Detailed Project Report on investment casting

 
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 Thereafter, the pattern is withdrawn from the slurry and is manipulated to drain of the excess slurry to produce a uniform coating layer.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