BWEL Project Report

INDUSTRIAL TRAINING AT BHARAT WAGON &
ENGINEERING COMPANY LIMITED
PROJECT REPORT
SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR
THE AWARD OF THE DEGREE OF
BACHELOR OF TECHNOLOGY
(Mechanical Engg.)
Submitted by
ASHISH KUMAR
ROLL NO – 1244815
Submitted to-
GIANI ZAIL SINGH PUNJAB TECHNICAL UNIVERSITY CAMPUS
JUN-OCT 2015
PUNJAB TECHNICAL UNIVERSITY
JALANDHAR, PUNJAB

ACKNOWLEDGMENT
We are deeply indebted to our Training Manager V.S. BHATT who modeled us
both technically and morally for achieving greater success in life.
We express our sincere thanks to V.S. BHATT for his constant encouragement
and support throughout our course, especially for the useful suggestion given
during the course of the project period.
We are very grateful to our internal guide, for being instrument in the completion
of our project with his complete guidance. We also thank all the staff member of
our college and technicians’ for their help in making his project a successful one.
Finally we take this opportunity to extend our deep appreciation to our Family
and friends, for all that they meant to us during the crucial times of the completion
of our project.
ASHISH KUMAR

ABSTRACT
As a part of our curriculum for Bachelor of Technology in Mechanical Engineering, the
students are to undergo industrial training. The objective of industrial training is to gain
inside knowledge into functioning of technical department with respect to an
organization. I got the opportunity to undergo the 4 months industrial training in the
reputed organization, Bharat Wagon & Engineering Company Limited.
Entering in this industry was like a steep step into the world of manufacturing. Every
concept taught in the class room is practical and in different dimension in the industry.
And study on the subject practice in the organization gives a deep insight into practical
side of technique and industry itself.

TABLE OF CONTENTS
CERTIFICATE
ACKNOWLEDGEMENT
ABSTRACT
1. PRESS AND SMITHY SHOP 3-12
1.1 HYDRAULIC PRESS 4
1.2 PRESS MACHINE 6
1.3 POWER HAMMER 8
2. CUTTING AND WELDING SHOP 13-18
2.1 SHEARING MACHINE 16
2.2 CROPPING MACHINE 16
2.3 CHIPPING MACHINE 17
2.4 POWER HACKSAW MACHINE 18
3. TEMPLATE SHOP 19-21
3.1 WAGON FLOW CHART 20
4. DRILLING SHOP 22-24
4.1 UNIVERSAL DRILLING MACHINE 23
4.2 HYDAULIC RADIAL MACHINE 23
4.3 GANG DRILLING MACHINE 24
5. MACHINE SHOP 25-29
5.1 LATHE MACHINE 25
5.2 CENTER HEAVY DUTY LATHE 26
5.3 CAPSTAN LATHE 27
5.4 SLOTTING MACHINE 29
6. STRUCTURAL SHOP 30-31
6.1 INTRODUCTION 30
7. WAGON ASSEMBLY SHOP 32-34
7.1 PARTS OF BUFFER 33
8. FINISHING SHOP 35-38
8.1 FLOW CHART OF BOXN-HL MBS 35
8.2 PRECAUTION FOR PAINTING 37

1
INTRODUCTION
This industry is manufacturing wagon only now days. In this industry there are
ten shops among which eight shops are now used for manufacturing purpose of
wagon for Indian Railways. One shop is foundry shop which was used for casting
sugar mill roller and other agricultural implements and other components. And
one shop is Electrical and Maintenance shop whose work is to maintain power
full time supply power to the different sections. Electrical power source in this
factory is mainly a generator and government electric supply. Besides these shops
there are five departments. It produces about 18 to 22 goods train wagon at an
average per month. Now a day’s only wagon BOXN-HL MBS is manufacturing.
These wagon are made up of stainless steel. The weight of the wagon is about 40
KT and it can carry about 72 KT. Now this wagon is under testing of carrying
capacity of 90 KT. The length, breadth and height of the wagon is respectively.
Mainly galvanized metal are welding (GMAW) method is used for welding
purpose. About 200 to 250 ampere current and 28 to 31 volt DC (+) voltage is
required for welding purpose.
List of shops present in this factory:-
1. Press & smithy shop
2. Cutting and welding shop
3. Template shop
4. Drilling shop
5. Machine shop
6. Structural shop
7. Foundry shop
8. Wagon Assembly shop
9. Finishing shop
10. Electrical maintenance shop

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List of departments:-
1. Finance & Account
2. Personal
3. Works
4. Materials
5. Quality Control department

