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Ref: CGW 0001 (Rev. 3) Page 1 of 22 Date of issue: July, 2017 Spec. No. CK605 (Rev-2) Signature Name & Designation Prepared By:- D. Kulshrestha JE/Carriage Checked By:- Ansuman Sonkar SSE/Carriage Approved By- A.K. Singh Director/E&S and Brake/Carriage INDIAN RAILWAYS SCHEDULE OF TECHNICAL REQUIREMENTS FOR SELF LUBRICATING POLYESTER RESIN BASED COMPOSITE BRAKE GEAR BUSHES TO BE USED IN MAINLINE COACHES (BG) S. No. Month/Year of Issue Revision/ Amendment Page No. Reason for Amendment 1. March, 2006 - - First issue 2. August, 2009 Rev.1 - New tests added 3. March, 2010 Amendment-1 4 S.No.2 of table-I of section-A modified 3. September, 2016 Amendment-2 3 To include the ISO Doc. No. QO-D-7.1- 11, New sub clause No.1.2 added under clause no. 1 of Scope. 4. July, 2017 Rev.2 3, 4, 5, 6 and 7 Added amendment. Modified clause no. 2.2.1 and 5.6 of Section-A. Added new clause no. 9 (Section-A) of warranty. New tests on finished bush added. Issued By: Research Designs and Standards Organization Manak Nagar, Lucknow - 226011.

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Ref: CGW 0001 (Rev. – 3)

Page 1 of 22 Date of issue: July, 2017 Spec. No. C–K605 (Rev-2)

Signature

Name & Designation

Prepared By:- D. Kulshrestha JE/Carriage

Checked By:- Ansuman Sonkar SSE/Carriage

Approved By- A.K. Singh Director/E&S and Brake/Carriage

INDIAN RAILWAYS

SCHEDULE OF TECHNICAL REQUIREMENTS

FOR SELF LUBRICATING POLYESTER RESIN BASED COMPOSITE BRAKE GEAR

BUSHES TO BE USED IN MAINLINE COACHES (BG)

S. No. Month/Year of Issue

Revision/ Amendment

Page No. Reason for Amendment

1. March, 2006 - - First issue

2. August, 2009 Rev.1 - New tests added

3. March, 2010 Amendment-1 4 S.No.2 of table-I of section-A modified

3. September, 2016 Amendment-2 3

To include the ISO Doc. No. QO-D-7.1-

11, New sub clause No.1.2 added under

clause no. 1 of Scope.

4. July, 2017 Rev.2 3, 4, 5, 6 and 7

Added amendment. Modified clause no.

2.2.1 and 5.6 of Section-A. Added

new clause no. 9 (Section-A) of warranty. New tests

on finished bush added.

Issued By:

Research Designs and Standards Organization Manak Nagar, Lucknow - 226011.

Ref: CGW 0001 (Rev. – 3)

Page 2 of 22 Date of issue: July, 2017 Spec. No. C–K605 (Rev-2)

Signature

Name & Designation

Prepared By:- D. Kulshrestha JE/Carriage

Checked By:- Ansuman Sonkar SSE/Carriage

Approved By- A.K. Singh Director/E&S and Brake/Carriage

INDEX

SECTION-A Clause No. Description Page No.

0. Foreword 3 1. Scope 3

2. Requirements 3 3. Performance Requirements 4

4. Sampling Criteria for conformity 5 5. Approval of firms 7

6. Marking 7

7. Packing 8 8. Storage 8

9. Warranty 8

SECTION-B Clause No. Description Page No.

1. Scope 10 2. Requirements 10

3. Plant, Machinery & Infrastructure Requirements

10

4. Testing Facilities 11

5. Quality Control Requirements 11 6. Documentation 12

7. Training 13 8. Appendix - A 14

9. Appendix -B 15 10. Appendix - C 16

11. Appendix - D 16

12. Appendix - E 17 13. Appendix - F 18

14. Fig.1 19 15. Fig.2 20, 21

16. Fig.3 22

Ref: CGW 0001 (Rev. – 3)

Page 3 of 22 Date of issue: July, 2017 Spec. No. C–K605 (Rev-2)

Signature

Name & Designation

Prepared By:- D. Kulshrestha JE/Carriage

Checked By:- Ansuman Sonkar SSE/Carriage

Approved By- A.K. Singh Director/E&S and Brake/Carriage

SECTION-A

SCHEDULE OF TECHNICAL REQUIRMENTS FOR SELF LUBRICATING POLYESTER RESIN BASED COMPOSITE BRAKE GEAR BUSHES TO BE USED IN MAIN LINE

COACHES (BG)

0. FOREWORD

0.1 This schedule consists of two parts viz. Section A and section B. Section A covers

the technical requirements/provision relating to material, manufacture and tests and does not include all the necessary provisions of the contracts. Section B covers the infrastructural, testing and quality control facilities required for manufacture of Self-lubricating polyester resin based composite brake gear bushes.

