203378526-training-report-at-rail-coach-factory-rcf.pdf
TRANSCRIPT
-
7/23/2019 203378526-Training-Report-at-rail-coach-factory-RCF.pdf
1/27
Rail Coach Fac to ry
Kapurthala
SUBMITTED TO: SUBMITTED BY:
Dr. H.K.Kansal Sukhjit Singh
Roll No.- UE109073
Mechanical/5thSem.
TRAINING REPORT
6 WEEKS)
-
7/23/2019 203378526-Training-Report-at-rail-coach-factory-RCF.pdf
2/27
OBJECTIVES OF TWO MONTH INDUSTRIAL
TRAINING
The main objective of the Training was to get first hand technical andpractical knowledge about the industry.
The main purpose was that the students would become familiar withindustrial environment so that they can take up future challenges whenthey turn up in an industry with good confidence.
The students will thus understand the flow of control and information inan industry.
This two-month Industrial Training has been introduced in DegreeEngineering Courses for the enhancement of students administrativeand professional knowledge about their respective fields.
After completion of their Degree Courses, this training experience willhelp them to make their workplace stronger in the ever-competitive jobfields.
-
7/23/2019 203378526-Training-Report-at-rail-coach-factory-RCF.pdf
3/27
INTRODUCTION RCFs Origin:
Taking into account countrys large population, a proper system of transportation
is inevitable.
The demand of more and more passenger trains is the result of the countrys
ever increasing prosperity and population.
The decision to set up a Rail Coach Factory at Kapurthala, Punjab in August85
was a timely step towards making good shortfall and complementing the coachmanufacturing capacity of Railways other manufacturing units.
Location:
The foundation stone of this factory was laid by the honorable Prime Minister
(Late Shri Rajiv Gandhi)of India on 17thAugust 1985.
It is located 9 kms. From Kapurthala, near the JalandharFerozepur railway line
and state highway, near the Hussainpur village.
Growth of RCF:
During year 2001-02, RCF has manufactured 1250 coaches having 974 non-AC
and 276 AC.
During recent development RCF is now started manufacturing the new series of
L.H.B coaches with the help of agreement of German Technology in design andmanufacturing.
-
7/23/2019 203378526-Training-Report-at-rail-coach-factory-RCF.pdf
4/27
OBJECTIVES OF RCF DESIGN IMPROVEMENT: The emphasis is on light-weight Passenger
Coaches with higher passenger capacity, improved safety and comfort and
high speed.
TECHNOLOGY:Keeping pace with latest technological developments.
PRODUCTIVITY:Improvement in productivity vis--vis the existing coachunit.
QUALITY:Maintaining workmanship of higher International standards.
MANPOWER DEVELOPMENTS:Development of an effective organizationwith pride in their work and faith in the organization.
NATIONAL OBJECTIVES:
Self sufficiency
Energy conservation
Increased employment
Pollution free environment
-
7/23/2019 203378526-Training-Report-at-rail-coach-factory-RCF.pdf
5/27
VARIOUS SHOPS IN RCF
Sheet Metal Shop
Fabrication Shop
Shell Assembly Shop
Paint ShopBogie Shop
Furnishing Shop
Finishing Shop
-
7/23/2019 203378526-Training-Report-at-rail-coach-factory-RCF.pdf
6/27
SHEET METAL SHOP In sheet metal shop, all the raw material is transported which is
required for the coach manufacturing of components. This materialis either brought from steel authority of India or is imported fromJapan.
Commonly used sheet for the part is carbon steel and the SAILsupplies mild steel.
The carbon steel can be divided in to four groups or categories: -
1. Low Carbon Steel: It has the composition of carbon ranging from0.05to0.25%. These are use only when moderate strength isrequired together with considerable plasticity. These are generallyused for sheets, strips, tubing, wire nails, rivets, screws and partsto be case hardened.
2. Structure Steel: This type of carbon steel has carbon contentsbetween0.2 to 0.35%. They have high yield point (3300 kg/sq.cm.)and are best suited for both welding and riveted operation.
3. Forging Steel: These contain carbon between 0.30 to 0.40% andare used for axles, bolts, pins, connecting rods, crank shaft etc.
4. Tool Steel: Steel containing 0.6 to 1.30% carbon is called toolsteel and is used for the manufacture of tools due to its property of
hardness and roughness.
-
7/23/2019 203378526-Training-Report-at-rail-coach-factory-RCF.pdf
7/27
FABRICATION SHOP It consists of sections including under frame, side wall, roof & end
wall.
