This document is a summer internship report submitted by Iqubal Husain, a 2nd year mechanical engineering student, about his 4-week internship at Banaras Locomotive Works in Varanasi, India. The report includes an introduction to BLW, which was formerly known as Diesel Locomotive Works and now produces electric locomotives. It also describes some of the main shops at BLW, including the Maintenance Service Shop and Sheet Metal Shop, and provides details on key locomotives produced, such as the WAP-7 and WAG-9.

1. SUMMER INTERNSHIP REPORT -2022
BANARAS LOCOMOTIVE WORKS
VARANASI-221004
SUBMITTED TO:
PRINCIPAL
Technical Training Centre
BLW/VARANASI
SUBMITTED BY:
NAME : IQUBAL HUSAIN
REGISTRATION NO. : 2022071265
TRANING DURATION : 4 Weeks (July Month)
COURSE : B.Tech.
BRANCH NAME : Mechanical Engineering
YEAR : 2nd
Year
COLLEGE NAME : SIR CHHOTU RAM I E & T, C C S UNIVERSITY CAMPUS, MEERUT

2. ACKNOWLEDGEMENT
Summer training has an important role in exposing the real life situation
in an industry. It was a great experience for me to work on training at
BANARAS LOCOMOTIVE WORKSHOP through which I could learn
to work in a professional environment.
I would sincerely like to thank the employees and the officers of BLW,
VARANASI for their help and support during the vocational training.
Despite their busy schedules, they took time out for us and explained to
us the various aspects of the working of the plant from the production
shops.
I would sincerely like to thank all the concerned engineers and senior
officials who were instrumental in arranging the vocational training at
BLW Varanasi, and without whose help and guidance the training could
not have materialize.
I express my deep sense of gratitude to Mr. Ramjanm Chaubey Sir
(Principal TTC), BLW for given me such a great opportunity.
IQUBAL HUSAIN
M.E. 2nd
Year
SCRIET (CCSU, MEERUT)

3. CONTENTS
[1] ACKNOWLEDGEMENT........................................................
[2] INTRODUCTION TO BLW…………………………………
[3] MAINTAINANCE SERVICE SHOP (MSS)………………..
[4] SHEET METAL SHOP (SMS) ……………………………..
[5] HEAT TREATMENT SHOP (HTS)…………………………
[6] HEAVY MACHINE SHOP (HMS) …….……………………
[7] CONCLUSION……………………………………………….
[8] BIBLIOGRAPHY...…………………………………………...

4. INTRODUCTION TO BLW
The Banaras Locomotive Works (BLW) (formerly Diesel Locomotive
Works (DLW)) in Varanasi, India, is a production unit of Indian Railways. DLW
stopped manufacturing diesel locomotives in March 2019 and was renamed BLW
in Oct 2020.
Banaras Locomotive Works
Type Indian Railways production unit
Industry Electric locomotive
Predecessor Diesel Locomotive Works
Founded August 1961; 61 years ago
Headquarters
Varanasi, Uttar Pradesh
India
Area served India & South East Asian Countries
Key people Anjali Goyal (General Manager)
Products
WAP 7
WAG 9
WAG 11
Owner Indian Railways
Website blw.indianrailways.gov.in
Banaras Locomotive Works i.e. BLW was formerly known as Diesel Locomotive
Works (DLW). It is a locomotive production unit of Indian Railways. "DLW"
stopped manufacturing diesel locomotives in March 2019 and its name was
changed to Banaras Locomotive Works (BLW) in October 2020.
The foundation stone of DLW (Diesel Locomotive Works) was laid on 23 April
1956 by the first President of India Late Rajendra Prasad and on August 1961
Banaras Locomotive Works was established as "DLW". Three years later, on 3
January 1964, DLW released its Broad Gauge Locomotive (WDM-2) by (Late)

5. Shri Lal Bahadur Shastri. It has produced several variants based on the GM EMD
designs of the 1990s, with the original ALCO design from the 1960s.
Banaras Locomotive Works has consistently won the "Best Production Unit
Shield 2015-16, 2016-17, 2017-18" of Indian Railways. In March 2018, it
successfully created history by converting two old ALCO Diesel Loco WDG3A
into Electric Loco WAGC-3 (WAG-10). This happened for the first time in the
world. Before discontinuing diesel loco production, DLW was the largest diesel-
electric locomotive manufacturer in India. Altogether BLW has manufactured
8298 Diesel and 1050* Electric Rail Locomotives.
In March 2019, it developed the country's first bi-mode locomotive, WDAP-
5. Today, Banaras Locomotive Works produces mostly electric locomotives
WAP-7, WAG-9, WAG-11.

