Detailed Project Report on aluminium alloy wheel
Detailed Project Report on aluminium alloy wheel
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ALUMINIUM ALLOY WHEEL
[CODE NO.3973]
Wheel is a component that supports tire .Alloy wheels are wheels that are made from an alloy of aluminium. Aluminum alloy wheel is the second most popular wheel after steel one
For the production of aluminum alloy wheel, A 356 Al alloys are mostly used as the raw material. Because of their good casting properties, this type of alloys provides the alloy wheel to have good corrosion resistance and strength so that the vehicle can adapt to the road and weather conditions. Aluminum casting alloy wheels are generally produced using low-pressure diecasting. For the application of this casting method, Al-Si casting alloys should be chosen owing to their high adaptation capability to the permanent metal molds. By the help of alloying elements, it is possible to achieve effective and efficient aluminum alloy wheel production.
The advantages of Al alloy wheel are:
? Highly styling versatility
? Any size available
? Unique style
? Weight savings
? Minimum trim
? Best wheel uniformity
? Various “bright look” options
? Low tooling costs
The advantages of Al alloy wheels over the steel wheels are:
1. They provide less fuel consumption. Because density of Al is only 1/3 of the steel. And for 4-aluminum wheels/car, the total weight reduction is 4-8 kg. Consequently, the fuel saving rate is about 7%.
2. Al wheels have better performance than steel wheels. Because of lighter weight, Al wheels gain more quick acceleration and short braking distance.
3. With Al wheels, driving is more comfortable. It means to get excellent impact absorption and more accurate balancing.
4. Al wheel utilization maintains effective dissipation of heat. It improves the service life.
5. By using Al wheels, there becomes no air leakage. Because of precise and accurate machine usage, there occurs very rare air leakage and excellent safety.
6. Al alloys wheels have good corrosion resistance. They are suitable for running under very severe weather conditions.
7. Al alloy wheels have outstanding appearance. Actually, they have various style and brightly shining surface. They are also very attractive.
Types of Al Alloy Wheels
1. Forged Al Alloy Wheels
2. Single piece Al Alloy Wheels
3. Multi piece Al Alloy Wheels
Forged Al alloy wheels are generally used in medium and heavy trucks. Al. Forged wheels are manufactured by using one piece of aluminum alloy that gives fuel savings, greater payloads and lower weight.
Most Al wheels are single-piece castings manufactured from a variety of casting processes The cast product provides an infinite number of styling iterations and optimized for minimum weight and cost. This type of wheels can be used in passenger cars, minivans, sport utility vehicles and etc.
Multi piece wheels are actually manufactured from two or more components that are securely welded together. The process has the unique advantage of having a rolledand- spun wrought aluminum rim combined with a cast disc, made of mold This cast disc can provide lower tooling cost.
COST ESTIMATION
Plant Capacity 2500 Nos/Day
Land & Building (3000 sq.mt.) Rs. 4.56 Cr
Plant & Machinery Rs. 1.62 Cr
Working Capital for 2 Months Rs. 19.21 Cr
Total Capital Investment Rs. 25.66 Cr
Rate of Return 121%
Break Even Point 19%
INTRODUCTION