1. Under Frame:
Under-frame constitutes the chassis
of the coach.
Four jigs are used to make the
assembly of under-frame. The assemblies are placed in the jigs
and then welded together.
After this, it is lifted with the help of
overhead cranes and placed on the
tracks for the 2ndstage on the other
side of the frame.
The components, which are located
on this side, are welded and after
final welding, the frame is painted in
black paint and transferred to the
transfer bay for main assembly of the
shell.
-
7/23/2019 203378526-Training-Report-at-rail-coach-factory-RCF.pdf
8/27
2. Side Wall:
The sidewall is assembled in thepneumatic operated jigs.
The major parts of the sidewall are
body side pillar, sidewall sheet, light
rail, waist rail and stiffeners.
All these components are placed in the
jig and welded together.
The sidewalls are of eight window
sheets and lavatory sidewall sheet.
A number of other components like
window ceiling angel etc. are welded
after the wall is taken out of the jig.
-
7/23/2019 203378526-Training-Report-at-rail-coach-factory-RCF.pdf
9/27
3. Roof:
The main roof is assembled on a rotary
jig on which the basic components i.e.
car line is located and after location, U-
stiffener is welded to hold them.
After welding of these components, the
roof sheets that are eight in no. are
located together and tied properly with
the help of stainless steel fasteners.
The Jig is then turned round to position
and the roof sheet is welded together.
The roof is then removed from the jig &
put on trestles for providing other
components like fan brackets, lamp,
brackets etc.
-
7/23/2019 203378526-Training-Report-at-rail-coach-factory-RCF.pdf
10/27
4. End Wall:
This is the end portion of the coach.
The main component of end wall is end
sheet, side sheet, end stanchions and
center stiffeners.
All these components are positioned in
the jig located and weld together. When welded, these are taken out and
placed on trestles for fixing pipes and
other fittings.
All the components are welded with
MIG welding.
-
7/23/2019 203378526-Training-Report-at-rail-coach-factory-RCF.pdf
11/27
SHELL ASSEMBLY SHOP
In the shell assembly shop, sidewall, end wall, roof, under-frame is
assembled and other necessary operation for making shell is done.
Shell assembly operations are done in five stages:
Stage 1:
In first stage, under-frame is placed on the jig.
Then setting of camber is done to avoid bending of under-frame downward.
Then sidewalls and end walls are placed on shell jig along with under-frame and are
fully welded.
Afterwards roof is placed and full welding is done, the sidewalls and roof are made
tight for welding by using tie rods.
After welding all clamps and tie rods are removed and checking for final camber is
done.
Cables pipes are also attached.
-
7/23/2019 203378526-Training-Report-at-rail-coach-factory-RCF.pdf
12/27
Stage 2:
In this stage End walls and Sidewalls are welded to each other.
Residual welding for shell integral from first stage is also done.
Door corner fitting, Conditioning of under-frame, junction box and cable box are fitted,
flooring work is also done in this stage.
Stage 3:
In this stage, vestibule doorsill, alarm tube bends; ceiling support angle and window barfitting is done.
Skin tensioning is also done in this stage.
In Skin tensioning heating on spots at some distances is done and then hammering is done
to remove any deformations.
Stage 4:
In this stage partition framing of lavatory and seating is done.
Besides this, door fitment operations are also performed.
Stage 5:
Buffer and draw Gear assembly is done at this stage.
Components of Buffer are:
CASING
STEEL ROD
PLUNGER
RUBBER PAD
SPRINGS PLATE
-
7/23/2019 203378526-Training-Report-at-rail-coach-factory-RCF.pdf
13/27
PAINT SHOP In this shop, the shell is painted manually or with automatic
painting plants with different coats of chemical and paint etc.
Various operations done in paint shop are:-
1. Shot Blasting:
Small steal balls are made to strike against the external surfaces of the shell with
great speed.
Firstly marking is done to render steel balls to enter inside the shell.
It is done with wooden boards size of shots are 170mm,230mm,280mm.
Centrifugal machines are used in plants.
-
7/23/2019 203378526-Training-Report-at-rail-coach-factory-RCF.pdf
14/27
2. Primer Application:
After that shot blasting primer is
applied with automatic machines with
nozzles which moves up down and
side ways are used for this purposein primer plant.
There are mainly two type of primer:
1.Internal Primer 2.External Primer
3. Putty Application:
To obtain uniform thickness, putty
cutting is done.
