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Industrial Training Project by Praveen Kumar Upadhyay
Industrial Training Project by Praveen Kumar Upadhyay
Industrial Training Project by Praveen Kumar Upadhyay
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
LIST OF CONTENT
1. INTRODUCTION TO GORAKHPUR RAILWAY WORKSHOP
2. MACHINE SHOP
3. SMITHY AND CARRIAGE COMPONENT SHOP
4. HEAT TREATMENT SHOP
5. SPRING SHOP
6. WHEEL AXLE SHOP
7. BOGIE SHOP
8. BRAKE SHOP
9. SHELL SHOP
10. FURNISHING SHOP
10.1 PAINT SHOP
10.2 SEAT SHOP
10.3 AC-SHOP
10.4 WATER TANK SHOP
11. MATERIAL HANDLING SYSTEM
12. OBSERVATION AND REPORT
13. REFERENCES
1. No of officers -19.
2. No of supervisors-378.
3. On roll strength- 5282.
4. Total area covered-29.8 Hectare.
5. Covered area-12.6 Hectare.
6. Township area Gorakhpur.
7. Power consumption- 208662 KWH.
In Mechanical workshop there are various shops dedicated to meet the
requirements. Every shops are provided to carry out the different
manufacturing processes that are required in overhauling processes. The
various shops are listed below. To get the desired efficiency the
supervisors and workers are given with a specific shop to perform the
machining and non-machining processes.
1. Machine Shop
2. Shell Shop
3. Heat Treatment Shop
4. Spring Shop
5. Brake Shop
6. Air Conditioning Shop
7. Wheel Shop
8. Bogie Shop
9. Paint Shop
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.
In the bed mill , however, the table moves only perpendicular to the
spindle's axis, while the spindle itself moves parallel to its own axis.
A horizontal Shaping machine to produce lever hold for the
Gas Blast cylinders
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 Vertical Drilling machine to drill holes in the Al-Based-
Electric nose and caps
The Smith Shop should be divided into the following three sub-shops:
Forge.
General Smithy.
Bolt Shop.
Cost of Metal.
Direct labour charges.
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
Vertical Shearing Machine
Hand Sheet blanker
Hand Sheet Press
Guletting Shearing Machine
Trimming Press
Front Shearing Press
Various product outcomes of carriage component shop are:-
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
Visual and magnetic crack detection. The visual test with the help of magnifying
lens and glass the spring the is inspected of-
Corroded--------------- Fail
Deep seam of mark -------------------- Fail
Surface crack ------------- Fail
No sound defect ------------- Fail
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.
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 AND AXLE SHOP
In this shop, repair work of the wheel and axel is under taken. As it is known that,
the wheel wears throughout its life. When at work the profile and diameter of the
wheel constantly changes. To improve it’s working and for security reason, it is
repaired and given correct profile with proper diameter.
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.
AXLE TURNING MACHINE
External and internal diameter is corrected by this lathe, wheel is tightened on the
rotating clutch. The stationary is carbide tool cut the wheel to correct diameter. This
section was completed in the Machine shop only using a C.N.C. In this shop surface
commissioning is done so as to remove the rust and wear due to atmosphere on the
surface of the wheel. This process not only enhances the surface finish but also gives
surface tolerance due to washing in after machining.
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.
ROLLER BEARING SECTION IN THE WHEEL-AXLE SHOP
Roller Bearing Section in the NER deals with the processing and testing of the load
bearing slots and disks. Initially the cleaning process is done in the Bosch – Water
tank and Roller Bearing Cleaning Plant.
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.
BRAKING SYSTEM
Working-By means of frictional force between wheel and brake pad.
Mainly two types of braking system is used-
1. Air-Braking system.
2. Vacuum-brake system.
3. Electronically control Pneumatic Brakes
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.
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
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.
The production done in this shop follows the scheduling requirements on a monthly
basis and depending on which daily prouction is being carried out. The raw material
for this shop are hig grade cushion materials, base and Raxine covers.
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.
Then the compressor is installed to the assembly of the AC body and this assembly
is the placed on the roof using overhead cranes and various attaching arrangements.
The end connections of the batteries and the electric supply is done in the
powerhouse where entry of the trainees is banned without proper approval and
guidance of the officials.
WATER-TANK SHOP
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.
2. In Smithy Shop the main operations undertaken were to rivet the shocker glass
with the circular steel plate using a rivet head. The rivet head was preheated
on an Open-Furnace fuelled by coal. It was then placed manually along the
bore of steel plate and shocker glass then hammered for penetration and then
allowed to cool down. Then the surface was properly smeared using
horizontal hand grinders. Other operations performed were Laser cutting, Gas
cutting of steel sheets to circular plate.
In carriage component shop major operations performed where SHEET
METAL ones. They were performed on white iron sheet or steel sheets of
different thickness majorly greater than 6mm. The operation performed on the
press where blanking, nibbling, Bending, Shearing, Trimming, Embossing,
etc. The main production outcome of this shop are boxes, welded drain pipes,
etc.
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.
9. Furnishing is high cost intensive job as everything is purchased from the third
party firms like H.E. Ltd., Crompton. The testing and installation is done with
conventional techniques. In AC shop the engineering section basically dealt
with the quality check of the supply of the compressor for various standards
pre-fixed by the Indian railway R&D department. In the paint shop various
kinds of paints like enamel coat, bituminous coal, mineral paints are mixed
with the dryer and the other chemicals. Then the coach is painted by the
painters. Also flooring of the coach is done in this section- It’s a three layer
coat of base, cushion and epoxy sheets. In seat shop the basic stitching of the
seat covers require labour and assembly is also done by them for bot AC and
SLEEPER coaches. In the water tank shop the emphasis is given to make the
water compartment sealed and leak-proof.
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.