it is a help to my dear friend

1. 1
NORTH EAST RAILWAY GORAKHPUR (U.P)
INDUSTRIAL TRAINING REPORT 2015-2016
IIMT ENGINEERING COLLEGE , MEERUT(127)
SUBMITTED BY-
NAME - KISHAN BHARTI
ROLL NO - 1312740061

2. 2
DECLARATION
I hereby declare that the IndustrialTraining Reportis an authentic record of my
own work as requirement of Industrialtraining during the period from 16-06-
2016 to 15-07-2016for theaward of degree of B.Tech ( Mechanical Engineering
),AKTU UNIVERSITY , Lucknow , UTTAR PRADESH , under the guidance of MR.
ANIRUDH SINGH .
DATE: KISHAN BHARTI
Roll number: 1312740061
Certifiedthat the above statement made by the student is correct tothe best
of our knowledge and belief .
HEAD OF DEPARTMENT
(Signature and Seal)

3. 3
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 – KISHAN BHARTI
ROLL NO – 1312740061

4. 4
LIST OF CONTENT PAGE NO
1. INTRODUCTION OF INDIAN RAILWAY 6 to 8
2. MACHINE SHOP 9 to 13
3. PAINTING SHOP 14 to 15
4. WHEEL SHOP 16 to 18
5. SPRING SHOP 18 to 20
6. HEAT TREATMENT SHOP 21 to 22
7. JIG AND FIXTURE SHOP 23 to 24
8. BRAKING SYSTEM 25 to 27
9. SHELL SHOP 28 to 29
10.MATERIAL HANDLING SYSTEM 30 to 31
11. SMALL INDUSTRIAL CAR 32

5. 5
FIGURE NAME
1. FIG :- VIEW OF WORKSHOP
2. FIG :- MANUALLY OPERATED MACHINE
3. FIG :- DRILLING MACHINE
4. FIG:- LATHEMACHINE
5. FIG :- SHAPER
6. FIG :- PLANNER
7. FIG :- PAINTBOX
8. FIG :- THINNER
9. FIG :- WHEEL OF TRAIN
10. FIG :- ZYGLO TESTING MACHINE
11. FIG :- SPRING
12. FIG:- BRINELL HARDNESS TESTING MACHINE
13. FIG :- HEATTREATMENT
14. FIG:- IRONCARBONDIAGRAM
15. FIG:- JIG
16. FIG :- FIXTURE
17. FIG:- BLOCK DIAGRAMOF BASIC AIRBRAKEEQUIPMENT
18. FIG :- Welding by torch
19. FIG:- OXY-ACETYLENEPLANT
20. FIG :- OVER HEAD CRANE
21. FIG:- BELT CONVEYER
22. FIG :- SMALL INDUSTRIAL CAR

6. 6
INTRODUCTION
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 passenger’s 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 twork of broad, metre and narrow gauges. It also
owns locomotive and coach productionfacilities at several places in India
and are assigned codes identifying
Their gauge,kind of powerand type of operation.Its operations cover also
provide 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
dieseland 4,568 electric locomotives). The trains have a 5 digit numbering
system and runs 12,617 passengertrains 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, Since1960, almost all electrified
sections on IR use 25,000 Volt AC traction through overhead catenary
delivery.

7. 7
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

8. 8
ABOUT GORAKHPUR MECHANICAL WORKSHOP
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.ThePOH of
MG coaches was also stopped from January 2002.Atpresent, 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.
STAISTICS AND SPECIFICATION
1. No of officers -19.
2. No of supervisors-378.
3. On roll strength- 5282.
4. Total are covered-29.8 Hectare.
5. Covered area-12.6 Hectare.
6. Township area Gorakhpur.
7. Power consumption- 208662 KWH.
1. FIG :- VIEW OF WORKSHOP

9. 9
MACHINE SHOP
In this section all kinds of machining is done to obtain the correctsize 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.
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
panelby pushingbuttons.The jobis machined according to theparameter 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.
4. Central lathe section.
5. Heavy machine section.

10. 10
2. FIG :- 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 provides.
3. FIG :- DRILLING MACHINE

11. 11
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.
4. FIG:- LATHE MACHINE
SHAPER-The machine is also called horizontalshaping machine. Itworks 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.

12. 12
5. FIG :- SHAPER
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 .
N.C.BORING-By this boring machine, various different operations can be
done such as drilling machine etc. The depth of cutand 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.

