NORTH EASTERN RAILWAY GORAKHPUR (U.P)

INDUSTRIAL TRAINING REPORT 2016-17

UNSIET VBS PURVANCHAL UNIVERSITY JAUNPUR

DEPARTMENT OF MECHANICAL ENGINEERING

SUBMITTED TO:- SUBMITTED BY:-

Er. AWADHESH KUMAR HIMANSHU TIWARI (ASSISTANT PROFESSOR) ROLL NO.- 213422 DEPARTMENT OFMECHANICAL B. TECH IVth YEAR

ENGINEERING SEM VIIth

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ACKNOWLEDGEMENT

Mechanical workshop of north eastern railway, Gorakhpur is a well-known public sector

industry. I am deeply grateful to Chief Workshop Manager, Who gave me a chance to have

an insight of the vocational training of four weeks.

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-instructor MR. ANIRUDH SHINGH who provided me

every help and removed my doubts about the particular shop.

NAME –HIMANSHU TIWARI

DATE-16/07/2016

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ABSTRACT

Gorakhpur workshop was established in 1903 for repair and overhauling of MG steam

locomotives, coaches and wagons. Due to gauge conversion from MG to BG, POH activity of

50 BG coaches /month was started in sep1984.The POH of MG coaches was also stopped

from January 2002.At present, this workshop is mainly carrying out POH of BG AC and

NON-AC coaches in number 180 per months. Capacity augmentation and modernization

project phase-1(coasting RS.22.7 crore) and phase -2(coasting Rs.18 cr.) has been sanctioned

and are under progress.

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LIST OF CONTENT

S.N. TOPIC PAGE NO.1. CERTIFICATE I

2. ACKNOWLEDGEMENT 2

3. ABSTRACT 3

4. INTRODUCTION OF INDIAN RAILWAY 6

5. MACHINE SHOP 8

6. PAINTING SHOP 13

7. SPRING SHOP 16

8. HEAT TREATMENT SHOP 18

9. JIGS AND FIXTURES SHOP 20

10. SHELL SHOP 22

11. MATERIAL HANDELING SYSTEM 24

12. REFERENCE 26

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LIST OF FIGURE

S.N. FIGURE NAME PAGE NO.1. CNC MACHINE 92. DRILLING MACHINE 93. LATHE MACHINE 104. SHAPER MACHINE 115. SLOTTER MACHINE 116. PLANNER MACHINE 127. PAINT BOX AND THINER 148. SPRING COIL 169. HEAT TREATMENT 1810. IRON CARBON DIAGRAM 1911. FIXTURE 2012 WELDING BY TORCH 2313. OXY ACETYLINE WELDING PLANT 2314. BELT CONVEYOR 2415. OVE HEAD CRANE 2516. SMALL INDUSTRIAL TRUCK 25

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INTRODUCTION OF INDIAN RAILWAY

Indian Railways is an Indian state-owned enterprise, owned and operated by the

Government of India through the Ministry of Railways. It is one of the world's largest railway

networks comprising 115,000 km (71,000 mi) of track over a route of 65,436 km (40,660 mi)

and 7,172 stations. In 2013–14, IR carried 8,425 million passengers annually or more than 23

million passengers daily (roughly half of which were suburban passengers) and 1050.18

million tons of freight in the year. In 2013–2014 Indian Railways had revenues of  1441.67

billion (US$23 billion) which consists of  940.0 billion (US$15 billion) from freight and 

375.0 billion (US$6.1 billion) from passengers tickets.

Railways were first introduced to India in the year 1853 from Bombay to Thane. In 1951

the systems were nationalised as one unit, the Indian Railways, becoming one of the largest

networks in the world. IR operates both long distance and suburban rail systems on a multi-

gauge network of broad, metre and narrow gauges.

It also owns locomotive and coach production facilities at several places in India and are

assigned codes identifying. Their gauge, kind of power and type of operation. Its operations

cover also provides limited international services to Nepal, Bangladesh and Pakistan.

