DIESEL LOCOMOTIVE WORK SHOP

Submitted by

SHIVESH SINGH◦ Roll-110106259◦ Branch- Mechanical D◦ 4th Year

INTRODUCTION Diesel locomotive works was established in 1961 in Varanasi.

Asia's Second largest Railway diesel engine production industry.

By The End of March 2005 DLW has Manufactured 4707 Locomotive .

How does it work? It converts the chemical energy available in fuel into mechanical energy

This mechanical energy moves pistons up and down inside cylinders

This motion creates the rotary motion needed to turn the wheels of a train forward

It uses a four stroke combustion cycle: intake, compression, combustion, and exhaust

TYPES OF SHOPS observed

1. HEAVY MACHINE SHOP

2. HEAVY WELD SHOP

3. ROTOR

4. PAINT SHOP

TYPES OF WORKSHOPS ALLOTED.

HWS (heavy welding shop)

This is one of most sophisticated workshop.

Types of welding performed are:-

ARC welding:- An electric arc between work piece and electrode produces heat , which is sufficient enough to melt the work piece together.

Current requirement of 5 to 500 ampere.

Voltage is ranged from 20 to 30 volts, either AC or DC.

Both current and voltage are determined on basis of material thickness.

CLASSIFICATION OF ARC WELDING

SHEILD METAL ARC WELDING……..(stick SMAW)

GAS METAL ARC WELDING………….(GMAW)

FLUX CORE ARC WELDING…………..(FCAW)

GAS TUNGSTEN ARC WELDING…..(GTAW)

Related termsELECTRODE – Place where current passes from welder to workpiece.

It is of two types:-

1) Contact

2) Non Contact

Atmospheric protection

1) Flux2) Shielding gas

HEAVY MACHINE SHOP Various machining process are done in this shop.

Machines like lathe machine, CNC etc. are available at this shop.

Mainly CNC are used because of easiness they provide. Various cutting ,shaping process are done by coding commands. It is an automatic device which works on numerical coding.

is a machine tool which rotates the work piece on its axis to perform various operations such as cutting, knurling ,drilling, or deformation facing, turning, with tools that are applied to the work piece to create an object which has symmetry about an axis of rotation.

ROTOR SHOP Deals with manufacturing of turbocharger.

Turbocharger is important part of diesel locomotives.

Basically manufacturing, assembly and subassembly of turbo charger takes place. Outer casing is made in HMS(Heavy Machine Shop)

Turbocharger is used to provide fresh air to the locomotive. Used to increase power and efficiency of engine.

No extra motor or generator is used for functioning of rotor. It works with help of exhaust gases.

COMPONENTS OF TURBOCHARGER

1) IMPELLAR

2) INDUCEOR

3) NOISE PIECE

4) STUD ROTOR

5) NUT

6) WASHER

7) THRUST WASHER

8) KEY

9) OIL SLINGER

10) TURBINE DISC

11) TURBOSHAFT

12) LOCKPLATE

Assembly of turbocharger is done by dividing it into three parts:-1) rotor- It is inlet part of turbocharger which consists of many sub parts like rotor disc, washer, locknut etc.2) compressor- Combination of impeller and inducer. Impeller is made of al alloy. These parts are used for sucking fresh air from environment.3) casing- casing is made of mild steel and special coating is done on it so as to resist the heat.

LOCO PAINT SHOP After the chassis of bogie and engine is made they are sent for final work of painting. Loco painting is done by spray paint. Skilled workers are employed who can make markings take shape and size under consideration.

Spray paint gun

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