Practice School 1

PS 1 FINAL PRESENTATION

Prepared By: Pramit Kumar Munshi (2013BtechMe027)

Rajesh Kumar Sah (2013BtechMe033)

Diptanshu Keshote (2013BtechMe008)

JK Lakshmipat University

For our Practice School-1, we went to Carriage and Wagon Repair Workshop, New Bongaigaon, Assam.

It is an Indian state owned enterprise, owned and operated by the government of India through the Ministry of Railways.

We were assigned to Wheel Repair Shop, Machine Shop, Bogie Repair Shop, Carriage Lifting Shop and Corrosion Repair Shop.


COACH

POH (Periodic Overhauling) of BG AC, Non-AC and DEMU Coaches.

Repair of Accident involved damaged Coaches and Special Repair Coaches.

Modification as recommended by Railway Board & RDSO to improve the reliability of safety and better passenger’s amenities.

Rehabilitation of BG Coaches.

Conversion of conventional air brake coaches to Bogie Mounted Air Brake coaches.


WAGON

POH of BTPN, all types of BCN Wagons, DBKM, BRN, BOBYN and Brake Van.

MANUFACTURING & REPAIRING

Manufacturing and fabrication of components and subassemblies of BG Coach and Wagon.

Manufacturing of new wheel set for BG & NG Coaches.

Heat treatment, reclamation and testing of critical safety items like screw coupling, suspension system, draw gear equipment and testing of chain and Rope.

Shot Blasting, Magnaflux testing to detect crack and load testing of all types of C&W springs.

Phosphating of In-house manufactured component like Long beam, Bottom side wall sheet etc.


METALLURGICAL & CHEMICAL LABORTORY

Non-destructive testing including ultrasonic testing of axles & wheels.

Hardness testing of wheel.

Chemical analysis, micro & macro analysis and physical testing of ferrous and non-ferrous components and materials.

Testing of oils, paints, lubricant, varnishes, coal etc.

MAINTENANCE

The workshop undertakes in house preventive maintenance and brake down attention of machinery, plants and equipment both for Electrical and Mechanical.

Power supply for workshop and colony.


Wheel Turning Shop


Train Wheels have a conical geometry, which is the primary means of keeping the train’s motion alignedwith the track.

Train wheels have a flange on one side to keep the wheels, and hence the train keeps running on the rails,when the limits of the geometry based alignment are reached.



Why Conical Train Wheels?

The conical shape allows the wheels to shift and slide across the tracks, thus

effectively varying their radii and allowing them to cover different distances

while rotating at the same angular velocity.


Machines used in Wheel Turning Shop

Wheel Turning Lathe

CNC Wheel press machine

Vertical Turret Lathe.


Wheel Turning Lathe

A lathe machine for turning wheel set having a common

axis, comprising two headstock fitted with one four jaw

hydraulic chuck on each headstock.

It has two tool posts for holding two tools for turning the

two disc on the wheel set simultaneously.

It has two control panels which facilitates to control the

two tool post separately. The machine is hydraulically

operated.

Work done: Turning of wheel set.

Tool used: Carbide tip tool.


Wheel Press Machine

It is used for removing wheels that are already fitted to axles and also for fitting wheels in axles, whose wheel seat diameter is greater than wheel bore diameter.

For different axle types different force for pressing is needed.

Work done: Demounting of disc from axles.


Vertical Turret Lathe:

Vertical Turret Lathe is one which allows the headstock to seat on the floor and the face plate to become a horizontal rotating table, analogous to a huge potter’s wheel.

Here the rotating table are bigger in size to hold the disc of all size of the wheel set.

It has the facility of Programmable Logic Control (PLC).

Work done: Boring of bore diameter on the wheel disc.

Tool used: Square tip tool.


MACHINE SHOP


Machines used in Machine Shop

Vertical lathe / Boring Machine

Centre Lathe

Slotting Machine

Shaper Machine


Vertical Lathe/ Boring Machine

Vertical Lathe is one which allows the headstock to seat on the floor

and the face plate to become a horizontal rotating table, analogous to

a huge potter’s wheel.

This is useful for the handling of large, heavy, short work pieces.

Work done: Turning of face plate of the buffer body plunger.

Tools used: Side cutting tool, V-tool and Square tool.


Centre Lathe

The centre lathe is used to manufacture cylindrical shapes from a range of materials, including steels and plastics.

This lathes may be operated directly by people (manual lathes) or computer control lathes (CNC) that have been programmed to carry out a particular task.

Work done: Thread cutting.

Tool used: Side cutting tool


Slotting Machine

A reciprocating machine in which the ram holding the tool reciprocates in the vertical axis and the cutting action of the tool is only during the downward stroke.

It is also known as vertical axis shaper.

The work piece that cannot be held conveniently in shaper can be machined in slotting machine.

The stroke of the ram is smaller in slotting machine than in shaper.

Work done: Machining of equalizing beam i.e. to flatten the two adjacent sides at the end of the equalizing beam.

Tool used: Bottom tool.



Shaper Machine

In this machine the tool is clamped to the tool post mounted to a dapper box which in turn is mounted to a reciprocating ram.

The ram, while under taking the cutting stroke, pushes the cutting tool through the work piece to remove the material. Here the quick return mechanism is employed.

Work done: Making of centre pin cross cutter by radius tool.

Tool used: Radius tool.


BOGIE REPAIR SHOP


BOGIE

A bogie is a wheeled wagon or trolley. In mechanics

terms, a bogie is a chassis or framework carrying

wheels, attached to a vehicle, thus serving as a modular

sub assembly of wheels and axels.

Parts Of Bogie:

Bogie Frame

Brake Equipment

Axle Box Suspension

Transmission


THE BOGIE FRAME

This can be of inside frame type where the main frame and bearings are between the wheels, or (more

commonly) of outside frame type where the main frame and bearings are outside the wheels.


AXLE BOX SUSPENSION

Absorbs shocks between the axle bearings and the bogie frame. The axle box suspension usually consists of a

spring between the bogie frame and axle bearings to permit up-and-down movement, and sliders to prevent

lateral movement.


POWER TRANSMISSION


CARRIAGE LIFTING SHOP


Lifting of Coach Body:In this shop the body is separated from the bogie. This can be done only when the connecting pipes and the

lighting wires are disconnected or cut out from the bogie to the body.

Before lifting following components are removed and disengaged:

Dynamo belt

Brake pull rod

Lavatory chute

Centre pivot of cotter nut

Air vent screws on bogie frame


Corrosion Repair Shop


Causes of Corrosion in Indian Railway Coaches:

Water seepage through the flooring to the top of trough floor.

Leakage of water through lavatory flooring.

Defective water pipe fittings.

Flushing the flooring with the water jet for cleaning.

The design of the window seal leaves the gap between the side panel to allow the rain water flow through the panel and to drain out at the bottom.


Area subjected to High Rate of Corrosion in Coaches

Body pillar: Bottom portion of pillar near doorways and

lavatory area.

Cross bearer : Joint between sole bar.


Train Roof : Generally occurs due to Rain water.

Trough floor : Adjacent to wash basin and lavatory


Head stock: Outer head stock and tubular sections are heavily corroded due to lavatory.

Battery box : Corrosion due to acid action


Existing SystemAt present high carbon steels are not used for structural work due to its lack of ductility and weld ability.

To prevent corrosion, IRS M-41/97 steels are used which have high ductility, yield strength and weld ability.

These steels have good atmospheric corrosion resistance.

In order to Overcome Corrosion, the following steps are used:

Improve surface coating

Corrosion prevention design adapted



Engineering

Practice School 1