Escolar Documentos
Profissional Documentos
Cultura Documentos
SUBMITTED BY:
RAHUL RAJPAL
ROLL NO: 3912662
M.I.E.T.
SUBMITTED TO:
Mr. SANDEEP SODHI
HEAD OF DEPARTMENT
MECHANICAL ENGG.
CONTENTS
Introduction.
Acknowledgements.
Introduction to Indian Railways.
Introduction to D.M.W.
Production in different shops of D.M.W.
Technical Training Centre (T.T.C.)
Light Machine Shop (L.M.S.)
The process of manufacturing camshaft.
Heat treatment shop.
Carbon Brush Shop.
Power Pack Shop.
Major specifications of power pack.
Bogie Shop.
Bibliography.
M.I.E.T.
INTRODUCTION
According to the syllabus and requirements of Kurukshetra University, all
the B.tech students of mechanical engineering had to take six weeks
industrial training.
Industrial Training aims at exposing the students to field practices, size
and scale of operation and work culture at practical sites. For this
purpose, students at the end of fourth semester are required to be sent for
a period of 6 weeks to industry.
Each student is supposed to study the material and technology used at site
and prepares a detailed report of the observation of process seen by
him/her. These students should be supervised and guided by respective
staff members and workers of the industry.
I had decided to take this four weeks industrial training at D.M.W.
workshop, Patiala. I had joined the workshop on 01/07/2014 and
completed my training on 11/08/2014.
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ACKNOWLEGMENT
I am highly indebted to Mr. Kuldeep Singh for providing me this
wonderful opportunity of doing training at D.M.W. Patiala. I am grateful
to him for providing me with a great learning environment and helped me
sharpen my technical skills by assigning challenging tasks. It was
wonderful working in real networks and direct implementation of
technology was a great learning.
Name:
Rahul Rajpal
M.I.E.T.
Railways serve the people of India since 1853. Indian Railways is the biggest
organization in our country, which is engaged in transportation. Indian Railways have
continuously influenced the social, economic, cultural and political life of the people.
Some important aspects of railways are together people from all casts, communities
and religions of trade and commerce, development of industries, influence on
literature, poetry, music, films etc. Indian Railways is giving employment to a big part
of population of India.
6
Railway was opened to public traffic, inaugurating the beginning of railway transport
on the Eastern side of the sub-continent.
In south the first line was opened on 1st July, 1856 by the Madras Railway Company.
It ran between Veyasarpandy and Walajah Road (Arcot), a distance of 63 miles. In the
North a length of 119 miles of line was laid from Allahabad to Kanpur on 3rd March
1859.
The first section from Hathras Road to Mathura Cantonment was opened to traffic on
19th October, 1875. These were the small beginnings which is due course developed
into a network of railway lines all over the country. By 1880 the Indian Railway
system had a route mileage of about 9000 miles.
Indian railway is an industry engaged in the movement of persons and things from
one place to another. It comes into existence after independence and presently, it
constitutes the second largest railway network in the world, it has four gauges of
Railway tracks:
1.
2.
3.
4.
Railway tracks in india is mostly Broad gauged where as meter gauge is used in
mountain or hilly areas and other type of narrow gauges are used for special purpose
applications like mining etc.
6. Indian railway has about 7800 locomotive, 40000 coaches, and 338000
wagons.
7. The manufacturing of steam loco in the country was stopped in 1972
8. Largest network of railways under single management: INDIAN RAILWAY.
9. Longest rail route in the world: Train Siberian express from Moscow to
Vladivostok in Russia. The express covers 9296 kms in 7 days.
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INTRODUCTION TO D.M.W
The foundation stone of D.M.W Patiala was laid on 24.10.1981 by the minister of
Railways Shri Kedarnath Pandey. This production unit is under the ministry of
railways. Government of India has been set up to provide maintenance support to the
fleet of over 3500 Diesel Locomotives of Indian Railways through:1. Manufacture & supply of high quality component & assemblies as spares.
2. Remanufacture of critical assemblies for the unit exchange system of Diesel
Loco Maintenance.
3. Midlife rebuilding of Diesel Locos & power packs.
4. Manufacturing of components for import substitution & timely availability.
THE PROJECT:
The project report for setting up facilities to undertake these activities consulting:
PHASE-1 was approved in Feb 1981 and estimate was sanctioned in May
1982.
