vocational training

1. IIMT COLLEGE OF ENGINEERING
GREATER NOIDA
MECHANICAL ENGINEERING
2016-2017
VOCATIONAL TRAINING
SUPERVISED BY :- PRESENTED BY:-
Dr. Deo Raj Tiwari
Mr. K.P. Singh
Deepak Singh
Roll:-1321640055

2. Summer training report
on
diesel locomotive works Varanasi

3. Introduction
 DLW, was founded by Late Railway Minister Mr. Lal Bahadur Shastri on 23 April 1956. It is spread in 300
acres area at Varanasi.
 It is a production unit owned by Indian railways , for which it manufactures diesel–electric locomotives and
its spares parts.
 To meet the increased transportation needs of the Indian railways it was established in collaboration with
ALCO( American Locomotive Company), USA in 1961.
 DLW rolled out its first locomotive three years later, on January 3, 1964. It manufactures locomotives.
 Got its first ISO certification in 1997 and ISO-9001 and ISO-14001 in December 2002.
 With technology transfer agreement from manufacturers such as GM-EMD, DLW today produces advance
locomotives having output range from 2600 to 4000 hp.
 At present the latest locomotive produced by DLW; i.e. WDG 5 has capacity up to 5000 HP & trying to make
it 5500 HP.
 It has supplied locomotives to other countries such as Sri Lanka, Bangladesh, Malaysia, Tanzania and
Vietnam etc.
 DLW is supplying locos to PSU’s & Industries Like NTPC, COAL, INDOGULF etc.

4. DLW’s annual production - 250
Cost of one loco - 12 to 14 crore (EMD)
8 crore (Alco)
Weight of one Loco - 121 Ton
Fuel Consumption; At Full Load - 540 lt/hr.
Idle Load - 40 lt/hr.
Max. Speed - 160 Km/hr.
Dia of Wheel - 1092 mm
Wheel to Wheel Distance - 1596.5 mm
Length of Under Frame - 19962 mm
SOMEFACTSABOUTDIESELELECTRICLOCOMOTIVE

5. CLASSIFICATIONOFLOCOMOTIVES
Locos, except the older steam ones, have classification codes that identify them.
This code is of the form
WDG5A “ [ gauge ][ power ][load ][ series ][ sub type ]”
• The first letter (gauge)
W- Indian broad gauge
Y- meter gauge
Z- narrow gauge(2.5 ft)
N- narrow gauge (2 ft)
• The second letter (motive power)
D- Diesel
C- DC electric (can run under DC traction only)
A- AC electric (can run under AC traction only)
CA- Both DC and AC (can run under both AC and DC tractions)
B- Battery electric locomotive (rare)

6. • The third letter (load type)
G-goods
P-passenger
M-mixed traffic ; both goods and passenger
S-Used for shunting
U-Electric multiple units (E.M.U.)
R-Railcars
• THE fourth letter (series)
The series digit identifies the horsepower range of the locomotive.
Example for the series letter ‘3’ means that the locomotive has power over
3000 hp but less than 4000 hp.
• The fifth letter (subtype)
an optional letter or number that indicates some smaller variations in the
basic model.
For ex: ‘A’ for 100 hp,
‘B’ for 200 hp and so on……..

7. WORKSHOPS
These are the workshops in DLW plant.
• HWS
• HMS
• LMS
• ROTOR
• HTS
• SAS
• EES
• ET
• LFS
• SMS
• TMS
• PS
• LAS
• LTS
• LPS
• TR
• TAS
• MA-I
• MA-II
• MA-III
• MA-IV
• MSS
• MRS
• CMT LAB
• ELECT. LAB
These all work in coordination in the overall fabrication of engine and then
finally locomotive.

8. ALLOTED WORKSHOP
I was allotted in the following workshop to perform my training.
1) WRI Welding Research Institute.
2) ROTOR Rotor shop.
3) LMS Light machine shop.
4) LAS Locomotive assembly shop.
The following slides deals with what I have learnt during My training in
these workshop.

