This presentation is useful for that every person who complete their summer training under Railway Carriage Workshops For fulfillment for award of degree of B.Tech.

1. Practical Training
at
CARRIAGE WORKSHOP
NORTH-WESTERN RAILWAY, JODHPUR
PRESENTED BY :- SACHIN DEORA
MECHANICAL ENGINEERING
VII SEM (FINAL YEAR)
14EVEME055
SUBMITTED TO :-
Prof. SHAILENDRA BOHRA
HOD (MECHANICAL DEPT.)
27 MAY 2017 – 15 JULY 2017
SESSION - 2014 - 2018

2. TRAINING PRESENTATION ON
ROLLER BEARINGS
VYAS INSTITUTE OF ENGINEERING AND TECHNOLOGY
JODHPUR

3. CONTENT
• Introduction
o Role of Carriage Workshop
o Railway Zones and Head Quarter
o Hierarchy in Carriage Workshop Jodhpur
• Shop Details of Roller Bearing
• Flow Process Chart
• Introduction to Roller Bearing
• Why Roller Bearing are Used
• Dismounting of Roller Bearings
• Zyglo Testing of Roller Bearing
• Why Bearings are Rejected
• Condition of Defects
• Mounting of Roller Bearings

4. ROLE OF CARRIAGE WORKSHOP
• Periodic Over Hauling of Railway Coach and
Bogies at a level.
• Manufacture and Repairing of all the
machines.
• Production of some components, which needs
to be replaced in coaches and bogies.

5. RAILWAY ZONES AND HEAD QUARTER
S.No. Zone Head Quarter
1. Central Railway Mumbai
2. East Central Railway Hajipur
3. East Coast Railway Bhubaneswar
4. Eastern Railway Kolkata
5. North Central Railway Allahabad
6. North Eastern Railway Gorakhpur
7. North Western Railway Jaipur
8. North East Frontier Railway Guwahati
9. Northern Railway Delhi
10. South Central Railway Secunderabad
11. South East Central Railway Bilaspur
12. South Eastern Railway Kolkata

6. S.No. Zone Head Quarter
13. South Western Railway Hubli
14. Southern Railway Chennai
15. West Central Railway Jabalpur
16. Western Railway Mumbai
17. Metro Railway, Kolkata Kolkata

7. HIERARCHY IN CARRIAGE WORKSHOP
JODHPUR
• Chief Workshop Manager (CWM)
o MECHANICAL
 Dy. Chief Mechanical Engineer (Dy. CME)
 Works Manager (WM)
 Asst. Production Engineer (APE)
o ELECTRICAL
 Dy. Chief Electrical Engineer (Dy. CEE)
 Workshop Asst. Electrical Engineer (WAEE)
o PERSONNEL
 Dy. Chief Personnel Officer (Dy. CPO)

8. o FINANCE AND ACCOUNT
 Senior Asst. Finance Advisor (SAFA)
 Asst. Finance Advisor (AFA)
o ENGINEERING
 Executive Engineer (XEN) – Construction
o STORE
 Dy. Chief Material Manager (Dy. CMM)
 Asst. Material Manager (AMM)
o SUPERVISORS
 Senior Section Engineer (SSE)
 Junior Engineer (JE-I)

9. SHOP DETAILS OF ROLLER BEARING
• POH work of roller bearing of wheels for
Coaches and Diesel Locomotive.
• Dismounting and Mounting of roller bearing.
• Testing of roller bearing.

10. FLOW PROCESS CHART
Receipt of wheel from lifting shop
Cleaning axle box by iron brush
Open split pin & remove front cover
Dismount axle box housing
Load zone marking
Dismounting of roller bearing by
hydraulic pressure machine
Cleaning of bearing & axle box by
cleaning plant
Inspection of roller
bearing & accessories
OK
Fitment of accessories in sequence,
mounting of coller & roller bearing
Greasing, fitment of axle box front cover
cover seal
Check free rotation & final
inspection of assembly
Dispatch wheel set to bogie lifting shop
NOT OK
Rejected bearing & other accessories

11. INTRODUCTION TO ROLLER BEARING
• Roller bearings are named according to the
shape of rollers. Roller Bearings with spherical
rollers are called as Spherical Roller Bearings.
• The inner ring bore of Roller Bearing is
130mm are being used in ICF coaches.
• They are Directly shrunk fit on the Axle
journals.

