Description
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)
