STRUCTURAL SHOPThis shop plays an important function in the production process by carrying out different operations as per the requirements.

WELDING: This is the art of joining two metals by the application of heat. Heat makes the metals to flow and then with or without application of pressure the joining operation is being carried out.

The different types of welding operations carried out are:

1. Electric arc welding2. Gas welding3. Submerged arc welding

ELECTRIC ARC WELDING: In this type of welding process no mechanical pressure is applied for joining the metal.

The metal pieces to be joined are heated locally to the melting point temperature by creating an electric arc and then allowed to solidify to form the welded joint. In some cases an additional material called “filler

metal” is used in addition with the metal pieces to form the joint.

GAS WELDING: In company generally CO2 gas welding is performed that is called MIG (Metal Inert Gas) welding.

Here CO2 is used as a shielding gas.

The arc is struck between the electrode and the workpiece and shielding is provided by the gas developed during combustion of flux plus the CO2 gas fed around the arc for this purpose.

While welding is done by flux coated electrode a magnetized granular flux is fed into the arc through the gun nozzle and there is attached itself to the electrode.

The coating is provided to safeguard the electrode from contamination. The arc and weld are protected against the atmospheric contamination by the shield of CO2 gas. The method of feeding the electrode wire into the arc is again similar to that in the standard MIG welding process.

ADVANTAGES:

1. It is a fast welding process.

2. The decomposition rate is high.3. Penetration of arc is deep.4. Minimum edge preparation is required.

SUBMERGED ARC WELDING: It is basically an arc welding process in which the arc is struck between a consumable metal electrode and the workspace.

For starting welding the pieces to be joined are placed in position, flux from the hopper is then fed on to the joint through the flux feeding tube.

The electrode wire is fed into this blanket of flux and the arc is struck. The heat generated melts the metals, the surrounding flux granules and the filler metal. The latter form the weld bead and the former fuses in to form covering of the slag over the bead.

It protects against the atmosphere until it cools down. The process continues as the welding head advance along the joint with a proper speed, the flux hopper unit sliding ahead of the arc. The entire flux fed by the hopper is not melted. This unused part of the flux is been collected by another unit, following the welding

head, and fed back to the hopper for further use. After the slag is cooled down it is removed.

This process is suitable for welding of low carbon steels, stainless steels, medium carbon steels, copper alloys, nickel and nickel alloy etc.

ADVANTAGES:

1. As the arc is completely submerged so no shielding is needed.

2. Shallow grooves can be used for making joint, requiring less consumption of filler metal.

3. Higher welding speed can be applied, so welding time is reduced.

4. Deposit rate is very high.5. No chance of welding spatter.6. Flux act as a deoxidizer to purify the weld metal.

DISADVANTAGES:

1. Flux may get contaminated and lead to porosity in the weld.

2. Slag removal is an additional follow up operation.3. To obtain good weld the base metal have to be

cleaned and made free of dirt, oil, rust.

4. It is not suitable for welding of metal thickness less than 4.8mm.

WELDING MACHINE SPECIFICATION

Oil cooled welding transformer:

ESAB 450 OC natural oil cooled, manual single arc welding transformer. It is portable source of welding current where single phase ac mains supply at 390-440 volts, 50 Hz is available.

TECHNICAL SPECIFICATIONS:

INPUT:

Supply voltage- 440 V

2 line of 3 phases

50 Hz

Rating at 60% duty cycle- 32.5 Kva

Primary current- 78 A

OUTPUT:

Open circuit voltage- 80 V

Welding current range- 60-450 A

Type of welding current- step less

Insulation class- ‘A’

Type of cooling- Natural oil

Weight- 235 kg

Oil required- 200L

CO2 MACHINE SPECIFAICATIONSModel- Surac daiden move 400

Rated current- 400 A

Rated input power- 20 Kva (3 Phase)

Frequency/Primary current- 50/28 Hz/A

Rated duty cycle- 60%

Output current range- 50-40 A

Output voltage range- 14-36 V

Dimension- 375X 560X 730 (w X d X h)

Weight- 100 kg

Wire feeding speed- 1.5-15 m/min

WELDING TORCH

Rated current- 400 A

Welding wire- 0.8, 1.2, 1.6 m

Cable length- 3m

Cooling style- Air cooled

SHOT BLASTINGAfter complete assembly and before painting the wagon is sent in the shot blasting shop. In there the wagon is sent in the shot blasting room. The shot is thrown on the body of the wagon at very high pressure and speed.

