Prepared by: ViswanadharaoJ

Approved by: Venkatesh

Ver.1.0
 Amendments Sheet

Slide Prepared
Ver. No Date Amendments made Approved by
No: by

1 27/07/2009 nil Initial release J V Rao Venkateshwar

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 POWER AXLE MANUFACTURING PROCESS

MANUFACTURING SEQUENCE OF
OPERATIONS
Component: POWER AXLE
Drawing. No.: SOCHI 0016

Ver.1.0
 STEEL QUALITY REQUIREMENT
FOR AXLES
 THE STEEL FOR AXLES SHOULD BE FROM OPEN HEARTH OR
ELECTRIC
 PROCESS. THE STEEL MUST BE OF KILLED QUALITY. KILLED
STEELS ARE
 DEOXIDISED WITH A STRONG DEOXIDIZING AGENT TO REDUCE
OXYGEN
 LEVEL TO VERY LOW VALUE TO PREVENT REACTION WITH
CARBON.

 CHEMICAL COMPOSITION
 CARBON: 0.4 TO 0.55%
 MANGANESE: 0.6 TO 0.9%
 SILICON: 0.15% MIN.
 SULPHUR: 0.05% MAX.
 PHOSPHOROUS: 0.045% MAXVer.1.0
 MANUFACTURING PRACTICE
STEEL INGOTS ARE ROLLED DOWN TO
BLOOMS. THE MINIMUM CROSS SECTION
OF INGOT SHOULD BE TWICE THE
MAXIMUM CROSS SECTION OF BLOOM.

THE BLOOMS ARE SHAPED TO PROFILE OF

AXLES BY FORGING UNDER HAMMER OR
PRESS. THE MINIMUM CROSS SECTION OF
BLOOM SHOULD BE TWICE MAXIMUM
CROSS SECTION OF AXLE.
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 1. FORGING
PRESS DIE GAUGE
FORGING FORGING CALIPE
PRESS OR DIE R-
POWER GAUGE
HAMMER TEMPLA
TE
Dust shield collar Dust shield collar

Journal Wheel seat Axle body Wheel seat Journal

Gear seat

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 2. HEAT TREATMENT
 ALL AXLES WILL BE SUBJECTED TO HEAT-
TREATMENT AS AGREED BETWEEN
PURCHASER AND SUPPLIER.
 NORMALISING OR
 OIL HARDENING AND TEMPERING OR
 ANY OTHER TREATMENT

Dust shield collar Dust shield collar

Journal Wheel seat Axle body Wheel seat Journal

Gear seat
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 3. ROUGH MACHINING
Machine Fixture Tools Gauges
Single point
Depth gauge
Lathe V Block Tool.
Vernier
Centre drill
Forged axles are rough machined to facilitate ultrasonic test
prior to further machining operations.
Sequence of operations: 1. End facing
2.Centre machining
3. Rough turning with allowance for
finish turning.
Dust shield collar Dust shield collar

Wheel seat Wheel seat Journal

Journal Gear seat Axle body

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 4. ULTRASONIC TEST

AXLES ARE TESTED ULTRASONICALLY TO DETECT CRACKS AND OTHER

DEFECTS PRIOR TO FURTHER MACHINING OPERATIONS.
CHEMICAL COMPOSITION BY STEEL MAKER –’HEAT’ WISE;
MECHANICAL PROPERTIES ON TEST SAMPLE AS PER TEST PROCEDURE TO
BE CHECKED AND CONFIRMED.
TENSILE STRENGTH: 570 TO 690 NEWTONS/SQ.MM (MPA)

Dust shield collar Axle body Wheel seat

Gear seat Probe
Journal Wheel seat for U.Test Dust shield collar
Journal

Probe
for U.Test
Probe
for U.Test

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 5. DRILLING AND TAPPING

Drilling and Tapping Machine

Fixture Tools Gauges

Centre drill
Drill Jig, Depth gauge
17.5 dia Drill
Horizontal drilling M/C. Clamping- Vernier Calipers
M20 Tap
Fixture Thread plug gauge
22 dia drill

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 6. ROUGH TURNING
6
Machine Fixture Tools Gauges
Single point Vernier Calipers
Hydraulic Turning Tool Snap Gauges
Copying Lathe fixture Copying template (Go-No go type)
Follower
The cutting tool follows the path traveled by tracer on template and
produces replica of template on the part being turned.

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 7. FINISH TURNING
Machine Fixture Tools Gauges
Single point
Turning Vernier Calipers
CNC Lathe Tools
fixture Micrometer

All the diameters are finish turned leaving stock for cylindrical grinding.

