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AT
MECHANICAL WORKSHOP
NORTH EASTERN RAILWAYS,
GORAKHPUR
FOR COURSE -
B.TECH. (5th SEMESTER)
PRODUCTION AND INDUSTRIAL ENGINEERING
PI-319 VOCATIONAL TRAINING REPORT
SUBMITTED BY -
PRAVEEN KUMAR UPADHYAY
SUBMITTED TO –
Prof. V.S.N. Reddy
Dept. Of Mechanical Engineering, N.I.T.KURUKSHETRA
ACKNOWLEDGEMENT
Machine shop
Description
In this section all kinds of machining is done to obtain the correct size
and shape of the job. Besides, machining of steel job, Aluminium-plates
are also machined here. Machining is either performed manually or on
automatic machines.
Machines are two types...
1. Automatic
2. Manual
There are three types of automatic machine.
1. Numerical control
2. Computer numerical control
3. Direct numerical control machine
Numerical Control
The machining parameter are feed from the control panel by pushing
buttons .The job is machined according to the parameter There are N.C.
boring machine in this shop.
The latter is due to the toolpath's being controlled by the machine, either
in jig-like fashion, via the mechanical limits placed on it by the turret's
slide and stops, or via electronically-directed servo mechanisms for
computer numerical control lathes.
A capstan machine is a processing machine used to make the same parts
again and again. The cutting bits are mounted on a rotatable turret
known as a capstan, which permits the client to rapidly change the
introduction of the bits for slicing without needing to take off the first bit
and afterward mount the second. A bit of crude material, off and on
again known as a clear, is mounted into the capstan machine and is then
spun at high velocity.
MILLING SECTION
A turret mill has a stationary spindle and the table is moved both
perpendicular and parallel to the spindle axis to accomplish
cutting. The most common example of this type is the Bridgeport,
described below. Turret mills often have a quill which allows the
milling cutter to be raised and lowered in a manner similar to a
drill press. This type of machine provides two methods of cutting
in the vertical (Z) direction: by raising or lowering the quill, and by
moving the knee.
DRILLING SECTION
Drilling operation is carried out here. A large for the operation .To
complete the operation faster a few gauge milling machine are also
provided. Cutting fluid is sometimes used to ease this problem and to
prolong the tool's life by cooling and lubricating the tip and chip flow.
Coolant may be introduced via holes through the drill shank, which is
common when using a gun drill. When cutting aluminium in particular,
cutting fluid helps ensure a smooth and accurate hole while preventing
the metal from grabbing the drill bit in the process of drilling the hole. In
computer numerical control(CNC) machine tools a process called peck
drilling, or interrupted cut drilling, is used to keep swarf from
detrimentally building up. Peck drilling involves plunging the drill part
way through the workpiece, no more than five times the diameter of the
drill, and then retracting it to the surface. This is repeated until the hole
is finished. A modified form of this process, called high speed peck
drilling or chip breaking, only retracts the drill slightly.
(A) SHAPER
The machine is also called horizontal shaping machine. It works on
quick-return mechanism .The arm of shaper reciprocating horizontally.
The cutting take place only in the forward stroke. The bed of the
machine is fixed and the tool reciprocating. Shaping, Planning,
Grooving etc. are performed by this machine.
(B) SLOTTER
The slotter is vertical shaping machine .The arm reciprocating in the
vertical direction. Most parts are the same as shaper .Slotting is the
process that is carried on this machine.
(C) N.C.BORING
By this boring machine, various different operations can be done such as
drilling machine etc. The depth of cut and the feed is controlled by
pushing the button of control panel. The fig.is displayed while machine,
the work table rotates and the tool is fixed.
(D) PLANER
A planer is a type of metal working machine tool that uses linear relative
motion between the work piece and a single-point cutting tool to cut the
work piece.
A CNC used for the production of the Axles with required dimensions
SMITHY AND CARRIAGE COMPONENT
SHOP
Smithy Shop
Hand forging is the term used for the process when it is done by
hand tools. Similarly, forging done with the help of power
hammers is known as power forging, when carried out by means of
drop hammers as drop forging, and when by forging machines as
machine forging.
Applying pressure for shaping the metal, the primary requirement
always is to heat the metal to a definite temperature to bring in into
the plastic state.
7. Rail tongs,
The Smith Shop should be divided into the following three sub-shops:
Forge.