The shot is nothing but a dust of iron whose diameter is near about 0.5 to 0.7 mm.

The shot is shot in the shot storage tank due to the pressure difference which is created by the air compressor. The shot is poured on the blade which is present in the shot blasting room. The blade is moved at very high speed. When the shot is poured in the blade it is discharged at a very high speed.

Used shots are not reused.

OBJECTIVES

To make good surface finishTo make smooth surface Improve material quality Improve machinability

CRANE MAINTENANCE1- Preparation for the operation : The cranes are operated by manipulating the controller, governing each type of motion. Before operating to start the crane maintain the following rule.

Press the bottom switch to close the main circuit magnetic contractor in this case however if the controller handle is not at ‘0’ notch, the main circuit magnetic contractor cannot be closed by pressing bottom switch.

OPERATION:HOISTING AND LOWERING:

For hoisting slowly move the controller handle across the notch from 1st motor to last motor so that the resistance are cut off in the step (in case of slipping motor).

Controller should move in the reverse direction for lowering through zero notches. In case of floor operated crane, push button is inching type and respective should be pressed and full speed will be achieved by cutting of resistance in step through automatic timer.

TRAVERSING AND TRAVELLING

For this also controller should be moved slowly across the notch to left or right depending upon the desirable trolley or bridge movement.

It is desirable to bring controller on zero position before reversing in case plugging control is not provided.

For push bottom crane respective should be pressed for desired motion and resistance will be cut off in step through timers automatically.

2. SAFETY AND PROTECTIVE DEVICE:In the following case the operating circuit is opened and main circuit is cut off.

a) When the floor switcher has been pressed by the operator.

b)When stopping, push bottom switch has been pressed.

c) When the over current relay or enclosed fuse has functioned.

d)When the power has been interrupted.

After a limit switch is in.

Above has functioned, preparation can be made for resumption of returning the traversing or travelling controller is in zero position and pressing (on).

Again in this case even if an attempt is made to operate in the direction in which the limit switch has gone off. Operation will not be possible.

3.EMERGENCY STOP:In case of an emergency, quickly press the stop push button switch (off) this will cut off main ckt.

4.COMPLETION OF OPERATION:When all operations are completed, perform the following routine before leaving the crane.

I. Press the button for stopping to release the air circuit brakes.

II. Break all of the fuse free breaks.

III. Check to make sure that the entire controller is at zero position and there is no abnormal overheating of any of the press of the electrical equipment.

SAFE HOISTING PRACTICESHand operated, elastic hoists and trolley of all types are designed keeping in mind the safety of the operator. Our own safety and that of our fellow workers will be assured when over head material handling equipment is used as recommended by the manufacturer.

Some of the safety rules are enlisted as follows:

i. The immediate danger is the possible failure of some load carrying parts. Overloading might also start a defect which could lead to serve future failure event less than rated capacity.

ii. Do not use any overhead material handling equipment for handling personnel.

iii. Conduct a periodic visual inspection for sign of damage or wear.

iv. Do not use the hoisting cables or chains as a substitute for slings.

v. Whenever the host is lowered in such a manner as to take the load of the wire-rope.

vi. Always “inch” the hoist into the load.vii. Limit switches are for emergency use only and

should not be tripped during the normal operation.

viii. Be sure the hoist raises and lowers properly when the corresponding buttons for controllers are operated.

ix. Centre the hoist over the load before lifting.x. The wire ropes for load handling should not be

placed against portions of the load which may cause them to move or slip off.

GAS CUTTINGIn the gas cutting department, generally thick mild steel plate or the plate which are long i.e., large in dimension.