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 8. CYLINDRICAL GRINDING
Machine Fixture Tools Gauges
Grinding wheels
Micrometer
Cylindrical Grinding-
Dial gauge
Grinding Machine wheel Dresser
Master gauge

Relief grooves are ground using grinding wheels dressed to the form.
Diameters are ground with Straight grinding wheels.

Axle body

Wheel seat Wheel seat Journal

Journal Gear seat

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 CYLINDRICAL GRINDING
(Contd…)
Cylindrical Grinding

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 9. ROLLER BURNISHING
 Roller Burnishing
Machine Fixture Tools Gauges
Burnishing
Holding
BURNISHING M/C Rollers Radius gauges
fixture

TURNED AND GROUND AXLES ARE BURNISHED BY REVOLVING HARDENED

ROLLERS. THIS OPERATION IMPROVES THE FATIGUE RESISTANCE OF
AXLES.
Gear seat
Dust shield collar Wheel seat Wheel seat Journal

Journal Axle body

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 ROLLER BURNISHING THEORY
 Roller Burnishing Notes:
 FOR METAL PARTS, SURFACES PREPARED BY
CONVENTIONAL MACHINES ARE COLD- WORKED UNDER
MECHANICAL PRESSURE FROM A SERIES OF FINISHING
ROLLERS.
 IN BURNISHING PROCESS, THE HARD MIRROR-
FINISHED ROLLERS FIRST PRESS UPON THE CRESTS IN
THE ROUGHNESS PROFILE AND FLATTEN THEM
THROUGH PLASTIC DEFORMATION. MATERIAL IS
SQUEEZED INTO BOTTOM OF VALLEYS AND THE LEVEL
IS RAISED.
 FINALLY PEAKS AND VALLEYS REACH THE SAME LEVEL
RESULTING IN FINE FINISH.
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 10. INSPECTION
INSPECTION HAS TO BE CARRIED OUT AFTER EVERY OPERATION
• Inspection:
DURING MANUFACTURE. FINAL INSPECTION HAS TO BE DONE
AFTER ALL MACHINING OPERATIONS

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 11. PROTECTION AND
PACKAGING
 PROTECTION: AFTER INSPECTION AND APPROVAL THE AXLES
HAVE TO BE PROTECTED WITH THREE COATS OF ANTI-RUST
COMPOUND SPECIFIED IN DRAWING OR BY CUSTOMER.
(BITUMINOUS PAINT IS SPECIFIED IN INDIAN RAILWAY STANDARDS.)
 AFTER THE LAST COAT IS DRIED, THE JOURNALS, WHEEL SEATS
AND GEAR SEAT ARE COVERED WITH WATER-PROOF PAPER AND
GUNNY COVER TIED WITH JUTE STRING.
 THE JOURNALS, WHEEL SEATS AND GEAR SEAT ARE FURTHER
PROTECTED WITH WELL FITTED AND TIGHTLY BOUND WOOD
LAGGING OR ANY OTHER APPROVED MATERIAL. THE WOOD USED
SHALL BE DRY AND HELD IN PLACE BY HOOP IRON BANDS OR
STEEL WIRE OF 1.6 DIA OR MORE IN THE GROOVES CUT ON THE
PERIPHERY OF WOODEN PIECES.

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PIVOT MANUFACTURING PROCESS

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 PIVOT MANUFACTURING PROCESS

 MANUFACTURING SEQUENCE OF
OPERATIONS
Component: PIVOT
Drawing. No.: 100117544

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 INSPECTION OF INPUT
INSPECTION COMPONENTS
PROCESS OF
INPUT
COMPONENTS.
 Chalk painting
 Centerline marking with
punch marks
 Dimensional inspection
for machining allowance Note:
Surfaces to be
 Reject if there is no machined are
indicated by M.
machining allowance on
faces to be machined
due to distortion. Ver.1.0
Inspection of welded pivot prior to machining
2. ROUGH MACHINING OF BASE
Machine Fixture Tools Gauges
Face Milling
Milling Vernier
Vertical Milling M/C Cutter Dia250
Fixture Calipers

Mill face maintaining dimn 531. Mill 4 sides maintaining symmetry

Milling Cutter

Resting Resting Resting Resting

Clamping Location Location

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3. FINISH MACHINING OF BASE
Machine Fixture Tools Gauges
Vernier
Clamping Fly Cutter; Calipers
Horizontal Boring M/C
Fixture Boring tool Bore Gauge
1.Finish face. 2. Bore Dia 170H7

Resting
Clamping

FLY CUTTER

Location
Resting

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 4. MACHINING OF STEP ON BASE
Machine Fixture Tools Gauges
Vernier
Milling End Mill Cutter
Horizontal Milling M/C Calipers
Fixture

Clamping

Clamping

CUTTER
Location
Resting

Resting

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5. MACHINING OF STEP ON 2nd SIDE OF BASE

Machine Fixture Tools Gauges

Vernier
Milling End Mill Cutter
Horizontal Milling M/C Calipers
Fixture

Clamping

Clamping

CUTTER
Location
Resting

Resting

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 6. MILLING OF TOP FACE
Machine Fixture Tools Gauges
Face Milling
Milling Vernier Calipers
Vertical Milling M/C Cutter
Fixture
End mill
Milling Cutter

Location

Clamping Clamping

Resting Resting
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 MILLING OF TOP FACE CONTD.

