Glass Processing and Sheet Metal Working (Cap: 1666.667 sq.mt/Day)
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GLASS PROCESSING AND SHEET METAL WORKING (CAP: 1666.667 SQ.MT/DAY)
[EIRI/EDPR/4515] J.C.: 2732INR, 2732US$
INTRODUCTION
Glass has evolved from its humble origins to encompass manifold functionalities, unheard of a couple of decades ago. Today, it is a celebrated building material among architects and interior designers, used in various structures such as skywalks, walkways, floorings, etc. Yet, one of the most common misconceptions among people regarding glass is that it breaks easily and when it does so, can lead to serious injuries. And for such concerns exists a product tough enough to resist heavy impact – laminated glass.
If you’re looking for a suitable safety and security glass for the windows of your home, laminated glass may be your best choice. Laminated glass is a layered type of glass with a laminated sheet resting between 2 layers of glass. This laminated sheet is usually made of polyvinyl butyral or PVB and acts as a sort of adhesive to reduce danger in case the glass gets broken. The number of layers can extend up to 9 as well, keeping in mind that every 2 sheets of glass will have a film of PVB between them.
Laminated glass is manufactured by adhering two or more layers of glass together with a flexible PVB interlayer. This takes place through a heat and pressure process in which the chemical bond formed between the glass and PVB interlayer does not merely join them but ‘conjoins’ them to create an entirely new material.
Laminated glass is a special type of safety or security glass that holds together in case of accidents. It is simply made by sandwiching layers of polyvinyl Butyral (PVB) or structural interlayer material in between two or more glass layers. The layers are usually bonded permanently using both mechanical and chemical bonds.
COST ESTIMATION
Plant Capacity 1666.667 sq.mt/Day
Land & Building (6000 sq.mt.) Rs. 7.82 Cr
Plant & Machinery Rs. 3.00 Cr
Working Capital for 1 Month Rs. 2.36 Cr
Total Capital Investment Rs. 13.60 Cr
Rate of Return 40%
Break Even Point 49%
CONTENTS
INTRODUCTION
TYPES OF SHEET METAL
VIP WORKS WITH A WIDE VARIETY OF SHEET METAL TYPES, BUT HERE ARE THE MOST COMMON:
SHEET METAL THICKNESSES
BELOW ARE THE CONVERSIONS OF GAUGES/THICKNESSES FOR COMMON SHEET METAL TYPES:
ADVANTAGE OF LAMINATED GLASS
USES OF LAMINATED GLASS
APPLICATION OF SHEET METAL
ADVANTAGE OF SHEET METAL
MARKET OVERVIEW OF GLASS
LAMINATED GLASS MARKET
MARKET OVERVIEW OF SHEET METAL
MARKET OF SHEET METAL FABRICATION
GLOBAL MARKET FOR SHEET METAL FABRICATION SERVICES
B.I.S. SPECIFICATION
RAW MATERIALS FOR GLASS PROCESSING
DETAILS OF GLASS PROCESSING
PREPARATION AND SELECTION OF GLASS
GLASS CLEANING
LAMINATING PROCESS
1.) PVB FILM STORAGE AND CUTTING
2.) LAMINATING THE GLASS WITH INTERLAYER
GLASS COMPRESSING
AUTOCLAVE -HIGH TEMPERATURE & PRESSURE TREATMENT
PHASES IN GLASS LAMINATION
TYPES OF METAL FABRICATION PROCESS
TYPES OF METAL FABRICATION PROCESSES
THERMAL CUTTING
MECHANICAL CUTTING
PUNCHING
BENDING
ASSEMBLING
POWDER COATING
SHEET METAL WORKING PROCESS
1. SHEET METAL GRADES AND MATERIALS
2. SHEET METAL THICKNESS AND TYPES
3. THE FORMING PROCESS – BENDING AND ROLL FORMING
COMMON SHEET METAL FORMING PROCESS
1) CURLING
2) BENDING
3) IRONING
4) LASER CUTTING
5) HYDROFORMING
6) PUNCHING
STEPS INVOLVED IN SHEET METAL FABRICATION
1. WORKING WITH BLUEPRINTS
2. FINALIZING DRAWINGS
3. METAL FABRICATION
4. PRODUCT FINISHING
CUTTING
1. CUTTING WITH SHEAR
2. CUTTING WITHOUT SHEAR
BENDING AND FORMING
JOINING
FINISHING
DETAILS OF SHEET METAL FABRICATION