In here raw material to be cut are sheet metal or plates and are cut according to the dimension or draft material list. Draft material list are prepared by on the basis of minimum scrap and the minimum utilization of sheets and plates.

OXY-ACETYLENE TORCH CUTTING:

This is the most common and convenient method now a days. The principle on which it is based on is that oxygen has a strong affinity for iron and steel at elevated temperature. At high temperature oxygen forms iron oxide with iron which has low melting temperature. As a result at high temperature it melts out and the metal is cut.

Thus the steel is first heated to a red colour and then a jet of pure oxygen is blown upon the surface, instantaneously the steel is burned in an iron oxide slag like appearance which under pressure falls down and steel is cut. The pressure is very rapid and metal up to thickness of 7.5cm can be cut by this process. The nozzle is kept above the 4mm of the work.

For 6mm thick mild steel plate 1.2mm nozzle and cutting speed of 30-45 m/hr is employed with acetylene consumption of 1.38 to 2.7 m3/hr. As the thickness increase all the parameters increase.

This process has become versatile. Now due to its simplicity several cutting machines has been employed based on this principle which are automatically controlled by the movement of the torch to cut any desired shape.

GAS CUTTING MACHINE1. TEMPLATE CUTTING MACHINE:It cut the metal plate according to the template of the component or item. In the template cutting machine small components are cut by good accuracy and finishing. This type of machine is used for mass production. This type of machine do not require high skilled operator.

In this type of machine the template to be cut is placed on the top of the machine. Machine has an adjustable case for template for the setting of different type of templates.

D.C power 220V is used for this type of cutting machine. It has D.C motor panel to regulate the D.C motor speed. The motor generates the magnetic field and the roller moves around the templates because the roller becomes the magnet due to the magnetic field generated by the motor.

The movement of the arm of the machine depends upon the roller movement. Thus the roller guides the movement of the arm of the machine. Arm of the machine consist of oxygen and acetylene release nozzle and control knob.

Arm of the machine upward, downward, leftward, rightward motion. Metal plate which is to be cut is placed on the machine table and is marked at the point at which cutting is to start. Adjust the arm of the machine and the gas release knob. Motor speed and distance between plate and nozzle point is controlled and maintained according to the thickness of the plate.

PUG MACHINEBy this type of machine straight or horizontal plates are cut. Pug machine travel on the fixed path which is placed on the metal plate which is to be cut.

The movement of the PM on the well defined path is achieved with the help of a universal motor. Universal motor is fitted with the pug machine.

The speed of the universal motor is controlled by thiristor controlled system. Speed is controlled by the operator by revolving the knob which is present in the thiristor control system which depends on the thickness of the plate.

BOBRN TYPE WAGON SPECIAL FEATURES OF BOBRN WAGON:

1.Bottom discharge doors Doors are electro-pneumatically operated by the line side equipment. Door’s operating pipe shall be changed from the locomotive with compressed air at a pressure of 6.2 bar.

2. Brakes Single pipe graduable release air brake system fitted with auto slack adjuster and automatic load sensing device to cater for the brake power requirement in empty and loaded condition.

3.Bogies 2-axel cast steel bogie type CASNUB-22 NLB of R.D.S.O specification no. WD-21-CASNUB-22NLB-BOGIE-93 REV which is fitted with the spring plank, long travel helical spring, damping device, taper roller cartridge bearing of R.D.S.O specification.

4.Coupler High tensile centre buffer coupler is used.

5.Bottom discharge door Doors are to be operated by manual pneumatic valve. Door operating pipe may be changed from the locomotive with compressed air at a pressure of 6.2 bar.