6. Due to the hard work and efficiency of the workers of this factory, orders are
being received for making engines from many countries. In addition to Indian
Railways, BLW regularly exports locomotives to countries such as Sri Lanka,
Nepal, Bangladesh, Mali, Senegal, Tanzania, Angola, Mozambique and Vietnam
and some users within India such as ports, large power and steel plants and
private railways. Offers its services to.

7. PRODUCTS OF BLW
1. Indian locomotive class WAP-7
Type and origin
Power type Electric
Builder Chittaranjan Locomotive Works,
Banaras Locomotive Works,
Patiala Locomotive Works
Build date 1999 - present
Total produced 1423 as of July 2022
Specifications
Gauge 5 ft 6 in (1,676 mm)
Bogies Co-Co, Fabricated Flexi coil Mark
IV bogies; bogie wheelbase 1,850 mm
(72+7⁄8 in) + 1,850 mm (72+7⁄8 in)
Wheel diameter 1,092 mm (43 in) new, 1,016 mm
(40 in) worn
Wheelbase 15,700 mm (51 ft 6+1⁄8 in)
Length:
• Over beams 20,562 mm (67 ft 5+1⁄2 in)
Width 3,152 mm (10 ft 4+1⁄8 in)
Height:
• Pantograph 4,255 mm (13 ft 11+1⁄2 in)
Axle load WAP 7
20.5 t (20.2 long tons; 22.6 short tons)
WAP 7HS
18.08 t (17.79 long tons; 19.93 short
tons)
Loco weight 123 t (121 long tons; 136 short tons)
Power supply 3-phase 2180 V 50 Hz
Electric
system/s
25 kV 50 Hz AC Overhead

8. Current
pickup(s)
Pantograph
Traction
motors
6FRA 6068 3-phase squirrel-cage
induction motors
850 kW (1,140 hp), 2180 V, 1283/2484
rpm, 270/310A;
Weight-2,100 kg (4,600 lb), forced-air
ventilation, axle-hung, nose-suspended;
Torque 6,330–7,140 N⋅m (4,670–
5,270 lbf⋅ft)
~88% efficiency.
Transmission Electric
Gear ratio WAP 7
72:20
WAP 7HS
70:22
Loco brake Air and regenerative
Train brakes Air

9. The Indian locomotive class WAP-7 is a class of 25 kV AC electric
locomotives that was developed in 1999 by Chittaranjan Locomotive
Works (CLW) for Indian Railways. The model name stands for broad gauge (W),
AC Current (A), Passenger traffic (P) engine, 7th generation (7). They entered
service in 2000. A total of 1423 WAP-7 have been built, with more units being
built at CLW, Banaras Locomotive Works (BLW) and Patiala Locomotive
Works (PLW).
The WAP-7 is one of the most successful locomotives of Indian Railways
serving passenger trains for over 22 years. It is a passenger variant of the WAG-
9 freight locomotive with a modified gear ratio to pull lighter loads at higher
speeds. With an output of 6,350 hp (4,740 kW), it is the most powerful passenger
locomotive in the Indian Railways fleet, and the most numerous passenger
locomotive in India, with a total of 1423 locomotives built as of April 2022. The
WAP-7 is capable of hauling 24 coach trains at speeds 110–140 km/h (68–
87 mph)
2. Indian locomotive class WAG-9
WAG-9
Type and origin
Power type Electric
Builder Chittaranjan Locomotive Works,
Electric Locomotive Works
(Bhusawal), Bharat Heavy
Electricals Limited, Banaras
Locomotive Works,
Patiala Locomotive Works
Build date 1995 - present
Total
produced
3284 as of July 2022
Specifications
Configuration:
• UIC Co′Co′
Gauge 5 ft 6 in (1,676 mm)

