Bearings, Gears & Power Transmission calculator
Heat Treat Distortion Scrap Cost Calculator
Heat treat can create distortion, grind stock loss, hardness rejects, and cracked parts that consume expensive machined gears, bearing races, and shafts. This calculator helps manufacturing and quality teams quantify scrap cost for a batch, supplier issue, or process improvement case.
What this calculator does
- Estimate cost exposure from gears, shafts, or bearing components scrapped after heat-treat distortion or hardness nonconformance.
- a gear or bearing operation needs to estimate the financial impact of heat-treat distortion scrap on a production lot
- Returns estimated dollar impact of heat-treat related scrap for a lot or incident.
Formula used
- Scrapped component value = scrapped components × cost per scrapped component
- Total heat-treat distortion scrap cost = scrapped component value + fixed heat-treat batch cost + containment and rework overhead
Inputs explained
- Scrapped heat-treated components: Use gears, shafts, bearing races, rollers, or housings rejected for distortion, hardness, cracks, or grind stock loss.
- Cost per scrapped component: Include machined blank value, material, prior operations, outside heat treat, and normal inspection cost per part.
- Fixed heat-treat batch cost: Add batch furnace charges, load setup, tooling, quench fixture, lab test, freight, or supplier minimum charges.
- Containment and rework overhead: Include sorting labor, engineering review, expedite cost, replacement planning, and customer containment.
How to use the result
- Use it for corrective action, supplier chargebacks, process changes, quoting risk, and rework-versus-scrap decisions.
- It does not predict metallurgical distortion; it only values the scrap once rejects, costs, and adders are known.
Common questions
- Should reworked parts be included? Include only scrapped parts in the first field; put extra sorting or rework labor in the overhead field.
- Can supplier costs be included? Yes. Include outside heat-treat, freight, inspection, or supplier minimum charges in the relevant cost fields.
- What if only a percentage of the batch is scrap? Enter the actual rejected count, not the total batch count, unless every part was rejected.
- How can I use the result? Use it to justify fixture changes, heat-treat trials, stock allowance updates, or supplier corrective action.
Last reviewed 2026-05-12.