Final Report.pdf Supervised Industrial Report

INDUSTRIAL TRAINING REPORT
Name Muhammad Shahid
Registration No 19AU023
Industrial Training Course BS Automobile Engineering
Technology
Training Period 24th Mar 2023 to 22th Jul 2023
Training Organization Pakistan Railway Workshops

Abstract
This report describes the work conducted during the internship at the moghalpura railway
works. This internship is part of the degree. The main purpose of my internship report is
to clear the concept and try to explain Railway works. I learned about how locomotives
and their parts work. I came to know different types of locomotives. I inspect all the
workshops process
The main subject of my work is the application of technical skills to correct equipment
problems causing equipment downtime and maintenance work. Dedication to
maintenance function and is focused on elimination of repetitive failures. Ensuring the
maintainability of new installations. Identifying and correcting chronic and costly
equipment problems, eliminate repetitive failures. Proper operation and care of parts.
Inspection, adjustments, replacements, overhauls, etc., for selected equipment.
I think this internship is a great experience for my future. In my opinion, internships are
one of the most important things in the engineer schooling. Indeed, they contain a lot of
things the student engineer will need to start in his career; for example, taking contact with
companies, writing cover letters, visualizing management skills, and going through
interviews.

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Acknowledgement
First of all, I’m very thankful to Allah Almighty who blessed me and made capable to
complete this task. After that, I’m grateful to Pakistan Railways department (especially
MET) which provided me the opportunity to do Internship, over there. It pleasures me a
lot in paying tribute to all the staff members working at Railways department thus showing
their zeal and zest attitude towards their working area. Their support in guiding me the
technical points of the work being done at workshops, is greatly appreciable. This helped
me significantly in the completion of my report. This training wasn’t possible if the
Coordinator Ghilman Haider would not have allowed in the first place. So, thanks for him
as well.
Further I am very thankful to Foreman Rehabilitation Locomotive Shop, Mr. Adeel,
Foreman Diesel Locomotive Shop, Foreman Engine Locomotive Shop, Foreman Machine
Locomotive Shop, Foreman Tool Locomotive Shop, Foreman Motor Shop C&W,
Foreman Lifting Shop Machine Shop C&W, and all the respective chargemen and sub-
engineers for guiding me and my mates so very good in every matter.
I express my sincere thanks to the senior section engineer, who through his expert
guidance helped me throughout the course of this training. If it was not for his motivation
and encouragement, I would not have seen through this training course an honest course
to the splendor of success.

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Contents
Chapter No 01.............................................................................................................................. 10
1.2 Railway Board .................................................................................................................... 10
1.3 Pakistan Railways comprises three functional units:......................................................... 10
1.3 Divisions ............................................................................................................................. 10
1.4 New lines............................................................................................................................ 11
1.5 Classes................................................................................................................................ 11
1.6 Design office....................................................................................................................... 11
1.7 Construction of a communication system......................................................................... 12
1.8 Vision & Mission Statement............................................................................................... 13
1.8.1 Vision Statement......................................................................................................... 13
1.8.2 Mission Statement...................................................................................................... 13
1.9 Organizational Structure of Pakistan Railway.................................................................... 14
Chapter No 2................................................................................................................................ 15
2.1 Schedule of Training & Duties, as a Trainee ...................................................................... 15
2.2 Duties as the Trainee ......................................................................................................... 17
2.3 Literature Review Mughalpura Railway Lahore................................................................. 17
2.3.1 Workshops in moghalpura locomotive....................................................................... 17
2.3.2 Carriage and Wagon Shop........................................................................................... 17
Chapter No 03.............................................................................................................................. 19
3.0 Working Experience........................................................................................................... 19
Chapter No 04.............................................................................................................................. 37
4.0 Project Carried Out ................................................................................................................ 37
4.1 Carriage and Wagon shops (1908)..................................................................................... 37
4.1.1 POWER SHOP .............................................................................................................. 38
Diesel Generator.................................................................................................................. 39
4.1.1.1Perkins Diesel Engine................................................................................................ 40
............................................................................................................................................. 41
4.1.1.2 Parts of Engine and Alternator................................................................................. 41
4.1.2 MOTOR SHOP.................................................................................................................. 43
4.1.2.1 Working of Diesel and Petrol Engines...................................................................... 43
4.1.2.2 Difference................................................................................................................. 44

