INDIAN RAILWAY INTERNSHIP

INDIAN RAILWAYINTERNSHIP RAIL COACHMECHANICAL DEPARTMENT GORAKHPUR

From 23-06-2017 to 21-07-2016

Prepared by: Sandeep Kumar Yadav

INDIAN RAILWAY

History of Indian Railway First Indian Railway line was opened on 16th April 1853.

The first train consisting of one steam engine and four coaches , traversed a stretch of 21-miles between Mumbai(Bombay) and Thane.

Indian Railway has a glorious past of more than150 years serving the nation.

Features of Indian Railway

Indian Railway has a 3 tier management system.

No strike in last 30 years inspite of 17 lakhs workers.

It runs 12000 trains everyday.

It is largest railway system in World under one management system.

It carries 1.4 crore passengers and 16 lakh tonnes of goods every day.

Speed of Trains

Shatabdi max 140kmph.

Rajdhani max 130kmph.

Others max 110kmph

About Gorakhpur Railway WorkshopGorakhpur railway establish in 1903 for repair and overhauling of steam locomotive ,coaches and wagons.In workshop there is different shop for different process.Gorakhpur Railways Station now become world largest and longest platform (1.34kmlong)

THE SHOP WHICH I HAVE VISITED MACHINE SHOP:

HYDRAULIC WHEEL PRESS MACHINE: It is used to mounting the shaft and wheel by the help of hydraulic pressure (72-108 ton or kg/cm^2).

The machine has the capacity of 500 tonn.

Hydraulic wheel press machine

Allowance is 0.2- 0.5 mm between shaft diameter and wheel diameter.

Lubricant use for this operation is boil lean seed oil + white lean powder (100ml+120 gm in ratio) lubricant increases the strength and contact between wheel and shaft .

To remove the wheel from shaft double pressure is required .

VIDEO

Axle :

Total excel size is 2316 mm.

Disc diameter is 917 to 835 mm

Area covered on axle by wheel is called axle sheet.

The wheel in Indian railway first manufacture for Mal Gari and when it little wear due to break then it used in superfast and passenger trains.

COMPUTER NUMERIC CONTROL MACHINEIn this machine all the data from initial work piece to final work piece is feed into the computer . And all the process required in order is fed with the help of program .This is used in railway workshop for tougher and complex object production. In railway shop there is one cnc chucker turret lathe machine

Lathe machine

Lathe machine is used for cutting, sanding, knurling,drilling, or deformation, facing, turning,operation on shaft.

VERTICAL TURRET LATHE MACHINE

It is used to make the bore in Rail Wheel.The bore diameter of rail wheel 168.778- 177.8 mm.Maximum depth of cut of turret lathe is 6 mm.Total time for bore is 45-50 minute.The disc is made up of gray cast iron.

Vertical turret lathe

SHAPER, PLANER AND SLOTTER MACHINE:Shaper: It is horizontal shaping machine and it works on quick return mechanism. In this tool reciprocate and work piece stationary.

Planer: It is used for large production . In this work piece rotate and tool stationary.

Slotter: This is vertical shaping machine. The arm reciprocate in vertical direction. Most part are same as shaper.

HEAT TREATMENT SHOP

Heat treatment process is employed to get desired properties in work piece. In workshop mainly the heat treatment is for suspension hanger , different processes is used;

CARBURIZING: It also referred to as Case Hardening, is a heat treatment process that produces a surface which is resistant to wear , while maintaining toughness and strength of core.

It is applied after the machining process. for suspension hanger in Indian railway carburizing take place for 20-22 hour Pre heat 5.5 hour temp 950 degree Hold 15.5 hour temp 950 degree

REFINING:It remove impurities or unwanted element from a substance .It is approx 2.5 hour process and temp required is 860 degree Celsius.

Hardening this treatment will result in an improvement of the mechanical properties as well as an increase in the level of hardness , producing a tougher , more durable item. alloys are heated above the critical transformation temp for the material then cooled rapidly to get stronger structure .Tempering By changing the structure to keep the martensite tempering is used.

BOGI HEARTH FUNACE

BOGI HEARTH FURNACE

BOGI HEARTH FURNACE

BOGI HERATH FURNACE

BREAKING SYSTEM

The breaks are used on the coaches of railway train to enable deceleration, control acceleration or keep them standing when break is fully applied. while the basic principal is similar to road vehicle.

There are two types of breaking system is used:

VACCUM BRAKE SYSTEM

AIR-BRAKE SYSTEM

AIR -BRAKE SYSTEM:

This is new method of breaking system, which is more efficient than the vacuum brakes It is used first in Rajdhani and Satabadi coaches.

Block diagram of air brake system

Block diagram

WORKING OF AIR BRAKE SYSTEM: In this system coaches is provided with twin pipe,brake pipe and feed pipe . The brake pipe is charged to 5kg/sq cm while the auxiliary reservoir charged by the feed pipe at 6 kg/sq cm through a choke valve and choke valve from locomotive .for apply the brake pressure of break pipe is reduced which in turn to charge the break cylinder through the distributor valve to a pressure 3.8 kg/sq cm when the break are released then the break pipe is charged to 5 kg/sq cm . And this process take place every time when driver apply the brake

PASSENGER EMERGENCY ALARAM DEVICE(PEAD)It is fitted in the coach. And it is connected to alarm chain for actuating passenger emergency valve.

Disc break system

Queries Please?