General Smithy.
Bolt Shop.
Cost of Metal.
Oncost.
In the Forge, General Smithy and Bolt sub-shops, the metal and direct
labour charges should be booked to individual work orders issued by the
Production Office, or to revenue maintenance standing work orders. The
charges which cannot be directly allocated to any particular work order
should be booked against the work orders for shop oncost, within the
respective sub-shops, and distributed in the usual way over the jobs done
during the month, in proportion to the productive labour booked against
each.
Labour—In the Smithy, more than one man is often employed on any
one particular job done and the Job Card for squad work (W. 507) is best
used for recording the daily labour charges incurred on various jobs.
Carriage components are the items that are machined for the purpose of
carriage in the coach and drain wastes produced during the premise and
run life of the train. This part of the workshop generally deals with the
sheet metal operations in large with a pinch of welding in order to create
an assembly.
Various machineries used here are basically a plethora of dies and press.
Different type of presses present in the shop are:-
Press dreck
Trimming Press
Angle Lug, U-plug for the Anchor-link bracket, Wheel tag, Bracket and
the clamps, Body side pillar for the ICF Coaches, Steel Mug Holder,
Stiffing Prop, Back rest Catch Bottom Cover Complete, Top Liner for
Lower Hytrel Washer, Side Panel with lug, Alarm Signal Box, Chute
complete for Washbasin, Suggestion Box for S.L.Rs, Feed box for the
dogs, Side Wearer Cap (I.C.F.), Suspension arrangement for Air
reservoir, Seat Support Bracket Double, Funnel for Drain Pipe, etc.
HEAT TREATMENT SHOP
Heat treatment is the process of heating and cooling of a material to
change its physical and mechanical properties without changing the
original shape and size. Heat treatment of steel is often associated with
increasing its strength, but can also be used to improve machinability,
formability, restoring ductility, etc. Basic heat treatment process for
steels are described in the following subsections.
Hardening.
Tempering.
Austempring.
Martempring.
Annealing.
Stress relieving.
Spheroid zing.
Normalizing
Case hardening.
Cyaniding.
Flame hardening.
Induction hardening.
Nitriding.
Here the operations are majorly performed over the different type of
furnaces in different kind of flames. There is an open tank of water
and multiple other tanks of oil or other dissipiant used whenever rapid
quenching is required.
ANNEALING
HARDENING
MARTEMPERING
SPRING SHOP
In this section the helical and leaf spring are prepared. The helical spring
is the most commonly and vastly used in the coaches as well as in the
engine. Every helical spring undergoes a specific set of testing before
application in the coaches. For this purpose there are certain machine for
testing, grading and repairing it. All materials to some degree show
elastic properties and will deform to some extent when they are
subjected to external loads. “When the load is removed, the material will
return to its original shape” without any deformation provided its elastic
limit is not exceeded. A material which shows these properties can be
considered a spring
In the magnetic testing a mixture of kerosene oil and magnetic red ink is sprayed
on the spring and inspected for the clinging of the oil droplets. If oil clings at same
place if present the presence of crack. There are variation reasons for the failure of
the helical spring such as free height load test, dent mark, corrosion and breakage.
SPRING SCRAGING
After the buckling test, the spring should be put on scraping machine and the
camber should be measured. In this test, the spring should be pressed quickly and
camber should be measured 2 times. The spring should be test such as, it should
not be more than ½ of the plate. In helical spring scraping, the spring is kept on the
machine and its free height us measure. Now the spring is compressed, under
certain and its compression is noted down. The compression is matched from the
table provided for springs. If the compression matches, the spring is passed
otherwise rejected.
VARIOUS REASONS OF SPRING FAILURE
1. Over camber of the spring.
2. Short camber of the spring.
3. Leaf broken.
4. Gap between the leaves of the spring.
D’ BUCKLING
On this machine, buckling is performed on laminated spring. The leaves of the
springs are assembled and pressed. Now it is put on the buckling machine axial and
longitudinal forces are applied.
CLEANING AND SHORT PINNNING OPERATION ON SPRING
Short Pinning operation is performed in the Airless Centrifugal Shot
Blasting Machine following the given flow chart.