10. Bogies Adtranz Fabricated Flexicoil IV
Wheel
diameter
New:1,092 mm (3 ft 7 in),
Half worn:1,054 mm
(3 ft 5+1⁄2 in)
Full worn:1,016 mm (3 ft 4 in)
Wheelbase 15.7 m (51 ft 6 in)
Length 20.562 m (67 ft 5+1
⁄2 in)
Width 3.152 m (10 ft 4+1⁄8 in)
Height 4.525 m (14 ft 10+1⁄8 in)
Axle load WAG-9 : 20.5 tonnes (20.2
long tons; 22.6 short tons)
WAG-9H/Hi/9i : 22.0 tonnes
(21.7 long tons; 24.3 short
tons)
Loco weight WAG-9 : 123 tonnes (121 long
tons; 136 short tons) WAG-
9H/9Hi/9i : 132 tonnes (130
long tons; 146 short tons)
Electric
system/s
25 kV 50 Hz AC Overhead
Current
pickup(s)
dual pantographs
Traction
motors
WAG-
9/9H/9i : Adtranz 6FRA6068
MU working 2
Loco brake Air and Regenerative
Train brakes Air
Safety systems Slip/slide control, Main
overload relay, Over voltage
relay, No volt protection,
Vigilance Control Device, Fire
Detection Equipment, Fire
Extinguishers and Earth fault
relay

11. The Indian locomotive class WAG-9 is a class of 25 kV AC electric
locomotives that was developed in 1995 by ABB Group (ABB) for Indian
Railways. The model name stands for broad gauge (W), AC Current (A), Goods
traffic (G), 9th generation (9) locomotive. They entered service in 1996. A total
of 3284 WAG-9 have been built at Chittaranjan Locomotive Works (CLW), with
more units being built at Banaras Locomotive Works (BLW), Bharat Heavy
Electricals Limited (BHEL) and Patiala Locomotive Works (PLW). It was the
most powerful freight locomotive of its fleet until the formal introduction of
the WAG-12.
The WAG-9 is one of the most successful locomotives of Indian Railways
serving freight trains for over 26 years. A passenger variant of the WAG-9 was
developed namely the WAP-7 locomotive by modifying the gear ratio to pull
lighter loads at higher speeds. Nowadays, It is a common locomotive used in
freight trains.

12. MAINTAINANCE SERVICE SHOP (MSS)
Maintenance shop is the combination of many shops. The shops which comes
under the maintenance shop are
a) Assembly Shop
b) Machining Shop
Many engine parts manufactured from various other shops are machined and
assembled in the maintenance shop. They include:
1. ASSEMBLY SHOP
a) Camshaft Assembly
b) Crankshaft Assembly
c) Governor Assembly
d) Radiator Fan Assembly
e) Lubrication Oil Pump and Water Pump Assembly
f) Lube Oil Filter and Cooler
g) Water Cooled Air Compressor for EMD Locomotives
h) Fuel Pump Support Assembly
i) OST Assembly
2. MACHINING SHOP
a) The frontal engine surfaces
b) Machining of assemblies after welding operations
c) Machining of the various engine parts smooth operation
d) Machining of the inside holes and grooves

13. PRINCIPAL OF MAINTENCE
(A) Breakdown Maintenance
Break down of machine can occur due to the following two reasons: -
a) Due to unpredictable failure of component which cannot be prevented.
b) Due to gradual wear and tear of the parts of the machine which can be
prevented by regular inspection known as preventive maintenance.
(B) Preventive maintenance
a) Also termed as “planned maintenance” or “systematic maintenance”.
b) An extremely important function for the reduction of the maintenance cost
and to keep the good operational condition of equipment.
Objective of preventive maintenance
a) To obtain maximum availability of the plant by avoiding break down and
by reducing shut down period to a maximum.
b) To keep the machine in proper condition so as to maintain the quality of the
product.
c) To ensure the safety of the workers.
d) To keep the plant at the maximum production efficiency.
e) To achieve the above objectives with most economical combination.

