Date of Award

Spring 2002

Document Type


Degree Name

Doctor of Philosophy (PhD)


Mechanical & Aerospace Engineering


Mechanical Engineering

Committee Director

Han P. Bao

Committee Member

Sebastian Bawab

Committee Member

Gene Hou

Committee Member

Resit Unal


A major drawback of current cost estimation models is their incapability of embracing effectively complete product development stage. Parametric estimation works well in early stages of design, but in detail design stage, a more complete estimation is provided by process model based and detail estimation techniques. A major paradigm shift is proposed in this work whereby ‘Cost’ is to be considered as a design parameter from scientific perspective, and it is to be treated as a design consequence rather than as an operational outcome. A comprehensive framework using System Analysis fundamentals is designed to study ‘Process Cost’ aspects of part or design. The work gives detailed implementation of this new approach for objects manufactured largely by milling operation. The thesis also suggests a methodology to extend this approach to other operations. The proposed Generic Cost Estimation Model shows good agreement with cost estimation by commercial estimation software. It also promises integration of ‘Cost’ with other disciplines in Multidisciplinary Optimization and Collaborative Engineering. The integration is achievable through new technologies like API, OLE and similar interface tools.