Indian Railways is the world's seventh largest commercial or utility employer, by number of

employees, with over 1.307 million employees. As for rolling stock, IR holds over

239,281 Freight Wagons, 62,924 Passenger Coaches and 9,013 Locomotives (43 steam,

5,345 diesel and 4,568 electric locomotives). The trains have a 5 digit numbering system and

runs 12,617 passenger trains and 7421 freight trains daily. As of 31 March 2013, 20,884 km

(12,977 mi) (31.9%) of the total 65,436 km (40,660 mi) route length was electrified,

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Since1960, almost all electrified sections on IR use 25,000 Volt AC traction through

overhead catenary delivery.

DIVISION IN INDIAN RAILWAY

The Indian Railways is divided into zones, which are further sub-divided into divisions, each

having a divisional headquarters. There are a total of sixty-nine divisions.

Each of the divisions, is headed by a Divisional Railway Manager (DRM) who reports to the

General Manager (GM) of the zone. A DRM can be appointed from any services of Indian

railway, Indian Administrative Service (IAS) and Indian Revenue Service (IRS) for the

tenure of 3 years but it can be exceeded on the recommendation of Railway Board.

Divisional officers heading all departments viz. engineering, mechanical, electrical, signal

and telecommunication, accounts, personnel, operating, commercial, safety, medical, security

branches report to the Divisional Railway Manager. The DRM is assisted by one or two

Additional Divisional Railway Managers (ADRM) in the working of the division.

There are seventeen main division in Indian railway listed below….

1. Central railway-CR- Mumbai

2. East central railway-ECR- Hajipur

3. East coach railway-ECoR- Bhubaneswar

4. Eastern railway-ER- Kolkata

5. North central railway-NCR- Allahabad

6. North eastern railway-NER- Gorakhpur

7. North western railway-NWR- Jaipur

8. North east frontier-NFR- Guwahati

9. Northern railway-NR- Delhi

10. South central –SCR- Secunderabad.

11. South eastern-SER- Kolkata

12. South western –SWR- Hubli

13. Southern railway-SR- Chennai

14. South east central-SECR- Bilaspur

15. West central railway-WCR- Jabalpur

16. Western railway-WR- Mumbai

17. Kolkata Metro- Kolkata

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MACHINE SHOP

In this section all kinds of machining is done to obtain the correct size and shape of the job.

Besides, machining of steel job, Aluminum-plates are also machined here. Machining is other

performed manually or on automatic machines.

Machines are two types:-

1. Automatic.

2. Manually.

1. AUTOMATIC OPERATED MACHINE

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.

COMPUTER NUMERICAL CONTROL- In this machine all the data corresponding to the

initial work piece to the final product is feed into the computer. All the process required in

the order of action is fed with the help of programmer .In this machine one, has to just fix the

job is to the chuck. All the other process is done automatically. This is the machine use for

large scale production. In this shop there is one CNC chucker turret Lathe machine.

DIRECT NUMERICAL CONTROL-This machine is controlled by installing a control

room away from the work place .These machine are D.N.C. machine. These are fully

automated .The machine shop is divided into different divisions to the task

accomplished .Theses sections are-

1. Capstan and turret lathe section.

2. Milling section.

3. Drilling section.

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4. Central lathe section.

5. Heavy machine section.

FIG:- 01. CNC MACHINE

2. MANUALLY OPERATED MACHINE

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.

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FIG:-02. DRILLING MACHINE

CENTER LATHE SECTION-Heavier lathes are provided in this section. All the lathes

have four jaws chuck for better holding centering is done either manually or with the help

of universal scriber. All kinds of turning are performed here. Parting off is other major

operation done.

FIG:- 03. LATHE MACHINE

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.

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FIG:-04. SHAPER MACHINE

SLOTTER-The 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 .

FIG:- 05. SLOTTER MACHINE

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.

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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.

FIG:- 06.PLANNER MACHINE

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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. POLSIH SECTION.

PURPOSE OF PAINTING-

1. FOR PROTECTION AGAINST COROSION.

2. FOR DECORATION.

3. FOR COVERING.

MATERIAL USED IN 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.

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FIG:-07. PAINT BOX AND THINNER

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.

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9. Graphite paint.

