Detailed Project Report on fabrication of steel

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