The document summarizes an internship report on the design and manufacture of metro car bodies at BEML Limited in Bangalore. It describes the key sections and processes involved, including fabrication of the sidewalls and roof using robotic spot welding, seam welding of the underframe sections, and fitting of components in the furnishing section. The internship provided insights into industrial practices such as quality control, communication hierarchies, and maintenance processes. The intern gained new skills and knowledge about metro car body production.

1. Internship report Presentation on
“DESIGN AND MANUFACTURE OF METRO CAR BODY”
Submitted by
SYED YAHYA
(1VE15ME100)
Under The Guidance of
Internal guide External Guide
Dr. SHRISHAIL KAKKERI Mr. H.B. LINGA REDDY
HEAD OF DEPARTMENT, MED, Sr.Manager – training
SVCE , BANGALORE BEML LIMITED
SRI VENKATESHWARA COLEGE OF ENGINEERING
(Affiliated to VTU, Belgavi, Approved by AICTE, New Delhi)
DEPARTMENT OF MECHANICAL ENGINEERING
(NBAAccredited)

2. LIST OF CONTENTS
• ORGANIZATION/INDUSTRY CERTIFICATE
• EXECUTIVE SUMMARY
• COMPANY PROFILE
• ABOUT THE COMPANY
• TASK PERFORMED
• REFLECTION
• CONCLUSION
• REFERENCES

3. ORGANIZATION/INDUSTRY CERTIFICATE

4. • BEML limited is a premier ISO 9001-2000 company in India and
the second largest manufacturer of earthmoving equipments in
Asia.
• BEML limited, Bangalore complex is currently dealing with
mining, defence, metro etc. It manufactures a rolling stock for
Delhi metro, Kolkata metro and Bangalore metro in a consortium
with Hyundai Rotem BEML supplies a DMRC from Bangalore.
• Mission: Improve competitiveness through collaboration, strategic
alliances and joint ventures, to sustain and enhance market share in
product groups BEML operates.
• Vision: Become a market leader, as a diversified Company,
supplying quality products and services to sectors such as Mining
& Construction, Rail & Metro, Defence & Aerospace and to
emerge as a prominent international player.
EXECUTIVE SUMMARY

5. COMPANY PROFILE
• BEML Limited (formerly Bharat Earth Movers Limited) is
public sector undertaking under ministry of defence (Govt. of
India) with headquarters in Bangalore. BEML’s products meet
the requirement sectors of economy viz. urban transportation,
construction and mining, defence equipment etc.
• It manufactures a variety of heavy equipment, such as that
used for earth moving, transport and mining.
• BEML Limited was established in May 1964 as a public sector
undertaking for manufacture of rail coaches and spare parts
and mining equipments.
• BEML Limited, a ‘Miniratna – Category-1’ company, plays
pivotal role and serves India’s core sectors like Defence, Rail,
Power, Mining and Infrastructure.

6. ABOUT THE COMPANY
• BEML Limited (formerly Bharat Earth Movers Limited) was
established in May 1964 as a Public Sector Undertaking for
manufacture of Rail Coaches & Spare Parts and Mining
Equipment at its Bangalore Complex.
• The company has 9 manufacturing units spread over the
following locations:
1.Kolar Gold Fields (KGF) Complex (around 100 Km from
Bangalore) Earth Moving Division, Rail Coach Unit II, Heavy
Fabrication Unit and Hydraulic & Powerline Division.
2. Mysore Complex (around 130 Km from Bangalore) Truck
Division and Engine Division.
3. Bangalore Complex - Rail & Metro Division, Palakkad
Complex and Vignyan Industries, a subsidiary located at Tarikere
(around 300 km from Bangalore) - Steel Castings.

7. TASK PERFORMED
DESIGN AND MANUFACTURE OF METRO CAR BODY
INTRODUCTION:
• Metro car is a type of high-capacity public transport generally found
in urban areas.
• Also known as Rapid transit or mass rapid transit (MRT),
heavy rail, subway, tube, U-Bahn or underground.
Fig. Namma metro

8. Metro cars are classified as :
• Standard gauge
• Broad gauge
Fig. Broad gauge metro car(25 KV AC) Fig. Standard gauge metro car(750 V DC Rail)

9. The following are the specifications of the Metro cars:
• Gauge : Standard/Broad gauge (1435/1676 mm).
• Car formation : 3/6 cars (DMC-TC-DMC)/(DT-M-TC-M-M-DT).
• Passenger capacity : 1000/2000 persons in full load condition.
• Axle load : 15/16 tons per axle.
• Speed control : By Variable Voltage Variable Frequency (VVVF).
• Max design speed : 90 kmph.
• Max operating speed : 75 kmph.
• Input power : 750V DC through 3rd rail bottom collector system.
• Traction motor type : AC 3- phase induction motor (squirrel cage).
• Other specifications : All stainless steel body, fully AC to run
under.

10. Shipping/Delivery
Planning
Order from Customer
Product Design
Progress
Marketing
Inspection
R & D
Finished Goods
Production/Manufacturing
Purchase
Inspection
WORK FLOW MODEL

11. PRODUCTION DEPARTMENT
Each metro car consist of six modules.
• Underframe
• Sidewall L H
• Sidewall R H
• End wall
• Cab
• Roof
Each of the above mentioned components start their journey from stainless steel
parts that are sub-contracted to other companies.
The side wall and the roof are fabricated in the car body shop.