14. SHEET METAL SHOP (SMS)
Machines Used in SMS:
1. CNC Shearing Machine
2. CNC Hydraulic Turret Press Punch Machine
3. Layer Cutting Machine
4. CNC Bending Machine
5. Angle Shear Machine
6. Oil Furnace
7. Axial Drilling Machine
8. MIG Welding wing CO2
9. Punching Machine
10. Band Saw Machine
Operations:
1. Driver Cab
2. Hood Over Engine
-Engine Hood
-Cooling Hood
-DB Hood

15. 1. Fully-Automatic CNC Shearing Machine
Automation Grade Fully-automatic
Brand HUBOW
Max Shear Width 2000-3000 mm
Material to be Sheared Stainless Steel, Carbon Steel
Automatic Grade Automatic
Working principle shearing machine
⑴ Shearing machine is widely used for direct shearing of various metal materials according
to different needs. It is mainly used in steel manufacturing, shipbuilding, automobile,
container manufacturing, switchgear, machinery manufacturing, and light industry.
⑵ The shearing machine is driven by the hydraulic system to press the pressing material to
press the steel plate, and the left and right cylinders drive the tool holder to move up and
down. The upper blade on the tool holder is fixed to the lower blade of the lower blade seat
and adopts reasonable blade clearance and various thicknesses. The sheet metal is subjected
to shearing forces to cause the sheet to break apart at the desired size.

16. 2 . CNC Bending Machine
The CNC bending machine uses the equipped mold to bend the cold metal sheet into various
geometric cross-sectional shapes. It is a sheet forming machine designed for cold-rolled
sheet metal processing, and is widely used in sheet bending processing in industries such as
automobiles, aircraft manufacturing, light industry, shipbuilding, containers, elevators, and
railway vehicles.
Features of CNC Bending Machine:
1. Direct angle programming with angle compensation function.
2. The grating ruler real-time detection feedback correction, full closed-loop control, back
gauge and slider dead gauge positioning accuracy is ±0.02mm.
3. The upper mold adopts a quick clamping device, and the lower mold adopts a wedge
deformation compensation mechanism.
4. With multi-step programming function, it can realize multiple automatic operation,
complete one-time processing of multi-step parts, and improve production efficiency.
5. The imported hydraulic system with stable performance and compact structure can be
selected according to user requirements, and the back gauge can be driven by ball screw and
timing belt.

17. Operating procedures of CNC Bending Machine
1. Strictly abide by the safety operating procedures and wear labor protection equipment as
required.
2. Before starting, carefully check whether the motor, switch, circuit and grounding are
normal and firm, and check that the control parts and buttons of the equipment are stuck in
the correct position.
3. Check the overlap and firmness of the upper and lower molds; check whether each
positioning device meets the requirements of being processed.
4. When the upper slide plate and each positioning axis are not at the origin, run the return to
origin program.
5. After the equipment is started, run dry for 1-2 minutes, and move on the slide for 2-3
times at full stroke. If abnormal sound or malfunction is found, stop immediately, remove the
malfunction, and work after everything is normal.
6. When working, one person should command uniformly, so that the operators and the
feeding and suppressing personnel should cooperate closely to ensure that the cooperating
personnel are in a safe position before they can send out the bending signal.
7. When the sheet is bent, it must be compacted to prevent the sheet from lifting up and
hurting people during bending.
8. The power supply must be cut off when adjusting the sheet metal die, and the operation
should be stopped.
3. CNC Hydraulic Turret Press Punch Machine