After this Operations, Testing of the spring is done. Majorly two operations are
required to be performed:-
First the crack detection is done, reason being the primary rejection is done on the
basis of Crack and not the Load. The Crack detection is done following the
following algorithm:-
After this the load testing is done majorly in the Coventry Load Testing Machine
following the following flowchart:-
Wheel can be used certain minimum diameter after which it is discarded. The
diameter of the wheel when it is condemned are-
In this shop wheel sets are removed from the bogies, the entire wheel is first
inspected for assessing the condition of the component of wheel such as axel trial
wheel disc and guttering.
The wheel is pressed on the axle with the help of this machine. A calculated
amount of pressure is applied and the wheel is pressed.
On this machine the bore of the wheel is adjusted so as to press the axle inside the
bore on the Computer operated hydraulic press.
Bosch- Tank is basically the cleaning tank with a prepared solution. The roller
bearing is dipped into the solution in order to create a film of protective layer and
wash out the earthly gangue. Composition of thre solution in the Bosch tank is
given in the following table:-
Roller Bearing Section is the assembly of parts given in the following figure:-
The assembly is preheated on the induction heater to increase the bore and
adhesion in the assembly parts.
Then the heated assembly is tested using the Ultrasonic testing machine for
different Roller track crack, roller crack, cage crack, outer race crack and inner
race crack. Then this assembly is axially placed on the outer axle and wheel. Then
this roller bearing is pressed by the C.N.C. wheel press unit.
Final Completed assembly after the Wheel shop and Roller-Bearing Shop
Bogie shop
Railway bogies are hardly noticed by the average passenger but they are
an essential part of the train, its drive system and its guidance
mechanism. A standard railway vehicle will have two bogies, generally
located near the vehicles ends. Each bogie is a 4-wheeled or 6-wheeled
truck that provides the support for the vehicle body and which is used to
provide its traction and braking. Each carriage (called a car in North
America and some other English speaking countries and still so called in
the electric traction business) has two bogies. The bogies support the
mass of the vehicle, use the wheels to guide it along the track and
provide some degree of cushioning against the shocks transmitted from
the track during motion. See also Vehicle Suspension Systems.
BRAKE PIPE
This is charged from the locomotive at 5 kg/cm3 and causes application and
release of brakes due to change in its pressure through the locomotive control
system. The pipe linked to distributor system.
FEED PIPE
It having 6kg/cm3 pressure, and keeps the auxiliary reservoir charge at fuel
pressure even when brakes are applied. Feed pipe are also connected to the
distributor valve.
DISTRIBUTOR VALVE
It is connected to the brake pipe auxiliary reservoir and brake cylinder. It controls
the pressure in the brake cylinder. It controls the pressure in the brake cylinder in
proportion to the reduction of pressure in brake-pipe.
ANGLE COCK
It is use for alarming purpose.
BRAKE DISC IN COACHES
HOUSE COUPLING
Both the brake-pipe and feed pipe are fitted to the angle cock outlet for the passage
of compressed air from one coach to another mean of braided rubber and metal
coupling.
GUARD VAN VALVE AND PRESSURE GAUGE
These are provided in the guards compartments. These are provided to control the
train movement.
ISOLATING COCK
Use for isolating the air from one point to the other point.
CHOKE
It is device for restricting the flow of air from one point brakes circuit to other
point. The handle of this cock is kept parallel to the pipe to indicate that it is in
open conditions.
Shell shop
Shell shop is divided into two parts-
1. Fitting Shop
2. Welding Shop
MAIN PARTS OF SHELL
Various parts of shell are as follows-
1. Under Frame
Sole Bar
Head Stock Assembly
Body Bloster Assembly
Through Floor
Crops Bearer
Tubular Structure
2. Side Bar
3. Roof
4. End bar
5. Center Pivot (Guide of turning of train)
FITTING SHOP
Fitting work is a very important work in engineering. In fitting shop unwanted
material is removed with the help of hand tools. It is done for mating, repair and
manufacturing purposes. The person working in the fitting shop is called a fitter. A
fitter should have the complete knowledge of the tools used in the shop.
Commonly used tools are hacksaw, files, chisels etc.