12. SIDEWALL DESIGN
• According to the drawings both the side wall and roof are fabricated using
robotic spot welding machines.
• The weld points are also specified in the drawing. The fixtures are welded
using TIG (tungsten inert gas welding).
Fig. TOP VIEW OF SIDE WALL Fig. SIDEWALL

13. All the extra fittings are welded
using TIG welding to either the
roof top or the mid and end
sections.
Basic structure of roof top is
made.It is then spot welded to the
panel.
End panels are fabricated,spot
welded and levelling operation is
done.Mid section also fabricated
here.spot welding is used.locators
and clamps are used to arrest the
motion of the parts .
DLD panels of mild steel are
attached by spot welding in which
workbase acts as a second
electrode.hence the machine has
only one electrode .
FABRICATION PROCESS

14. UNDERFRAME SECTION
• This section forms an integral part of the overall assembly as it has to
support the weight of the car.
• This section manufactures underframes for Indian railways, suburban trains
and metro.
• For the metro stainless steel is used which is in contrary to the mild steel
used for Indian railways and the sub urban trains.
• Basic process that are involved are MIG, spot and seam welding.

15. SEAM WELDING
• Principle-when the power supply is switched on due to the high resistance of
the roller wheel, heat is generated. When this roller is touched to the SS
sheets they melt and solidify joining the two sheets.
• The seam welding machine consist of a roller which has high electrical
resistance.it also has a supply of cooling water which helps in solidifying the
weld immediately.
Fig. SEAM WELDING MACHINE

16. • The three sheets are placed on a jig with the seam welding machine running
along the side of the jig.
• The X in the figure indicate the initial tact weld.
• Once this is done a complete weld as indicated by the line is done.
Fig. UNDERFRAME
Contd..

17. • Shown above is under frame with the end under section visible.
• The metro trains use a similar end under frame.
• The sub-assemblies of the body bolster and center sill are welded using
MIG welding.
END- UNDERFRAME
Fig. Parts of end underframe

18. • Initially tact weld is performed then continuous weld is done.
• All the components are welded using MIG welding.
• Vertical welding is also performed by using a jig that can rotate 360º.
• After vertical welding the given assembly is turned 180º and welding on the
underside is done.
• Then the end under frame is grinded and buffed. After this tests are
conducted in order to check for any defects present.
Fig. 360 degree under frame welding jig.
Contd..

19. Spot welding of roof sheets
Serves as one of the input to the section Assembly of the entire car body
shell
The side frames shown
below are integrated to
form the side wall.
Welding used is MIG
welding.
All the fabrications of
the roof made are
assembled here using
MIG welding.
Hardening of the shell is
carried out. Electrochemical
grinding is performed to
remove stains of spot weld.
The assembled body is
washed.
CAR BODY SHOP

20. Once the car rolls out from the car body shop its outer structure is complete .This
serves as the input to this section. The car body then spends the next thirty days
in this section.
The following are added to the car body shell in this section.
• Floor boards over which linoleum covers are put.
• Glass wool insulation is done. Since the metro car is an air-conditioned car it
is imperative to carry out the insulation properly.Infact only after the customer
is satisfied with this does he clear the car to move further.
• Window glasses are installed using seals.
• Roof and under frame cable ducts are added.
• Doors and their opening and closing systems are installed.
• Interior panels are installed throughout the car.
• Plastic seats are also installed.
• Piping for the braking is installed as per drawings.
• Electrical units are installed.
• Compressors, battery boxes, invertor units are installed.
FURNISHING SECTION

21. Fig. Cable ducts Fig. Interior panels
Fig. Completed/Furnished interior
Contd..

22.  This interaction gave me an insight and first-hand experience Of
industrial scenario, outside The institute curriculum.
 In addition, the exposure gave me the practical knowledge into the
overall functioning of the organisation, human behaviour in
industry and also helped me co-relate theoretical concepts of
classroom and practical approach to industrial production.
 I came to know about how the hiererchy of communication
between employees happens in the system.
REFLECTION

23. I came to know about the role of employers in their department
and how they hand over the works to new scheduled employees.
I came to know about how maintenance of the department works.
The employees are very expressive in sharing their knowledge.
Our external guide Mr. Linga reddy was helping towards my task.
He also shared the knowledge about quality control and quality
management.
Contd..

24. CONCLUSIONS
• On the whole, this internship was a useful experience.
• I have gained new knowledge, skills and met many new people.
• I achieved several of My learning goals.
• I got insight into professional practices currently advocated in the
industry.
• I learned the different facets of working within a well established
industry.
• The entire duration of four weeks in BEML was professionally
managed by all the responsible persons I came across, very
informative and I have no doubt, it will retain its significance when
I embrace my professional careers as an engineer.
• In doing so, I gratefully acknowledge my institution for giving me
an opportunity to complete this internship in this company.

25. REFERENCES
1. https://en.m.wikipedia.org/wiki/Namma_Metro
2. https://www.railway-technology.com › …Namma Metro,
Metro Development in Bangalore, India –
RaiTechnologyhttps
3. https://www.bemlindia.in/
4. https://www.slideshare.net/saba/bangalore-metro-rolling-
stock
5. https://www.slideshare.net/davaltechno/beml-bharath-earth-
movers-limited
6. https://www.slideshare.net/engineering/beml-limited
7. https://en.m.wikipedia.org/wiki/Rapid_transit