PHASE-2 of project comprising of rebuilding POWER PACKS and
LOCOMOTIVES was sanctioned in June 1986.
PROJECT OBJECTIVE:
DMW is engaged to manufacture various diesel loco components along with
rebuilding of diesel locomotives and power packs. The activities & products are given
below:
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Various items of meter gauge locos such as YDM4 are also manufactured &
supplied
DMW LAYOUT:
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SCOPE
Phase 1 was sanctioned in May 1982 and that of phase 2 in June 1986.
PHASE 1
For phase 1 group of shops an area of 47,000 Sq.m has been provided which is
distributed in following shops:
1. CARBON BRUSH SHOP: Manufacturing of brushes for traction machines.
2. LIGHT MACHINE SHOP: - Manufacturing of spare parts of diesel
locomotives.
3. HEAVY MACHINE SHOP: - Remanufacture of engine blocks and traction
motors.
4. TRACTION MACHINE SHOP: Remanufacturing of traction machine
including manufacturing of coils.
5. CYLINDER LINER SHOP: Remanufacture of cylinder liner by chrome
plating.
6. HEAT TREATMENT SHOP: Heat treatment of components.
7. PLANT MAINTENANCE SHOP: Installation and maintenance of machine
tools and facilities which includes material handling.
8. CENTRAL TRANSPORT SHOP: Material handling and transportation.
9. TOOL ROOM: - Maintenance and manufacturing of jigs and fixtures.
PHASE 2:
Construction of phase 2 group of shops, where rebuilding of diesel annualy is to be
undertaken, was taken up in 1986-87 at an estimated cost of 46.63 Crores. For this
purpose covered area of 25,000 Sq.m. and 7 plants has been provided. Facilities for
rebuilding of power packs & diesel locomotives are distributed in the following
shops:
1
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Layout of workshops is such that there is a smooth flow of jobs from one
workshop to another.
Layout of machines is such that there is smooth flow of jobs from one
machine to another according to the operations.
Machines are placed according to group technology so that final job comes
outs as single.
Inspection and testing is done 100 percent with very accurate instruments for
good quality.
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BSNL:
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ENVIRONMENT POLICY:
Diesel loco modernisation works, engaged in rehabilitation & modernisation of diesel
locomotives and manufacture / remanufacture of component & sub-assemblies, and is
committed to continuous improvement of its environment inside the workshop &
colony through:
Control of air, water, land & noise pollution and solid hazardous/medical
waste.
Compliance to relevant environmental legal & other applicable requirements.
Enhanced awareness of employees & interested parties towards environment.
Conservation of natural resources.
QUALITY POLICY
Diesel loco modernisation works engaged in rehabilitation and modernisation of
diesel locomotives and manufacture and remanufacture of components and
subassemblies is committed to maximize customer satisfaction through:
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Tool Room
Tool room is a room where different types of tools are manufactured. Different
operations done in tool room are:
1 Manufacturing of jigs & fixtures, dies and templates.
2 Preventive maintenance of tools.
3 Repair of different tools and equipments.
4 Cutting and re- sharpening of tools.
5 Repair of chucks.
6 Repair and preventive maintenance of punching chucks.
7 Lapping tool for cylinder liner.
8 Boring head large end of connecting rods.
Bull gear.
Spider.
Pinion gear.
Cam shaft.
Connecting rod.
Studs.
Seats.
Cam shaft gear, crank shaft gear.
Drive gear lop, compeller follower lop, face plate lop.
Frame bearing.
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Bogie Shop
This shop is concerned with the manufacturing, remanufacturing and testing of bogie.
Bogie is the lower part of the locative, which supports the engine. It is a unit where
the main power of the Locomotive is utilized.
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15
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16
17
50
-----------------------Z
25
15
----------------------
X+
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Z+
18
S.NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
CODE
G71
G90
G50
M03
G00
G91
G73
G00
G01
G00
G00
G06
G90
G00
M05
M02
Metric
Absolute
Off-set
Spindle start
X 13 Z 0.5
Feed (1200) T.No.-1.