10. Oil paint

11. Silicate paint.

12. Luminous paint.

13. Enamel paint.

14. Emulsion paint.

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SPRING SECTION

In this section the helical and leaf spring are prepared. For this purpose there certain machine

for testing, grading and repairing it.

FIG:-8. SPRING COIL

The test performed on helical spring and laminated spring are-

(1) Visual and magnetic crack detection.

(2) Spring scraping machine.

(3) D’ buckling

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.

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CAUSE PERCENTAGE OF FAILURE

Free of height 8.93%

Load test 82.08%

Dent mark, corrosion & breakage 08.39%

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 ARE AS FOLLOW-

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.

VARIOUS OTHER MACHINES IN THIS SECTION-

1. Quenching tank.

2. Tempering furnace.

3. Rolling machine.

4. Cambering and hardening.

5. Hardness testing machine.

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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.

FIG:-9. HEAT TREATMENT

DIFFERENT TYPES OF HEAT TREATMENT PROCESS

1. Hardening.

2. Tempering.

3. Austempring.

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4. Martempring.

5. Annealing.

6. Stress relieving.

7. Spheroid zing.

8. Normalizing

9. Case hardening.

10. Cyaniding.

11. Flame hardening.

12. Induction hardening.

13. Nitriding.

FIG:- 10. IRON CARBON DIAGRAM

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JIG AND FIXTURE SHOP

If a component to be produced in small numbers then procedure adopted is marketing out,

setting on machine, clamping to machine table. Nevertheless. It would not be suitable for

producing same component in large quantities because of economic reason. A faster and

more profitable method calls for a device JIG&FIXTURE.

JIGS

Jig may be described as a plate, or metal box, structure or a device usually made of which

metal is clamped or fastened or located one after others for the other for specific operation in

such a way that it will guide one or more cutting tools to the same position.

FIXTURE

This may be structure for locating holding and supporting a component or work piece

securely in a definite position for a specific operation but it does not guide the cutting tool.

The cutting tool are set in position by machine adjust or by trial& error method.

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\ FIG:-11. FIXTURE

DESIGN OF JIG& FIXTURES

1. Sharp corners may be avoided.

2. Adjustment locator must be provided.

3. Locating pins should be tapered.

4. Quick acting, clamps should be provided.

5. Safety criterion should be provided.

6. Accuracy is the basic need should not be compromised.

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SHELL SHOP

Shell shop is divided into two parts-

1.FITTING SHOP.

2.WELDING SHOP.

CAUSE OF CORROSION-

1.WATER SLEEPAGE.

2. AIR-TRAP BETWEEN FLOOR AND PLYWOOD.

3. FLYING BLAST (DUE TO FORMATION OF SPOT).

MAIN PARTS OF SHELL- Various parts of shell are as follows-

1. UNDER FRAME

(A)SOLE BAR

(B)HEAD STOCK ASSEMBLY.

(C)BODY BLOSTER ASSEMBLY.

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(D)THROUGH FLOOR.

(E)CROPS BEARER.

(F)TUBULAR STRUCTURE.

2. SIDE BAR.

3. ROOF.

4. END BAR.

5. CENTER PIVOT (GUIDE OF TURNING OF TRAIN).

TYPES OF WELDING USED IN SHELL SHOP-

1. CO2 ARC WELDING.

2. .MANUAL METAL ARC WELDING.

3.BHARAT CUTTING GAS.(B.C.G)

4. LIQUEFIED PETROLEUM GAS.

5. OXY-ACETELENE GAS WELDING.

FIG:- 12. Welding by torch

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FIG:-13.OXY ACETYLINE GAS WELDING PLANT

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

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rooms in breweries. Material handling can also consist of sorting and picking, as well

as automatic guided vehicles.

MATERIAL HANDLING EQUIPMENT-

FIG:-14. BELT CONVEYER

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 mat erial handling.

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FIG:-15. OVER HEAD CRANE

FIG:- 16..SMALL INDUSTRIAL TRUCKS

REFERENCES

1. www.wikipedia.org

2. www.slideshare.com

3. V.B. Bhandari.

4. Google images.

5. John Wiley & sons.

6. Nptel lectures.

7. Ghosh& Malik.

8. Indianrailway.org.in

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