INVESTMENT CASTING
(CODE NO.1994)
Ceramic Shell Investment Casting (CSIC) is one of the near net shape casting technologies. The process is based on expendable wax patterns for producing joint-less moulds that are required for near net shape castings.
The main difference between investment casting and ceramic shell investment casting is that, in the former process, before dewaxing the wax pattern, it is immersed in a refractory aggregate. Whereas in the ceramic shell investment casting, a ceramic shell gets built around the tree assembly through repeated dipping of the pattern into slurry (refractory material such as zircon with binder). After getting the required thickness of cross section, the tree assembly is de-waxed. The shell obtained is further immersed in a refractory coating and the metal is poured into it.
In this process, a wax pattern assembly is first dipped into a ceramic slurry bath for its primary coating. Thereafter, the pattern is withdrawn from the slurry and is manipulated to drain of the excess slurry to produce a uniform coating layer. The wet layer further stuccoes through sprinkling the relatively coarse ceramic particles on it or by immersing it into such fluidized bed of particles. The ceramic coating is built by successive dipping and stuccoing process. This procedure is further repeated till the shell thickness as desired is obtained. Upon completion, the entire assembly is placed into an autoclave or flash fire furnace at a high temperature. In-order to burnout out any residual wax, the shell is heated to about 982℃ which helps to develop a bonding of high-temperature in shell. Such molds are stored for future use wherein they are preheated for removing the moisture content from it and then, molten metal can be poured into it.
COST ESTIMATION
Plant capacity 3.00 MT/day
Land & Building (2000 Sq.Mtr) Rs. 1.05 Cr
lant & Machinery Rs. 93.90 Lacs
W.C. for 1 Month Rs. 1.25 Cr
Total Capital Investment Rs. 3.38 Cr
Rate of Return 80%
Break Even Point 42%
INTRODUCTION
USES AND APPLICATIONS
B.I.S SPECIFICATION
MARKET SURVEY
INDIAN INVESTMENT CASTING INDUSTRY
ADVANTAGES TO INDIAN IC MARKET
SCOPE OF INVESTMENT CASTINGS
INVESTMENT CASTING IN THE WORLD
INVESTMENT CASTING IN INDIA
SURVEY OF INVESTMENT CASTING FOUNDRIES IN RAJKOT CLUSTER
MANUFACTURERS/SUPPLIER OF INVESTMENT CASTING
MANUFACTURING PROCESS
SEQUENCE OF PRODUCING CERAMIC SHELL INVESTMENT CASTING
INVESTMENT CASTING PRODUCTION EQUIPMENTS
WAX MELTING MACHINE
SLURRY COATING MACHINE
DUST COLLECTION SYSTEM 6 FILTES
WAX INJECTION PRESS
WAX DEWAXING MACHINE
PROCESS FLOW CHART
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF M.S. INGOT
SUPPLIERS OF ALUMINIUM INGOT
SUPPLIERS OF ALUMINIUM ALLOY INGOT
SUPPLIERS OF BRASS INGOT
SUPPLIERS OF WAX
SUPPLIERS OF POWDER COATING PAINT
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF INVESTMENT CASTING MACHINES
SUPPLIERS OF INDUCTION FURNACE
SUPPLIERS OF EOT CRANES
SUPPLIERS OF DG SETS
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF ETP PLANTS
SUPPLIER OF MEASURING AND TESTING INSTRUMENTS
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
SUPPLIERS OF AIR COMPRESSOR
SUPPLIERS OF ELECTRONIC WEIGHING MACHINE
PLANT LAYOUT
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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