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4.1.2.3 DIESEL ENGINE OVERHAULED.................................................................................. 45
4.1.2.4 Signs Your Diesel Engine May Be In Need Of An Engine Overhaul.......................... 46
4.1.3 Heat Treatment Shop...................................................................................................... 47
4.1.3.1 Types of Heat Treatment Processes ........................................................................ 48
4.1.3.2 Furnaces................................................................................................................... 52
4.2 Locomotive Workshop........................................................................................................... 54
4.2.1 Project Carried Out ......................................................................................................... 55
4.2.1.1 Rehabilitation shop.................................................................................................. 55
Disassemble Section: ........................................................................................................... 56
Bogie of Locomotive ............................................................................................................ 56
Hand on Skills In Rehabilitation Shop .................................................................................. 57
4.2.1.2Project Carried Out in the Rehabilitation Shop ............................................................ 58
Preventive Maintenance of the PR Locomotives................................................................. 58
PR Steam and Diesel Locomotives....................................................................................... 58
Schedule shed maintenance of PR Locomotives ................................................................. 59
Electric Locomotives ............................................................................................................ 60
Schedule of maintenance of electric Locomotives .............................................................. 61
Classification of railways locomotives ................................................................................. 62
ENGINE CONTROL UNIT ....................................................................................................... 64
LOCOMOTIVE EVERSPEED.................................................................................................... 64
How Productivity can enhance in a given system................................................................ 65
Quality Management system in PR...................................................................................... 66
Safety at Work...................................................................................................................... 66
Work Experience in Rehabilitation shop.............................................................................. 66
4.2.2 Diesel Classified Repair Shop .......................................................................................... 67
Diesel Classified Repair Shop C.C. 7026............................................................................... 67
4.2.2.1 SECTIONS OF DIESEL CLASSIFIED.............................................................................. 69
Schedule of maintenance .................................................................................................... 69
Supervisory Work in Diesel Shop Types of Diesel Engine .................................................... 69
4.2.3 Project Carried Out Dismantling of Locomotive ............................................................. 76
LUBRICATING SYSTEM.......................................................................................................... 77
Engine Fuel injectors............................................................................................................ 77
Traction motor..................................................................................................................... 77

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Cooling system of PR Loco ................................................................................................... 78
Prime Mover ........................................................................................................................ 79
Bogie assembly section........................................................................................................ 80
Supervisory works in Diesel Shop ........................................................................................ 81
Wheel Assembly................................................................................................................... 81
Wheels Dismounting Machine............................................................................................. 82
Hand on skills in Diesel Shop................................................................................................ 82
Problems facing.................................................................................................................... 83
Problems Solving.................................................................................................................. 83
How the productivity can be further enhanced in diesel shop?.......................................... 84
Quality management ........................................................................................................... 84
Safety at work ...................................................................................................................... 84
My Work Experience in Diesel Shop .................................................................................... 85
4.2.4 Machine Shop ................................................................................................................. 86
Centre Lathe......................................................................................................................... 87
Bench Lathe.......................................................................................................................... 88
Turret Lathe ......................................................................................................................... 88
Capstan Lathe....................................................................................................................... 89
Milling Machine ................................................................................................................... 90
Horizontal Milling Machine.................................................................................................. 92
Universal Milling Machine ................................................................................................... 93
Milling Cutters...................................................................................................................... 93
Supervisory works in Tool Shop........................................................................................... 94
Working Principal of Shaper Machine ................................................................................. 94
Problems Facing................................................................................................................... 94
Problem Solving ................................................................................................................... 94
How Productivity can be enhanced in Tool Shop ................................................................ 95
Quality Management........................................................................................................... 95
Safety at Work...................................................................................................................... 95
My Work Experience in machine shop ................................................................................ 95
4.2.5 Engine Block Shop........................................................................................................... 96
Engine block......................................................................................................................... 96
Supervisory Works in Engine Block...................................................................................... 97