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1. PRESS AND SMITHY SHOP
This shop is under the supervision of Mr. Taukir Ahmad (Executive Engineer),
Mr. Purshotam Sharma (Foreman), and Mr. A. K. Verma (Supervisor). In this
press and smithy shop there are seven small open hearth furnaces. These furnaces
are connected with blower is drive by induction motor. The outlet of the blower
is connected to the bottom portion of the furnace where coal burns on the bed. In
this shop many components are manufactured. These are Head stock (drilling and
pressing), Stiffner, bolster, Extension, Back plate etc. these parts are made by
stainless steel of 8mm thick plates. One stiffner is welded on a back plate and this
back plate and other 5 stiffners are then welded in an extension. For making these
materials jigs and fixtures are made on which these materials are fixed and then
welded.
List of machines in press and smithy shop:-
Machines name Capacity Quantity Specification
of motor
A. Hydraulic press (400T) I.M 1 20HP
B. Hydraulic press (250T) I.MS 2 16HP
C. Press machine (600T) I.M 1 25HP
D. Power hammer (400Kg) I.M. 1
E. Power hammer (250Kg) I.M 1
F. Power hammer (100Kg) I.M 1
G. Water hydraulic press 1
H. Coal fired forge 1
I. Oil fired furnace 1

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A. HYDRAULIC PRESS (400T):-
This hydraulic press is used to manufacture anchor plate. For this the plate is
heated in the oil furnace. The heated plate is kept horizontally on the machine
table and the ram is allowed to press the plate, due to downward movement the
U shaped anchor plate is manufactured

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Specification of hydraulic press (400T):-
 Capacity 400T
 Stroke 800mm
 Shut height (from top of bolster) 200mm
 Maximum pressure 172 kg/cm2
Precautions taken on working in hydraulic press
machine:-
 Never place any part of own body under the platen (ram) or written the die
area unless power is off and the platen (ram) is blocked up.
 Never operate install dies or maintain this machine without proper
instruction and without first reading understanding the operators or
machine manuals.
It is necessary to check proper dies, guards, devices or means that may be
required for any particular use, operation setup or services.
B. HYDRAULIC PRESS (250T):-
This machine is used to fold small components in U and V shape by using two
dies called as male and female dies. One die is fixed on the work table and the
other fixed in the press.

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Specification of hydraulic press (400T):-
 Nominal pressure 250 tons.
 Working pressure 200 atm.
 Speed 0.020 m/sec.
 Motor capacity 50 hp.
 Pressure exerted by slider 80 tons.
 Speed of slide 0.063 m/s.
 Stroke of slide 500 mm.
 Max. Distance between table & slide 630 mm.
 Total weight 7.3 tons.
 Operating voltage 420 volts.
 Control voltage 220 volts.
 Connected load 11 kw.
C. PRESS MACHINE (600T):-
This machine is also called as ECCENTRIC PRESS. In this machine, a ram is
fitted which is reciprocating up and down on which tool is fitted. This machine is
generally used for making holes. So it is used for making washer. Tool diameter
is exactly equal to the hole diameter of the washer. In this a bed is present in
which a big hole is present, on which work piece is placed. The work piece
thickness should be equal to the thickness of the washer. First of all the work
piece should be straight piece on which cutting points are marked. Then work
piece is putted on work table and as the ram comes it make hole and when the
ram goes up the work piece is fixed for next cut. This machine is used for mass
production.

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Specification of press machine (600T):-
 Total weight 6.65 Tons.
 Operating voltage 420 volts.
 Control voltage 220 volts
 Connected load 4 kg.
 Power 80 T.
 Torque 144000 kg-cm.
 Finished surface 1775 mm2
.
 Ram lifting 20-100 mm.
 Maximum distance between benches to ram 355 mm.
D. POWER HAMMER (400KG):-
This machine is also called as PNEUMATIC HAMMER. On this machine the
part which is to be manufactured is kept on the die after heating on the furnace
and the ram is allowed to strike the component on the die. Due to the strike of
ram the component takes the shape that of the die. This is driven by 3 phase
induction motor. In this air is blowing. Due to this suction, compression,
expansion and exhaust, these four processes are taking place. In this machine, two
workers are needed one for handing lever and another for holding the job.

