Abhi Engineering Works
Costing Tool  ·  v3.0 Professional
Inquiry: —  ·  Date: —
aew COSTING
⚙ Master Rates — Single Source of Truth
Change once · Updates every sheet automatically
Material Master (₹/kg)
Grade₹/kgTypical Use
EN8General purpose
EN19Alloy steel
ST52Honed tube
C45Medium carbon
SS410Stainless martensitic
SS316Marine grade SS
Process Rate Master
ProcessRateUnit
Heat Treatment₹/kg
Induction Hardening₹/cm²
Honing (area-based)₹/cm²
Grinding (area-based)₹/cm²
Chrome Plating₹/cm²
Polishing₹/cm²
Painting — Tube₹/cm²
Painting — Rod₹/cm²
Profile Cutting₹/kg
Packing — Loose₹/kg
Packing — Wooden Box₹/kg
Assembly Labour₹/hr
Testing Labour₹/hr
Machine Rate Master (₹/hr)
Machine₹/hr
Band Saw
CNC Lathe
Heavy CNC / HMC
VTL
Boring Machine
Milling Machine
Radial Drill
Honing Machine
Cylindrical Grinder
Welding Formula (aew Standard) Length = π × Dia × Beads (mm) Time = Length ÷ 3600 (hours) Labour = Time × ₹375/hr Wire = Time × 0.8 kg/hr × ₹360/kg Total = Labour + Wire
Engineering Formulas Hollow Wt = (π/4)×(OD²−ID²)×L×7.85×10⁻⁶ kg Solid Wt = (π/4)×OD²×L×7.85×10⁻⁶ kg Ext Area = π×OD×L÷100 cm² Int Area = π×ID×L÷100 cm²
📋Customer & Order
🏭Job Classification
📐Cylinder SpecificationsAll sheets auto-populate from these values
ℹEnter bore, rod and stroke above. Tube bore ID auto-fills in the Tube sheet. Rod finished diameter auto-fills in the Piston Rod sheet. Tube length = Stroke + 200mm. Rod length = Stroke + 350mm.
Tube Process SequenceCutting → Rough Turning → Drilling → Part Welding → Rough Honing → Finish Turning → CEC Welding → Rear Eye Welding
AMaterial InputsWeight auto-calculated
Weight = (π÷4) × (OD² − ID²) × Length × 7.85×10⁻⁶ kg
BProcess RoutingMachine hours from lookup tables
ProcessMachineParametersHoursRate ₹/hrCost ₹
1. CuttingBand Saw · Table AOD: —mm · L: —mm—₹0
2. Rough TurningCNC Lathe · Table BSR: —mm · Factor: ——₹0
3. DrillingRadial Drill · Table CØmm × holes—₹0
4. Part WeldingMIG WeldingØmm × beads—Formula₹0
5. Rough HoningHoning MachineInt. Area: — cm² × ₹0.30/cm²—Area rate₹0
6. Finish TurningCNC Lathe · ×0.70= Rough Turning Hours × 0.70 (lighter cut, less stock)—₹300/hr₹0
7. CEC WeldingMIG WeldingØmm × beads—Formula₹0
8. Rear Eye WeldingMIG WeldingØmm × beads—Formula₹0
Total Process Cost₹0
🔵 TUBE TOTAL COST (per piece)₹0
Rod Process SequenceCutting → Rough Turning → Heat Treatment → Induction Hardening → Finish Turning → Grinding → Chrome Plating → Polishing
AMaterial InputsSolid round bar weight
Weight = (π÷4) × OD² × Length × 7.85×10⁻⁶ kg (solid round bar)
BProcess Routing
ProcessMachine / VendorParametersHrs / AreaRateCost ₹
1. CuttingBand Saw · Table A——₹/hr₹0
2. Rough TurningCNC Lathe · Table BSR: —mm · ×——₹/hr₹0
3. Heat TreatmentVendorWeight × ₹12/kg— kg₹/kg₹0
4. Induction HardeningVendorExt. Area × ₹0.45/cm²— cm²₹/cm²₹0
5. Finish TurningCNC Lathe · ×0.70= Rough Turning × 0.70—₹300/hr₹0
6. GrindingCyl. Grinder · Table FArea × ₹0.30/cm²— cm²₹/cm²₹0
7. Chrome PlatingVendorArea × ₹0.85/cm²— cm²₹/cm²₹0
8. PolishingBarrel FinishingArea × ₹0.20/cm²— cm²₹/cm²₹0
Total Process Cost₹0
⚡ PISTON ROD TOTAL COST (per piece)₹0
ℹCap End Cover, Head End Cover, and Gland are machined from solid billets. Enter material and process costs per piece. Future version will auto-calculate from dimensions.
ℹStop Tube uses solid round raw material. Rear Eye, Rod Eye, and Piston start with profile cutting based on plate weight.
📦Bought Out ItemsManual entry
ItemQtyUnit Cost ₹Total ₹
Fasteners (bolts, studs, nuts)₹0
Guide Rings₹0
Wear Rings₹0
Grease Nipples₹0
Bearings₹0
Position Sensors₹0
Other Bought Out₹0
Bought Out Total₹0
🔧Seal KitVendor quote
ℹAlways obtain fresh seal quotes. Seal prices vary by bore size, material (NBR/FKM/PTFE), and working pressure rating.
🔧Assembly & Testing
Assembly = Hrs × ₹100/hr  |  Testing = Hrs × ₹100/hr
🎨PaintingFrom surface areas
📦Packing
Manufacturing Cost / pc
₹0
Before profit margin
Profit Margin
₹0
@ 20%
Selling Price / pc
₹0
Inclusive of margin
Total Order Value
₹0
for 1 piece
Component Costs
🔵 Tube₹0
⚡ Piston Rod₹0
🔩 Cap End Cover₹0
🔩 Head End Cover₹0
🔩 Gland₹0
⚙ Cushion Bush₹0
⚙ Stop Tube₹0
⚙ Rear Eye₹0
⚙ Rod Eye₹0
⚙ Piston₹0
Sub-total — All Components₹0
Bought Out & Services
📦 Bought Out Items₹0
🔧 Seal Kit₹0
🔧 Assembly₹0
🔧 Testing₹0
🎨 Painting₹0
📦 Packing₹0
Total Manufacturing Cost / pc₹0
💰Margin & Selling Price
Abhi Engineering Works
Manufacturer & Reconditioning Specialist — Hydraulic Cylinders
Peenya Industrial Area, Bangalore — 560 058, Karnataka, India
AEWTel: +91 80 ________
Email: sales@aew.com
GST: ______________
PRODUCT COST SHEET & QUOTATIONRef: —
Customer—
Inquiry No.—
Cylinder—
Date—
Bore × Rod × Stroke—
Working Pressure—
Mounting Type—
Quantity—
DescriptionMaterial ₹Process ₹Total ₹
Terms & Conditions1. Validity: 30 days from date of issue
2. Payment: 50% advance, balance before dispatch
3. Delivery: 3–4 weeks from PO + advance receipt
4. Taxes: GST @18% extra as applicable
5. Warranty: 12 months against manufacturing defects
6. FOB: aew Works, Peenya, Bangalore
Prepared by: ___________________
Name & Date
For Abhi Engineering Works
Authorised Signatory: ___________________
✦ aew Certified Quality ✦