Incremental
Count 10 Do Loop start
X-1, Z 0
Feed (1000)
X0, Z -50.5
Feed (80)
X 0.5, Z 0
Feed(1200)
X 0, Z 50.5
Feed (1200)
Do loop end
Absolute
X 15, Z 5
Feed (1200) T.No.-0
Spindle stop
Prog. end
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GUN DRILLING:
A gun drill is a single point end cutting tools used for drilling of deep holes. The
single tip design of gun drill incorporating bearing pads to support and guide the tool
forces the cutting edge to cut in a true circular pattern and maintain its position
throughout the length of the hole. To initially guide the tool an accurate pilot hole is
necessary. The type of arrangement in which work piece rotates and drill is stationary
tends to give aligned holes. The other machines in this section are: - stamping
machine, deep hole drilling machine, radial drill, centre lath, cam grinder.
GEAR SECTION:
It is one of the most important sections of LMS. About 12 types of gears like bull
gear, cam shaft gear, pinion gear, idle gear, and crank shaft gear are being produced in
this section. This section has the following machines:
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INTERNAL GRINDER:
It is used for the grinding of the bores of the gears. It is a NC machine. It can do
facing and grinding on all the gears except bull gear. Differential type of grinding
wheel is required according to type of gear. It is made by CINCINATI,
MILAERION.
HORIZONTAL MILL:
It is an electrically operated machine. Many operations like milling, gear cutting, key
way cutting, facing, drilling, reaming etc. can be done on the machine itself. It has a
HSS cutter with carbide tip. Horizontal, vertical, to and fro motions are possible on
machine. The machine was made by HMT PINJORE
RADIAL DRILL:
It is used for drilling of holes in the gears. Holes are provided in the gears of fitting.
Any gear can be drilled. The machine is made by HMT PINJORE
TURRET LATHE:
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This machine is used for mass production. Eleven tools are loaded on this machine
four on tool post, six on hexagonal turret head and one on rear tool post. Taper
attachment also provided on this machine. The saddle of this machine is equipped
with many heavy slides on which heavy tool post is provided. The slide and saddle
moves with leads screw up to required length. All types of light gears blank can be
turned on this machine.
GEAR GRINDER:
It is a NC machine. It is basically used for grinding the gear profile. The operation on
this machine is done after cutting the teeth. It finishes the gear. There is a gear train to
set no. of teeth and profile according to type of gear. Servo cut 335 is used as coolant.
The main components produced include bull gear, camshaft gear, drive gear lop.
UNIVERSAL GRINDER:
The grinder head can be rotated to any angle and the table can be moved horizontally.
There is a fixture to hold the components. Connecting rod and Rod caps are main
compound is coolant.
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SIZE DIAMETER
1.
2.
3.
4.
5.
6.
LENGTH
PILOT:- 1.5 INCH
BEARING :-2.62 INCH
RELEAVE:-3.64 INCH
FLANGE:- 2.2 INCH
GROOVE:- 1.5 INCH
CAMS :- 1.25 ,1.5 , 1.25 INCH
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OBJECTIVE:
1
2
3
4
5
6
7
To improve machinability.
To change grain size.
To relieve the stress of the metal induced during hot or cold working.
To improve mechanical properties i.e. tensile strength hardness, ductility,
shock resistance etc.
To improve the electrical and magnetic properties.
To produce a hard surface on ductile interior.
To increase the resistance to wear heat and corrosion.
INDUCTION HARDENING
CASE HARDENING
INDUCTION HARDENING:
Surface hardening of steel done by means of induction is known as induction
hardening. This method involves heating the component by an induced current to
temperature at which the rate of formation of austenite is very rapid and then
quenching it to transform the austenite to martensite. For the purpose of induction
heating from 50 Hz to 450 Hz. Induction hardening is mainly used for gears, cam
shaft, automobiles parts, lath beds, axles etc.
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STRESS RELIVING:
This process is carried out on cam shaft and bull gears. This involves heating of 8 lots
10 numbers of cam shaft up to a temperature of 500 degree Celsius in pit furnace,
then soaking it from about 4 hours at the same temperature and then cool it down in
the furnace itself up to a temperature of about 180 degree Celsius and then it is
unloaded from the furnace and then it is allowed to cool down to ambient
temperature. This process takes about 3 hours to all.