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Basic Working in Engine Block Shop Engine Block............................................................... 97
Cylinder Liners...................................................................................................................... 98
4.2.5.1 Project Carried Out In Engine Block......................................................................... 98
Scoping................................................................................................................................. 98
My Work Experience in Engine Block Shop ......................................................................... 99
4.2.6 Tool Shop Loco Shop..................................................................................................... 100
Project Carried Out ............................................................................................................ 100
Milling Section.................................................................................................................... 100
Lathe Section...................................................................................................................... 101
Grinding Section................................................................................................................. 102
Fitting Section .................................................................................................................... 102
How Productivity can enhance in a tool system................................................................ 103
Quality Management system in PR.................................................................................... 103
Safety at Work.................................................................................................................... 103
My Work Experience in tool shop...................................................................................... 103
4.2.7 E & DC SHOP.................................................................................................................. 104
E&DC Shop and Parts Prepared ......................................................................................... 104
4.2.8 FOUNDRY SHOP ............................................................................................................ 106
Parts prepared in brass foundry ........................................................................................ 106
Parts prepared in iron foundry .......................................................................................... 107
CASTING:............................................................................................................................ 107
Chapter 5.................................................................................................................................... 108
5.1 Conclusion........................................................................................................................ 108
Chapter no 6 .............................................................................................................................. 109
6.1 Recommendations........................................................................................................... 109
7 Chapter.................................................................................................................................... 110
7.1References ........................................................................................................................ 110

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Table Of Figure
Figure 1 Bogies Classes ................................................................................................................ 11
Figure 2 Organogram of Pakistan Railway .................................................................................. 14
Figure 3 My Internship Schedule ................................................................................................. 16
Figure 4 Diesel Engine Generator ................................................................................................ 38
Figure 5 Perkins Diesel Generator ............................................................................................... 39
Figure 6 Diesel Generator Part..................................................................................................... 41
Figure 7 Control Panel.................................................................................................................. 42
Figure 8 Circuit Breaker................................................................................................................ 43
Figure 9 Engine Working.............................................................................................................. 44
Figure 10 Diesel Engine Overhauling ........................................................................................... 45
Figure 11 Steps Of Heat Treatment ............................................................................................. 47
Figure 12 Anealing Process .......................................................................................................... 48
Figure 13 Normalizing Process..................................................................................................... 49
Figure 14 Hardening Process ....................................................................................................... 49
Figure 15 Tempring Process......................................................................................................... 50
Figure 16 Nitriding Process .......................................................................................................... 50
Figure 17 Process Of Carburizing ................................................................................................. 52
Figure 18 Locoshop...................................................................................................................... 54
Figure 19 Steam Engine ............................................................................................................... 54
Figure 20 Traction Motor............................................................................................................. 57
Figure 21 Generator..................................................................................................................... 60
Figure 22 Engine Overhauling...................................................................................................... 67
Figure 23 Specification of Engine................................................................................................. 68
Figure 24 Diesel Injection Pump .................................................................................................. 68
Figure 25 Schedule Maintenance ................................................................................................ 69
Figure 26 Dismantling of Engine .................................................................................................. 76
Figure 27 Lubrication System....................................................................................................... 77
Figure 28 Injection System........................................................................................................... 77
Figure 29 Traction Motor............................................................................................................. 78
Figure 30 Cooling System Of generator....................................................................................... 78
Figure 31 Locomotive Part........................................................................................................... 79
Figure 32 Maintenance Chart ...................................................................................................... 81
Figure 33 Wheel Testing Machine ............................................................................................... 82
Figure 34 Wheel Dismantling Machine........................................................................................ 82
Figure 35 Drill MAchine................................................................................................................ 86
Figure 36Lathe Machine .............................................................................................................. 87
Figure 37 Bench Lathe.................................................................................................................. 88
Figure 38 Turret Lathe ................................................................................................................. 89
Figure 39 Turet Lathe................................................................................................................... 90
Figure 40 Vertical Miling.............................................................................................................. 91
Figure 41 Horizontal Milling......................................................................................................... 92
Figure 42 Miling Cutter ................................................................................................................ 93
Figure 43 Engine Block................................................................................................................. 96

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Figure 44 Fitting Section ............................................................................................................ 102