0.2 These self-lubricating polyester resin based composite brake gear bushes are to be

used in ICF/RCF/BEML Coaches 0.3 This schedule draws reference to some of the relevant ASTM/ISO specifications

shall be taken as reference unless mentioned otherwise. 0.4 For the purpose of deciding whether a particular requirement of the schedule is

complied with, the final value observed or calculated, expressing the result of a test or analysis shall be rounded off in accordance with IS:2-1960. The number of significant places retained in the rounded off value shall be the same as that of the specified values in this schedule.

0.5 While preparing this specification, due consideration has been given to the latest

developments in the field of polymeric materials and process technologies, service requirements of the Indian Railways and practices followed in advanced countries.

1. SCOPE

1.1 This schedule covers the requirements, sampling and methods of tests for compression moulded Self-lubricating polyester resin based composite brake gear bushes to be used in ICF/RCF/BEML Coaches.

1.2 All the provisions contained in RDSO’s ISO procedures laid down in Document No.

QO-D-7.1-11 dated 19.07.2016 (titled “Vendor – Changes in approved status”) and subsequent versions/amendments thereof, shall be binding and applicable on the successful vendor/vendors in the contracts floated by Railways to maintain quality of products supplied to Railways.

2. REQUIRMENTS

2.1 Material

2.1.1 The raw material used in the manufacture of brake gear bushes shall be graphite filled, self lubricating, unsaturated polyester resin based composites which should be procured from source whose material is being used extensively in brake gear bushes in rail road application in India or abroad. The material should be reinforced with

Ref: CGW 0001 (Rev. – 3)

Page 4 of 22 Date of issue: July, 2017 Spec. No. C–K605 (Rev-2)

Signature

Name & Designation

Prepared By:- D. Kulshrestha JE/Carriage

Checked By:- Ansuman Sonkar SSE/Carriage

Approved By- A.K. Singh Director/E&S and Brake/Carriage

fibres which are not in the form of yarns or cloth and it shall not cause the brake rigging pins to wear fast. The vendor seeking registration wilh RDSO should have a suitable MOU for supply of raw material and technical support from the such source of material.

2.1.2 Use of regenerated/reconstituted material is not permitted. A guarantee shall be

given by the manufacturer that no reconstituted and recovered material has been used for the manufacture of Brake Gear Bushes.

2.1.3 The raw material shall be resistant to oil contamination. A certificate from primary

manufacturer of raw material will be required for compliance of this requirement. 2.1.4 The color of the Brake Gear Bushes shall be black/dark grey. 2.2 Construction, Workmanship and Finish

2.2.1 Self-lubricating polyester resin based composite brake gear bushes shall be made by in house compression molding of raw materials into tubes and subsequent machining of the same into bushes.

2.2.2 The surface of the composites Brake Gear Bushes shall be smooth, sound and free from moulding defects such as bubbles, voids, surface sinking, grazing and blistering of the surface, cracks etc. All edges shall be neatly finished and free from flash.

2.3 Dimensions & Tolerances

The dimensions and tolerances of the polyester resin based composites Brake Gear Bushes shall be same as given in RDSO drawing No. SK-81039 with latest alteration.

3. PERFORMANCE REQUIREMENTS

3.1 Unless otherwise specified, all tests shall be carried out under the following atmospheric conditions;

a) Temperature 27 + 2C

b) Relative humidity 50 + 10% The temperature and humidity shall be substantially constant during a series of measurements carried out as part of one test on one lot.

3.2 The raw material used for the manufacture of Brake Gear Bushes shall conform to

the requirements prescribed in table-1 and shall be measured on prepared test specimen.

3.3 The finished brake gear bushes shall conform to the requirement given in the

Table -2(A) & 2(B).