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Specification of power hammer (400T):-
 Falling weight 400 kg (800 lbs).
 Maximum strike of ram 700 mm.
 Number of blows per minute 130.
 Clear working space 530.
 Distance from centre of ram to housing 520 mm.
E. POWER HAMMER (250KG):-
induction motor. In this air is blowing. Due to this section, compression,
workers are needed one for handling lever and other for holding the job.
 Falling weight 250 kg.
F. POWER HAMMER (100KG):-

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induction motor. In this air is blowing. Due to this section, compression,
workers are needed one for handling lever and other for holding the job.
 Falling weight 100 kg.
G. WATER HYDRAULIC PRESS:-
This is a special type of press. In this press water is used as a fluid. In this press
two dies are present, one at the top portion and another at the bottom portion in
the machine. These dies are fitted should be according to the job. In this a motor
is present with which a pulley is joined. This pulley is joined with shaft by rope
drive, and in this shaft many rams are joined. With this ram piston is joined, and
a fixed cylinder is present in which water is present as fluid. This piston increases
the pressure in the cylinder. And this cylinder is joined with machines by pipes.
As the pressure increases in the cylinder, through the pipes the pressure increases
in the machine and due to this the bottom part of the machine goes up. In this
machine T-slots are given in both upper and lower portion of the machine holding
the job and dies. In this job is fixed on the upper portion of the machine.
The unique feature of this machine is that it can start any time whether it is not
used or maintained for a long time. Its maintenance cost is very low.
H. COAL FIRED FORGE:-
Coal fired forge is a type of forging method in which a big furnace is present in
which coal is burned, in this, metals are given for heating, as metals are heated,

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then it is putted in PNEUMATIC HAMMER for the tempering. This method is
cheapest than oil furnace.
I. OIL FIRED FURNACE:-
This furnace in air is supplied by a fan and oil is sprayed in the furnace. Due to
the oil is burnt very fastly and then in produce very much heat. It is used for same
work as of COAL FIRED FURNACE. That is it is used for heating the metals
and after heating these metals are tempered by PNEUMATIC HAMMER. This
method is more costly than COAL FIRED FORGE.
Welding sequence:-
1. Proper gap must be maintained (as given in the diagram).
2. Before starting the welding complete penetration should be ensured for the
root pass.
3. Welding is to be done in such a way so as to minimize distortion.
4. Welding is to be done in down hand position by positioning the job.
Steps taken for forging:-
1. Take different types of tools own which are to be used such as hammer,
scale, punch etc.
2. Measure the size of bar/billet. In case, if its size is more then cut it
according to the prescribed size.
3. Heat bar/billet equally from all side according to necessity.
4. Complete forging operation of bar/billet before cooling it.
5. Measure the size of ready forging items.
6. After the forging if any defects are seen like crack, cavities etc. then repair
it.
7. Do heat treatment on forging items if necessary.

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Steps taken for pressing:-
1. Measure the size of blank using gauge.
2. Put die and punch in a right manner.
3. If necessary, then heat blank equally.
4. Heat blank on the die in a proper manner.
5. Before searching the blank, complete pressing operation.
6. Measure the pressing using

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2. CUTTNING AND WELDING SHOP
This shop is under the supervision of Mr. Taukir Ahmad (Executive Engineer),
Mr. Ganesh Chowdhary, Mr. Mohan Thakur and Mr. Shatendra kr. Shrivastava
(Foreman). This is one of the shops in which the basic work is performed. As the
name indicates this shop is mainly involved in cutting the plates of different
thickness in the desired shape & size and in the profile cutting. And then they are
miscellaneous parts are manufacturing in this shop. About 200 to 250 ampere
current and 28 to 31 volts DC (+) voltage is necessary for welding.
Welding sequence of bolster and crossbar:-
1. Proper gap must be maintained (as given in diagram).
2. Before starting the welding complete penetration should be ensured for the
root pass.
3. Welding is to be done in such a way so as to minimize distortion.
4. Welding is to be done in down hand position by positioning the job.
Welding sequence of side body:-
Body side plates, Side top coping, Middle coping, Side stanchion, Door way
stiffening, Cross bar etc. assembled on welding fixture and tack welding, then
outer side of fixture and reversed then, inner side is completely welded down
hand position.
Welding electrode rod:-
In welding, a filler material is used on which flux is coated. This filler material is
of same material as of the material to be weld. Before welding, the plate is cut
inclined at its edge from one side if it is up to a thickness of 10 mm and cut
inclined from both side at the edge if the plate thickness is more than 10 mm. the

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filler rod used according to the thickness of the plate. If the plate thickness is
more, then more diameter of filler rod will use because it saves time. Welding rod
used are SS-308L of Classic Company and STALOY-1A(L) of Prima Company.
SS-308L of Classic Company’s electrode rod is a heavy coated rutile type
electrode for joining of low carbon variety of 19 Cr – 9 Ni and equivalent grade
of stainless steel. The deposit is heaving excellent resistance to corrosion and high
temperature scaling.
Size length in mm Current range (Amps.)
2.5 X 350 40 – 60
3.15 X 350 70 – 90
4.0 X 350 90 – 120
5.0 X 350 130 – 150
STALOY – 1A (L) of prima’s company is a semi – basic type stainless steel
electrode giving extra low carbon 19Cr – 10 Ni controlled. Ferrite weld metal
which is highly resistance to cracking and corrosion. Weld metal is of
Radiographic Quality and offers excellent corrosion resistance to various media,
scaling and oxidation resistance is satisfactory up to 8000
C. Electrode can be
used for welding AISI 301, 302, 304, 304L, 308, 308L and their equivalent
stainless grades.
Chemical composition in percentage:-
A. Carbon 0.04 Max.
B. Chromium 18-21
C. Manganese 2.50 Max.