9. WELDING shop

10. WELDINGSHOP
Welding is a process which produces joining of materials by heating them
to suitable temperatures with or without the application of pressure and with
or without the use of filler material.
Welding is used for making permanent joints.
It is used in the manufacturing of automobile bodies, aircraft frames,
railway wagons, machine frames, structural works, tanks, furniture, boilers,
general repair work and ship building.

11. Shielded Metal Arc Welding [SMAW]
Submerged Arc Welding [SAW]
Gas Shielded Metal Arc Welding [MIG]
Flux Cored Arc Welding [FCAW]
TYPESOFWELDINGUSED
INDLW

12. WHATISSMAW?
 It is a welding process which joins metals by heating the metals to their
melting point with an electric arc set up between the end of a coated metal
electrode and the work piece.
 Molten metal droplets and the molten weld are shielded from the
atmosphere by the gases produced from the decomposition of the flux
coating .

13. ADVANTAGESOF SMAW
•Equipment used is
simple, inexpensive.
•Electrode provides
and regulates its own
Flux.
•This process has
excellent suitability for
outdoor use lower
sensitivity to wind and
even for use under
water.
•All position capability

14. SAWPROCESSPRINCIPLES
 SAW is a welding process which joins metals by heating the metals to their melting
point with an electric arc or arcs set up between a bare metal electrode and the job.
 The arc, the end of electrode and molten pool remains completely hidden and are
invisible being submerged under a blanket of granular flux.
 The continuously fed bare metal electrode melts and acts as filler rod.

15. SAWFEATURES
•High Productivity, high
amperages may be used
•Easy to de-slag
•High Quality
•Deep penetration
•Excellent mechanical
properties
•Environment friendly
•Very little fume
•No radiation
•Easy operation

16. GMAW
 Gas Metal Arc Welding is a welding process
which joins metals by heating the metals to their
melting point with an electric arc, produced
between continuous consumable electrode wire
and the metal being welded.
 Wire is fed continuously and automatically from
a spool through the welding gun
 Shielding gases include inert gases such as
argon and helium for copper and aluminum
welding, and active gases such as CO2 for steel
welding
 Bare electrode wire plus shielding gases
eliminate slag on weld bead. No need for
manual grinding and cleaning of slag.
Applications:
•Used for C, Si, Cu, Ni, Ti etc.
•For welding tool steels and dies.
•For the manufacture of refrigerator parts.

17. Gas Metal Arc ( MIG ) Welding
 Uses continuous wire 0.6 – 2.0 mm as
electrode
 Gas shielded, inert or active gas
 Manual, automatic or semi-automatic
process
 High productivity
 If the wire feed speed is increased more
current is drawn to burn it off .
 Increasing the current increases the arc
energy and therefore the heat input. This in
turn increases fusion and penetration, wire
deposition rate and travel speed.

18. LIGHTMACHINESHOP

19. Types of machines
1. Conventional machine
2. NC machine
3. CNC machine
1. Conventional machine:
It is a simple machine which is now an old technique.
2. Numerical control machine:
Numerical control is defined as a system in which the actions of the machines are
controlled by the insertion of the numerical data. In other words number
controls the action.

20. CLASSIFICATIONOFNUMERICCONTROL
1. Point to point system:
This feature is only useful for drilling and boring
operations. The machine operations are possible at specified positions.
2. Straight line system:
In this system the control can command a path
operation in a single axis at a time.
3. Continuous path system:
In this system the control instructs the machine
to make movements like 2 or 3 axis at a time. The machine may be
directed to make helical or circular path.

21. COMPUTERIZEDNUMERICALLYCONTROLLED MACHINE
In CNC the control system further energized with a mini computer or a
post processor.
The control unit stores the programmed information of the work piece,
the travel limits, collisions zones and the diagnostic information etc. it
also gives a feedback to the operator about the current position and
distance to be travelled etc.
CNC machines have the ability to edit or alter the existing program in
no time.