Ref: CGW 0001 (Rev. – 3)

Page 5 of 22 Date of issue: July, 2017 Spec. No. C–K605 (Rev-2)

Signature

Name & Designation

Prepared By:- D. Kulshrestha JE/Carriage

Checked By:- Ansuman Sonkar SSE/Carriage

Approved By- A.K. Singh Director/E&S and Brake/Carriage

Table-1

(To be measured on Type test specimen’s prepared from Raw Material)

Sl. No.

Properties Values Specimen size Test Direction

Number of

samples

Test Method

1 Compressive Strength

160 MPa (min)

12mmX12mm X12mm right prism

Into moulded

face

5 ISO 604

2 Impact Strength Izod Un notched, KJ/sq.mt

Average Value ≥ 75 Minimum Values ≥ 68

12.7mm X 12.7 mm X 64mm

Into moulded

face

10 ISO 180

3 Rockewell hardness; M

75 (min) Min 6 mm thick sheet

Into moulded

face

3 ISO 2039-2

4 Residual ash at 950 degree C

22 to 27% Nominal 3 gm NA 3 ISO 3451-1

5 Density(gram/cc) 1.60-1.68 10 g to nearest 1 mg

NA 3 ISO 1183

Table - 2(A)

(To be measured on finished Brake Gear Bush)

S. No.

Property Value Unit Test Method

1 Density (gram/cc) 1.60-1.68 - ISO 1183

2 Residual ash at 950 0C 22 to 27% % ISO 3451-1

3 Water Absorption- 2 Hrs 0.75% % As per Appendix C

4 Rockewell hardness; M 75 (min) M ISO 2039-2 & Appendix B

Table- 2(B)

(To be measured on finished Brake Gear Bush)

S.No. Property Value Unit Test Method

1 Drop Impact Strength Test (min)

3.35 & 2.25 (item 11only)

Kg-m As per Appendix D

2 Wear Test – Mass Loss For 2 Hrs

Less than 0.60 % As per Appendix E

3 Wear Test – Mass Loss For 24 Hrs

Less than 1.2 % As per Appendix E

4 Crush Strength Test (min)

As per Appendix E

tonne As per Appendix F

5 Ring Crushing Test

Load at 50% deflection of OD

of bush should be minimum 75% of ultimate strength

- As per Appendix A

Ref: CGW 0001 (Rev. – 3)

Page 6 of 22 Date of issue: July, 2017 Spec. No. C–K605 (Rev-2)

Signature

Name & Designation

Prepared By:- D. Kulshrestha JE/Carriage

Checked By:- Ansuman Sonkar SSE/Carriage

Approved By- A.K. Singh Director/E&S and Brake/Carriage

4. TEST AND SAMPLING CRITERIA FOR CONFORMITY 4.1 Tests

4.1.1 The tests in Table-1 and wear test-mass loss (24 Hrs) in Table 2(B) shall

constitute Type Test performed on the raw material specimen.

4.1.2 The tests in Table-2(A) & 2(B), except wear Test – mass loss (24 Hrs), are “Acceptance Tests” and shall be carried out on finished bushes on each lot/batch.

4.1.3 The Type Test, for all the requirements laid down in this schedule is mandatory for

product approval. However Approving Authority reserves the right to repeat the test at their discretion.

4.1.4 In any consignment, all the bushes of the same type manufactured by the same

factory during the same period shall be grouped together to constitute a lot. 4.1.5 From each lot a certain number of bushes shall be selected at random and subjected

to Acceptance Test as given in Clause 4.2.

4.1.6 In case, ordered bushes are not covered in the RDSO drawing No. SK-81039 (latest alteration), the tests specified under Table 2(A) shall only be carried out on each lot/batch.

4.2 Acceptance Test

4.2.1. The Acceptance Test shall consist of the following:

i. Visual Inspection ii. Dimensional Check iii. Specific Gravity (as per Table 2A) iv. Ash Content (as per Table 2A) v. Ring Crushing Test (As per Table 2B) vi. Hardness (As per Table 2A) vii. Water Absorption - 2 Hrs (as per Table 2A) viii. Drop Impact Strength Test (as per Table 2B) ix. Wear Test – Mass Loss For 2 Hrs. (as per Table 2B) x. Crush strength test (as per Table 2B)

4.2.2. The inspection lot shall consist of 2500 Nos. of Brake Gear Bushes or part thereof.

Ref: CGW 0001 (Rev. – 3)

