Abhishek Shahi 1509040009
Abhishek Shahi 1509040009
Abhishek Shahi 1509040009
at
Indian Railway
Gorakhpur
by
Submitted to
By seeing the good management of the plant, I learnt a lesson three D’s Discipline,
Determination and Devotion. I also grasp an idea of state-of-the-art technology and plant.
I am also grateful to each of my chief-instructors who provided me every help and removed my
doubts about the particular shop
1509040009
ABSTRACT
The North Eastern Railway is one of the seventeen railway zones in India. It is headquartered
at Gorakhpur and comprises Lucknow and Varanasi divisions as well as reorganized Izzatnagar
division.
This Railway passes through/connects to many important tourist and cultural centres like
Varanasi, Sarnath, Lucknow, Allahabad, Kushinagar, Lumbani, Ayodhaya, Nainital, Ranikhet,
Kausani and Dudhwa. Main Stations are Lucknow, Gorakhpur, Varansi, Chhapra etc. It also
have some stations like Siwan, Gonda, Basti, Khalilabad, Barabanki etc.
Mechanical Workshop, North Eastern Railway, Gorakhpur completed his glorious centenary
years on 04-06-2003. It was established in year 1903. Earlier it was the main loco workshop of
this railway. Steam engine were maintained here for a long time., but now coaches and wagons
are repaired and maintained here.
CONTENTS
CHAPTERS Pages
1. INTRODUCTION 1-2
2.4 Shaper 6
2.5 Slotter 6
2.6 Planer 7
2.11 Wheel 13
2.13 Thinner 15
2.14 Spring 16
1. No of officers -19.
2. No of supervisors-378.
3. On roll strength- 5282.
4. Total are covered-29.8 Hectare.
5. Covered area-12.6 Hectare.
6. Township area Gorakhpur.
7. Power consumption- 208662 KWH.
CHAPTER-02
MAIN SHOPS IN WORKSHOP
1. AUTOMATIC.
2. MANUALLY.
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.
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 provides.
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.
PLANNER-Planner is used for the very large jobs. The basic difference between shaper and
planner is procedure of giving relative motion between the work piece and tool .In the shaper,
the tool reciprocates while in planner the table reciprocates.
TEMPERING
Tempering involves heating steel that has been quenched and hardened for an adequate period
of time so that the metal can be equilibrated. The hardness and strength obtained depend upon
the temperature at which tempering is carried out. Higher temperatures will result into high
ductility, but low strength and hardness. Low tempering temperatures will produce low
ductility, but high strength and hardness. In practice, appropriate tempering temperatures are
selected that will produce the desired level of hardness and strength. This operation is
performed on all carbon steels that have been hardened, in order to reduce their brittleness, so
that they can be used effectively in desired applications.
Austempering
Austempering is heat treatment that is applied to ferrous metals, most notably steel and ductile
iron. In steel it produces a bainite microstructure whereas in cast irons it produces a structure
of acicular ferrite and high carbon, stabilized austenite known as ausferrite.
Martempering
Martempering is a heat treatment for steel involving austenitisation followed by step
quenching, at a rate fast enough to avoid the formation of ferrite, pearlite or bainite to a
temperature slightly above the martensite start (Ms) point.
Annealing
Annealing is a heat process whereby a metal is heated to a specific temperature /colour and
then allowed to cool slowly. This softens the metal which means it can be cut and shaped
more easily. Mild steel, is heated to a red heat and allowed to cool slowly.
Spheroidizing
Spheroidizing is a form of heat treatment for iron-based alloys, commonly carbon steels, in
order to convert them into ductile and machinable alloys.
A spheroidized structure in high-carbon steel is usually obtained by a divorced eutectoid
transformation (DET) reaction, which occurs during slow cooling of aus- tenite with fine
cementite particles.
Normalizing
Normalizing Heat Treatment Definition. Normalizing Heat Treatment process is heating a steel
above the critical temperature, holding for a period of time long enough for transformation to
occur, and air cooling.
Nitriding
Nitriding is a heat treating process that diffuses nitrogen into the surface of a metal to create a
case-hardened surface. These processes are most commonly used on low-carbon, low-alloy
steels. However, they are also used on medium and high-carbon
steels, titanium, aluminum and molybdenum. Recently, nitriding was used to generate unique
duplexmicrostructure (Martensite-Austenite, Austenite-ferrite), known to be associated with
strongly enhanced mechanical properties.
1. Shielded metal arc welding (SMAW) - also known as "stick welding", uses an
electrode that has flux, the protectant for the puddle, around it. The electrode holder
holds the electrode as it slowly melts away. Slag protects the weld puddle from
atmospheric contamination.
2. Gas tungsten arc welding (GTAW) - also known as TIG (tungsten, inert gas), uses a
non-consumable tungsten electrode to produce the weld. The weld area is protected
from atmospheric contamination by an inert shielding gas such as Argon or Helium.
3. Gas metal arc welding (GMAW) - commonly termed MIG (metal, inert gas), uses a
wire feeding gun that feeds wire at an adjustable speed and flows an argon-based
shielding gas or a mix of argon and carbon dioxide (CO2) over the weld puddle to protect
it from atmospheric contamination.