Machine Fixture Tools Gauges

6.Vertical
Milling
Milling M/Cof Top Face (contd)
Milling
Fixture
Face Milling
Cutter
Vernier Calipers
End mill

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 7. Drilling of 16 holes Dia22 and
spot facing of 4 holes on Base
Machine Fixture Tools Gauges
Center drill
Radial Drilling Drill Drill dia 10 Vernier Calipers
M/C Jig Drill Dia 22
Reverse spot facer dia35

DRILL Reverse spot

Location
facing cutter
DRILL JIG
Resting Resting Resting Resting

Clamping

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8. Drilling of 4 holes Dia 14 on face
Machine Fixture Tools Gauges
Center Drill DepthGauges
gauge
Drill Vernier Calipers
Radial Drilling M/C Drill Dia 10 Vernier Calipers
Jig
Drill Dia 14 Thread plug gauge

14 Dia DRILL

DRILL JIG

Clamping Clamping

Location
Resting Resting

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 9. MILLING OF SIDES
Machine Fixture Tools Gauges
Gauges
Face Milling Depth gauge
Milling Vernier Calipers
Vertical Milling M/C Cutter Vernier Calipers
Fixture
Thread plug gauge
Mill one side

Resting
Clamping
Location

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 10. MILLING OF SIDES
Machine Fixture Tools Gauges
Gauges
Face Milling Depth gauge
Milling Vernier Calipers
Vertical Milling M/C Cutter Vernier Calipers
Fixture
Thread plug gauge
Mill other side maintaining dimn.126 and symmetry.

Resting
Clamping
Location

Ver.1.0
 11.
11.MILLING OF
MILLING OF SIDES
SIDES
Machine Fixture Tools Gauges
Face Milling Gauges
Vernier
Depth Calipers
gauge
Milling Cutter
Vertical Milling M/C Vernier
Bevel Protractor
Calipers
Fixture End mill
Thread plug gauge
Mill sides maintaining dimn 343
Mill 74 deg angle and R10 slot. Mill face maintaining dim445

Resting CUTTER

Clamping
Location Clamping
Clamping

Resting
Ver.1.0
 12. MILLING OF SIDES
Machine Fixture Tools Gauges
Face Milling Gauges
Vernier
Depth Calipers
gauge
Milling Cutter
Vertical Milling M/C Vernier
Bevel Protractor
Calipers
Fixture End mill
Thread plug gauge
Mill sides maintaining dimn 340 and symmetry
Mill 74 deg angle and R10 slot. Mill face maintaining dim445

Resting CUTTER

Clamping
Clamping
Location

Clamping

Resting

Ver.1.0
13. DRILLING OF DIA 13 HOLE
Machine Fixture Tools Gauges
Gauges
Centre drill Depth gauge
Drill Vernier Calipers
Drilling M/C 13 dia drill Vernier Calipers
Jig
Thread plug gauge

Resting
DRILL

Clamping
Location

Clamping

Resting
Ver.1.0
14. REPEAT OPERATION 11 ON
OPPOSITE SIDE
Machine Fixture Tools Gauges
Gauges
Centre drill Depth gauge
Drill
Drilling M/C 13 dia drill Vernier Calipers
Jig
Thread plug gauge

Resting
DRILL

Clamping
Location

Clamping

Resting
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 15. DRILLING OF 2 HOLES, COUNTERBORING AND
TAP TO M12.

Machine Fixture Tools Gauges

Centre drill
Depth gauge
Drill Drill dia 10.2
Drilling M/C Vernier Calipers
Jig Tap M12
Thread plug gauge
C’bore dia 13

Resting
Clamping
Location

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 16. REPEAT OPERATION 12 ON OPPOSITE SIDE

Machine Fixture Tools Gauges

Centre drill Gauges
Depth gauge
Drill Vernier Calipers
Drilling M/C Vernier Calipers
Jig
Thread plug gauge

Resting
Clamping
Location

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 17. INSPECTION

Equipment Gauges
Vernier calipers
Surface Table
Micrometer
Angle block
Thread plug gauge
Dial indicator and dial stand

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