Page 7 of 22 Date of issue: July, 2017 Spec. No. C–K605 (Rev-2)

Signature

Name & Designation

Prepared By:- D. Kulshrestha JE/Carriage

Checked By:- Ansuman Sonkar SSE/Carriage

Approved By- A.K. Singh Director/E&S and Brake/Carriage

4.2.3. The number of Brake Gear Bushes to be selected from the lot for Acceptance Test

shall be as under:

i. Visual Inspection 5% of the lot shall be checked as per clause No. 2.2.2.

ii. Dimensional Check 10 samples selected at random from each lot shall be checked as per clause No. 2.3.

iii. Specific Gravity 10 samples shall be drawn at random from each lot. Out of these, 5 nos. shall be tested for hardness as per ISO 2039-2 and Appendix B. Balance shall be tested for Specific gravity, water absorption and

ash content test shall be done as per Table 2A on bushes.

iv. Ash Content

v. Hardness

vi. Water Absorption- 2 Hrs

vii. Drop Impact Strength Test 10 samples shall be drawn at random from each lot and 1 bush each shall be tested for Drop impact strength, Ring Crushing and crush strength.

viii. Ring Crushing Test

ix. Crush strength test

x. Wear Test – Mass Loss For 2 Hrs

10 samples shall be drawn at random from each lot (consist of all types of bushes) and 1 (except for item 11) bush shall be tested.

4.2.4. Each sample selected for Acceptance Test shall conform to the requirements as laid

down at clause no. 4.2 Should any one of the test samples fail to meet the requirements of Acceptance Test, double the number of samples from the same lot shall be drawn for re-testing. Should any of these samples fail, the entire lot shall be rejected.

4.2.5. In case of non-compliance in regard to dimensional check, the manufacturer may be

given one chance to segregate the lot for dimensional conformity. 4.2.6. In the event of rejection of the lot, all Self lubricating polyester resin based composite

brake gear bushes constituting the lot shall be made unusable in the presence of the Inspecting Authority.

4.2.7. During inspection, Purchasing/Inspecting Authority, at their discretion may conduct

Type Test and the samples shall conform to the values specified in Table 1 and Table 2(A) and Table 2(B) of this schedule.

4.2.8. RDSO may draw the sample for quality checks at its discretion and conduct tests at

manufacturer’s premises or at RDSO. If need arises, sample shall be sent a reputed outside laboratory as decided between RDSO and manufacturer and the testing charges shall be borne by the manufacturer.

Ref: CGW 0001 (Rev. – 3)

Page 8 of 22 Date of issue: July, 2017 Spec. No. C–K605 (Rev-2)

Signature

Name & Designation

Prepared By:- D. Kulshrestha JE/Carriage

Checked By:- Ansuman Sonkar SSE/Carriage

Approved By- A.K. Singh Director/E&S and Brake/Carriage

5. APPROVAL OF FIRMS

5.1 Self-lubricating polyester resin based composite brake gear bushes shall be procured from firms approved by RDSO.

5.2 During Bulk Production, the Supplier shall not alter any material or process after

having successfully undergone the approval process. 5.3 The firm shall have all the facilities mentioned in Section-B of this STR. 5.4 A request for the registration for the item shall be made in the prescribed form to

RDSO. The request for registration shall be accompanied with in-house test results of the product and a valid copy of MOU as specified under clause 2.1.1 of this schedule.

5.5 The firm will be assessed by RDSO for compliance of STR and QAP in accordance

with extent procedure. All tests mentioned in this schedule are mandatory for product approval.

5.6 Based on satisfactory assessment, verification of infrastructure facilities and type

test, firm shall supply a minimum of 50 coach sets of Polyester Resin based Composites Brake Gear Bushes for extensive field trial for a period of 18 months. Final approval of the firm will be granted after satisfactory performance of the field trials. For the purpose of field trial, RDSO will nominate at least 3 Railways where

trial will be carried out. In case manufacturer is procuring and using the same raw material and technology support from the primary raw material supplier with whose material and technical support the other manufacturer has already manufactured brake gear bushes and which have been cleared for regular use after successful field trials, the field trials is also necessary before approval for verify the processing which is very important for manufacturing of brake gear bushes and such vary from machine to machine and firm to firm.

6. MARKING

6.1 Each polyester resin based composite brake gear bushes shall be suitably marked on the upper face with the following legend as per size and location indicated in the drawing.

i. Manufacturer’s name/initial/trade mark. ii. The month and year of manufacture. iii. Drawing Number/Part Number.