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Chapter No 01
1.2 Railway Board
The Railway Board functioned from 1959 to 2000 and was modified with addition of the
"Executive Committee of Railway Board" between 2000 and 2014. However, the
Railway Board was reconstituted again on February 20, 2015. The Minister of Railways
Secretary serves as the official chairman of the Pakistan Railway Board.
 Secretary (Minister of Railways)
 Secretary, Communications Division
 Secretary, Finance Division
 Secretary, Planning & Development Division
 General Manager (Operations)
 General Manager (Manufacturing & Services)
Member Finance, Ministry of Railways. This composition could not get
parliament approval and presently the Board co ns is ts of ex. officio member listed
above with three members from private sector, appointed by Govt. The Secretary
Railways is also Chairman of the Board. The secretariat of Board is headed by Secretary
Railway Board. The seat of Board is Ministry of Railways, Islamabad.
1.3 Pakistan Railways comprises three functional units:
 Operations
 Manufacturing
 Welfare & special initiative unit
1.3 Divisions
Pakistan Railway comprises seven territorial operating divisions:
 Karachi
 Lahore
 Multan
 Peshawar
 Quetta
 Rawalpindi
 Sukkur

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Figure 1 Bogies Classes
1.4 New lines
New rail lines have been proposed by Pakistan Railways to connect Gwadar Port to
Central Asia, including:
 Karachi–Gwadar Railway Line (Makran Railway)
 Gwadar–Mastung Branch Line
 Basima–Jacobabad Branch Line
 Bostan–Zhob–Dera Ismail Khan Branch Line
 Islamabad–Muzaffarabad Branch Line
 Jhang Sadar–Risalewala Branch Line
1.5 Classes
Pakistan Railways has several classes of travel. Depending on the route, certain trains
may only have a single class. The fares for all classes are different with unreserved seating
class being the cheapest. The following table lists the classes in operation.
1.6 Design office
The success of any transportation project depends on its construction. With well-
thought-out and well-designed stations, cars, and other components of the public transport
network, an effective design can attract more users. On all railways, the design office
provides the following services:
Track design (alignment, positioning, blank line and shift and crossing, gauge
specification) Signal and train control design (scheme development, building design)

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1.7 Construction of a communication system
Top catenary design
 Mechanical and Electrical Design
 Channel design
 Community design and structure
 Internal and external parts design
The design and painting office is equipped with state-of-the-art technology and can design
and organize any type of stock. During project implementation, the design office provides
support to the production department, and any problems are solved by qualified design
professionals. In this office, there is also a library.
There are currently two types of coaches available in Pakistan:
 German coaches
 Chinese coaches
Maximum trainers/Dimensions of coaches:
The size of the Railway in Pakistan is measured in mm.
Trainer length = 22606mm
Coach width = 3251mm
Coach height = 2899mm
There are some coaches who are designed for a specific purpose.
Power Van: Designed to carry an engine to power appliances and air conditioners.

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Luggage Van: Used to carry passengers' luggage. Restaurant: It is like a train traveling on
a long train. Wedding car: Specially designed for long-distance weddings.
1.8 Vision & Mission Statement
1.8.1 Vision Statement
To achieve excellence in Engineering Services with special emphasis on Railway Sector
and to become an international commercial company operating beyond Pakistan’s
borders.
1.8.2 Mission Statement
To lead the public and private sector in the engineering disciplines including Railways by
providing highest quality and safety standards in an economical and efficient manner

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1.9 Organizational Structure of Pakistan Railway
Figure 2 Organogram of Pakistan Railway

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Chapter No 2
2.1 Schedule of Training &
Duties as a Trainee
In this chapter, we will look at the details of the workshops and workshops, as well as the
training program in the areas where I spent four months training (16 weeks). There were
several places in the train interviews where I completed my training days and did various
jobs and activities related to the workshop environment.
The roles and training program are explained in more detail below. We should complete
the exercise five days a week eight hours a week, according to NTC requirements.
Workshop entry and exit times are 8:00 AM and 4:00 PM, respectively. There is a 2-hour
lunch break available. There are other job sites out there where I completed my training
listed below;
In our 17 week schedule for internship program, we were directed to visit ten workshops
in total five from locomotives and five from C&W shops.
The schedule of my training is given below:

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Figure 3 My Internship Schedule

