At 1,200 pcs/a the annual steel demand is about 13 t — below mill minimum order quantities — so the material is bought from a steel stockist, not directly from the mill. The delivered price therefore starts at the mill index price for 18CrNiMo7-6 (1,591 €/t in Jul 2026) and carries the stockist's markup for freight, inventory, traceability, overheads and profit. Turnings are credited back at the alloy-scrap revert price.
| Mill base price — index, Jul 2026 | 1.60 €/kg |
| Stockist markup — freight | +8% |
| Stockist markup — inventory | +5% |
| Stockist markup — traceability | +2% |
| Stockist markup — overheads | +15% |
| Stockist markup — profit | +10% |
| Delivered stockist price — × 1.40 | 2.24 €/kg |
| Chip revert price — alloy steel turnings | 0.15 €/kg |
| Bar stock | Ø95 × 6,000 mm |
| Bar weight 70.88 cm² section × 600 cm × 7.85 g/cm³ | 333.9 kg |
| Bar cost 333.9 kg × 2.24 €/kg | €747.84 |
| Cut length per part part 194 + saw kerf 4 | 198 mm |
| Parts per bar usable 5,960 (6,000 − 40 clamping) ÷ 198, rounded down | 30 pcs |
| Charge weight bar ÷ 30 pcs — the unused 60 mm is carried by the parts | 11.13 kg/pc |
| Material, gross bar cost ÷ 30 pcs | €24.93/pc |
| Finished part | 2.23 kg |
| Chip revert credit 8.90 kg turnings × 0.15 €/kg | −€1.33/pc |
| Direct material, net | €23.59/pc |
| Material utilisation 2.23 of 11.13 kg — the rest becomes turnings | 20% |
| Investment — replacement + installation | €294,000 |
| Working hours 85% productivity | 3,264 h/a |
| Imputed depreciation — 8 a 36,750 €/a ÷ 3,264 h | 11.26 €/h |
| Imputed interest 4,410 €/a ÷ 3,264 h | 1.35 €/h |
| Floor space — 25 m² 2,808 €/a ÷ 3,264 h | 0.86 €/h |
| Maintenance — 1.8% of investment 5,292 €/a ÷ 3,264 h | 1.62 €/h |
| Electricity 15 kW × 66% use × 0.37 €/kWh | 3.66 €/h |
| Coolant & compressed air | 4.65 €/h |
| Machine-hour rate | 23.40 €/h |
| Stock | Ø95 × 6,000 mm round bar · 18CrNiMo7-6 |
| Cut length | 198 mm/pc |
| Blade cycle Ø95 section ÷ 34 mm/min blade feed | 168.0 s/pc |
| # | Operation | Feature | Insert | Cycle s/pc | Wear €/pc |
|---|---|---|---|---|---|
| 10.1 | Face | end face Ø54.9 face Ø95 → centre · 1 pass · f 0.15 · vc 235 | CNMG 190616-PR | 14.3 | 0.01 |
| 10.2 | Rough | taper 28.6° Ø95 → Ø54.9–Ø90 cone · 17 × 13 mm · ap 1.15 · f 0.15 · vc 235 | CNMG 190612-PR | 89.5 | 0.06 |
| 10.3 | Rough | rim bead + taper 67° Ø95 → Ø90 rim + relief · 3 × 27 mm · ap 1.15 · f 0.15 · vc 235 | CNMG 190612-PR | 39.4 | 0.03 |
| 10.4 | Rough | journal Ø37.2 + fillet R4 Ø95 → Ø37.2 × 41 mm · 25 × 24 mm · ap 1.15 · f 0.15 · vc 235 | CNMG 190612-PR | 215.1 | 0.14 |
| 10.5 | Semi-finish | full profile 1 pass × 130 mm · ap 0.5 · f 0.30 · vc 235 | DNMG 150608-PM | 19.9 | 0.01 |
| 10.6 | Finish | fillets R2/R3/R4 · tapers 28.6°/67° 1 pass × 130 mm · ap 0.4 · f 0.10 · vc 235 | DNMG 150608-MF · 0.8 nose | 54.7 | 0.05 |
| # | Operation | Feature | Insert | Cycle s/pc | Wear €/pc |
|---|---|---|---|---|---|
| 20.1 | Centre drill | stem end — temporary centre drill Ø8.5 × 9 mm · f 0.10 · n 1,200 rpm | Ø8.5 · 60° HSS-Co | 3.7 | — |
| 20.2 | Rough | taper 20° + journal Ø32 Ø95 → Ø32 × 55 mm · 27 × 32 mm · ap 1.15 · f 0.15 · vc 235 | CNMG 190612-PR | 290.8 | 0.19 |
| 20.3 | Rough | taper 20° + journal Ø29 Ø95 → Ø29 × 53 mm · 29 × 33 mm · ap 1.15 · f 0.15 · vc 235 | CNMG 190612-PR | 319.9 | 0.21 |
| 20.4 | Face | end face Ø29 face Ø29 → centre · 1 pass · f 0.12 · n 3,000 rpm | CNMG 120408-PM | 4.7 | 0.01 |
| 20.5 | Semi-finish | full profile 1 pass × 140 mm · ap 0.5 · f 0.30 · vc 235 | DNMG 150608-PM | 11.8 | 0.01 |
| 20.6 | Finish | journals Ø32/Ø29 · tapers 20° 1 pass × 120 mm · ap 0.4 · f 0.10 · vc 235 | DNMG 150608-MF · 0.8 nose | 30.5 | 0.03 |
| 20.7 | Form | spherical recess R14.5 R14.5 sweep × 20 mm arc · f 0.08 · n 3,000 rpm | VCGT 160404 · small nose | 5.4 | — |
| Scope | 100% visual & burr check · 1-in-50 dimensional sampling (journals Ø37.2 / Ø29) |
| Operation | Cycle min | Post min | Machine €/h | Operator €/h | Operators | Setup min | Setup €/batch | Wear €/pc | € / pc | % of prod. |
|---|---|---|---|---|---|---|---|---|---|---|
| Saw | 3.30 | 0.20 | 23.4 | 35.0 | 1.0 | 20 | 19.47 | 0.05 | 3.57 | 13.2% |
| Turn Op 10 | 8.72 | 0.40 | 23.4 | 35.0 | 1.0 | 45 | 43.80 | 0.30 | 9.45 | 35.0% |
| Turn Op 20 | 12.86 | 0.40 | 23.4 | 35.0 | 1.0 | 47 | 45.75 | 0.45 | 13.66 | 50.5% |
| Final inspection | 0.25 | — | 23.4 | 35.0 | 1.0 | 12 | 11.68 | — | 0.36 | 1.3% |
| Direct production | 25.13 | 1.00 | 124 | 120.69 | 0.80 | €27.05/pc | 100% |