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D. Nickel 8-11
E. Silicon 0.90 Max.
F. Sulphur 0.03 Max.
G. Phosphorous 0.04 Max.
H. Molybdenum 0.50 Max.
Current range (AC/DC (+): OCV 70):-
Dia (mm) Length (mm) Current (Amps.)
2.00 350 40 – 50
2.50 350 60 – 80
3.15 350 80 – 100
4.00 350 110 – 140
5.00 350 150 - 180
Precautions taken in welding:-
A. Protect yourself AND others. Road and understand this information.
Fumes and gases can be dangerous to your health. Arc rays can injure eyes
and burn skin. Electric shock can kill.
B. Before use, read and understand the manufacturer’s instructions and yoyr
employer’s safety practices.
C. Keep your head out of the fumes.
D. Use enough ventilation, exhaust at the arc or both, to keep fumes and gases
away from your breathing zone and the general area.

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E. Wear correct eye, ear, and body protection.
F. Do not electrical parts.
Machines available in cutting and welding shop:-
Machine Quantity
A. Shearing machine 2
B. Cropping machine 2
C. Chipping machine 1
D. Profile cutting machine 1
E. Plasma cutting machine few
F. Circular saw cutting machine 1
G. Power hacksaw machine 1
A. SHEARING MACHINE:-
In this shop there is two shearing machine (one large for large plate cutting and
another small for small plate cutting). On the shearing machine the plate to be cut
should be flat & the thickness should not be more than 8 mm. For cutting the flat
plate is kept on the bed of the machine & is moved manually. The plate to be cut
is kept on the bed. The machine consists of a cutting blade & no. of pressing bolts.
As the plate is moved inside the machine the pressing bolts press the plate and
keep it rigidly fixed the downward movement of the cutting blade cuts the plate.
B. CROPPING MACHINE:-
This machine is also called as cropping shearing machine. Because it cut the
plates by shearing. On the cropping shearing machine numbers of works are
performed. This machine can cut flat plate of small sizes, angle plates, square
hollow rod & circular hollow rod. Also this machine can be used as punching
machine.

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C. CHIPPING MACHINE:-
This machine is use to produce an inclined shape at the end of plate which is
necessary in the end to welding. This machine has a gun through which high
pressure air comes this machine holds a chisel. The high-pressure air pushes the
chisel, which causes to cut the plate.
D. PROFILE CUTTING MACHINE:-
The machines consist of a vertical column and two horizontal arms. One arm
consists of the template and another arm consists of the welding torch and the
small driving motor. This machine can cut the plate of thickness of 35 to 40 mm.
Through the welding torch acetylene and oxygen gas is supplied. This machine
requires extra amount of oxygen gas. So, two oxygen pipes are connected to the
torch to cut the plate in the desired shape. The same shape template is fitted to the
upper arm and the magnetic roller of the second that is lower arm is touched to
the template. The driving motor dives the torch. The torch moves through the
profile of the template and the plate cut in the desired shape. In this cutting
machine we can cut 3-4 plates together (if all these are of same shape and size)
by joining arms and all these arms consist only torch. In these entire torches we
supply individually acetylene and oxygen gas. And these entire torches will move
by a single driving motor. So it can produce many plates of same shape and size
in a time spent in cutting of one plate.
E. PLASMA CUTTING MACHINE:-
This is a machine in which there is a torch in which mixture of acetylene gas and
oxygen gas is supplied. It can cut the plate of the size of 35 to 40 mm thick plate.
This machine can be moved manually.

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F. PLAMA CUTTING MACHINE:-
This is cutting machine in which a circular saw is present. The cutting tooth of
this machine is made of high speed steel. The cutting tooth is in many parts which
are joined together by rivets. It is in many parts because if its any teeth will break
then only that part will charge. After changing of any one tooth the whole saw
tooth are machined. In this machine the saw is fixed and the bed is moved. In this
machine a long job is fixed in bed and the circular saw rotate and cuts the job.
And after cutting the job is again fixed to the marked position manually.
G. POWER HACKSAW MACHINE:-
This is a machine in which a motor rotates. This motor is joined with hacksaw by
compound gears which are used for decreasing the cutting speed of the job. In
this machine hacksaw is moving forward and reverse at a constant speed. In the
hacksaw, a blade is fixed. The job is fixed in the bed.