WELDING SHOP
Welding is a fabrication or sculptural process that joins materials, usually metals
or thermoplastics, by causing fusion, which is distinct from lower temperature
metal-joining techniques such as brazing and soldering, which do not melt the base
metal. Some of the best known welding methods are
1. Shielded metal arc welding (SMAW)
2. Gas tungsten arc welding (GTAW)
3. Gas metal arc welding (GMAW)
4. Flux-cored arc welding (FCAW)
5. Submerged arc welding (SAW)
6. Electro slag welding (ESW)
TYPES OF WELDING USED IN SHOP
1. CO2 arc welding
2. Manual metal arc welding.
3. Bharat cutting gas(B.C.G.)
4. Liquefied Petroleum Gas
5. Oxy-acetylene gas welding
GAS WELDING
The most common gas welding process is oxy-fuel welding, also known as oxy-
acetylene welding. It is one of the oldest and most versatile welding processes, but
in recent years it has become less popular in industrial applications. It is still
widely used for welding pipes and tubes, as well as repair work.
The equipment is relatively inexpensive and simple, generally employing the
combustion of acetylene in oxygen to produce a welding flame temperature of
about 3100 °C. The flame, since it is less concentrated than an electric arc, causes
slower weld cooling, which can lead to greater residual stresses and weld
distortion, though it eases the welding of high alloy steels. A similar process,
generally called oxyfuel cutting, is used to cut metals.
Given above are the used inflammable shop used in the shop. This
cylinder is then asssed with a welding torch and then welding is done in
prescence of flame and flux. The whole assembly is then assembled
holistically with sufficient time and precision.
FURNISHING SHOP
PAINT SHOP
The Work of this shop is to paint the coaches and bogie. In this shop there are
many sections and they are following –
1. Coach Painting
2. Letter Section
3. Trimming Section
4. Corrosion Section
5. Polish Section
PURPOSE OF PAINTING
1. For protection against corrosion
2. For Decoration
3. For covering
MATERIAL USED IN PAINTING
1. Paint Materials
2. Enamel Materials
3. Varnish Materials
4. Laquer Materials
PAINT MATERIAL
1. Base
2. Binder
3. Thinner
4. Drier
5. Pigment
6. Inert or Filler Material
THE MAIN PROCESS INVOLVE IN PAINTING
Firstly, Putin is prepared and it gets filled at the places where holes and cracks has
been found. Secondly, the primer is put on the body and then finally painting is
done in order to give the body desire shape.
The overhauling of the coaches has been in given time interval it improves the
quality of coaches and it also prevents the coaches from break down. The
maintenance of coaches is according to time being is done as following-
1. MAIL EXPRESS- 12 MONTHS.
2. PASSENGER- 18 MONTHS.
3. NEWLY COACHES- 24 MONTHS.
SEAT SHOP
There are variety of seats depending upon the type of facility in the coach and
general distinctions like the type of the coach – 1AC, 2AC, 3AC, SL or GEN
coaches. They all have different type of seats decided on the level of the comfort
the Indian Railways decide to provide to their customers which primarily comes
out after interviewing different sect of people ranging from common men to VIPs.
At NER Gorakhpur Railway Workshop primarily two types of seats are framed and
assembled to the seat slot of the shell of the coach. These are for SL- seating and
sleeping section, ACs sleeper seats and General Coach all seats.
AC- SHOP
Air conditioning basically are mounted upon the roof of the coach following
conventional type packing RMPU technique. The coach is equipped with two
compact air conditioning units installed in the roof area at the coach tails above
false ceiling. These units are supplied by three phase mains.
Control and regulation are carried out by a common controller, mounted in switch
cabinet S1 and fed from battery net. The operating and display elements of the air
condition control are equally contained in the switch cabinet S1.
At NER Gorakhpur Railway Workshop the first process is basically of testing the
faults in the brought part of the LHB RMPU based AC body, Basic installation of
the Compressor is done after performing following operations:-
WATER-TANK SHOP
Various Water tanks of different capacities and material are fabricated,
assembled or prepared here. The prepared water tank is then tested in
order to prevent water wastage during travel usage. Water harvesting is
the major priorities and Indian railways claim to save around 400 gallons
of water every day through their techniques.
Conveyer Belt
Small Trucks
OVERHEAD CRANES
An overhead crane, commonly called a bridge crane, is a type of crane found in
industrial environments. An overhead crane consists of parallel runways with a
traveling bridge spanning the gap. Overhead cranes are commonly used in the
refinement of steel and other metals such as copper and aluminium. Overhead
Crane in Workshop were used to lift and displace parts like wheel- axle assembly,
bogies, shell, AC chasis and overhead tanks.
