Detailed Project Report on aluminium extrusion

ALUMINIUM EXTRUSION [CODE NO.3702]  


Extrusion is a plastic deformation process in which a block of metal (billet) is forced to flow by compression through the die opening of a smaller cross-sectional area than that of the original billet Extrusion is an indirect-compression process. Indirect-compressive forces are developed by the reaction of the workpiece (billet) with the container and die; these forces reach high values. The reaction of the billet with the container and die results in high compressive stresses that are effective in reducing the cracking of the billet material during primary breakdown from the billet. Extrusion is the best method for breaking down the cast structure of the billet because the billet is subjected to compressive forces only.

Extrusion can be cold or hot, depending on the alloy and the method used. In hot extrusion, the billet is preheated to facilitate plastic deformation


COST ESTIMATION

Plant Capacity            10 MT/Day       
Land & Building (10,000 sq.mt.)      Rs. 7.38 Cr         
Plant & Machinery                      Rs. 5.94 Cr     
Working Capital for 2 Months     Rs. 6.52 Cr
Total Capital Investment              Rs. 20.48 Cr
Rate of Return            43%                   
Break Even Point             47%            
              

INTRODUCTION    
FACTORS AFFECTING EXTRUSION    
ADVANTAGES OF THE EXTRUSION PROCESS    
TYPES OF EXTRUDED PROFILES    
CLASSIFICATION OF ALUMINIUM EXTRUSION    
(A) DIRECT (FORWARD) EXTRUSION    
(B) INDIRECT (BACKWARD) EXTRUSION    
(C) HOT EXTRUSION    
(D) COLD EXTRUSION AND WARM EXTRUSION    
PROPERTIES    
PROPERTIES OF ALUMINIUM    
WEIGHT    
STRENGTH    
LINEAR EXPANSION    
MACHINING    
FORMABILITY    
CONDUCTIVITY    
JOINING    
REFLECTIVITY    
SCREENING EMC    
CORROSION RESISTANCE    
NON-MAGNETIC MATERIAL    
ZERO TOXICITY    
USES AND APPLICATION    
USES    
APPLICATION    
B.I.S. SPECIFICATION    
PROCESS FLOW CHART    
MANUFACTURING PROCESS    
THE STEPS IN THE EXTRUSION PROCESS ARE AS FOLLOWS    
DESCRIPTION OF PROCESS    
MANUFACTURING PROCESS OF ALUMINIUM INGOT    
(1) SCRAP PRETREATMENT    
METHODS OF PRETREATMENT    
(A) COMMINUTION    
(B) CLEANING    
METHODS OF CLEANING    
(I) MECHANICAL CLEANING    
(II) PYROMETALLURGICAL CLEANING    
(III) HYDROMETALLURGICAL CLEANING    
(C) SORTING    
METHODS OF SORTING    
(I) MAGNETIC SEPARATION    
(II) AIR SEPARATOR    
(III) EDDY CURRENT    
(IV) DENSE MEDIA SEPARATOR    
(V) HAND SORTING    
(VI) HOT CRUSH    
(VII) INNOVATIVE SORTING SOLUTIONS    
(D) DECOATING    
(2) CHARGING AND FLUXING    
CLASSIFICATION OF FLUXES FOR MELTING ALUMINUM    
(A) COVER FLUXES    
(B) DROSSING FLUXES    
(C) CLEANING FLUXES    
(D) WALL CLEANING FLUXES    
(E) DEGASSING FLUXES    
(F) GRAIN REFINERS    