QUENCHING:
It is method of rapid cooling of the metal in the bath of liquid during heat treatment, if
the piece of steel is heated above its critical temperature and plunged into water to
cool it on extremely hard, needle shaped structure known as martensite is formed.
Sudden quenching of steel increases its hardness. The degree of hardness, oil however
gives the best balance between hardness, toughness and distortion for standard steel.
Clear cold water is often used, while the addition of salt increases. The heating time
for certain steel and medium alloy steel should be from 25 to 30% more than for
carbon structural steels. The heating time for high alloy steel should be from 50 to
100% higher.
TEMPERING:
CASE HARDENING:
The process of surface hardening is based upon inductive hardening. A high
frequency current is first transformed from high to low voltage, and the heavy low
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voltage current is passed through the inductor block which surrounds the bearing
journal to be hardened without actually touching it. The inductor block current induce
a current in the surface of the metal which the block surround and it is this induced
current which heats the surface to be hardened. When the area in the question has
been subjected to an accurately controlled high frequency current for proper length of
time. The electrical circuit is open and simultaneously the heated surface is quenched
from a water jacket.
CARBURISING:
Carburizing is the process of adding carbon the surface of steel. The purpose of
carburizing is to obtain a hard surface with high wear resistance. This is
accomplishing by enriching the surface with carbon to the concentration of 0.8%
followed at low temp. Carburizing and subsequent heat treatment is called case
hardening.
CHEMICAL USED
The chemical used for degreasing the components is trichloroethylene. It is volatile
substance having boiling point less than 85 degree Celsius.
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6. RESIN BONDED GRAPHITE: The resin bonded brushes are used for A.C
Commutator motors working with low current densities.
Specified resistance.
Current density.
Transverse strength.
Hardness.
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Stripping section
Reconditioning section
Turbo supercharger section
Valve lever assembly section
Fuel injection pump section
Governor room
Lube oil pump
Assembly section
Test bed
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POWER
PACK
FROM
LRS
STRIPPING
SECTION
TG
ENGINE
BLOCK ON
MANUPUL
ATOR
ENGINE
BLOCK
POWER
PACK
ASSY.
POWER
PACK
TESTING
ON TEST
BED
ENGINE
BLOCK
TRACTION
MACHINE SHOP
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POWER
PACK TO
LRS
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PISTON PIN:
The piston pin has a floating fit in the piston and running fit in the steel backed,
bronze lined connecting rod bushing. A rolled sleeve is installed in the pin bore to seal
in the cooling oil. Special snap rings are provided at each end of the pin to hold it in
place.
CONNECTING ROD:
The connecting rod is a high strength alloy steel forging with the conventional rod
cap. Pressed into the piston end of the rod is steel backed bronze lined split piston pin
bushing. Joining both ends of the rod is a drilled passage for pressure fed lubrication.
The rod cap is aligned to the rod by a short and long dowel and is secured by nuts and
bolts.
PISTON RINGS:
The rings are wholly replaced. They maintain the compression in the cylinder piston
enclosure. Various types of rings are square, taper, and conformable and scarper.
Square and taper rings are cast.
CYLINDER LINER:
They fit in the cylinder block with a metal to metal fit. Each liner has a collar on its
upper end which seats in the cylinder block. One seal ring in a groove near the top of
the line and two seal rings in the groove near the bottom of the liner seal the fits
between the liner and cylinder block. Metal to metal joints of the flat type from the
compression seal between the liner and cylinder heads are there.
CYLINDER HEAD:
The cylinder head is secured to the cylinder block by 7 studs. Water jumpers from the
cylinder block to each cylinder head conduct water from the cylinder block to water
cooling passage in the cylinder heads. Each head has suitable chambers for two air
inlet valves two exhaust valves and a fuel injector nozzle.
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AIR ELBOW:
Individual air elbow conduct air from air passage in the cylinder block to the cylinder
head. A gasket is used for air elbow and cylinder block fitment.
STRAINER:
The lube oil strainer is of the basket type with the oil entering the strainer at the
bottom shell connection of the oil. Oil flows up through a hollow tube and strainer
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screen. The oil then passes through the fine mesh screen and out of the strainer shell.