CONVEYER BELT
A conveyor belt is the carrying medium of a belt conveyor system (often shortened
to belt conveyor. In Workshop Conveyer Belt was used at different levels during
testing like magnetic testing, moving assemblies, stocks, seats, etc.
Used when there is insufficient (or intermittent) flow volume such that the
use of a conveyor cannot be justified.
3. In Heat Treatment Shop all the operations were majorly performed on the
furnaces like New Bogie Hearth Furnace, Fixed Hearth Furnace, Open
Hearth Furnace, Electric Furnace, Double Chamber Furnace majorly used
for basic Heat Treatment Operations like Stress Relieve, Cleaning,
Annealing, Hardening, Case-Hardening, Hardening, Quenching,
Normalising, Carburising, Nitriding, etc. The material was first heated to a
predetermined temperature by placing it in the furnace. Then, the material
was checked for even heating and quenched in the required dissipiant
medium depending upon the process of heat treatment being performed
upon. Various parts being heat treated are; Lower Spring Seat protection
tube, Buffer plunger I.C.F., Hanger Axle Box Housing, All forging
equipment.
This shop required Skilled Labour and had a better layout for waste-disposal
techniques, etc.
4. In spring shop the spring was imported from the Railway Spring Factory at
Central-North zone of railways basically from Mitholi, Gwallior. This
imported springs are checked for their properties like crack on surface, sub-
surface or lattice. Then passed from here they are verified for load bearing
capacity. Shot-Pinning of the spring is done in order to relieve them from the
residual stresses generated during their manufacturing. Then the passed
springs are bituminous coated to install in the bogies.
5. In wheel axle shop initially the bore and steps of both the wheel and axle
previously girded and machined in earlier shops is met to the requirement of
the assembly. Then the axle is pressed into the wheel using the computer
operated hydraulic press. This completes the assembly and then anchor links
are placed in the slots of wheel and the assembly is lifted up through
overhead cranes. As informed this process once turned out fatal as the
anchor link broke during the flight. Thus to prevent this situation the anchor
links are checked for crack and load every now and then. Then the roller
bearings are placed axially into the axle from outer side in the roller bearing
assembly section. Details of the process are mentioned earlier in the Wheel
axle section.
6. In Bogie shop the basic framework is of repair and follow the Bolster
assembly strictly. Also all the component except the electric one are installed
in this shop holistically. The Bogie brought here is initially physically
analysed for all kind of the defects and severe damages during the run time
of the bogie. Each part is bolted and analysed following different type of
testing procedure in the screw coupling zone. Various test like load test,
shear test, tensile test, crack test, Zyglo test, etc. are done here before and
after installation. The readied assembly is the marched onto the powerhouse
for battery installation and other kind on tests.
7. In Brake shop basically two brakes are first assembled part by part and then
installed to the bogie – wheel axle assembly. These two types of brakes are
A.B.S and E.C.P brakes. The assembly is done by very skilled labour as
minor faults would lead to catastrophic failure of the brakes and which may
lead to rail accidents.
8. In Shell shop the outer boundary of the coach is repaired in this workshop.
As informed to us the major coach framework is done in the Southern and
North-west railway due to sufficient availability of resources and cheap
manual labour. The basic operations done here are welding and fitting done
by medium skilled workers thus distributing the wages unevenly and in a
way that depends upon the labour skill quality.
Outlines of report:-
1. Skilled labour with good work involvement, determination to completion of
job and experience.
2. Some of the labourers lacked technical knowledge of machinery they were
handling.
3. NERs Women-Empowerment approach by giving equal chance of
involvement to women in workforce.
4. Lot of Waste generation. No emphasis on recycling at ground level.
5. Fair amount of cleanliness due to boom of Swach Bharat Abhiyaan.
6. Job Scheduling type was of Preventative Machine Scheduling. It followed
the basic concept of Batch Production on regular basis to prevent the
Mismatch of excessive demand and meet the required demand anytime.
REFERENCES
1. Codes Manual of Indian Railways-
http://www.indianrailways.gov.in/railwayboard/uploads/codesmanual/Mech
Dept/Mechanical_index.html
2. Report of the Court of Inquiry into the Circumstances Attending the Double
Collision on the Great Northern Railway which occurred at Abbotts Ripton
on the 21st January 1876, HMSO, 1876
7. Data of Indian Railways System given by Er. R.M. Srinivasan, Head South-
East Zone Indian Railways.