SINTERED METAL BEARING
[EIRI/EDPR/0804] J.C : 9419
INTRODUCTION
Powder-metal parts are formed by compressing metal powders with a press and dye and then sintering the piece thus formed. The basic process includes as a first step the selection of pure metals or alloys in suitable powder from and the weighing and mixing of them with or without nonmetals.
The mixed powder is accurately metered into suitable dyes contained within an automatic high-speed compacting press. The powder is molded to the required shape, at room temperature, by the application of high-tonnage compacting pressure. No binder or adhesive materials is used in this operation.
Following compaction, the "green compacts" are heat treated by the process known as sintering to induce optimum strength. Specialized sintering furnace, utilizing accurately controlled atmospheric conditions to suit the particular alloy being produced, are used for this operation. For certain products, manufacture is now complete and the components are ready for use without further processing.
Should dimensional tolerances of extreme accuracy be required, the components can be subjected to a repressing or calibrating operation, carried out in high-speed presses, utilizing tools manufactured to a maximum degree of accuracy. Certain sintered alloys, owing to their extremely high strength and capability of resisting deformation under load, cannot be repressed or calibrated. These must be accepted within the tolerances achieved at the sintering stage of manufacture.
COST ESTIMATION
Plant Capacity 2000 Nos/Day
Land & Building (2000 sq.mt.) Rs. 1.17 Cr
Plant & Machinery Rs. 1.38 Cr
Working Capital for 3 Months Rs. 1.31 Cr
Total Capital Investment Rs. 4.60 Cr
Rate of Return 21%
Break Even Point 65%
CONTENTS
INTRODUCTION
CONSOLIDATION
USES AND APPLICATIONS
POWDERS & HARDENING PROPERTIES
TYPICAL PROPERTIES OF POROUS SINTERED METALS
BIS SPECIFICATIONS
MARKET SURVEY
PRESENT MANUFACTURER/EXPORTER/SUPPLIER OF SINTERED BEARING/BUSHES
COMPACTION OF METAL POWDER
SPECIAL FEATURES OF A HOT ISOSTATIC PRESS
DESCRIPTION OF A TYPICAL SET OF MOULD & ISOSTATIC PRESS
WORKING PROCESS
LIMITATIONS AND ECONOMIC SCALES OF PRODUCTION
MANUFACTURING PROCESS
PROCESS FLOW SHEET
PLANT LOCATION FACTORS
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF RAW MATERIALS
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)