7. PACKING 7.1 The brake gear bushes shall be securely packed in plastic bags indicating by a

sticker the above-mentioned markings on each bag. These plastic bags shall be packed in a wooden/cardboard carton strong enough to resist damage in transit/storage.

Ref: CGW 0001 (Rev. – 3)

Page 9 of 22 Date of issue: July, 2017 Spec. No. C–K605 (Rev-2)

Signature

Name & Designation

Prepared By:- D. Kulshrestha JE/Carriage

Checked By:- Ansuman Sonkar SSE/Carriage

Approved By- A.K. Singh Director/E&S and Brake/Carriage

8. STORAGE

8.1 The brake gear bushes shall be stored in a cool and dry place. 8.2 The brake gear bushes shall be kept covered and free from exposure to bright light,

particularly sunlight. 8.3 The brake gear bushes shall be stocked and arranged in such order as the ensure

use of old stock first. 9. WARRANTY

9.1 The bushes supplied against an order shall bear a warranty of the contractor against defective material/workmanship and performance for a minimum period of 24 months from the date of supply or 18 months from the date of fitment whichever is earlier. In case, any bush cracks/breaks within 18 months of service, it shall be replaced by new one free of cost within 60 days of receipt of information.

Ref: CGW 0001 (Rev. – 3)

Page 10 of 22 Date of issue: July, 2017 Spec. No. C–K605 (Rev-2)

Signature

Name & Designation

Prepared By:- D. Kulshrestha JE/Carriage

Checked By:- Ansuman Sonkar SSE/Carriage

Approved By- A.K. Singh Director/E&S and Brake/Carriage

SECTION – B

INFRASTRUCTURE & TESTING FACILITIES REQURIED FOR MANUFACTURE OF SELF LUBRICATING POLYESTER RESIN BASED COMPOSITE BRAKE GEAR BUSHES

TO BE USED IN MAIN LINE COACHES (BG) 1. SCOPE

1.1 This Section covers the infrastructure requirements for manufacture of Self

lubricating polyester resin based composite brake gear bushes for main line coaches (BG)

2. REQUIREMENTS

2.1 All vendors seeking registration with RDSO must fulfill the requirements of this schedule.

3. PLANT, MACHINERY & INFRASTRUCTURE REQUIRMENTS.

3.1 The Manufacturer shall have adequate space and covered area with cemented floor

to accommodate the following & for smooth logistics:

a) Damp-free place for storage of raw materials. b) Adequate manufacturing area. c) Finishing, Assembly and Inspection area. d) Storing and dispatch of finished products.

3.2 In cases where the firm is manufacturing its own raw material, it must have all items of plant and machinery required for the manufacture of the same.

3.3 In case where the firm is molding the tubes made out of raw material manufactured

by itself or purchased from approved source, it must be in possession of the following additional items of plants and machinery:

b) The manufacturer shall have at least one 100MT Hydraulic Press with digital

temperature controller and Hydraulic ejector. c) Mold for different sizes of tubes. d) Manufacturer shall have an Air Compressor of suitable capacity. e) Lathe machine for machining of the tubes.

3.4 The Manufacturer shall have suitable tools, cutters, polishing files, and Buffing

Machine for de-flashing of moulded products. 3.5 The Manufacturer shall have a system to ensure that moulds are checked at regular

intervals and adequate mould handling facilities like Chain Pulleys or Electric Hoists or other suitable equipment for moving heavy moulds.

3.6 Prior to release of dies/moulds for production, these are to be checked dimensionally

and records containing details of such inspection and date maintained.

Ref: CGW 0001 (Rev. – 3)

Page 11 of 22 Date of issue: July, 2017 Spec. No. C–K605 (Rev-2)

Signature

Name & Designation

Prepared By:- D. Kulshrestha JE/Carriage

Checked By:- Ansuman Sonkar SSE/Carriage

Approved By- A.K. Singh Director/E&S and Brake/Carriage

3.7 Two Electronic Weighing Machines of reputed make, one of maximum 3 Kg. capacity and the other of 100 Kg. capacity with an accuracy of 1 g and 100g shall be provided. Weighing machines shall be calibrated regularly and the frequency of calibration shall be as per directives issued by the Government.