(G) SILICON MODIFIERS    
(H) DEMAGGING FLUXES    
(3) MELTING PROCESS    
TEMPERATURE CONTROL    
SKIMMING    
ALLOYING    
(4) DEGASSING (MELT TREATMENT)    
(5) INGOT CASTING    
(6) QUALITY CONTROL    
(5) EMISSIONS AND CONTROLS    
(A) SCRAP PRETREATMENT EMISSIONS    
(B) SMELTING/REFINING EMISSIONS    
(6) SHIPMENT    
EXTRUSION PROCESS    
(1) BILLET PREHEATING    
TABLE 1 TYPICAL BILLET TEMPERATURES OF SOFT AND MEDIUM-GRADE ALUMINUM ALLOYS    
TABLE 2 TYPICAL BILLET TEMPERATURES OF HARD ALUMINUM ALLOYS    
(2) EXTRUSION    
(3) QUENCHING    
(4) STRETCHING    
(5) CUTOFF    
(6) ARTIFICIAL AGING    
TABLE 3 TYPICAL HEAT TREATMENT PARAMETERS OF SOME 6XXX ALLOYS    
(7) INSPECTION AND TESTING    
EXTRUSION MATERIALS INSPECTION    
ALUMINUM ALLOY CHECK    
EXTRUSION DYE CHECK    
ADDITIVES CHECK    
EXTRUSION VISUAL INSPECTION    
VISUAL DEFECTS CHECK    
COLOR AND GLOSSINESS CHECK    
DIMENSIONAL INSPECTION    
COATING AND FINISHING CHECK    
WEIGHT AND DENSITY CHECK    
EXTRUSION PERFORMANCE INSPECTION    
TENSILE TEST    
WELDABILITY CHECK    
WORKABILITY CHECK    
CORROSION RESISTANCE    
FLAMMABILITY TESTING    
HARDNESS TEST    
WEATHERING RESISTANCE TESTING    
ABRASION RESISTANCE    
CHEMICAL RESISTANCE    
PLANT AND MACHINERY    
EXTRUSION PRESS    
DESCRIPTION OF EXTRUSION PRESS    
PROCESS FLOW CHART    
(A) FOR INGOT    
(B) FOR EXTRUSION    
MARKET SURVEY    
THE GROWING DEMAND OF ALUMINIUM EXTRUSIONS    
ALUMINIUM EXTRUSIONS THE PROS AND CONS    
THE PLAYERS    
THE FUTURE    
SPREADING AWARENESS    
THE SCENARIO OF THE ALUMINUM EXTRUSION INDUSTRY    
FUTURE OUTLOOK    
CHALLENGES IN THE INDIAN EXTRUSIONS MARKE    
RISKS AND AREAS OF CONCERN    
EXPORT DATA OF ALUMINIUM EXTRUSION    
IMPORT DATA OF ALUMINIUM EXTRUSION    
PLANT LAYOUT    
SUPPLIERS OF ALUMINIUM EXTRUSION SECTIONS    
SUPPLIERS OF ALUMINIUM PROFILE    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF ALUMINIUM SCRAP    
SUPPLIERS OF SILICON POWDER    
SUPPLIERS OF IRON POWDER    
SUPPLIERS OF COPPER POWDER    
SUPPLIERS OF MAGNESIUM POWDER    
SUPPLIERS OF NICKEL POWDER    
SUPPLIERS OF ZINC POWDER    
SUPPLIERS OF LEAD POWDER    
SUPPLIERS OF TIN POWDER    
SUPPLIERS OF PACKING MATERIAL    
SUPPLIERS OF PICKLING CHEMICALS    
SUPPLIERS OF DEGREASING CHEMICAL    
SUPPLIERS OF OIL AND GREASE    
SUPPLIERS OF PLANT AND MACHINERY    
SUPPLIERS OF CRUCIBLE FURNACE    
SUPPLIERS OF INGOT CASTING MACHINE    
SUPPLIERS OF SILICON CARBIDE CRUCIBLE    
SUPPLIERS OF SHEREDDER    
SUPPLIERS OF DE-COATER    
SUPPLIERS OF MAGENETIC SEPARATOR    
SUPPLIERS OF CASTING LADDLE    
SUPPLIERS OF SPECROMETER    
SUPPLIERS OF POROSITY TESTING MACHINE    
SUPPLIERS OF ALUMINIUM EXTRUSION PLANT    
SUPPLIERS OF DG SETS    
SUPPLIERS OF EOT CRANE    
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)