19. CNC turret punch servo system is an automatic control system that controls the position and
speeds of the moving parts of the machine tool, also known as follow-up system, drag
system or servo mechanism. In CNC machine tools, the servo system receives the feed
generated by the computer interpolation software. The pulse or feed displacement is
transformed and amplified into the displacement of the moving part. The servo system can
be divided into position servo (the position of the table and the position and starting angle of
the main shaft) and speed servo (the speed of the rotation of the table motor).
The composition and working principle of the servo system
The CNC turret punch servo system consists of a speed loop and a position loop. As shown
in the figure, this is a double closed-loop system. The inner loop is the speed loop and the
outer loop is the position loop. Speed control is an important part of the servo system, and
the speed loop consists of a speed control unit, a servo motor and a speed detection device.
The speed control unit is used to control the speed of the motor and is the core of the speed
control system. It is an independent unit, composed of speed regulator, current regulator and
power drive amplifier.
The detection devices used for speed feedback in the speed loop are tachogenerators, pulse
encoders, etc. The position loop is composed of the position control module, speed control
unit, position detection and feedback control in the CNC device. The position control is
mainly to control the motion coordinate axis of the machine tool. The coordinate axis control
is the required position control. It not only has strict requirements on the control of the
movement speed and position accuracy of a single uranium, but also requires that each
moving uranium has a Good dynamic coordination can ensure processing efficiency,
processing accuracy and surface roughness.
【Analysis of the advantages and disadvantages of CNC turret punch press】
CNC turret punching machines have many advantages. They are: strong adaptability to parts
and can process parts surfaces of complex shapes; high productivity; high machining
accuracy and stable machining quality; shortened production preparation time, facilitated
modern management; reduced labor for workers strength.
(1) Compared with ordinary machine tools, CNC turret punching machines can improve
production efficiency by 3 to 5 times, and use CNC machining center machine tools to
achieve productivity of 5-10 times;
(2) CNC turret punching machine can obtain higher machining accuracy than the machine
tool itself;
(3) Complex shape parts can be processed without special fixtures;
(4) One machine can be used for multiple purposes, reducing labor intensity and saving plant
area:

20. (5) It is conducive to the development of computer control and management, and is
conducive to the development of comprehensive automation of machining;
(6) The initial investment and maintenance technology of CNC turret punch presses are
relatively high, and the quality of management and operators is also high.
The CNC turret punching machine better solves the problems of complex shape, high
precision, small production batch, short production cycle and frequent product replacement.
It is a flexible and high-efficiency automatic machine tool. CAI (DNC), flexible
manufacturing system (FMS), computer integrated manufacturing system (CIMS, computer
integrated manufacturing) and other important devices for flexible processing and the basis
of the temperament manufacturing system.
CNC turret punching also has disadvantages. They are: expensive and large initial
investment in equipment; high technical requirements for users and maintenance personnel
due to the integration of mechanical, electrical, hydraulic and computer technologies; manual
programming workload when processing complex-shaped parts.
Band Saw Machine

21. HEAT TREATMENT SHOP (HTS)
Different heat treatment operations like- Quenching, Normalising, Case Hardening, Stress
Relieving, Induction Hardening are employed.Low steel or Class-II jobs are first carburised,
i.e., the carbon content is increased on the surface before any heat treatment. The carburizing
temperature is 920-930⁰C.
Stress Relieving is a process of heating up to a lower critical temperature and holding there
for a definite time before slow cooling. It’s purpose is to remove internal stresses.
Example:
a) Eng. Block - 640⁰C/10hrs.
b) Cam Shaft - 450⁰C/4hrs.
Induction Hardening is a process of surface hardening. It works on the principal of mutual
induction; hardening by high frequency AC-current. The conditions are:
a) Voltage – 410-450V
b) Temperature - 840⁰C
c) Quenching Pressure – 14-30psi
d) Quenching Water Temperature – 20-30⁰C
Heat treatment process is defined as:
An operation or combination of operations
Heating and Colling of a metal /alloy in solid state
To obtain desirable
Conditions, e.g., that
of relieve stresses
Properties e.g.
-Better machinability
- Improve ductility
-Homogeneous structure.

22. PURPOSE
a) Cause relief of internal stresses developed during cold working, forging etc.
b) Harden and strengthen metal
c) Improve machinability
d) Change grain size
e) Improve ductility and toughness
f) Increase,heat,wear, and corrosion resistance of material
STAGES OF HEAT TREATMENT
a) Stage l—Heating the metal slowly to ensure a uniform temperature.
b) Stage 2—Soaking (holding) the metal at a given temperature for a given time and
cooling the metal to room temperature.
c) Stage 3—Cooling the metal to room temperature.
Stages of Heat Treatment

23. 2.1.1.Heat Treatment Process:
a) Annealing (815 °C)
b) Normalizing (815 °C)
c) Hardening (815 °C)
d) Tempering (200 °C – 300 °C)
Fig.2.2. Heat Treatment (Phase Diagram)
2.1.2. STEEL COMPOSITION