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3. TMPLATE SHOP
This shop is under the supervision of Mr. Shashi Bhushan Prasad Shrivastava
(Executive Engineer) Mr. Hemant Kumar Shrivastava. Before describing the
template it is worthwhile to elaborate the word “template”. This is a pattern or
gauge a time in mass scale. This saves a lot of time, as no marking is necessary
when using template. Now creep angle, top capping (fitting and welding), and D
S bar (welding and fitting) are manufacturing in this shop. Basically templates
are of two types.
The two types of template are:-
A. Marking template
B. Checking template
The main objective of this shop is making templates of all the consigned wagon
components where a certain profile cutting is necessary. The manufacturing of
template is done with the help of the design and drawing provided by R.D.S.O.
Lucknow. Also the required allowances for different tools are taken into
consideration during marking the templates. This is very matching to machine.
The templates here are usually made of mild steel. They are of small thicknesses
about 8 to 10 mm. working in this shop needs greatest accuracy because shape all
the components made with the help of template depend upon the shape of the
template. Thus a minor fault can create a great fault in the production. Its work is
to make the procedure of manufacture easy so that manufacture the wagon in a
series production which saves time and money.

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Wagon flow chart:-
Air brake, air brake cylinder, and air brake pipes are fitting in AIR BRAKE FITTING
Bolster 4 pieces, Cross bar 8
pieces and Head stock 4
pieces from CUTTING AND
WELDING SHO
Centre sill from
STRUCTURAL SHOP
Sole bar from
DRILLING SHOP
Sole bar from
DRILLING SHOP
UNDER FRAME FIXTURE
Horizontal and vertical welding in NDER FRAME FIXTURE
Crib angle and floor plate is fitting and welding in FLOORING
Draft gear and buffer and fitting

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Side body 2 pieces from
CUTTING AND WELDING
SHOP
BODY FITTING
End body 2 pieces from
MACHINE SHOP
Pivot riveting
MANUPULATOR WELD
Doo fitting and Huck bolting
Wheel fitting
Painting
Air brake testing
Final inspection by R.D.S.O. Inspector

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4. DRILLING SHOP
This shop is under the supervision of Mr. Sashi Bhushan Prasad Shrivastava and
Mr. Kedar Nath Singh. In this shop there are different types of drilling machines.
In this shop drilling is done by two method, i e. by marking and by jig. The
following are the drill size & which are used for drilling in this shop is 5mm,
6mm, 11mm, 13.5mm, 17.5mm, 21.5mm and 23.5mm. There are the drill size
which are used here. For drilling marking takes a lot of time and it requires more
skilled person for marking. So drilling of components by marking is used for a
few, component where it is difficult to set a jig. For mass production of
components jig is used for drilling. The thickness of the jig plate, which is in
practice, is 12mm. to manufacture jig a hole greater die. Is done in the jig plate
and bush of required drill size is fitted in the hole. The material of the jig bush is
class IV and IS: 1875. The material made in this shop is sole bar (drilling), casing
(drilling), taper tapping, change over bracket, extensions of side and end body
(drilling) etc.
Steps of drilling in the job:-
1. Clamp the job on the table or vice of the machine.
2. Use proper design of drill.
3. Check the drilling point is met to the punching point before drilling.
4. Check that at the start of the drilling, the front head of drill is in the right
position.
5. Use coolant.
6. Always apply less pressure on the rotating drill.
7. Use proper drilling jig according to the job.
8. Clamp the jig on the job in such a manner that the stamper of jig to be
match with end portion of the job.
9. Check that all the bush is fixed and no one should be damage.

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Machines present in drilling shop:-
Machines Quantity
A. Universal drilling machine 1
B. Simple radial drilling machine 9
C. Hydraulic radial drilling machine 2
D. Gang drilling machine 2
A. UNIVERSAL DRILLING MACHINE:-
This is one of the important drilling machine. The drilling machine can produce
a hole in any direction at any angle. The universal drilling machine consists of a
vertical column and a horizontal arm. The horizontal arm can move in any
direction i.e. horizontally, vertically and at any inclination. The drilling can be
done by automatic feed mechanism and by manual operation.
B. SIMPLE RADIAL DRILLING MACHINE:-
This type of drilling machine can move horizontal, vertical and rotate but few
drilling machines cannot move vertical. This machine consists of one electrical
motor, which is used for the operation of drilling. This machine can work by both
manually and automatic. In this machine water is used as a coolant the chip which
comes out from the operation is continuous chips.
C. HYDRAULIC RADIAL DRILLING MACHINE:-
This machine is working same as simple radial type of drilling machine but the
difference between these two machines is that the simple type drilling machine is
setup by manually but the hydraulic radial type drilling machine can setup by
hydraulic. This drilling machine can move horizontally, vertically and rotate, in

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this drilling machine a fixed bed is present in which T-slots are present for holding
the job.
D. GANG DRILLING MACHINE:-
The machine has a very long bed and a gang of three drilling machine. This
machine is used to produce a hole in the very long channel. For operation the
channel is kept on bed and the jig is fitted to the channel and with the help jig
bush the hole is produced at desired position.

