FABRICATION OF STEEL
(Focussed on manufacture of auto piston, piston pin, piston ring, con rod and crankshaft one of the most demanding engine parts)
[CODE NO. 2054]
The automotive industry is the key driver of any growing economy. The automobile industry comprises automobile and auto component sectors. The component production range includes engine parts 31%, drive transmission and steering parts 19%, suspension and braking parts 12%, electrical parts 10%, equipments 12%, body and chassis 9% and others7%. Indigenous firms like Bharat Forge, Sundaram Fasteners, Minda Industries and GabrialIndia Ltd. are in the limelight in auto component sector.
The Indian automobile industry is growing at a very high rate with sales of more than one million passenger vehicles per annum. The overall growth rate is 10-15 % for automobile industry and 28 % for automobile component sector annually. Today’s competitive market has put all major automobile companies upfront to design and develop varieties of vehicles as per customer demands. The replacement market is also likely to expand. This indicates scintillating prospects for much faster growth and development of new auto component industry. The Auto Component Manufacturers Association (ACMA) has pegged domestic demand for auto components at $ 20-25 billion in 2015 from current demand of approximately $ 10 billion.
This project report is mainly focussed on manufacture of auto piston, piston pin, piston ring, con rod and crankshaft one of the most demanding engine parts.
(1) PISTON
Piston is a cylindrical plug which is used for moving up and down the cylinder according to the position of the crankshaft in its rotation. Piston has multiple uses and functions. In the case of four-stroke engine the piston is pulled or pushed with the help of crankshaft while in the case of compression stroke, piston is pushed with the powerful explosion of mixture of air and fuel.
Piston comprises of several components namely:
(a) Piston Pins
(b) Piston Rings
In an Internal Combustion engine, piston converts the thermal energy of fuel into mechanical energy. The main functions of the piston are:-
(a) To transmit the gas forces via connecting rod to the crank shaft.
(b) To seal in conjunction with the piston rings and combustion chamber against gas leakage to the crankcase and to prevent the infiltration of oil from crankcase into the combustion chamber.
(c) To dissipate absorbed combustion heat to the cylinder liner and cooling oil.
COST ESTIMATION
Plant Capacity FABRICATION OF STEEL (AUTO PARTS)
Land & Building (4500 Sq.Mtr) Rs.4.95 Cr
Plant & Machinery Rs.2.28 Cr
W.C. for 2 Months Rs.2.45 Cr
Total Capital Investment Rs.10.14 Cr
Rate of Return 36%
Break Even Point 49%
INTRODUCTION
TYPES OF PISTON
DOME PISTON
BOWL PISTON
FLAT TOP PISTON
COATING
MATERIALS
TYPES OF PISTON PIN
B.I.S. SPECIFICATION
MANUFACTURING PROCESS
MANUFACTURING PROCESS OF PISTON
DETAILS OF PROCESSES INVOLVED IN MANUFACTURE
OF PISTON BY CASTING PROCESS
(B) MANUFACTURING PROCESS OF PISTON PIN
(C) MANUFACTURING PROCESS OF PISTON RING
HOT FORGING
POWDER METAL (PM) BASED PROCESS
(1) HOT FORGING PROCESS
QUALITY CONTROL & STANDARD
(2) BY CASTING METHOD
HEAT TREATMENT.
MACHINING
MARKET POTENTIALFOR PISTON
MARKET POTENTIAL FOR PISTON PIN
MARKET POTENTIAL FOR PISTON RING
MARKET FOR CRANK SHAFT
INDUSTRY PERFORMANCE IN 2014-15
GROSS TURNOVER OF THE AUTOMOBILE MANUFACTURERS
IN INDIA (IN USD MILLION)
SIAM MEMBERS
AUTOMOBILE DOMESTIC SALES TRENDS
AUTOMOBILE EXPORTS TRENDS
MANUFACTURERS/SUPPLIERS OF AUTO PISTON,
PISTON PIN AND PISTON RING
MANUFACTURERS/SUPPLIERS OF AUTO CON ROD
MANUFACTURERS/SUPPLIERS OF CRANK SHAFT
PLANT LAYOUT
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF RAW MATERIALS
APPENDIX – A :
1. COST OF PLANT ECONOMICS
2. LAND & BUILDING
3. PLANT AND MACHINERY
4. FIXED CAPITAL INVESTMENT
5. RAW MATERIAL
6. SALARY AND WAGES
7. UTILITIES AND OVERHEADS
8. TOTAL WORKING CAPITAL
9. COST OF PRODUCTION
10. PROFITABILITY ANALYSIS
11. BREAK EVEN POINT
12. RESOURCES OF FINANCE
13. INTEREST CHART
14. DEPRECIATION CHART
15. CASH FLOW STATEMENT
16. PROJECTED BALANCE SHEET
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