THE ADVANTAGES OF AL ALLOY WHEEL ARE:
THE ADVANTAGES OF AL ALLOY WHEELS OVER THE STEEL WHEELS ARE:
TYPES OF AL ALLOY WHEELS
FIG-1 SINGLE PIECE FORGED WHEEL
FIG-2 SINGLE PIECE CAST WHEEL
FIG-3 MULTI PIECE WHEEL
PROPERTIES OF ALLOY WHEEL
USES AND APPLICATION
TECHNICAL SPECIFICATION OF ALUMINIUM ALLOY WHEEL
B.I.S. SPECIFICATION
PROCESS FLOW CHART FOR ALLOY WHEEL
MANUFACTURING PROCESS
LOW PRESSURES DIE CASTING
THE MAIN ADVANTAGES OF LOW-PRESSURE DIE-CASTING
ARE GIVEN AS [11]:
AL WHEEL PRODUCTION INVOLVES WITH SEVERAL PRODUCTION
STEPS. THESE STEPS ARE:
THERE ARE SEVERAL STEPS DURING THE PRODUCTION OF ALUMINUM
CASTING ALLOY WHEEL WHICH ARE GIVEN BELOW:
MELTING PROCESS
MELTING OF AL ALLOY FOR DIE-CASTING ENTAILS THREE DIFFERENT
TYPES OF OPERATIONS
MELT PREPARATION
THE PRIMARY PURPOSE OF MELT TREATMENT IS
(A) DEGASSING
DEGASSING PROCESS
MEASURING HYDROGEN CONCENTRATION
REDUCED PRESSURE TEST (STRAUBE-PFEIFFER)
QUANTITATIVE REDUCED PRESSURE TEST (SEVERN SCIENCE)
DENSITY MEASUREMENTS
INITIAL BUBBLE TEST (HYCON TEST):
RECIRCULATING GAS TEST (TELGAS, ALSCAN)
(B) FLUXING
X-RAY INSPECTION (REAL TIME RADIOSCOPIC INSPECTION)
FIGURE: REAL TIME RADIOSCOPIC IMAGE OF CAST AL ALLOY WHEEL
FIGURE: RADIOSCOPIC INSPECTION SYSTEM
FIGURE: SCHEMATIC VIEW OF AL WHEEL INSPECTING RTR SYSTEM
QUALITY CONTROL
FINISHING PROCESS
PAINTING
TESTING
MARKET POSITION
MARKET OVERVIEW
GROWTH DRIVERS AND CHALLENGES
MARKET SIZE AND FORECAST
KEY PLAYERS:
ON THE BASIS OF COATING TYPE, THE MARKET CAN BE SEGMENTED INTO
ON THE BASIS OF WHEEL SIZE, THE MARKET CAN BE SEGMENTED INTO:
ON THE BASIS OF VEHICLE TYPE, THE MARKET CAN BE SEGMENTED INTO:
ON THE BASIS OF SALES CHANNEL, THE MARKET CAN BE
SEGMENTED INTO:
AUTOMOTIVE ALLOY WHEEL MARKET: REGIONAL OUTLOOK
AUTOMOTIVE ALLOY WHEEL MARKET: MARKET PARTICIPANTS
GLOBAL MARKET OVERVIEW OF ALUMINIUM ALLOY WHEEL
FEW KEY PLAYERS IN THIS INDUSTRY ARE AS FOLLOWS:
MAJOR CLASSIFICATIONS OF ALLOY WHEEL ARE AS FOLLOWS:
MAJOR APPLICATIONS ARE AS FOLLOWS:
GLOBAL SCENARIO OF AUTOMOBILE INDUSTRY
CURRENT PROFILE OF THE INDUSTRY
TRENDS IN DOMESTIC PRODUCTION
AUTOMOBILE PRODUCTION TRENDS
TRENDS IN DOMESTIC SALES
AUTOMOBILE SALES TRENDS
TRENDS IN EXPORTS
AUTOMOBILE EXPORTS TRENDS
MARKET SEGMENT
AUTOMOBILE WHEEL MARKET
MARKET DYNAMICS
DRIVERS
RESTRAINTS
OPPORTUNITIES
CHALLENGES
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
6. TRANSPORTATION:
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
8. TOTAL LOAD:
9. LAND AREA/MAN POWER RATIO:
PROJECT IMPLEMENTATION SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
PLANT LAYOUT
ADDRESSES OF RAW MATERIAL SUPPLIERS (IMPORTED)
ADDRESSES OF PLANT AND MACHINERY SUPPLIERS (IMPORTED)
SUPPLIERS OF ALUMINIUM ALLOY WHEEL
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF ALUMINIUM ALLOY INGOT
SUPPLIERS OF PICKLING ACIDS
SUPPLIERS OF PACKING MATERIALS
SUPPLIERS OF PAINT
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF LOW PRESSURE DIE CASTING MACHINE
SUPPLIERS OF ALUMINIUM MELTING FURNACE
SUPPLIERS OF CNC LATHE MACHINE
SUPPLIERS OF PAINTING EQUIPMENTS
SUPPLIERS OF DG SETS
SUPPLIERS OF EOT CRANES
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF ELECTRIC MOTOR
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF PLATFORM WEIGHING MACHINE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF SHOT BLASTING MACHINE
SUPPLIERS OF JIGS AND FIXTURE
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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