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5. MACHINE SHOP
This shop is under the supervision of Mr. S.P. Shrivastava (Executive Engineer),
Mr. K.D.P. Singh and Mr. Om Prakash Singh (Supervisor). This is the biggest
shop of this organization. In this shop there are various types of machines which
were mainly used for sugar mill and other mill components. Now here
manufacturing of sugar mill roller and other mill components is closed and only
end body (fitting, tacking, welding), solebar and stiffener (fitting and welding)
are manufacturing.
Machines available in this shop:-
Machines Quantity
5. Lathe machine 19
6. Drilling machine 2
7. Shaper machine 2
8. Planner machine 2
9. Boring machine 3
10.Slotting machine 1
11.Milling machine 2
12.Chaser machine 1
A. LATHE MACHINE:-
In this shop 19 lathes are available out of which 6 lathes are heavy duty lathe and
13 lathes are light duty lathe.
Type of lathe available:-

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Type of lathe Quantity
a. Centre heavy duty lathe 5
b. Vertical heavy duty lathe 1
c. Centre lathe 11
d. Capstan lathe 2
A. CENTRE HEAVY DUTY LATHE:-
This lathe is used for the finishing purpose of the shaft of sugar mill roller. For
the finishing of lathe firstly the shaft is tightened in the chuck. These are 4 jaw
chuck. In the chuck T-slots are present which is using for the holding the shaft
more tightly. Because this shaft is long so with the help of steady the shaft is
centered. Steady is a material used only for the shaft from other side and also if
the shaft is of small diameter then it is also used for neglecting the vibration. Then
after that a drill is made from other side for holding by tail stock. Then after a
small drill steady is remove and shaft is fixing in tail stock and after operation is
done on the surface of shaft.
B. VERTICAL HEAVY DUTY LATHE:-
This is a special type of lathe. In this lathe 2 tool head are available in which 4
tools can fix. Its benefit is that at time of one operation we can perfume 4
operations in the same job. In a very minimum time we can get very good surface
finish. In this lathe a work table in present in which T – slots are present. This
work table is rotating and operation is done.
C. CENTRE LATHE:-
This is a simple lathe. It is also called as engine lathe. It is used only for simple
works.

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D. CAPSTAN LATHE:-
This is a lathe in which hexagonal turret is present in place of tail stock in which
6 tools can be fixed. On the carriage 2 tool posts are present. Due to these facilities
we can perform different operations without the replacement of the tool. By this
it saves a lot of time.
B. DRILLING MACHINE:-
In this shop only simple radial drilling machine is available. This machine can
move up and down and horizontal and also it can rotate into any direction. In this
a work table is present which is round shaped and T – slots are present for holding
the job.
C. SHAPER MACHINE:-
In this shop two shapers are present. One is small in size and other is larger in
size. Both are of same types. In this machine a tool head is present which can
move up and down and also can move at any angle. And tool is a part of tool head
in which tool is fixed. In this machine work table can move horizontal, vertical
and circular. In this machine crank and slotted lever mechanism is done. In this
machine tool post is sliding and work table is stationary. In this work table T –
slots are present for holding the job. In the forward stroke tool is down and the
job is cutting and in reverse stroke tool becomes up and the job do not cut. In the
forward cutting about 2160 rotate the crank and in reverse cutting about 1440
rotate and the crank rotate at an average of 1400. In this machine T-slots,
keyways, and plane smooth surface e.t.c. can perform.

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D. PLANNER MACHINE:-
This is a machine in which work table is reciprocating and tool is fixed. In this
work table T-slots are present for holding the job. The work table is reciprocating
by the flat belt. If this belt will break then the work table do not stop and it will
remain go in one direction and drop from the bed. So for safety reason everyone
should be stand side of the planner. In this machine plane surface, T-slots, and
other cut can perform.
E. BOARING MACHINE:-
In this shop two types of boring machines are present. It is used boarding and
finishing the hole.
Type of boring machine:-
Machine Quantity
a. Horizontal boring machine 2
b. Vertical boring machine 1
A. HORIZONTAL BORING MACHINE:-
This machine is used for finishing the hole of the shell. First of all the shell is
fixed. Then the tool from other side is fixed to the machine. And then by rotating
the tool, operation will perform. The diameter of the tool should be equal to the
diameter of the hole.
B. VERTICAL BOARDING MACHINE:-
This is a machine in which a crank rotates. With this crank arm is fixed. Due to
this arm moves up and down. In this ram tool is fixed. The work table is circular