24. Fig.2.3. Different Structures of Steel
2.1.3. ANNEALING PROCESS
a) Annealing is the opposite of hardening
b) Relieve internal stresses, soften them, make them more ductile, and refine their grain structures.
c) Cooling method depend on the metal. For command use are furnace cooled.
2.1.4. NORMALIZING
a) Metal is heated to a higher temperature and then removed from the furnace for air cooling.
b) Remove the internal stresses induced by heat treating, welding, casting, forging, forming, or
machining.
c) low-carbon steels do not require normalizing (no harmful effects result).
2.1.5. HARDENING
a) In practice, 0.80 % C is required for maximum hardness.
b) When you increase the carbon content beyond 0.80 per cent, there is no increase in hardness, but
there is an increase in wear resistance.
c) This increase in wear resistance is due to the formation of a substance called hard cementite.
2.1.6. TEMPERING
a) The minimum temperature time for tempering should be 1 hour. If the part is more than 1 inch thick,
increase the time by 1 hour for each additional inch of thickness.
b) Tempering relieves quenching stresses and reduces hardness and brittleness.
PIT FURNACE

25. CARBURIZING FURNACE
INDUCTION HARDENING MACHINE

26. Induction hardening is a method of quickly and selectively hardening the surface of a metal
part. A copper coil carrying a significant level of alternating current is placed near (not
touching) the part. Heat is generated at, and near the surface by eddy current and hysteresis
losses. Quench, usually water-based with an addition such as a polymer, is directed at the
part or it is submerged. This transforms the structure to martensite, which is much harder
than the prior structure.
A popular, modern type of induction hardening equipment is called a scanner. The part is
held between centres, rotated, and passed through a progressive coil which provides both
heat and quench. The quench is directed below the coil, so any given area of the part is
rapidly cooled immediately following heating. Power level, dwell time, scan (feed) rate and
other process variables are precisely controlled by a computer.
Benefits of Induction Hardening
Increased Wear Resistance
There is a direct correlation between hardness and wear resistance. The wear
resistance of a part increases significantly with induction hardening, assuming the
initial state of the material was either annealed, or treated to a softer condition.
Increased Strength & Fatigue Life due to the Soft Core & Residual Compressive Stress at the Surface
The compressive stress (usually considered a positive attribute) is a result of the
hardened structure near the surface occupying slightly more volume than the core
and prior structure.
Parts may be Tempered after Induction Hardening to Adjust
Hardness Level, as desired
As with any process producing a martensitic structure, tempering will lower hardness while
decreasing brittleness.
Deep Case with Tough Core
Typical case depth is .030” - .120” which is deeper on average than processes
such as carburizing, carbonitriding, and various forms of nitriding performed at
sub-critical temperatures. For certain projects such as axels, or parts which are
still useful even after much material has worn away, case depth may be up to ½
inch or greater.

27. HEAVY MACHINE SHOP (HMS)
This shop carries out the machining of Cylinder BLOCK (M.G. & B.G.) main base,
saddler Main bearing caps, Splines, Turbo Super Charger. Lube Oil, Fuel Oil & Water
header bearing housing
OPERATION:
Planning. Milling, Drilling. Tapping. Boring Honing, Serration, milling etc.
Types of Machine provided in the shop are:
1. Double Housing planned machine (32", 24", & 16")
2. Radial drilling machine.
3. Radial drilling machine Traveling type.
4. Boring Machine
5. Angular Boring Machine
6. Tracer Planner machine.
7. Hill Acme king structural milling machine.
TOOLS USE:
1. O.K. Tool (Rough & Finish)
2. CC Milling cutter (4", 9", & 10")
3 Boring Tipped Tool (Rough & Finish)
4. Honing Stone (For hand honing)
MEASURING INSTRUMENT
1. Dial Bar gauge
2. Micron meter (out side and depth)