It is done with silicon water Emorypaper.
Putty cutting is done by applying
water at the required place.
This cutting is called wet cutting.
-
7/23/2019 203378526-Training-Report-at-rail-coach-factory-RCF.pdf
15/27
4. Surface Application:
After putty, surface is applied to the
external.
The surface are applied with the helpof air less spraying machines.
When it become dry than cutting of
surface is done with Emory papers.
5. Top Coat Application:
After drying surfaces top coat is
applied on the external surface with
the help of automatic and air less
spraying machines as used whileprimer application.
The thickness of paint on coaches is
200-250mm.
In paint shop, air film transversal is
used for shifting of coaches.
-
7/23/2019 203378526-Training-Report-at-rail-coach-factory-RCF.pdf
16/27
BOGIE SHOP Bogie is the part on which the coach
rests and due to which the coach runson the rail line Thats why it is
manufacture under strict precision so
that the dimensions do not vary too
much from drawing.
In the bogie shop the bogies of different
coaches are manufacture in the variousstages.
The various parts of the bogie are not
manufactured in that shop, only bogie
frame is manufactured in this shop and
the rest of the parts are imported from
out side sources. These parts are only
assembled here.
The coach consists of eight wheels and
these eight wheels are divided into two
sets of two wheels with suspension
frame, springs and dampers when
assembled properly then these two
sets are known as BOGIE.
-
7/23/2019 203378526-Training-Report-at-rail-coach-factory-RCF.pdf
17/27
The main parts of the bogie are: -
1. Frame:
In this part of the bogie, shell is placed.
It is made of Leo Fein steel sheet.
The thickness for general coaches and high-speed coaches is 8 mm and 12 mm
respectively.
Its parts are Head stock, transverse, Longitudinal and side frames
These parts are machined in this shop and at last are assembled in this shop with
the help of jigs.
2. Wheels:
These are the casting of Mild Steel and are flanged from inner side.
The diameter of the wheel is 890 mm and its thickness is 120 mm.
Two wheels are joined with frame by AXLE.
Each Bogie contains two wheels and a coach contains four wheels.3. Bearing:
In this section Bearing are fixed on journal.
The types of bearing used are roller bearings.
The diameter of wheels, journals & axles are 915mm, 130mm, and 155mm.
The distance between wheels is 1600mm.
-
7/23/2019 203378526-Training-Report-at-rail-coach-factory-RCF.pdf
18/27
4. Brake System:
Air Brake system is used for braking action.
For high speed coaches such as L.H.B and IRY coaches the disc brakes are used
and for other coaches block brake are used. The band blocks are used for breaking and the braking is system is basically of liver
pulley system.
The pressure is applied on the pipes from the cylinder to the liver and then thebrakes are applied.
5. Alternator:
It is a source of electricity when the train is moving.
For AC coaches two alternators of 25KW power each are used in a single coach.
For general coaches an alternator of 4.5 KW power per coach is used.
VBelts and Pulleys, connects the shaft of the alternator to axle.
6. Suspension System:
It is used for absorbing shocks. It consists of springs and shockers.
Springs are made of steel.
Suspension system has two parts:
a) Primary parts: It takes the load of shell only and restricted its vibrations.
b) Secondary parts: It takes the load of shell as well as the thrust from wheels.
-
7/23/2019 203378526-Training-Report-at-rail-coach-factory-RCF.pdf
19/27
Testing of Final Bogie:
STATIC TESTING MACHINE:
Static testing machine is used to test the bogie frame by applying same amount of
load as in actual service condition. Purpose of this testing is to check the strength and correctness of different Bogie parts
under the application of load on it.
Load is applied by hydraulic system at the center of bogie.
Under this load the deflection in spring is noted down and the deflection is compared
with specified deflection for particular spring.
If the deflection is with in the safe limit or with in the specified limit and the other parts
also behaved in specified way then the Bogie gets the OK signal. Otherwise, the
defective part is replaced and then again the testing is done, until it gets OK.
-
7/23/2019 203378526-Training-Report-at-rail-coach-factory-RCF.pdf
20/27
FURNISHING SHOP The furnishing shop is working for decoration of coaches. So all the decorative
work is done here in this shop.
In this shop seats, birth, electrical applications, portions, flooring, bogie
installation and many more other goods are fitted here.
The shop consists of no. of sections and these sections are:-
1. Flooring & PVC Section:
In this section flooring is done on the metal under frame.
First of all, the plywood flooring is done on the under frame.