29
in shape in which T – slots are present. Job is fixed in this work table at some
height so that the tool can completely pass the job. Work table can move left –
right, front – back and also can rotate. In this machine we can cut keyways and
other operations.
F. SLOTTING MACHINE:-
In this shop two slotting machine is present which joined in a single bed. Both
the machines have own motor and both the machines are working alone and
together if necessary. In this machine job is fixed and ram is reciprocating. Tool
is fixed in the ram. In this machine feed can be given in both automatic and
manual. In this machine rack, plane surface, keyways e.t.c. can cut.
G. MILLING MACHINE:-
This is a machine in which many operations can perform such as marking scale,
gear cutting, keyways, T-slots, done tail, plaining e.t.c. In this machine an arbor
is present which holds the tool. This arbor is rotating. For gear cutting, three index
plates are joined in the milling machine with the help of indexing head. In this
machine the work table can move horizontal and rotate. For marking scale firstly
we cut two lines then by rotating the hand wheel in which mark is present and in
one complete revolution of this wheel the table move one mm, we mark the scale
in mm and in other side we can mark in inch.
H. CHASER MACHINE:-
This is a machine used for cutting thread in the pipes and in any rod. It has four
cutting tooth. In this a pipe vice is present for holding the pipe. According to the
diameter of the pipe we can adjust the cutting tooth and also according to the
required pitch of the thread we can change the tooth.

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6. STRUCTURAL SHOP
This shoo is under the supervision of Mr. A.K. Barwn (Assistant Engineer), Mr.
Arjun Thakur and Mr. Narendra Sharma (Supervisor). This shop is also called as
SUB-ASSEMBLY SHOP. In this shop only centre sill is manufactured. Centre
sill is the middle part of the wagon. Centre sill is of the design of U shape which
looks like that Z type plates are joined. This is made up of stainless steel and the
thickness of this plate is 10 mm. The thickness of these plates are 10 mm. The
width of centre sill should be 327 mm in middle and from both end it should be
173.5 mm. the length of this centre sill is about 1038 cm. This centre sill is
tempered so that it bend and up to a height of about 6 to 8 mm in middle so that
when the wagon will be loaded then it becomes almost horizontal or up to bend
up to a height of about 1 to 2 mm in middle. For increasing the strength of centre
sill, 5 plates are welded at a position according to the given diagram. Then two
pivots are welded at the end positions in the centre sill at the given position in the
diagram. Then cuppler casting and Back stock are welding. Then centre sill is
drilled at both ends according to the diagram with the help of jig. In this shop two
ordinary radial type drilling machine is present. And then it is checked and passed
to the wagon assembly shop.

32
7. WAGON ASSEMBLY SHOP
This shop is under the supervision of Mr. Kr. S.N. Singh (Executive Engineer),
Mr. Pramod Kr. Sinha (Foreman), Mr. Ram Sevak Thakur and Mr. Umesh Singh
(Supervisor). In this shop the various components which are manufactured in the
different shops are assembled and the wagon is completed and the set to the
finishing shop.
List of components assembled in this shop:-
Components Quantity
A. Centre sill 1
B. Sole bar 2
C. Head stock 4
D. Cross bar 8
E. Bolster 4
F. Fevet 2
G. Channel
H. Crib angle
I. Break 1
J. Break cylinder 1
K. Break pipes
L. Buffer 2
First of all the centre sill is kept in opposite on the under frame fixture. Then
bolster is kept on both sides of pivot then cross bar is kept at its given position
and head stock is placed at the end position. Then sole bar is placed in both si9des.
Then all these components are welded. Then all the channels are fitted and then
welded. Then a plate sheet is kept on the centre sill at the position given in
diagram. Then fevet is placed over the pivot according to the given drawing.

33
Fevet is a circular disc which has hole according to the given manner in drawing.
The thickness of this plate is 20 mm. then the fixture is stand and then weld from
all sides. Then after that the fixture is kept in a right side and then crib angle is
welded from all dides of the fixture except door place and then by 10 mm plate
sheet, floor is made on the fixture. Then after that the fixture is turned and break,
break cylinder and break pipes are fitted. Then Buffer is joined which is in five
parts.
Parts of buffer:-
A. Back stoc
B. Draft gear
C. Cuppler casing
D. Cuppler head
E. Cuppler pin
First of all back stock and cuppler casing are already welded and here these are
huck bolted. Then draft gear is fitting then cuppler head is fitting and after that
draft gear and suppler head are joined by cuppler pin. Then this buffer is covered
by 20 mm thick plates. Then after that this under frame fixture is passed to sub
assembly shop.
Welding sequence of wagon in this shop:-
1. Assembly of under frame components are dine on a fixture in the top side
bottom condition.
2. All components and sub-assembly like centre sill, head stock, bolster, side
sill are to be fitted on under frame fixture, tacked and clamped property to
minimize distortion.