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2.2 Duties as the Trainee
As a trainee, we’ve to observe the all working process at different sites or working spaces.
Our duties are to analyze the general faults and their solutions including time management
and other important factors which affect the maintenance process of any working site.
These factors are the following:
To understand the manufacturing and repairing of rail coaches and wagons.
To observe and acquire knowledge about different mechanisms dealing with different
machines.
To apply the theoretical technical knowledge to real industrial applications.
To build good communication skills with a group of workers and learn proper behavior of
corporate life in the industrial sector.
To enhance the ability to improve students’ creativity skills and share ideas.
2.3 Literature Review Mughalpura Railway Lahore
Moghalpura Railway Workshops is located in the main stockpile of Pakistan Railways,
located in Lahore - Wagah Branch Line at Moghalpura Junction train station in Lahore,
Pakistan. The workshop began to emerge from its current location in 1904 to design,
refurbish and renovate passenger coaches and freight trains from the North Western State
Railway. After the liberation of Pakistan in 1947, it was the end of the Pakistan Railways.
2.3.1 Workshops in moghalpura locomotive
 Carriage and wagon works
 Locomotive works
2.3.2 Carriage and Wagon Shop:
In this shop spare parts for rail cars and locomotives are being prepared and machined.
This shop has following workshops:
 Power Plant Shop
 Motor Shop

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 Heat Treatment Shop
 Roller Bearing Shop
 Loco Shop
 Diesel Classified shop
 E&DC Shop
 Tool Shop
 Foundry
 Diesel Rehibition Shop

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Chapter No 03
3.0 Working Experience
In this chapter, we will discuss the key learning outcomes from this training, as
well as other important components and resources set out in Pakistan Railways workshops
across the country. Many types of manufacturing, production, processing, and special
purpose equipment are used in all forums. We all know that all machines work with some
kind of energy. Electric power is suitable for control, conversion, and various other
functions.
Therefore, for all of our manufacturing equipment, processing, and other purposes, we
used machine tools and equipment. As a result, I found useful equipment in various
workplaces. The following sections of this chapter provide a detailed discussion of several
relevant components and equipment set out in the workshops.
I have created workshops, listed here, and work-related information and other relevant
resources for these discussions and venues. The following paragraphs include a detailed
workshop and a quick description of my work in this workspace.

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Daily Training Log
Training Week: 1
st
Date Time Daily Entry
22-Mar-2023 9:30 to 4:00
It’s my first day at MET College introduction with
teachers
24-Mar-2023 9:30 to 4:00
Today I have attend the class about the history of
Pakistan Railway and introduction of existing
workshops in Pakistan Railway
25-Mar-2023 9:30 to 4:00
Today my 1st
day in Power Plant shop (C&W) and
introduction with staff
27-Mar-2023 9:30 to 4:00
Today I learn about the basic system operation use in power
plant shop
28-Mar-2023 9:30 to 4:00 I learn how to work Diesel generator
29-Mar-2023 9:30 to 4:00
Today I learn identification of diesel generator parts and
how many brands use in Pakistan Railway

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Daily Training Log
Training Week: 2
nd
30-Mar-2023 9:30 to 4:00
Today I learn about the control systems of generators
use in Pakistan railway
31-Mar-2023 9:30 to 4:00
Today I learn about the circuit breaker control panel
and their specifications
01-April-2023 9:30 to 4:00
Today I learn safety factor use in motor shop and how
to work in motor shop
03-April-2023 9:30 to 4:00
Today I learn basic difference in diesel and petrol
engines
04-April-2023 9:30 to 4:00
Today I learn how to check engine oil radiator
coolant and also know how check the vehicle
through visual inspection.
04-April-2023 9:30 to 4:00
Today I learn how to disassemble diesel engine for
engine overhauling.

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Training Week: 3rd
05-April-2023 9:30 to 4:00
I learn sign of diesel engine may be weak and need
to be overhaul or need to be change
06-April-2023 9:30 to 4:00
Today I learn sign of petrol engine maybe weak and
need to be overhaul or need to be replace.
07-April-2023 9:30 to 4:00
Today I learn how to piston ring adjustment in
diesel engine
08-April-2023 9:30 to 4:00
Today I learn how to adjustment of timing of diesel
engine during overhauling.
10-April-2023 9:30 to 4:00
Today I learn method of petrol engine overhauling and
how to adjust ignition timing during engine
overhauling
11-April-2023 9:30 to 4:00
Today I learn how to inspect engine after
overhauling.
Daily Training Log

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Daily Training Log
Training Week: 4th
12-April-2023 9:30 to 4:00
Today I learn about the safety factor use in heat
treatment shop
13-April-2023 9:30 to 4:00
Today I learn how to work in heat treatment shop and
know what are the operation perform in heat treatment
shop
14-April-2023 9:30 to 4:00 Today I learn about how to increase resistance in metal
15-April-2023 9:30 to 4:00
Today I learn how to mechanical and electrical
properties of metal and how to increase the
machinability properties increase
17-April-2023 9:30 to 4:00
I learn how to done annealing process for the softening
of metal , steel and copper and learn what are the basic
temperature use for this process.