28. 3. Vernier Height gauge.
4. Vernier calipers
5. Mandrill or optical shad rill machine
EX-CELLO ANGULAR BORING MACHINE:-
Motor R.P.M. in constant, Spindle, speed is control by clutch system.
H.M.T. ANGULAR BORING MACHINE:-
Spindle speed is directly controlled through motor. (Coated carbide is used in H.M.T.
angular Boring machine).
Cylinder Block made of fabricated class II material except main bearing cop as it made
class IV material.
The machining of cylinder Block is complicated and challenging job. It required great
skill and knowledge. After duly fabricated, stress relieved and shot blasted the block is
subjected to layout to ensure availability of adequate machining allowance, where
necessary and to provide guide linear for subsequent machining the weight of the block is
6:02 Tons approx. (Fabricated Material)
After completion of all operations as per drawings the black subjected to inspection in
addition to stage inspection dimension live radial distance between center of Crank bore
and com bore, distance between center of com bore and liner seat etc. are checked at this
stage the weight of the black is 05.02 tons apporx. 01 ton of material removed by the
machining and then blank is block send for assembly.
Two tools are used for boring both tools are fixed in slot of boring bar. Due to spindle
rotation boring is done. Tool movement and machine action is governed by G Code and M
Code respectively Absolute mode and incremental modes are used for tool movement. Single
point cutting tool (two) is first fitted in devise block then in boring bar

29. ANGULAR BORING MACHINE
HORIZONTAL BORING MACHINE

30. Main dimension of cylinder Block
1. Diameter of com bore = 4.750 to 4.7515"
(B.G. & M.G.)
2. Diameter of blank bore = 9.0355 to 9.0370"
(M.G. & B.G.)
3. Diameter of liner bore=10.750 to 10.752" (Upper)
(B.G. of M.G.)
= 10.621 to 10.623 (Lower)
4. Diameter of thirst Collar = 10sigma
5. Thickness of thrust bearing = 4,247" to 4.249"
6. Thickness of the plate free end = .."
=gen. End = 1omega
7. Radial distance between the centers of crank of Cam bore 10 499 to 19.501"
8. Distance of liner seat from center of crank Bore 32.480" to 32.485"
9. Total length of the M.G. black =106.370"
=106.380
10. Total length of main Bush B.G. = 172.380"
B.G=172.370
11. Total length of main Bush M.G. = 117.130"
= 117.120"
12 Total length of BG. Black =161.625
=161.630

31. TWO WAY ANGULAR BORING MACHINE
BEHRINGER BAND SAW

32. DOUBLE HOUSING PLANNED MACHINE
⚫It is the standard model & most widely used.
⚫ Very heavy and robust.
⚫ Has a bed and two vertical housings are fixed.
⚫ Table moves along the guide ways of the bed.
⚫Housing supports cross rail & tool heads.
⚫ Cross rail carries two tool heads.
⚫Tool head carries tools.

33. RADIAL DRILLING MACHINE
⚫ Intended for drilling medium to large and heavy work piece.
⚫ m/c consists of a heavy, round, vertical column mounted on a large base.
⚫ Column supports a radial arm which can be raised and lowered to accommodate work
pieces of different heights.
⚫ Arm may be swung around to any position over the work bed.
⚫ Drill head containing mechanism for rotating and feeding the drill is mounted on a radial
arm and can be moved horizontally on the guide ways and clamped at any desired position.
⚫ The work may be mounted on the table or on the floor.

34. CONCLUSION
The Mechanical maintenance is responsible for the running of BLW. It ensures
that the all the machinery and equipment are running at their top performance
level without being affected by failure and break down. Working with the
engineers of the Mechanical maintenance department, I have gained such an
amount of knowledge which would not have been possible in a classroom in a
similar period of time.
Also the practical experience have gained here in BLW, VARANASI gave me
knowledge of to what extent my theoretical knowledge learnt in my college in
applicable in the field. Although the theoretical knowledge forms the base of
practical knowledge required on the field
The field job also requires some different set of skills which I learnt about during
my training.
My skills in Mechanical engineering has definitely been taken to a much higher
level than it was when I first joined the training programme of 4 weeks back and
I truly consider myself highly fortunate to get this opportunity.

35. Bibliography
1 .SlideShare.net
2. www.wikipedia.com
3. https://blw.indianrailways.gov.in
4. https://www.hmtwatches.in