34
3. Final welding is to be started simultaneously from centre sill of under
frame and move towards both side of head stock ends.
4. After completion of welding in fixture in down hand position, the under
frame is taken out from fixture and is put on manipulator.
5. Rest of welding done in down hand position in manipulator starting from
the centre and processing towards both end of head stock.

35
8. FINISHING SHOP:-
This shop is under the supervision of Mr. B.K. Shrivastava (Assistant Manager),
Mr. Ranjeet Singh (Executive Engineer), Mr. Vinay Kr. Sinha and Mr. Shambhu
Nath Choudhary (Foreman). Work done in this shop are side body fitting, corner
fitting, manipulator stage welding, wagon wheeling, spatter and slag cleaning in
shot blast, brake fitting, door fitting and painting.
Flow chart of BOXN-HL MBS:-
Under frame from
SUB ASSEMBLY SHOP
Side body from
CUTTING AND
WELDING SHOP
Body assembly
Under frame from
SUB ASSEMBLY SHOP
Body inside welding
Body manipulator welding
Door from
SUB ASSEMBLY SHOP
Door fitting on wagon
Body huck bolting

36
In this shop, firstly End body which is coming from Machine shop are assembling
then Side body which is coming from Cutting and Welding shop is assembling in
Body assembly. Then the body is welding from inside. Then after that the body
is putted on the Manipulator where it is welded from outside by rotating the
Manipulator.Then after that Door is fitting which is coming from Sub Assembly
shop. Then after that by using Reamer machine which is used for clearing the
Body huck bolting
Wheel set, Bogie and other
components from Store
Wagon wheeling
Shot blasting
Air Brake, Hand Brake and under
Gear components from
STORE COMPONENT SECTION
Air brake and Hand brake fitting
Air brake testing
Painting and Marking
Final inspection and D.M.

37
hole and is working by the air compressor, all the holes are cleared. This machine
needs two persons for holding. Then all the holes are filled up by huck bolt.
Huck bolt is the new technology launched in India since 2003. But due to lackness
of skill and lackness of machines it is started since 2007. In this bolting method,
in the bolt circular ring is made and in the middle a groove is made and a ring
present whose internal diameter is just larger than the diameter of the bolt. Then
by the machine, tensile pressure is exerted on the bolt and compressive pressure
is exerted on the ring. Due to this the bolt is sheared from the groove and the nut
is tightened in the bolt.
Then after that wheel is fixed is the bogie and by lock and pivot pin the wheel is
locked. First is all on the bearing of the wheel arrestor is fit, then on pad is fit and
then on that bogie is fit. Then hydraulic brake is fit, then after that body is fixed
on this bogie.
After that the wagon is dent to shot blast where the wagon is shot blasted by stars.
Shot blast is same as abrasive jet machining, in this air is supplied which is dried
and then filtered and then mixed with abrasive particles. This abrasive air mixture
is projected on the wagon at high speed. Due to this all the rusts and oxidation
that are present on surface is removed. And then painting is done.
Precautions taken for painting:-
1. Before painting, check out the surface of the wagon.
2. Mix the colour in the mixing machine.
3. Use different brush and pot for different colours.
4. Colour the first coat within 4 hours of cleaning the surface.
5. Put the second coat after 24 hours of the first coat.
6. Put the next coat after rinse of the previous coat.
7. Put the wagon in the shed till rinse of the colour in the humid environment.
8. Check out that these should not be any bush mark, sanging, blestering,
piling etc.
9. Follow the painting schedule and inspect the thickness of the colour by
inspection officer.

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Then after that Air brake is testing. This wagon has two air brakes as if one brake
do not work then by another brake, we can stop the train, both these brakes are
working by only single brake and brake cylinder. The two brake pipes are called
as brake pipe 5 kg/cm2 air pressure is present and in the pit pipe 6 kg/cm2 air
pressure is present. Air brake is testing by decreasing the air pressure 1.3 kg/cm2
to 1.6 kg/cm2 in brake pipe and then noted down the movement of piston of brake.
In unloaded wagon, the movement of piston should be 85 – 10 mm to 85 + 10
mm, and in the loaded wagon, the movement of piston should be 120 – 10 mm to
120 + 10 mm, then we can say that the brake is working properly. For checking
the sensitivity of the brake, 0.6 kg/cm2 air pressure has been dropped in 60
seconds. If any one condition is not fulfilled then it means there is some fault in
brake system and then the problem is shorted out and again the brake is tested.
Then after that the wagon is painted and marked according to the given diagram.
And at last the wagon is inspection by the R.D.S.O. Lucknow representatives.

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