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Daily Training Log
Training Week: 5th
18-April-2023 9:30 to 4:00
Today I learn how to done normalizing process for
decrease the internal stress develop after the cold
working process
19-April-2023 9:30 to 4:00
Today I learn how to do hardening process for the
steel and matel toughness
20-April-2023 9:30 to 4:00
Today I learn how to do tempering and nitriding
process in matel
21-April-2023 9:30 to 4:00
Eid al-Fitr Holiday
22-April-2023 9:30 to 4:00
Eid al-Fitr Holiday
24-April-2023 9:30 to 4:00
Eid al-Fitr Holiday

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Daily Training Log
Training Week: 6th
24-April-2023 9:30 to 4:00
Eid al-Fitr Holiday
25-April-2023 9:30 to 4:00
Today I learn how to do cyanding and carburizing
process
26-April-2023 9:30 to 4:00
Today I learn purpose of these process in metal and
steel
27-April-2023 9:30 to 4:00
I learn about the types of furnaces and which material
use for making these furnaces
28-April-2023 9:30 to 4:00
Identification of parts of the locomotive engines use in
Pakistan railway
29-April-2023 9:30 to 4:00
Today I learn introduction of locomotive shop and
which kind of shops in locomotive block

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Daily Training Log
Training Week: 7th
01-May-2023 9:30 to 4:00 Introduction with team of locomotive diesel shop
02-May-2023 9:30 to 4:00 Today I learn about the basic specification of engines
use in Pakistan railway
03-May-2023 9:30 to 4:00 I identify the sensor use in locomotive engine
04-May-2023 9:30 to 4:00 Identification of parts of the locomotive engines use in
Pakistan railway
05-May-2023 9:30 to 4:00 I learn about electrical system and their working
06-May-2023 9:30 to 4:00 I learn about 6 month engine inspection checking point
08-May-2023 9:30 to 4:00
Today I learn about diesel injection pump and its
working

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Daily Training Log
Training Week: 8
th
09-May-2023 9:30 to 4:00
Today I learn how to inspect cylinder head valve
and valve guide
10-May-2023 9:30 to 4:00
Today I learn how to check water jackets and elbows
through visual inspection and then through different
types of test
11-May-2023 9:30 to 4:00
Today I learn how to check oil level oil and oil
condition in locomotive CAT&Piller engines
12-May-2023 9:30 to 4:00
Today I how to dismantle locomotive engine for the
overhauling
13-May-2023 9:30 to 4:00
Today I learn how to inspect engine internal parts after
dismantling the locomotive engine
15-May-2023 9:30 to 4:00
Today I learn how to check crankshaft and
camshaft inspection method

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Daily Training Log
Training Week: 9
th
16-May-2023
9:30 to 4:00
Today I learn how to inspect ring and piston and
play between the connecting rod and main journal
17-May-2023
9:30 to 4:00 Today I learn how to fix the any king of seepage
on engine. I learn the seepage fixing of oil sump.
18-May-2023
9:30 to 4:00
Today I learn about the diagnosing and fixing of
We Diagnose the engine oil comes from Engine
timing Side (Engine front Side). We replaced the
Oil seal to fix it.
19-May-2023
9:30 to 4:00
Today I fix or re assemble the engine with
complete overhauling and check the any kind of
leakage and seepage
20-May-2023
9:30 to 4:00
Today I learn about how to check all basic systems
after the engine overhauling
22-May-2023
9:30 to 4:00
Today I get an overview of engine
Troubleshooting
Engine misfire with abnormal internal lower
noises.

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Daily Training Log
Training Week: 10
th
23-May-23
9:30 to 4:00
Today I learn about the fault diagnose of
lubrication system and check the the all leakages
and seepages in system
24-May-23 9:30 to 4:00
Today I learn about the compression testing of
new assemble engine during the final inspection
of engine
25-May-23 9:30 to 4:00 I learn how to get an dry and wet compression test
26-May-23
9:30 to 4:00 Today I learn turbocharger function in locomotive
engine
27-May-23 9:30 to 4:00 I learn how to work of turbocharger in locomotive
engines
29-May-23 9:30 to 4:00 I learn how to diagnose the fault of turbocharger in
locomotive .

