has achieved three major optimizations through lean production transformation:

  1. Production scheduling optimization: The use of the "U-line" increased equipment utilization from 70% to 88%.
  2. Quality control optimization: Establish a "first article inspection + process inspection" mechanism, and the rework rate is reduced from 6% to 1.5%;
  3. Inventory optimization: Implementing "zero inventory" management resulted in a 40% reduction in raw material inventory costs.

Lean manufacturing is not a one-time transformation, but a continuous improvement process – it is recommended to set up a cost optimization team to analyze cost data on a monthly basis, identify waste points, and develop targeted improvement measures.

Yigu Technology thinks about milling cost control

The core of milling cost control is not "simple cost reduction", but the balance of "precise investment + efficiency improvement". In today's increasingly fierce competition in the manufacturing industry, enterprises should not only focus on the cost reduction of a single link, but also achieve comprehensive cost optimization through technological upgrading, management optimization, and supply chain collaboration from the perspective of the whole value chain.

Yigu Technology believes that digitalization and automation are the core trends of milling cost control in the future - through the introduction of intelligent machine tools, cost management software, and automated production lines, real-time monitoring and precise control of cost data can be realized, while improving production efficiency and product quality. For small and medium-sized enterprises, there is no need to blindly pursue high-investment automation equipment, and can start with "low cost and high return" measures such as CNC programming optimization, tool life management, and lean production to gradually realize the upgrade of cost control.

Ultimately, the goal of milling cost control is to "achieve the highest customer value with the lowest comprehensive cost", which requires enterprises to integrate cost awareness into every link of production and operation, and find a suitable cost optimization path through continuous learning and practice.

FAQ: About milling costs

1. Which part of the milling process is the easiest to optimize?

Answer: Tool wear cost and CNC programming optimization are the most effective optimization points. By selecting the right tool and establishing a tool life ledger, the tool cost can be reduced by 10%-30%; CNC programming optimization requires no additional investment, and can reduce machining time by 10%-20% simply by adjusting the machining path, indirectly reducing labor, depreciation, and energy costs.

2. How can low-volume production reduce milling costs?

A: The core of low-volume production is "reduced changeover time + centralized processing". Modular fixtures and quick change systems are recommended to reduce changeover time to less than 15 minutes; Use group technology to centralize the production of similar parts and share fixed costs; Share equipment capacity with other enterprises to reduce equipment idleness.

3. Is it cost-effective to buy a used CNC milling machine?

Answer: It needs to be judged based on the actual situation. If the budget is limited, simple parts are processed, and short-term use is used, second-hand equipment can reduce the upfront investment; However, when producing and processing precision parts for a long time, it is not recommended to choose second-hand equipment - its failure rate is high, accuracy and stability are poor, and the hidden cost may far exceed the price advantage. When purchasing, you need to focus on checking the accuracy of the equipment, maintenance records, wear and tear of core components, and set aside 10%-15% of the maintenance budget.

4. How to accurately calculate the quotation for milling operations?

Answer: The quotation calculation needs to cover all cost elements, and the steps are as follows:

  1. Calculate the cost of raw materials: part weight × material unit price × (1 + loss rate);
  2. Calculate machining time: estimate the total machining time according to the part structure and cutting parameters;
  3. Calculate various costs: labor cost (machining time × hour labor rate), depreciation cost (machining time × hour depreciation rate), tool cost (machining time × hour tool consumption), energy and auxiliary costs;
  4. Plus reasonable profit: total cost × (1 + profit margin), profit margin usually 15%-30%, which can be adjusted according to industry competition.

5. Is high-speed milling necessarily more cost-effective than traditional milling?

A: Not necessarily. The upfront investment (equipment + tools) for high-speed milling is higher, and if simple parts and small batches are machined, the benefits of efficiency improvement may not offset the additional investment; However, when machining complex parts and large batches, high-speed milling can significantly reduce machining time and unit cost, usually paying for itself in 3-6 months. It is recommended to comprehensively judge whether to use high-speed milling according to the complexity of parts, batch size, and accuracy requirements.

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