4. Flux-cored arc welding (FCAW) - almost identical to MIG welding except it uses a
special tubular wire filled with flux; it can be used with or without shielding gas,
depending on the filler.
5. Submerged arc welding (SAW) - uses an automatically fed consumable electrode and
a blanket of granular fusible flux. The molten weld and the arc zone are protected from
atmospheric contamination by being "submerged" under the flux blanket.
6. Electroslag welding (ESW) - a highly productive, single pass welding process for
thicker materials between 1 inch (25 mm) and 12 inches (300 mm) in a vertical or close
to vertical position.
Many different energy sources can be used for welding, including a gas flame, an electric arc,
a laser, an electron beam, friction, and ultrasound. While often an industrial process, welding
may be performed in many different environments, including in open air, under water, and in
outer space. Welding is a hazardous undertaking and precautions are required to avoid burns,
electric shock, vision damage, inhalation of poisonous gases and fumes, and exposure to intense
ultraviolet radiation.
Until the end of the 19th century, the only welding process was forge welding, which
blacksmiths had used for centuries to join iron and steel by heating and hammering. Arc
welding and oxyfuel welding were among the first processes to develop late in the century, and
electric resistance welding followed soon after. Welding technology advanced quickly during
the early 20th century as World War I and World War II drove the demand for reliable and
inexpensive joining methods. Following the wars, several modern welding techniques were
developed, including manual methods like SMAW, now one of the most popular welding
methods, as well as semi-automatic and automatic processes such as GMAW, SAW, FCAW
and ESW. Developments continued with the invention of laser beam welding, electron beam
welding, magnetic pulse welding (MPW), and friction stir welding in the latter half of the
century. Today, the science continues to advance. Robot welding is commonplace in industrial
settings, and researchers continue to develop new welding methods and gain greater
understanding of weld quality.
Wheel can be used certain minimum diameter after which it is discarded. The diameter of
the wheel when it is condemned are-
S.N TYPE OF WHEEL DIAMETER IN (MM)
1. ICF/BMEL SOLID 915-813
2. ICF TIRED 915-851
3. BMEL TIRED 915-839
On this lathe, the diameter of the axel is brought to the correct diameter. The cutting tool is
used of carbon tool.
The wheel is pressed on the axel with the help of this machine. A calculated amount of pressure
is applied and the wheel is pressed.
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.
The profile of the wheel is repaired on this machine. Correct profile is cut by carbide tool.
1. COACH PAINTING.
2. LETTER SECTION.
3. TRIMMING SECTION.
4. CORROSION SECTION.
5. POLSIH SECTION.
PURPOSE OF PAINTING-
1. PAINT MATERIALS.
2. ENEMAL MATERIALS.
3. VARNISH MATERIALS.
4. LACQUER MATERIALS.
PAINT MATERIALS-
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.
TYPES OF PAINT-
1. Aluminum Paint.
2. Anti-corrosive.
3. Asbestos paint.
4. Bituminous paint.
5. Cellule paint.
6. Cement paint.
7. Distemper.
8. Plastic paint.
9. Graphite paint.
10. Oil paint
11. Silicate paint.
12. Luminous paint.
13. Enamel paint.
14. Emulsion paint.
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.
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.
CHAPTER-03
MATERIAL HANDLING SYSTEM
Material Handling is the field concerned with solving the pragmatic problems involving the
movement, storage in a manufacturing plant or warehouse, control and protection of
materials, goods and products throughout the processes of cleaning, preparation,
manufacturing, distribution, consumption and disposal of all related materials, goods and
their packaging .The focus of studies of Material Handling course work is on the methods,
mechanical equipment, systems and related controls used to achieve these functions. The
material handling industry manufactures and distributes the equipment and services
required to implement material handling systems, from obtaining, locally processing and
shipping raw materials to utilization of industrial feed stocks in industrial manufacturing
processes. Material handling systems range from simple pallet rack and shelving projects,
to complex conveyor belt and Automated Storage and Retrieval Systems (AS/RS); from
mining and drilling equipment to custom built barley malt drying rooms in breweries.
Material handling can also consist of sorting and picking, as well as automatic guided
vehicles.
Material-handling equipment is equipment that relate to the movement, storage, control and
protection of materials, goods and products throughout the process of manufacturing,
distribution, consumption and disposal. Material handling equipment is the mechanical
equipment involved in the complete system. Material handling equipment is generally
separated into four main categories: storage and handling equipment, engineered systems,
industrial trucks, and bulk material handling.
1. Air-Braking system.
2. Vacuum-brake system.
1. Brake cylinder.
2. Brake pipe.
3. Feed pipe.
4. Distributer pipe.
5. Angle lock.
6. House pipe.
7. Auxiliary reservoir.
8. Guards van valve & pressure gauge.
9. Isolating cock.
10. Passenger emerging alarm signal devic 11. Dirt collector.
Fig 4.1
Description of some important parts of air-braking system-
BRAKE CYLINDER- There are two 355 mm brake cylinder under frame, which is fed by
common distributor valve. It has the piston-rod arrangement, which works under pressure.
Brake cylinder is connected to distributor valve on one side and by pivot to the block
cylinder.
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.
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 & 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.