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Daily Training Log
Training Week: 11
th
31-May-23 9:30 to 4:00 I learn about the cooling system of locomotive
01-Jun-23 9:30 to 4:00
Today I learn about the main fault of cooling
system and how to fix them
02-Jun-23 9:30 to 4:00 I learn how to replace water pump in locomotive
engines
03-Jun-23 9:30 to 4:00 I learn how to check thermostat valve and water
jackets
05-Jun-23 9:30 to 4:00 I learn how to work diesel lift pump in locomotive
06-Jun-23 9:30 to 4:00 Today I learn flywheel inspection of locomotive
engines

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Daily Training Log
Training Week: 12
th
07-Jun-23
9:30 to 4:00 Today i learn inspection of wheel assembly
.
08-Jun-23 9:30 to 4:00
I learn how check bearing play in wheel assembly
09-Jun-23 9:30 to 4:00 I learn how to dismantle the wheel bearing from
wheel assembly
10-Jun-23 9:30 to 4:00
I learn how to load test on a bearing
12-Jun-23 9:30 to 4:00 I learn how to refit bearing in wheel assembly
13-Jun-23 9:30 to 4:00 I learn how to check bearing after refitting on wheel

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Daily Training Log
Training Week: 13
th
14-Jun-23
9:30 to 4:00 Introduction with the staff of Tool shop
15-Jun-23 9:30 to 4:00 I learn parts identification of Lathe Machine
16-Jun-23 9:30 to 4:00
I learn how to make an clutch and flywheel hosing
and what are the basic operation use in clutch
housing
17-Jun-23 9:30 to 4:00 I learn how to do facing process
19-Jun-23 9:30 to 4:00 I learn how to drilling and honing process
20-Jun-23 9:30 to 4:00 I learn how turning and knurling process

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Daily Training Log
Training Week: 14
th
21-Jun-23 9:30 to 4:00 I learn how to check work piece after completing
the work
22-Jun-23 9:30 to 4:00 I learn how to do operation on specific angles
24-Jun-23 9:30 to 4:00 I learn how working a pneumatic tools
25-Jun-23 9:30 to 4:00 I learn how to cutting the tool on shaper machine
26-Jun-23 9:30 to 4:00 How to inspect the tool after completing the process
27-Jun-23 9:30 to 4:00 Eid-Ul-Adha

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Daily Training Log
Training Week: 15
th
02-Jul-23 9:30 to 4:00
Introduction with the team of E&DC Shop
03-Jul-23 9:30 to 4:00
Here I learn purpose of friction plate and how to
make it
04-Jul-23 9:30 to 4:00
I learn how to make an oil seal valve guide and
plunger .
05-July-23 9:30 to 4:00
I learn how to make bearing shell connecting rod
08-Jul-23 9:30 to 4:00
I learn how to face a crankshaft of parkins and
commins engine
10-Jul-23 9:30 to 4:00 Today I learn how to check dimension of crankshaft
after facing

35
Daily Training Log
Training Week: 16
th
11-Jul-23 9:30 to 4:00
Introduction with the foundry shop team and I
learn what are the safety factor in foundry shop
12-Jul-23 9:30 to 4:00
I learn how to make a mold and what type of
material use for making the mold and also know
how to inspect a mold after completing this
13-Jul-23 9:30 to 4:00 Today I learn how to melt a iron for
molding
14-Jul-23 9:30 to 4:00 Today I learn ow to check a brake system in train
15-Jul-23 9:30 to 4:00
I learn how to test vacuum and pressure brake
system during the half year inspection
17-July-22 9:30 to 4:00
I learn how to check traction motor and learn
how its work

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Daily Training Log
Training Week: 17
th
18-July-23
9:30 to 4:00
I learn how to dismantle traction motor and how
to change their stater
19-Jul-23 9:30 to 4:00
I learn how to refit the traction motor and inspect
again for final inspection
20-Jul-23 9:30 to 4:00
I learn how to check overhaul boggie inspection
21-Jul-23 9:30 to 4:00
I learn how to inspect boggie suspension system
and how to check shock absorber
22-Jul-23 9:30 to 4:00
I learn how to inspect fuel tank and Ac system
during the inspection