5 Corner gusset 46 Bolster assembly 27 Diagonal 48 Head stock 2R,2L9 Centre sill 110 End ridge x end assembly 1R,1L11 Cross ridge bracing 412 Bracket for Bp 2

BRAKING DETAILS OF BOBRN TYPE WAGON

Air brake:

1. Estimated weight of wagon–25.61 tonne2. Brake cylinder size-355 mm3. Number of cylinder used-1 4. Effective piston force;

i. Under tare-2016 kgii. Under gross-3600 kg

5. Rigging efficiency – 90%6. Rigging ratio

Bogies casnub-10.287. Total brake block pressure

i. Under tare-1775 kgii. Under gross-32414 kg

DOOR OPERATING ARRANGEMENTS

Parts:

i. Air receiver tank.ii. Pneumatic control valve.

iii. Air cylinder.iv. Dirt collector.v. Door pipe.

vi. Cut off angle cock.

Hot shopHot shop consists of bending with the help of forging, cold-heading, forming, punching, coining and heat treatment.

DS SHOP

It means Drop Stamping Shop. In this particular shop forging stamping, flashing, pouncing etc are carried out with the help of forging machine(both hydraulic and mechanical type).

FORGING:

It is defined as the controlled plastic deformation of metals at elevated temperature into a predetermined size using compressive force exerted through a type of die by a hammer, a press or a upsetting.

UPSETTING:

It is done to reduce the height of forging and to increase its diameter. Usually completely overlapping tool is used in this process.

IMPRESSIONS DIE FORGING:

It is used when the work-piece is small and intricate in the shop. A piece of heated metal is placed on the lower die is blocked. The metal placed into the shop of the die get blows from a machine hammer.

FORGING PRESS:

It defers from a forging hammer with respect to the energy which is applied more gradually to the work piece which is heated only one time in each impression.

BLANKING:

This is the operation which is carried out on the presses and which consists of cutting the outside contour of a stamping.

PUNCHING:

This is also a press operation which consists of cutting holes of various shapes.

MECHANICAL FORGING PRESS:

It consists of a heavy and rigid frame, an electric motor to supply energy and a flywheel to store energy. The

rotary motion can be converted into vertical movement by electrical shaft, crank shafts.

HYDRAULIC FORGING PRESS:

In this the ram is operated by a large piston which is driven by high pressure oil. The piston movement is quite slow in the process.

PS SHOP(A&B)

It means Press Stamping Shop where the forming processes are carried away.

Forming processes means converting the metal plates into desired shape and size by applying high pressure with the help of the punch and die on the hot metal sheets or plates. In this department two brake presses and two hydraulic presses are used to perform the job. Brake presses have a capacity of 300 tonnes.

In the hydraulic press, pressure is applied on two sides of a sheet. The range of the application is large and the thickness of the materials which can be hot pressed may vary widely, provided equipment is available for required pressure and size.

Two types of hydraulic presses are in use. In the first type the steel is gripped in stationary jaws and is

subsequently stretched by moving the form block vertically with a plate actuated by hydraulic piston placed in a cylinder. In the second type there is an advantage of positioning the jaw easily.

SMY SHOP

In the SMY shop different types of operations like upsetting, forging, straightening etc are carried away. In this shop there is one oil furnace which is used for the upsetting operation.

BENDING:

It is one of the most important process and is very frequently used. It may be classified as sharp corner bonds or more graduable bonds.

When the material is bonded by hammering, the outer and inner surface does not remain same. The inner surface is shortened while the outer surface is stretched which causes bulging at the side of the inner surface and increase in the radius of the outer surface. If a sharp corner is required an additional metal is required in that place.

UPSETTING:

This is very useful operation for the parts having uniform cross section throughout and some head at the end point on the end. E.g. a bolt rear axle drive shaft having flanged edge. In upset forging operation a bar of uniform section is gripped in the fixed end of the die so that the requested end could be projected. The pressure is applied at the heated end thus causing to be upset or forced to get desired shape, for which the stock is placed between the fixed and the movable die grips of the bar firmly when it is closed.

PRODUCTION PLANNING AND CONTROL

Production planning means planning of actual production of the component for which an actual demand has occurred. This quantity must be produced not only in required quantity but also in accordance with specification and in the time to meet customer’s delivery requirements.

If more than adequate capacity is provided in equipments and machinery, it becomes a simple task to show that an efficient use is done of the available capacity to make the output.

