S.S. ALLOY FOUNDRY
[CODE NO. 3212]
A foundry is a factory which produces metal casting from either ferrous or non-ferrous alloys. Metals are turned into parts by melting the metal into a liquid, pouring the metal in a mold, and then removing the mold material or casting. The most common metal alloys processed are aluminium and cast iron. However, other metals, such as steel, magnesium, copper, tin, and zinc, can be processed.
COST ESTIMATION
Plant Capacity : 4.00 MT./day
land & Building (20230 sq.mtrs) : Rs. 18.08 Cr
Plant & Machinery : Rs. 18.44 Cr
Working Capital for 2 Months : Rs. 3.42 Cr
Total Capital Investment : Rs. 39.69 Cr
Rate of Return : 22%
Break Even Point : 62%
INTRODUCTION
TYPES OF FOUNDRY
TYPES OF SAND MOLDING PROCESSES
1) GREEN-SAND MOLDING:
(A) PREPARATION OF THE PATTERN.
(B) MAKING THE MOLD.
(C) CORE SETTING.
(D) CLOSING AND WEIGHTING
ADVANTAGES
LIMITATIONS
(2) DRY-SAND MOLDS:
ADVANTAGES
DISADVANTAGES
(3) CARBON-DIOXIDE GAS MOLDING
(4) CEMENT BONDED SAND MOLDS.
(5) SHELL MOLDING
ADVANTAGES
DISADVANTAGES
MOLDINNG MATERIAL
MOLDING SANDS (FOUNDRYSAND)
PROPERTIES
CONSTITUENTS OF MOLDING SAND
A. SILICA SAND
B. BINDER
C. MOISTURE
D. ADDITIVES
E. COAL DUST
F. CORN FLOUR
G. DEXTRIN
H. SEA COAL
I. PITCH
J. WOOD FLOUR
J. PULVERIZED SILICA OR SILICA FLOUR
TYPES OF MOULDING SAND
1. GREEN SAND
2. DRY SAND
3. LOAM SAND
4. PARTING SAND
5. FACING SAND
6. BACKING SAND
7. SYSTEM SAND
8. CORE SAND
PATTERNS FOR SAND CASTING
ADVANTAGES OF SAND CASTING
DISADVANTAGES OF SAND CASTING
USES AND APPLICATION
1. TRANSPORT
2. HEAVY EQUIPMENT
3. HARDWARE
TYPICAL APPLICATIONS ARE
B.I.S. SPECIFICATION
INDIAN FOUNDRY INDUSTRY LOOKS TO DOUBLE TURNOVER IN 3 YEARS
MARKET POSITION 40
COMPETITION WITHIN THE SECTOR
ALLIED MSME SECTOR IN DEEP TROUBLE
SHORTAGE OF SKILLED MANPOWER
GROWING BUSINESS CONFIDENCE
CONCLUSION
GROWING DEMAND OF FOUNDRY SECTOR
OVERVIEW
SIGNIFICANCE OF FOUNDRY INDUSTRY
SIGNIFICANCE OF FOUNDRY INDUSTRY
INDIAN AUTOMOBILE INDUSTRY OVERVIEW
FOUNDRY INDUSTRY (CASTING)
INDUSTRY STRUCTURE AND DEVELOPMENTS
BACKGROUND
GLOBAL TRENDS IN THE CASTING INDUSTRY
INDIAN CASTING INDUSTRY
MANUFACTURERS/SUPPLIERS OF S.S. CASTING
PROCESS OF SAND CASTING OF STAINLESS STEEL
1. RAW MATERIALS AND RAW MATERIAL HANDLING
(A) SS 304 SCRAPE. SS, 410 SCRAP AND ALL TYPES OF FERRO
ALLOY METALS
(B) SILICA SAND
(C) CHROMITE SAND
(D) ZIRCON SAND
(E) OLIVINE SAND
(F) BENTONITE
(G) RESINS
(H) CEREAL BINDERS
(I) IRON OXIDE
2. SAND PREPARATION (TRANSPORT, SIEVING, COOLING, MIXING)
(A) RECONDITIONING WITH GREEN SAND MOULDING
(B) MOULDING WITH NATURAL SAND
(C) GREEN SAND MOULDING
3. PATTERN MAKING
A. MANUAL FABRICATION
B. COMPUTER NUMERICAL CONTROL MACHINING METHOD
C. FAST FREEFORM FABRICATION
4. MOULD AND CORE PRODUCTION
CORE FABRICATION PROCESS
FABRICATION OF CORE BOXES
FABRICATION OF SAND MOULD
STEPS INVOLVED IN MAKING A SAND MOLD
METHODS OF SAND MOLDING
A) BENCH MOLDING
B) FLOOR MOLDING
C) PIT MOLDING
D) MACHINE MOLDING
COATING PROCESS ON MOULD
5. RUNNING, GATING, FEEDING AND FILTRATION
6. MELTING AND METAL TREATMENT
(A) ELECTRIC ARC FURNACE (EAF)
NATURE OF ATMOSPHERIC EMISSIONS
(B). INDUCTION FURNACE (IF)
CORELESS INDUCTION FURNACE
ADVANTAGES:
DISADVANTAGES:
NATURE OF EMISSIONS
7. METAL TREATMENT OF STEEL
8. CASTING PROCESS WITH SAND MOLD
(A) POURING
(B) SOLIDIFICATION
(C) SHAKE-OUT
9. FINISHING AND POST CASTING OPERATIONS
COATING 110
(A) REMOVAL OF THE RUNNING SYSTEM
(B) SAND REMOVAL
C) REMOVAL OF BURRS
OTHER APPLIED TECHNIQUES INCLUDE:
10. HEAT TREATMENT
HEAT TREATMENT OF STAINLESS STEEL
SOLUTION TREATMENT AND QUENCHING
11. QUALITY CONTROL
PLANT LAYOUT
SUPPLIERS OF RAW MATERIALS
STAINLESS STEEL SCRAP
FERRO ALLOYS
CHROME SALT AND CHROMIC ACID
FOUNDRY SAND
BENTONITE POWDER
DEXTRINE
NITRIC ACID
PICKLING CHEMICALS
SUPPLIERS OF OIL AND GREASE
SUPPLIERS OF PLANT AND EQUIPMENTS
INDUCTION FURNACE
ANNEALING FURNACE
INTENSIVE SAND MIXTURE AND MULLER
SAND SIEVING MACHINE
SQUEEZE MOLDING MACHINE
SHAKEOUT MACHINE
SHELL MOLDING MACHINE
CORE SHOOTER MACHINE
DRYING OVEN
FOUNDRY TOOLS
SUPPLIERS OF SHOT BLASTING MACHINE
SUPPLIERS OF MOLDING BOXES
SUPPLIERS OF METAL TESTING MACHINE
SUPPLIERS OF PRECISION MEASURING TOOLS
NDT INSPECTION EQUIPMENT
BENCH GRINDER
DRILLING MACHINE
CNC MACHINES, CNC MACHINE TOOLS & LATHES
CNC LATHE MACHINE
POWER HACKSAW
GRINDING MACHINE
CNC MACHINING CENTRE
HARD CHROME PLATING PLANT
EOT CRANES
D.G. SETS
POWER TRANSFORMERS
COOLING TOWER
ETP PLANTS
AIR POLLUTION CONTROL EQUIPMENTS
AIR CONDITIONING EQUIPMENTS
AIR COMPRESSORS
WEIGHING MACHINE (PLATFORM TYPE)
MATERIAL HANDLING EQUIPMENTS
FIRE FIGHTING EQUIPMENTS
SUBMERSIBLE WATER PUMP
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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