12. • Roller Bearings are consists of an outer ring
having a continuous spherical raceway within
which operates, two rows of barrel shaped
rollers, which in turn are guided by an inner
ring with two raceway separated by centre rib.

13. WHY ROLLER BEARING IS USED..??
Roller bearing are a part of traction system
provided on excel.
Bearings carries the weight of the locomotive
by allowing free movement to the wheels.
Bearings are also subjected severe impact due
to track irregularities, lateral thrust and
sometimes due to wheel skid.

14. DISMOUNTING OF ROLLER BEARING
DISMOUNTING OF AXLE
BOX AND ROLLER
BEARINGS
• For dismounting of bearings,
special hydraulic pressure
machine is used. This machine
injects oil between the journal
and bore to the inner ring with
high pressure which expands
inner ring resulting in breaking
of interference. The bearing
becomes loose on the journal
and slides over it.

15. • The bearing is then removed
from the journal and sent to
the cleaning plants
• 3 stage cleaning plant or pre
wash, wash & water rinsing
• Cleaning of roller bearing
with kerosene. After cleaning
bearings are sent for the
zyglo testing.

16. ZYGLO TESTING OF ROLLER BEARING
1. In this method the Bearings are dipped into
fluorescent penetrate liquid.

17. 2. After flourescent penetrate bearings are taken
out from dye and passes to the drain stand.

18. 3. After draining of liquid penetrate bearings are
passes to washing tub for removing additional
penetrate.

19. 4. After washing of bearings these are passes to
drying chamber for removing water from it.
DRYING CHAMBER

20. 5. After drying, bearing are passes to developing
chamber. In this chamber developer is filled in
the cracks in roller bearing.
DEVELOPING CHAMBER

21. 6. After going through all these process bearings
are passes under UV lamp for checking of any
defect.
UV LAMP

22. 7. After checking of any defect if any defect is
found in bearings then it is rejected or if not
then it is stored in kerosene for resist to
corrosion.

23. WHY BEARINGS ARE REJECTED…??
• Bearings are rejected for the following defects :-
S.No. Defects Causes
1. Pitted and Flaked Excessive load, Improper handling &
mounting, Rusting
2. Smearing Improper lubrication, Excessive surface
roughness
3. Indentation Ingress of small dirt or dust particle,
Trapping of flaked particles, Careless
handling
4. Fretting Over size housing bore, Insufficient
lubrication
5. Seizure Insufficient grease, Bad quality of
grease, Excessive load
6. Cracking Excessive shock load & interference
Large flaking

24. CONDITION OF DEFECTS
• Pitted or Flaked - Flakes form on the surface of the
raceway and roller elements. When the flakes fall of,
the surface becomes rough and uneven.
• Smearing - Surface become rough with small
deposits.
• Indentation - Hole in raceway surface produced by
solid foreign objects trapped or impacts.
• Fretting - Producing red coloured particles that form
holes.
• Seizure - Bearing heats up, become discoloured.
• Cracking - Splits and cracks in bearing and roller.

25. MOUNTING OF ROLLER BEARINGS
MOUNTING OF COLLER
• The coller ring has an
interference fit on the journal,
and therefore requires heating
for shrink fitting. Heat the
coller ring up to a temp. of
100°C max.

26. MOUNTING OF REAR
COVER PLATE AND
FELT SEAL RING
• Wipe and clean the rear cover
and insert 4 nos. bolts. Fill
“V” grove of rear cover with
grease and fit rubber O-ring
in its position.
• Now soak the felt seal ring in
warm oil heated up to 40°C –
50°C for about 30 minutes.
Smear the felt seal by hand
with same grease as used in
axle box and fit into the
grove at rear cover.

28. MOUNTING OF
BEARING
• Direct mounted of spherical
roller bearing for passenger
coach has interference fit
with axle journal, therefore it
require heating and shrink
fitting. Heating of bearings
can be done by induction
heater within temp. range of
100°C – 120°C give
sufficient expansion for easy
sliding of bearing over
journal.

29. MOUNTING OF
RETURNING RING
AND LOCKING PLATE

30. MOUNTING OF AXLE
BOX HOUSING AND
FRONT COVER