3.8 In-house availability of minimum infrastructure for maintenance and polishing of dies

and moulds shall be ensured. 4. TESTING FACILITIES

4.1 The Manufacturer must have the following testing and other equipment installed in a laboratory set up with controlled temperature and humidity.

a. Digital Vernier caliper (0-150 mm range) b. Bore dial gauge (0-50 mm range OR 0-25 mm and 25-50 mm range) c. Compression testing machine / Tensile Testing Machine / Universal Testing

Machine equipped with computerized load Vs deflection recording facilities. d. Weighing Balance with specific gravity determination kit. e. Izod Impact Tester. f. Muffle furnace for temperature upto 1000 0C with temperature control and

indication. g. Rockwell hardness tester. h. Hydraulic press for compression molding of test specimens. i. Equipment to test Impact Strength Test. j. Wear test-mass loss testing equipment. k. Crush strength testing equipments. l. Equipments for water absorption test.

4.2 The manufacturer shall have dies/moulds for preparation of various test specimens

for the relevant tests. 4.3 All gauges required to ensure that the dimensions of Self lubricating polyester resin

based composite brake gear bushes are as per drawings shall be available. 4.4 Jigs & fixtures for conducting load test, compression, flexural test etc. shall be

available. 4.5 The Manufacturer shall have arrangements like vice, cutter, polishing files etc. for

preparation of various samples for tests such as tensile strength, hardness, specific gravity etc.

5. QUALITY CONTROL REQUIRMENTS

5.1 The manufacturer shall have their own valid ISO: 9001 – 2008 certificate from certifying agency accredited to NABCB and the product for which the approval is sought should be broadly covered in the scope of the certification for manufacture and supply.

`

Ref: CGW 0001 (Rev. – 3)

Page 12 of 22 Date of issue: July, 2017 Spec. No. C–K605 (Rev-2)

Signature

Name & Designation

Prepared By:- D. Kulshrestha JE/Carriage

Checked By:- Ansuman Sonkar SSE/Carriage

Approved By- A.K. Singh Director/E&S and Brake/Carriage

5.2 There should be the system to ensure the trace ability of the product beginning with raw material stage to finish product stage. The firm shall have a system for traceability of the raw materials used, especially the liquid resins.

5.3 There should be the system to ensure 'first-in first-out' for all raw materials and

intermediate stages to finish products. 5.4 It should be ensured that there is a Quality Assurance Plan for the product detailing

the following various aspects:

• Organisation chart • Process flow chart • Stage inspection details from raw materials stage to finish product stage • Various parameters to be checked and level of acceptance of such parameters

indicated and method to ensure control over them. • Disposal system of rejected raw material and components.

5.5 The quality manual of the firm for ISO:9001 should clearly indicate the control over manufacturing at every stage and testing of the said Railway product.

5.6 There shall be at least one graduate degree holder person in relevant technology

with field experience of at least 5 years or a diploma holder with experience of 10 years on thermo setting polymers for regular production and quality control.

5.7 It should be ensured that proper analysis is being done on monthly basis to study the

rejection at various stages of production and is documented. 5.8 Latest version of all the relevant specification IS, ASTM and RDSO standards and

drawings with latest alterations should be available with the firm. 6. DOCUMENTATION

Firm shall maintain following documents/records:

6.1 A well documented Quality Plan. 6.2 Incoming raw material register with Test Certificates references of suppliers and

internal test results. 6.3 Stage inspection results including finished products results. 6.4 Records of internal rejection and its analysis vis-a-vis action plan. 6.5 Records of final products inspection by external agencies (like RDSO), Non-

Conformity Reports and case analysis as well as action taken thereof. 6.6 Records for maintenance of dies/moulds. 6.7 Ensure that proper systems are available for dealing with customer complaint.

Ref: CGW 0001 (Rev. – 3)

Page 13 of 22 Date of issue: July, 2017 Spec. No. C–K605 (Rev-2)

Signature

Name & Designation

Prepared By:- D. Kulshrestha JE/Carriage

Checked By:- Ansuman Sonkar SSE/Carriage

Approved By- A.K. Singh Director/E&S and Brake/Carriage

7. TRAINING

7.1 Training needs should be identified for all concerned officials and regular training

shall be organised and imparted on maintenance of machines, quality assurance, safety parameters etc.