22. Flame cutting
Steel plates are ultrasonically
tested before being precision cut by
numerically controlled flame
cutting machines or by CNC
LASER machine.
CNC Laser cutting
• The laser beam is typically 0.2
mm (0.008 in) diameter at the
cutting surface with a power of
1000 to 2000 watts.
• Lasers work best on materials
such as carbon steel or
stainless steels because these
are difficult to cut due to their
ability to reflect the light as well
as absorb and conduct heat.
This requires lasers that are
more powerful.

23. Angular Boring Machine
• This special purpose machine
has two high precision angular
boring bars.
• Boring bars are mounted on
high precision bearings which
provide control on size during
angular boring.
Fabrication of Engine Block
• Components after flame cutting and
various machining operations are fit
and tack welded before taking on
rollovers. Heavy Argon-CO2
welding is done on these rollovers

24. CNCMILLINGMACHINES
CNC mills can perform the functions
of drilling and often turning.
CNC Mills are classified according to
the number of axes that they possess.
A standard manual light-duty mill is
typically assumed to have four axes:
Table x.
Table y.
Table z.
Milling Head z.

25. ROTOR SHOP

26. ROTOR SHOP
• This shop deals with the manufacturing of turbocharger.
• Turbocharger is known as the heart of diesel locomotive.
Basically in this section manufacturing of assembly and
subassembly of turbocharger is being made. But the
outer casing is made in heavy machine shop.
• Turbocharger is used for providing fresh air to the
locomotive.
• Due to this power and efficiency of engine is improved.
• For the running of turbocharger we are not using any
extra energy resources generator , motor etc. for starting
of turbocharger we generally use exhaust gases.

27. Components of turbocharger.
For assembly of turbojet following parts are manufactured in rotor shop.
1. Impeller
2. Inducer
3. Nose piece
4. Stud rotor
5. Nut
6. Washer
7. Thrust washer
8. Key
9. Oil slinger
10. Turbine disc
11. Turbo shaft
12. Lock plate

28. Assembly of Turbocharger:--
The assembly of turbocharger is done by dividing whole turbocharger in three
parts. These are as follows
1. Rotor
2. Compressor
3. Casing
1. Rotor:- Rotor is the inlet part of turbocharger which is comprises with following
parts. Turbo Disc, Rotor stud, Turbo shaft, thrust collar, Nose disc, Washer & Nut.
Rotor is rotating at speed of 18000 rpm & working at high temperature due to that
the rotor is made of steel.
2. Compressor:- Compressor is the combination of impeller & inducer. Impeller is
made up of Al-alloy. Impeller & inducer is use for sucking of fresh air from
environment.
3. Casing:- Casing is made of M.S. & also a special type of coating is done. Due
to that coating it can easily resist the heat.
For the proper working & life of Turbocharger balancing of impeller, inducer &
turbine disc is done by help of Dynamics Balancing Machine.

29. LOCO ASSEMBLY SHOP

30. • Tested engines are receives from Engine Division.
• Similarly under frames are received from Loco
frame shop and assembled trucks from Truck
machine shop.
• Super structure compartments and contractor
compartment are received from respective
manufacturing and assembly shops of Vehicle
Division.
• Important alignments like crank shaft deflection,
compressor alignment and Eddy Current
clutch/radiator fan alignment are done during
assembly stage.
LOCOASSEMBLYSHOP

31. • Electrical control equipments are fitted and control cable
harnessing is undertaken.
• The complete locomotive is thus assembled before being sent
onwards for final testing and spray painting.
• All locomotive are rigorous tested as per laid down test
procedures before the locomotive is taken up for final painting
and dispatch for service.

32. PROTOTYPE
FRAME

34. THANK U !
?