Detailed Project Report on Leaf Springs for Tractor Drawn Trolleys & Four Wheeler Tempos (Capacity 25 Ton per month)

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LEAF SPRINGS FOR TRACTOR DRAWN TROLLEYS & FOUR WHEELER TEMPOS

[EIRI/EDPR/1112] J.C.: 9758

INTRODUCTION

Leaf spring is a simple form of spring, Commonly used for the suspension in wheeled vehicles. It is also called laminated or carriage spring. An advantage of leaf spring over a helical spring is that the end of the leaf spring may be guided along a definite path. A leaf spring can either be directly attached to the frame at Both the ends or attached directly at one end, usually the front, with the other end attached through a shackle. Shackle is a short swinging Arm. The shackle takes up the Tendency of the leaf spring to Elongate when compressed and makes for softer springing ness. Leaf spring are formed by bending. They are made of long strips of steel. Each strip is named as leaf. The long leaf is called moster leaf and It consists of eyes at its both ends. One end is fixed to the chassis frame, the other end is fixed to the shackle spring. The spring will get elongated during expansion and shortened during compression. This change in length of spring is compensated by the shackle. The U Bolts and clamps are located at the intermediate position of the spring the bronze or rubber bushes are provided on both eyes on the master leaf.

Cost Estimation
Plant Capacity                                              1 Ton/Day
Land & Building (Area 1000 sq.mt.)         Rs. 1 Cr.
Plant & Machinery                                        Rs. 19 Lacs
W.C. for 2 Months                                         Rs. 43 Lacs
Total Capital Investment                             Rs. 1.72 Cr.
Rate of Return                                              26%
Break Even Point                                         63%

CONTENTS

INTRODUCTION

THERE ARE FIVE TYPES OF LEAF SPRINGS:-

THE LEAF SPRING HAS THE FOLLOWING CHARACTERISTICS

IN SHORT THE MANUFACTURING PROCESS IS GIVEN BELOW

USES

B.I.S. SPECIFICATIONS

MARKET POSITION

FACTORS CONTRIBUTING TO THE INCREASED DEMAND OF AUTOMOTIVES AND THE GROWTH OF INDIAN AUTO SECTOR

RISE IN THE INDUSTRIAL AND AGRICULTURAL OUTPUT INDIRECTLY HELPS INDIAN AUTO INDUSTRY

GROWTH IN THE ROAD INFRASTRUCTURE INCREASES DEMAND FOR VEHICLES

RISE IN THE PER CAPITA INCOME INCREASES TWO/FOUR WHEELER SALES

URBANIZATION CHANGES THE FACE OF INDIAN AUTO INDUSTRY

RISING WORKING CLASS AND MIDDLE CLASS CONTRIBUTE TO INCREASED DEMAND OF AUTOMOTIVES

EXHAUSTIVE RANGE OF OPTIONS IN PRICE & MODELS OF AUTOMOTIVES

ATTRACTIVE FINANCE SCHEMES FOR PURCHASE OF AUTOMOTIVES

FAVORABLE GOVERNMENT POLICIES FOR THE AUTO SECTOR

COST EFFICIENCIES CONTRIBUTING TO LOWER PRODUCTION COSTS

THE FUTURE OF INDIAN AUTO INDUSTRY

FUTURE OUTLOOK

AUTOMOTIVE MISSION PLAN 2006-2016

AUTO INDUSTRY: GLOBAL SCENARIO

WHAT DOES THE OUTPUT MEAN IN TERM OF INVESTMENTS?

FIXED ASSET TURNOVER

GROWTH POTENTIAL OF INDIAN AUTOMOTIVE INDUSTRY

AREAS TO FOCUS

COMPETITIVENESS IN MANUFACTURING

PRESENT MANUFACTURERS/EXPORTERS/SUPPLIERS OF LEAF SPRINGS

PROCESS FLOW CHART OF LEAF SPRING

PLANT LAYOUT

MANUFACTURING OF LEAF SPRINGS

CONSTRUCTION

PRODUCTION PROCESS:

FABRICATION PROCESS

FIG. 3. COMPLETE COMPOSITE MONO LEAF SPRING

TESTING OF STEEL AND COMPOSITE MONO LEAF SPRING

FIG. 4 (A). STATIC TEST OF COMPOSITE MONO LEAF SPRING

FIG. 4 (B). STATIC LOAD TEST FOR MAXIMUM DEFLECTION

FIG. 4 (C). STATIC LOAD TEST FOR STEEL LEAF SPRING

DESIGN PARAMETER OF STEEL LEAF SPRING

DESIGNS AND FABRICATION OF COMPOSITE MONO LEAF SPRING

TABLE 2. PARAMETERS AT CENTER AND END POINTS FOR COMPOSITE LEAF SPRING

AN IMPORTANT FACTOR FOR LEAF SPRING MANUFACTURE RAW MATERIAL FOR LEAF SPRINGS

TABLE 1 (CHEMICAL COMPOSITION)

SELECTION OF RAW MATERIAL

SILICON

CARBON

PHOSPHORUS AND SULPHUR

SUPPLIERS OF PLANT AND MACHINERY

ROLLING MACHINES

GRINDING MACHINE

SCREW PRESS

DRILLING MACHINE

PLATFORM TYPE WEIGHING MACHINE

DIESEL GENERATOR

HARDNESS TESTING MACHINE

OIL FIRED FURNACE

POWER HACKSAW

POWER PRESS

PILLAR DRILLING MACHINE

SUPPLIERS OF RAW MATERIALS

PAINTS

SPRING STEEL FLATS

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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