SHEET METAL FABRICATION: CUTTING
SHEET METAL FABRICATION: DEFORMATION
SHEET METAL FABRICATION: ASSEMBLY
PROCESS FLOW CHART FOR SHEET METAL WORKING
MANUFACTURING PROCESS OF SHEET METAL WORKING
(1) CUTTING (SHEAR) PROCESS
(A) CUTTING PROCESS WITH SHEAR
SHEARED EDGE
SUCH CUTTING PROCESSES INCLUDE THE FOLLOWING:
SHEARING
BLANKING
PUNCHING
(2) FORMING PROCESS
SHEET METAL FORMING PROCESSES INCLUDE THE FOLLOWING:
BENDING
BENDING DIAGRAM
NEUTRAL AXIS
SPRINGBACK
PRESS BRAKE (OPEN)
PRESS BRAKE (CLOSED)
V BENDING
WIPE BENDING
DESIGN RULES
BEND RADIUS
(B) SHEET METAL CUTTING WITHOUT SHEARING
LASER BEAM CUTTING
CAPABILITIES
DESIGN RULES
PLASMA CUTTING
WATER JET CUTTING
ROLL FORMING
ROLL FORMING LINE
SPINNING
SPINNING LATHE
DEEP DRAWING
DEEP DRAWING
STRETCH FORMING
(3) JOINING PROCESS
MAINL THREE TYPES OF JOING PROCESS ARE USED
THERE ARE THREE TYPES OF SOLDERING:
1. SOFT SOLDERING:
2. HARD SOLDERING:
3. BRAZING:
(B) WELDING
MAINLY TWO GROUPS OF WELDING ARE USED IN INDUSTRY:
(C) RIVETING
(4) FINISHING PROCESS
SURFACE FINISHING TECHNIQUES
ABRASIVE BLASTING CLEANING
INDUSTRIAL COATINGS
HOT GALVANISING PROCESS
SURFACE PREPARATION
CAUSTIC CLEANING –
PICKLING –
FLUXING –
GALVANIZING
INSPECTION
COATING STRUCTURE
COATING UNIFORMITY
COATING THICKNESS
HOT DIP GALVANIZED BENEFITS
CORROSION RESISTANCE
GALVANIZED COATINGS PROTECT STEEL IN THREE WAYS:
COATING TOUGHNESS
COMPLETE COVERAGE –
RELIABILITY –
SPEED OF APPLICATION –
FASTER CONSTRUCTION –
LOWEST LIFETIME COST
LONG LIFE –
EASE OF INSPECTION –
COMPETITIVE FIRST COST
BARRIER PROTECTION
COATING DEFECT
DE-LAMINATION
DRAINAGE SPIKES
DISTORTION
FLUX INCLUSION
FLAKING
ROUGH SURFACE CONDITION
RUNS
RUST BLEEDING
WELD SPATTER
WELDING BLOWOUTS
WET STORAGE STAIN
DROSS INCLUSIONS
BARE SPOTS
SAND EMBEDDED IN CASTING
TOUCH MARKS
POWDER COATING PROCESS
THE POWDER COATING SYSTEM
A BATCH POWDER COATING SYSTEM:
A CONVEYORIZED POWDER COATING SYSTEM:
COMPONENTS OF POWDER COATING SYSTEM
PRETREATMENT SYSTEM –
AIR COMPRESSOR
POWDER SPRAY SYSTEM
THERE ARE AT EAST THREE TYPES OF ELECTROSTATIC GUNS IN USE:
POWDER COATING BOOTH WITH RECOVERY SYSTEM –
CURING OVEN
MAIN STEPS
MELT, FLOW, GEL, CURE
POWDER COATING GUNS
DRYING AND CURING
ADDRESSES OF RAW MATERIALS SUPPLIERS
SUPPLIERS OF M.S STRIP COILS
SUPPLIERS OF MIG ELECTRODE WIRE
SUPPLIERS OF PACKING MATERIALS
SUPPLIERS OF PICKLING CHEMICALS
SUPPLIERS OF POWDER COATING PAINT
SUPPLIERS OF POWDER COATING PAINT
ADDRESSES OF PLANT AND MACHINERY SUPPLIERS
SUPPLIERS OF PUNCHING PRESS
SUPPLIERS OF POWER PRESS
SUPPLIERS OF SHEARING MACHINE
SUPPLIERS OF ROLLING MACHINE
SUPPLIERS OF FLYPRESS
SUPPLIERS OF BENDING MACHINE
SUPPLIERS OF MECHANICAL PRESS
SUPPLIERS OF CNC PLASMA CUTTING MACHINE
SUPPLIERS OF WELDING MACHINE
SUPPLIERS OF PROJECTION WELDER
SUPPLIERS OF SEAM WELDING MACHINE
SUPPLIERS OF SPOT WELDING MACHINE
SUPPLIERS OF GAS WELDING EQUIPMENTS
SUPPLIERS OF MIG WELDING MACHINE
SUPPLIERS OF SUBMERGED ARC WELDING EQUIPMENT
SUPPLIERS OF ARC WELDING MACHINE
SUPPLIERS OF EOT CRANES
SUPPLIERS OF D.G. SETS
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF ETP PLANTS
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
SUPPLIERS OF AIR COMPRESSOR
SUPPLIERS OF PLATFORM WEIGHING MACHINE
SUPPLIERS OF POWDER COATING MACHINE
SUPPLIERS OF ANODISING PLANT
SUPPLIERS OF HOT DIP GALVANISING PLANT
SUPPLIERS OF ELECTROPLATING PLANT
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF NDT INSPECTION EQUIPMENT
SUPPLIERS OF PAINTING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
SUPPLIERS OF SUBMERSIBLE WATER PUMP
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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