The strainer screen is star shaped to provide maximum straining area.
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GOVERNOR:
Governor used are GE Electro-Mechanical or Woodward mechanical governor. As is
clear from the diagram there are two coils, speed coil & stabilizing. The stabilizing
coil has 475 mA constant current supplied to it. Speed coil gets its feeding current
from Techno generator. Depending upon the increase or decrease in the speed the
piston moves up or down under the varying magnetic effect of coil. The valve system
moves the slave piston up or down. This interns further meshing with piston which
interns further connected to a lever of the control shaft. Thus the control shaft control
the FIP rack and hence the fuel inlet.
DISPLAY UNIT
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CONTROL UNIT
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Turbo charger
Load box testing:
Run the power pack as for testing format
Ensure all safety devices and cooling arrangement for rectifier is working
during WDM3A/WDM3C power pack load testing
Watch all electrical assemblies and power pack including water load box
during testing of power pack or any abnormality
Rectify electrical faults for power pack, if any
Record electrical readings i.e. voltage and current at specified r.p.m in terms
of TG voltage and current or TG rectifier voltage and current.
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Drain the governor oil and gear case oil.
Fill all terminals covers and inspection covers of traction alternator and
auxiliary generator and exciter.
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:
:
:
:
:
:
:
:
Power
Fuel type
No. of valves
Fuel tank capacity
V engine
16 cylinders
100000 to 1200000cc
Plunger type fuel injection
pump with injectors
3300 H.P.
Diesel
64 valves
6000 liters
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BOGIE SHOP
Bogie Shop:
This shop is concerned with the manufacturing, remanufacturing and testing of bogie.
Bogie is the lower part of the locomotive, which supports the engine. It is a unit where
the main power of the Locomotive is utilized.
PROCEDURE FOLLOWED FOR OPERATIONS ON BOGIE:
BOGIE STRIPING SECTION:
From the loco rebuilding shop the bogie frame is brought to bogie stripping section on
the rail tracks. Here all its levers, springs, traction motors, frame, oil, wheel and axle
assembly, bearing etc. are dismantled and send to the various respective sections for
further inspection and repair etc. the procedure followed for dismantling is as follows.
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Scrap bogie frame and then after cleaning with brush, put it in cleaning tank
for three days. Wash it then on high jet pressure machine.
After the process of dismantling, the dismantled parts are send to various sections,
which are as follows:
Frame section.
Wheel and assembly section.
Traction motor shop.
Lever section.
By studying these processes one by one we have:
FRAME SECTION:
After the frame has been dismantled it is thoroughly cleaned in three stages. These are
as follows, first of all the mud from the frame is scraped off with the help of brush
and a scrapped thoroughly till the red color is seen. Then the frame is taken to the
water-cleaning tank where the frame is put inside the tank in which water is
maintained at a temperature of 80-90 C and up to the outlet level of the tank. In the
tank caustic soda is put in the correct ratio and the frame is kept in this tank for
cleaning for about 48 hours. Then after the cleaning the frame is dispatched to the
frame section
After these checks are made the frame is made free i.e. discarded off if there is major
crack present and if not the various cracks are filled up with welding. Then after this
all the bushes of the frame are changed or replaced and all the worn off plates are
changed. Then after this the levers are assembled with the frame i.e. the fitment of
levers etc. after all the operations are over it is dispatched for the final assembly
section.
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DEPRESSING OR PRESSING OF WHEEL DISC, AXLE COLLARS, AND
BULL GEARS
IN PRESSING
S.NO
COMPONENT
1.
WHEEEL DISC
2.
COLLARS
3.
BULL GEAR
INTERFERENCE
0.009-0.011
0.002-0.004
0.008-0.010
PRESSURE OF
105-145 STONS
8-10 TONS
55-90 TONS
# 1 SHORT TON=907 KG
# 1 TON=1000 KG
# 1 TONNES=1016 KG
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BIBLIOGRAPHY
WWW.RAILMUESUM.COM
WWW.DMWPATIALA.COM
WWW.EFUNDA.COM
WWW.STEELLINKS.COM
WWW.INFOSTORM.COM
LIBRARY AT TTC
FROM
DISPLAY
BOARDS:
Which
reflects
the
detail
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