13. 13
PLANNER-Planner is used for the very large jobs. The basic difference
between shaper and planner is procedureof giving relative motion between
the work piece and tool .In theshaper, the tool reciprocates while in planner
the table reciprocates.
6. FIG :- PLANNER

14. 14
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.
FIG:- PAINT BOX

15. 15
8. FIG :- THINNER
THE MAIN PROCESS INVOLVE IN PAINTING – Firstly,Putin is preparedand
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 donein 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.
9. Graphite paint.
10. Oil paint

16. 16
WHEEL SHOP
In this shop, repair work of the wheel and axel is under taken. As it is known
that, the wheel wears throughout its life. When at work the profile and
diameter of the wheel constantly changes. To improve it’s working and for
security reason, itis repaired and given correctprofile with proper diameter.
The diameter of new wheel is-
Type Wheel dia. Distance b/w
journal center
(mm)
Journal
size(mm)
Axel wheel
seat dia.
(mm)
ICF 915 2159 120*113.5 172,0.25,0.35
BMEL 915 2210.2 120*179 171,0.45,0.63
Wheel can beused certain minimum diameter after whichit is discarded.The
diameter of the wheel when it is condemned are-
S.N TYPE OF WHEEL DIAMETER IN (MM)
1. ICF/BMEL SOLID 915-813
2. ICF TIRED 915-851
3. BMEL TIRED 915-839
9. FIG :- WHEEL OF TRAIN

17. 17
WHEEL TESTING & MACHINING
In this shop wheel sets are removed from the bogies, the entire wheel is first
inspected for assessingthecondition of the componentof wheelsuch asaxel
trial wheel disc and guttering.
The shop consist of-
(1) Axel journal testing lathe.
(2) Hydraulic wheel press with facility of mounting.
(3) Axel turning lathe.
(4) Vertical turning lathe.
Axel journal turning lathe.
On this lathe, the diameter of the axel is brought to the correct diameter.
the cutting tool is used of carbon tool.
Hydraulic wheel press with a facility of mounting.
The wheel is pressed on the axel with the help of this machine. A calculated
amount of pressure is applied and the wheel is pressed.
Axel turning machine.
External and internal diameter is corrected by this lathe, wheel is tightened on
the rotating clutch. The stationary is carbide tool cut the wheel to correct
diameter.
Wheel Profile Lathe.
The profile of the wheel is repaired on this machine. Correct profile is cut by
carbide tool.
ZYGLO TESTING
It is a non-destructive testing is used to detect the flows or discontinuities in
materials without using impairing their use fullness. This testing is used for
ferrous is non-ferrous metals.

18. 18
10. FIG :- ZYGLO TESTING MACHINE.
SPRING SECTION
In this section the helical and leaf spring are prepared. For this purpose there
certain machine for testing, grading and repairing it.
11. FIG :- SPRING
The test performed on helical spring and laminated spring are-
(1) Visual and magnetic crack detection.
(2) Spring scraping machine.
(3) D’ buckling
Visualand magnetic crack detection. The visualtest with the help of magnifying
lens and glass the spring is inspected of-
Corroded Fail
Deep seam of mark Fail
Surface crack Fail

19. 19
Inthe magnetic testing a mixtureof keroseneoil 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 presentthe presenceof crack. There are variation reasons for the
failure of the helical spring such as free height load test, dent mark, corrosion
and breakage.
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,undercertain and its compressionisnoted down.Thecompression
is matched fromthe table provided for springs. If thecompression 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.

20. 20
5. Hardness testing machine.
In hardness the use Brinell hardness test machine.
12. FIG:- BRINELL HARDNESS TESTING MACHINE

21. 21
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.
13. FIG :- HEAT TREATMENT

22. 22
DIFFERENT TYPES OF HEAT TREATMENT PROCESS
1. Hardening.
2. Tempering.
3. Austempring.
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.
IRON CARBON DIAGRAM-
14. FIG:- IRON CARBON DIAGRAM

23. 23
JIG AND FIXTURE SHOP
If a component to be produced in small numbers then procedureadopted is
marketing out, setting on machine, clamping to machinetable. Nevertheless.
It would not be suitable for producing same component in large quantities
becauseof economic reason. A faster and more profitablemethod 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.
15. FIG:- JIG

