Side-channel analysis is one of the most investigated hardware Trojan detection approaches. However, nearly all the side-channel analysis approaches require golden chips for reference, which are hard to obtain actually. Besides, majority of existing Trojan detection algorithms focus on the data similarity and ignore the Trojan misclassification during the detection. In this paper, we propose a cost-sensitive golden chip-free hardware Trojan detection framework, which aims to minimize the probability of Trojan misclassification during the detection. The post-layout simulation data of voltage variations at different process corners is utilized as a golden reference. Further, a classification algorithm based on the combination of principal component analysis and Naïve bayes is exploited to identify the existence of hardware Trojan with a minimum misclassification risk. Experimental results on ASIC demonstrate that the proposed approach improves the detection accuracy ratio compared with the three detection algorithms and distinguishes the Trojan with only 0.27% area occupies even under ±15% process variations.