The plywood is screwed to the metal floor of the coach, then after this the
water sealing compound ISOPATHIC PUTTY is applied on plywood joints and
is rub by emery paper later on for the uniformity of the flooring.
-
7/23/2019 203378526-Training-Report-at-rail-coach-factory-RCF.pdf
21/27
2. Electrical Stage:
In this stage, all the electrical wiring
is done for the electrical equipment.
D.C batteries are also loaded on the
coaches.
For A.C, S.G and general coach,
wires used are 1.5mm.
Equipment for which these batteries
and invertors are provided is Fans,
Lights, Air Conditioner, etc.
3. Window and Ceiling
Section:
After electrical wiring, windows andceiling covers are mounted on the
coach in window and ceiling stage.
These windows are not manufactured
in this factory. These are
manufactured by vendors as the
design recommended by R.C.F.
These windows consist of a
-
7/23/2019 203378526-Training-Report-at-rail-coach-factory-RCF.pdf
22/27
4. Panel Section:
After providing the windows and
ceiling covers the work of paneling is
done.
In this stage all the inner walls of
coach are covered with thin-mica
sheets, this is known as paneling.
These mica sheets are fastened with
help of screws.
5. Moulding Section: After paneling the work of molding is
done.
In this stage aluminum strips cover
all the joints of paneling.
The molding is done for better out
look of inner walls of coach.
Screws fasten these strips.
6. Lavatories Section:
In this stage, all the accessories of
lavatories are mounted such as
flushes, washbasins, water tanks.
-
7/23/2019 203378526-Training-Report-at-rail-coach-factory-RCF.pdf
23/27
7. Plumbing Section:
In this section, the fitting of pipes
from water tank to lavatory and to
wash basins is done.
8. Seat and Berth Section:
In this section, following work is done:
Fixing of chairs angels and sleeve for
single seats.
Fitting of luggage racks and back rests
arrangements.
Fitting of guard compartment.
Fitting of designation board.
Fitting on no. plates of seats and
berths.
Stench works indicating type of zonesand type of coach.
-
7/23/2019 203378526-Training-Report-at-rail-coach-factory-RCF.pdf
24/27
9. Lowering Section:
Fixing of bogies to the coaches is the
main function in this shop.
The procedure followed in this sectionis given below:
Fixing of center pivot pin.
Adjustment of buffer height.
Fitting of bearing plates in Bogie.
Taking bearing frame to the center.
Lowering of coach on bogie.
After lowering, the fitting of cotter and
split pin.
Buffer point adjustment.
10. Electrical Stage-1:
In this stage all the electrical
equipment are mounted on coaches.
This electrical equipments are fans,
lights, electrical switches and air
conditioner units.
The wiring is attached to theseequipments.
-
7/23/2019 203378526-Training-Report-at-rail-coach-factory-RCF.pdf
25/27
11. Air Brake Section:
After lowering of coach all the
connections of air brake are completed.
In early days Vacuum Brakes were
used but now-a days air pressurebrakes are used.
There are two types of pipes Feed pipe
and Brake pipe. Feed pipe is of white
color and Brake pipe is of green color.
Pressure in Feed pipe and Brake pipe
is 6Kg/cm and 5Kg/cm.
These two pipes are connected to a
diaphragm. With the help of this
diaphragm air pressure is released to
piston cylinder arrangement, with the
help of which brake is applied.
12. Finishing Stage:
In this stage, all the work that is
completed in furnishing, is checked
i.e. all equipments are switched on by
connecting to electric supply to the
coach.
-
7/23/2019 203378526-Training-Report-at-rail-coach-factory-RCF.pdf
26/27
FINISHING SHOP Following operations take place in this shop:
1. Installation of Air Brake
System and Testing:
Air brake system is installed in the
coach and is being tested by passing
the compress air in pipelines.
Generally two-pipe line exists in which
one is white and another is green.
2. Shower Testing:
In this the coach is placed below
water shower and then the shower is
started.
This inspection is done to check
whether the leakage is there in roof
or not.
This testing is mainly done to check
-
7/23/2019 203378526-Training-Report-at-rail-coach-factory-RCF.pdf
27/27
3. AC Generation Test:
This can be tested with the help of motor and belt.
After checking the electricity generation, the performance of the AC unit is also
checked by glowing number of high wattage bulbs and with AC unit ON.
So after all this a final inspection is done and after getting OK signal from inspectors,
the coach is sent to Delhi headquarters, from there they will sends to the various
railway zones according to their demand.