However in actual practice many errors and gap may occur in case of the available capacity i.e., it may be inadequate and unexpected in local times for purchase input. Labor efficiency may be lowered than which is estimated. So well thought out plans are made to meet all eventualities.

In production planning the production activities themselves and the production control should be integrated and blamed. Planning should carefully analyse the requirements and the ability to produce.

Productions should coordinate and organise related activities and production control should monitor programs and performance. In production planning the actual progress should not coincide with the schedule time and rate of progress.

NEED FOR PPC

1. Customer demand is likely to defer in quantity and delivery schedule and to meet this it may require a longer fluctuation in the production level.

A better alternative system should be planned for production purposes in the future for steady operation with minimum inventories. Production operation are subjected to a variety of uncertainties such as emergency orders brake down. PPC should also provide a way to take this factor into consideration.

OBJECTIVES OF PPC:

1. Determine the expected capacity of each work centre.

2. Allocate this capacity in each broad category of manufacture.

3. Prepare sequential local statement.4. Keep a record of each work.5. Convert the above into a presentation.

PROCEDURE OF PPC:

Purpose:

To ensure that planning of production process are suitable for providing input in manufacturing activities so that the delivery schedule and product quality both are maintained.

Scope:

These processes are applicable to;

1. Planning of production target.2. Material planning for major brought out/ non free

issue of raw materials and maintaining availability status of the same.

Method:

1. Based on order book position as received from commercial department.

2. The annual plan is subsequently revised in normally and half yearly basis based on the production basis.

3. Monthly production plan is made referring to the annual plan for all the product lines for wagon order.

PURCHASE DEPARTMENTDelegation of financial powers for purchase:

Tender value By whom to be exercisedUp to 1 lacs By Dy purchase managerUp to 2.5 lacs By purchase managerUp to 5 lacs By chief purchase managerUp to 10 lacs By Dy G.M. manufacturing

APPROVAL LIST OF SUPPLIERS:

To accelerate procurement it is essential that an exhaustive list of suppliers should be prepared and maintained by purchase department as it works.

i. In order to complete the list of suppliers, advertisement shall be relisted in a newspaper inviting application for registration, with the company, as approved suppliers for various type of materials, equipments etc. The application should be made on the prescription form as per system.

ii. On receiving the application from the interested firms, the same shall be scrutinized to see that the same are completed in all respect and that the replies to the questionnaire are not evasive.

iii. Factors which matters in considering the application for registration as approved suppliers are:

a) Management, financial standing and the capacity of the firm.

b)Types of customers and business holders.c) Specifications regarding to whom the

products are manufactured.d)Servicing testing facilities.e) Income tax clearance certificate. Etc

QUALITY CONTROLIt is an effective system for coordinating the quality maintenance and quality improvement effort of the various in an organisation so as to enable production at the most economic level which further allows customer satisfaction.

Advantages:

1. Improvement of product quality.2. Improvement of product design.3. Reduction in operating cost.4. Reduction in operating losses.5. Reduction in production line bottlenecks.6. Improvement in production moral.

Objectives:

1. To determine size, material, design, appearance, workmanship, finish and other relevant properties.

2. To ensure that the product of lower quality may not go into hands of customers.

3. To carefully observe and analyse the deviation from the set standard of quality during manufacture.

4. To apply corrective measure to achieve the real mission of quality control.

PRINCIPLES OF QUALITY CONTROL:

1. To ensure that the standard of measurement are uniformly applied.

2. For determining the variation of quality.3. A component personal takes the responsibility for

the quality of the product.

DEGREE OF QUALITY:

1. Standards and inspection.2. Inspection of materials.3. Statistical techniques.4. Inspection device.

QUALITY OF POLICY:

INSURE :

B.S.C.L is committed.

THROUGH:

Total customer satisfaction.

AT:

Quality production and timely supply of rolling stock and associated service.

UNDER:

Competitive price.

THROUGH:

Structured quality management through involvement of its committed employee aiming at continual improvement.