24. 24
16. FIG :- 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

25. 25
BRAKING SYSTEM
Working-By means of frictional force between wheel and brake pad.
Mainly two types of braking system is used-
1. Air-Braking system.
2. Vacuum-brake system.
AIR BRAKING SYSTEM
This is new method of braking system, which is more efficient than the vacuum
brakes. Itis used atfirstin Rajdhaniand satabdicoaches. Progress conversion of
vacuum brakes in air-brake has being undertaken.
The main parts of air-brake system are following-
1. Brake cylinder.
2. Brake pipe.
3. Feed pipe.
4. Distributer pipe.
5. Angle lock.
6. House pipe.
7. Auxiliary reservoir.
8. Guards van valve & pressure gauge.
9. Isolating cock.
10. Passenger emerging alarm signal device.
11. Dirt collector.

26. 26
17. FIG:- BLOCK DIAGRAM OF BASIC AIR BRAKE EQUIPMENT
Description of some important parts of air-braking system-
BRAKE CYLINDER-There are two 355 mm brake cylinder under frame,
which is fed by common distributorvalve. Ithasthe piston-rodarrangement,
which works under pressure. Brakecylinder is connected to distributor valve
on one side and by pivot to the block cylinder.
BRAKE PIPE-This is charged from the locomotive at 5 kg/cm3 and causes
application and release of brakes due to change in its pressurethrough the
locomotive control system. The pipe linked to distributor system.
FEED PIPE- It having 6kg/cm3 pressure, and keeps the auxiliary reservoir
charge at fuel pressure even when brakes are applied. Feed pipe are also
connected to the distributor valve.

27. 27
DISTRIBUTOR VALVE- Itis connected to the brakepipe auxiliary reservoir
and brake cylinder. It controls the pressurein the brake cylinder. It controls
the pressurein the brakecylinder in proportion to the reduction of pressure
in brake-pipe.
ANGLE COCK-It is use for alarming purpose.
HOUSE COUPLING- Both the brake-pipe and feed pipe are fitted to the
angle cock outlet for the passage of compressed air from one coach to
another mean of braided rubber and metal coupling.
GUARD VAN VALVE & PRESSURE GAUGE- These are provided in the
guards compartments. These are provided to control the train movement.
ISOLATING COCK- Use for isolating the air from one point to the other
point.
CHOKE- It is device for restricting the flow of air from one point brakes
circuit to other point. The handle of this cock is kept parallel to the pipe to
indicate that it is in open conditions.
FIG :- ANGLE CLOCK

28. 28
SHELL SHOP
Shell shop is divided into two parts-
1. FITTING SHOP.
2. WELDING SHOP.
CAUSE OF CORROSION-
1. WATER SLEEPAGE.
2. AIR-TRAP BETWEENFLOOR 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.
(D)THROUGH FLOOR.
(E)CROPS BEARER.
(F)TUBULAR STRUCTURE.
2. SLIDE BAR
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

29. 29
18. FIG :- Welding by torch
19. FIG:- OXY-ACETYLENE PLANT

30. 30
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 protectionof 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 rooms in breweries. Material handling can also
consist of sorting and picking, as well as automatic guided vehicles.
MATERIAL HANDLING EQUIPMENT-
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 material handling.

31. 31
20. FIG :- OVER HEAD CRANE
21. FIG:- BELT CONVEYER

32. 32
22. FIG :- SMALL INDUSTRIAL CAR
Up until about the end of the 19th century, most passenger cars were
constructed of wood. The first passengertrains did not travel very far, but
they were able to haul many more passengers fora longer distance than
any wagons pulled by horses.
One of the early coachdesigns was the "Stanhope".It featured a roof and
small holes in the floor for drainage when it rained, and had separate
compartments for different classes of travel. The only problem with this
design is that the passengers were expected to stand for their entire trip.
The first passenger cars in the United States resembled stagecoaches.
They were short, often less than 10 ft (3 m) long and had two axles.
British railways had a head start on Americanrailroads, with the first "bed-
carriage" (an early sleeping car) being built there as early as 1838 foruse
on the Londonand Birmingham Railway and the Grand Junction Railway.
Britain's early sleepers,when made up for sleeping, extended the footof
the bed into a boot section at the end of the carriage. The cars were still
too short to allow more than two orthree beds to be positioned end to end.

33. 33

34. 34