Detailed Project Report on sheet metal and painting shop
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SHEET METAL AND PAINTING SHOP
[CODE NO.4295]
Extremely thin thicknesses are considered as foil or leaf, and pieces thicker than 6mm (0.25 in) are considered as plates. It is one of the fundamental forms used in metalworking and it can be cut and bent into a variety of shapes. Sheet metal is metal formed by an industrial process into thin, flat pieces.
The next best is aluminum. It is lighter but harder to bend into tight shapes without cracking. It is also harder to weld in mass production. The most common sheet metal used in automotive to make bodies is steel. It is reasonably cheap and easy to press into shape to make body parts.
Despite the arrival of carbon fibre, Sheet metal forming is still of great importance to the automotive industry. Most high volume production cars are made from sheet metal. Metals are still the main materials used in the automotive industry. This is due to Metals being able to undergo plastic deformation. This means the metals can be made into most shapes.
Plastic deformation of metal act as the fundamental to all the sheet metal forming processes, without this property, metal will not be allowed to be shaped into all types of objects because they will break.
In the automotive industry the process of deformation starts with a blank. Blank is a metal in its basic form that will undergo the process. In the automotive industry the blank will most likely be made of a sheet of metal which then will cut, stamped or bent into shape.
The future of sheet metal in the automotive industry will largely depend on the future needs of the industry. With current tendency on lean manufacturing and cost cutting, the sheet metal forming process which suit that the most will be the most valuable to the industry.
Sheet metal is simply metal formed into thin and flat pieces. It is one of the fundamental forms used in metalworking, and can be cut and bent into a variety of different shapes. Countless everyday objects are constructed of the material. Thicknesses can vary significantly, although extremely thin thicknesses are considered foil or leaf, and pieces thicker than 6 mm (0.25 in) are considered plate
Automotive Sheet Metal Part
COST ESTIMATION
Plant Capacity 4 MT/Day
Land & Building (3000 sq.mt.) Rs. 1.98 Cr
Plant & Machinery Rs. 3.14 Cr
Working Capital for 2 Months Rs. 1.36 Cr
Total Capital Investment Rs. 6.78 Cr
Rate of Return 18%
Break Even Point 71%
- INTRODUCTION
- AUTOMOTIVE SHEET METAL PART
- TYPES OF SHEET METAL
- SHEET METAL THICKNESSES
- USES ANND APPLICATION
- B.I.S. SPECIFICATION
- PROCESS FLOW CHART
- MANUFACTURING PROCESS
- (1) CUTTING (SHEAR) PROCESS
- (A) CUTTING PROCESS WITH SHEAR
- SHEARED EDGE
- SUCH CUTTING PROCESSES INCLUDE THE FOLLOWING:
- SHEARING
- SHEARING
- BLANKING
- BLANKING
- PUNCHING
- 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
- 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
- THERE ARE FOUR PROCESSES OF RIVETING: RIVETING;
- (4) FINISHING PROCESS
- SURFACE FINISHING TECHNIQUES
- THE FIVE MAJOR PROCESSES THAT MAKE UP SURFACE FINISHING ARE:
- 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
- QUALITY CONTROL
- ANODISING PROCESS
- HARD ANODISING
- BENEFITS
- DISADVANTAGES
- MATERIALS THAT CAN BE ANODIZED
- IN EITHER CASE, ANODISING PROCESSES FOLLOW 5 STEPS:
- THE PROCESS
- METHODS OF ANODODIZING
- BATCH AND COIL ANODIZING
- PRE-TREATMENT
- 5. SEALING.
- BENEFITS OF ANODISING
- APPLICATIONS FOR ANODISED MATERIALS
- QUALITY CONTRL
- 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
- POWDER COATING BOOTH WITH RECOVERY SYSTEM –
- CURING OVEN
- MAIN STEPS
- MELT, FLOW, GEL, CURE
- POWDER COATING GUNS
- DRYING AND CURING
- ADVANTAGES
- DISADVANTAGES
- QUALITY CONTROL
- PHOSPHATING PROCESS
- CHEMISTRY OF PHOSPHATING PROCESS
- ZINC PHOSPHATE
- IRON PHOSPHATE
- MANGANESE PHOSPHATE
- THE FOLLOWING IS A TYPICAL PHOSPHATING PROCEDURE:
- THE MAIN USES OF PHOSPHATING ARE:
- MARKET POSITION
- PLANT LAYOUT
- SUPPLIER OF E-TWO WHEELER AND THREE WHEELER SHEET METAL COMPONENT
- SUPPLIER OF RAW MATERIALS
- 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
- SUPPLIER OF PLANT AND MACHINERY
- 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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