Ref: CGW 0001 (Rev. – 3)

Page 14 of 22 Date of issue: July, 2017 Spec. No. C–K605 (Rev-2)

Signature

Name & Designation

Prepared By:- D. Kulshrestha JE/Carriage

Checked By:- Ansuman Sonkar SSE/Carriage

Approved By- A.K. Singh Director/E&S and Brake/Carriage

Appendix- A

Ring Crushing Test

The geometry of ring crushing test is as shown in the figure below:

Test procedure:

a) The bushes are placed between platens of a Compression Testing Machine/ Tensile testing machine/ Universal Testing Machine and compressed at the rate of 10 mm per minute. Load and corresponding deflection shall be recorded.

b) For Self Lubricating Polyester resin based composite brake gear bushes ultimate point will be taken in the slope of the load Vs compression curve.

c) The test criterion is to see that when the bush is compressed to half its original outer diameter, the load supported by it should be 75% or more of the load supported by the bush at its ultimate point as above.

d) In case of flanged bushes, the test is to be performed after removing the flange from the bush by machining.

Ref: CGW 0001 (Rev. – 3)

Page 15 of 22 Date of issue: July, 2017 Spec. No. C–K605 (Rev-2)

Signature

Name & Designation

Prepared By:- D. Kulshrestha JE/Carriage

Checked By:- Ansuman Sonkar SSE/Carriage

Approved By- A.K. Singh Director/E&S and Brake/Carriage

Appendix- B

HARDNESS TEST FOR FINISHED BUSH:

Test Specimen : Longitudinally half cut pieces from finished bush. Apparatus : Standard ‘V’ shape anvil and cylindrical bar with diameter equivalent

to inner diameter of bush as per arrangement shown below. Testing Procedure : As per ISO 2039-2

Ref: CGW 0001 (Rev. – 3)

Page 16 of 22 Date of issue: July, 2017 Spec. No. C–K605 (Rev-2)

Signature

Name & Designation

Prepared By:- D. Kulshrestha JE/Carriage

Checked By:- Ansuman Sonkar SSE/Carriage

Approved By- A.K. Singh Director/E&S and Brake/Carriage

APPENDIX- C

WATER ABSORPTION TEST- 2 Hrs

1. Mark and weigh two bushes of each type and record the weight.

2. In a tank of suitable size, heat water to 1000C ± 50C.

3. Fully immerse the pre-weighed bushes in the water tank.

4. Turn off the tank heater and close the water tank with a lid.

5. Leave the bushes in the water tank for 2 hours.

6. After 2 hours, remove the bushes and wipe dry.

7. Weigh the bushes again.

8. Water Absorption should not be more than 0.75%.

9. Water Absorption % should be calculated as follows:

WA% = { WBAI – WBBI } X 100 WBBI

WA= Water Absorption

WBAI= Weight of Bush after Immersion

WBBI= Weight of Bush before Immersion

APPENDIX- D

DROP IMPACT STRENGTH TEST

The test shall be conducted on bushes of all types randomly selected. The Bush shall be placed in a fixture as shown in Fig.1. For all bushes, except Bush No. 11, a

striker of 2.5 kg. weight shall be allowed to fall freely on the bush from a height of 1.50 meters. This should be repeated thrice. The bush should not show any crack when inspected immediately after the third fall. For Bush No.11 of RDSO Drg. No. Sk-81039, a striker of 2.25 kg. weight shall be allowed to fall freely on the bush from a height of 1 meter.

Ref: CGW 0001 (Rev. – 3)

Page 17 of 22 Date of issue: July, 2017 Spec. No. C–K605 (Rev-2)

Signature

Name & Designation

Prepared By:- D. Kulshrestha JE/Carriage

Checked By:- Ansuman Sonkar SSE/Carriage

Approved By- A.K. Singh Director/E&S and Brake/Carriage

APPENDIX- E

WEAR TEST - MASS LOSS

Objective: To determine the moss loss of bush due to wear.

Test specimen: Finished bush

Apparatus: A schematic diagram of the Test Rig is shown in Fig.2. The features of

test rig are given below: - 1. Power Source: - Electrical Motor of capacity min. 3HP 2. Speed Reduction Gear Box: - Capable to reduce the electrical motor speed to

minimum 35 RPM. 3. Linkage: - To covert rotary motion to oscillatory motion. Linkage should be such

that mandrel can oscillate minimum 35 cycles/ minute at an angle of minimum 300 from the mean position.

4. The diameter of mandrel to be kept equivalent to pin diameter to be used for the bush. The surface finish of the mandrel to be kept N5 and electroplated to 25 micron to service grade No. 3 of IS:1068.

5. Arrangement for applying the load of 20 KN on the bush and maintained throughout the test.

6. The weighing device of measuring accuracy to 1mg. 7. Five digit counter attached to test rig to count oscillation cycles. Procedure:

Bush shall be weighed and subsequently mounted on mandrel of Wear Test Rig and subjected to a compressive load of 20 KN. The test Rig shall than be switched on for specified period of time. The operating speed to be kept minimum 35 cycles/minute. After the test duration (2hrs/24hrs), the bush shall be removed, and weighed. The mass loss in percent due to wear after test shall be calculated as under:

Moss loss = { Initial Weight of Bush - Final Weight of Bush } X 100

in % Initial Weight of Bush

For Bush of No 7 of RDSO Drg. No. SK-81039, the collar should be removed and then tested.

Ref: CGW 0001 (Rev. – 3)

Page 18 of 22 Date of issue: July, 2017 Spec. No. C–K605 (Rev-2)

Signature

Name & Designation

Prepared By:- D. Kulshrestha JE/Carriage

Checked By:- Ansuman Sonkar SSE/Carriage

Approved By- A.K. Singh Director/E&S and Brake/Carriage

APPENDIX- F

CRUSH STRENGTH TEST

The test shall be carried out with machine speed of 10 5 mm/minute. Each type of Bush shall be placed in a fixture as shown in Fig-3. The Brake Gear Bushes for Item No. 1 to 10 of RDSO drawing SK-81039 (Latest alteration) shall be subjected to load of 3 t and released immediately. The Brake Gear Bush for Item No. 11 shall be subjected to load of 1 t and released immediately. The

outer and inner diameter and length of bushes shall be checked after release of load and the dimensions should be within the tolerances specified in the drawing. Further, the bush shall be subjected to the relevant load stipulated below and released immediately. Bush should not crack/break even after permanent set or deformation. Sr. No.

ITEM No. of RDSO Drawing number SKETCH-81039

Minimum Load (tonne) per Bush

1 1 5

2 2 6

3 3 9

4 4 14

5 5 14

6 6 14

7 7 16

8 8 5

9 9 6

10 10 9

11 11 2

Fig.1

SCHEMATIC DIAGRAM

FOR

DROP IMPACT STRENGTH TEST

Ref: CGW 0001 (Rev. – 3)

Page 19 of 22 Date of issue: July, 2017 Spec. No. C–K605 (Rev-2)

Signature

Name & Designation

Prepared By:- D. Kulshrestha JE/Carriage

Checked By:- Ansuman Sonkar SSE/Carriage

Approved By- A.K. Singh Director/E&S and Brake/Carriage

X

DETAIL AT- 'X'

Fig.1

SCHEMATIC DIAGRAM

FOR

DROP IMPACT STRENGTH TEST

Ref: CGW 0001 (Rev. – 3)

Page 20 of 22 Date of issue: July, 2017 Spec. No. C–K605 (Rev-2)

Signature

Name & Designation

Prepared By:- D. Kulshrestha JE/Carriage

Checked By:- Ansuman Sonkar SSE/Carriage

Approved By- A.K. Singh Director/E&S and Brake/Carriage

Fig.2

SCHEMATIC DIAGRAM

FOR

WEAR TEST RIG – SHEET-1 OF 2

Ref: CGW 0001 (Rev. – 3)

Page 21 of 22 Date of issue: July, 2017 Spec. No. C–K605 (Rev-2)

Signature

Name & Designation

Prepared By:- D. Kulshrestha JE/Carriage

Checked By:- Ansuman Sonkar SSE/Carriage

Approved By- A.K. Singh Director/E&S and Brake/Carriage

Fig.2

SCHEMATIC DIAGRAM

FOR

WEAR TEST RIG – SHEET-2 OF 2

Ref: CGW 0001 (Rev. – 3)

Page 22 of 22 Date of issue: July, 2017 Spec. No. C–K605 (Rev-2)

Signature

Name & Designation

Prepared By:- D. Kulshrestha JE/Carriage

Checked By:- Ansuman Sonkar SSE/Carriage

Approved By- A.K. Singh Director/E&S and Brake/Carriage

SCHEMATIC DIAGRAM

FOR

CRUSH STRENGTH TEST

Fig.3