37
Chapter No 04
4.0 Project Carried Out
4.1 Carriage and Wagon shops (1908)
The Mughalpura Railway Workshops, on the Lahore–Wagah Branch Line at Mughalpura
Junction railway station (MGPR) in Lahore, is one of several rolling-stock repair sites.
The workshop complex emerged at its present site in 1904 to manufacture, repair, and
overhaul passenger coaches and freight wagons for the North Western State Railway. In
1947, it was the only state-of-the-art workshop for-Pakistan railways.
These are the following shops in which we have worked in Carriage and wagon shops:
 Power Plant Shop C&W Shop
 Motor Shop C&W Shop
 Heat Treatment Shop C&W Shop

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Figure 4 Diesel Engine Generator
 Roller Baring Shop C&W Shop
4.1.1 POWER SHOP
In this shop the piston and other mechanical parts of diesel engine used in power van are
overhauled and repaired. A power Van is basically a part of a train which consists of
generators and a controlling system that provides electrical power to the whole train to
utilize in form of light, fan or Air Conditions. There are two types of generators used in
power van. One is 300 KVA which is used in a combination of two generators and 500
KVA which is used alone. There is always a generator placed as a backup generator in the
power van for emergency conditions or in case of overload. The supply of fuel for these
generators is taken through the diesel tank which is placed in the power van separately for
each generator and called an auxiliary tank. Power Van has usually two people for
operation at a time during working. A control panel is used to control both generators
while operating.
Periodic Over Hauling POH
Complete repairing of carriage/ power van
NRM & NRE (Nominated Repair) Mechanical/Electrical

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Diesel Generator
A diesel generator is the combination of a diesel engine with an electric generator (often
an alternator) to generate electrical energy. This is a specific case of engine-generator. A
diesel compression-ignition engine often is designed to run on fuel oil, but some types are
adapted for other liquid fuels or natural gases.
Perkins Engine with Alternator
It is supplied by diesel through an auxiliary tank which is connected to the main tank and
a motor is used to pump diesel through the main tank to the auxiliary tank.
A 500 KVA diesel generator usually takes 30 liter/hour diesel in normal loads and 45
liter/hour in peak loads. The main tank can be from different ranges but mostly used a
3000-liter capacity tank. Trainload may vary from 3A to 55A, from normal to peak load.
In some cases, a generator of 75 KVA is also placed for extra load or if the load is very
less than 75 KVA generator is used.
Figure 5 Perkins Diesel Generator
Following Diesel Engines are used in power vans for generating electricity:

40
 Perkins
 Caterpillar
 Cummins
4.1.1.1Perkins Diesel Engine
Parts of a Diesel Generator:
Diesel generator has many parts but some main parts are below:
Diesel Tank:It is also called auxiliary tank in which diesel is placed for the supply of
generators. Both generators have their own auxiliary tank which is connected with main
tank and motor is use to supply diesel
Fuel Water Separator: Fuel water separator is used to separate water from fuel and
prevent water to flow in engine and prevent engine from rusting.
Fuel Filter/Oil Filter: It is used to filter the fuel from dust particles and other material
which may be harmful and impure.
Actuator: On a diesel engine, actuator is normally used to refer to the actuator in the
fuel system which controls the amount of diesel fuel injected into the engine.
Engine: A four-stroke engine is used in diesel generator. A diesel generator is basically
machinery that converts the chemical energy in diesel to electrical energy. It does this
using a diesel engine and an AC alternator, coupled together. Normally caterpillar and
Cummins company’s components are used in it.
Lube oil Filter: Lube oil is basically oil which is used in moving parts to prevent
friction and heat produced by friction and this filter is used to remove dust particles and
impurities from it.
Primary Lube oil pump: It is a pump which is used to pump lube oil in moving parts to
prevent friction and heat produced.
Coolant tank: Coolant tank is a tank which consists of coolant material which is used to
reduce heat in engine and it provide coolant in this regard. Normally distillated water is
used for coolant.

41
Radiator & Fan: It is another important part of diesel generator. The radiator on a
diesel generator is the part that transfers the heat from the engine coolant to the
surrounding air. When working correctly, this process keeps the engine from
overheating.
4.1.1.2 Parts of Engine and Alternator
Turbo Charger: A turbocharger increases an engine's compression by blowing extra air
into the combustion chamber. The higher air mass allows more injected fuel to be burned.
It also helps to outflow carbon dioxide produced in engine.
It is not painted normally because of very high temperature of it.
Silencer: It is used to reduce the noise of the generator. It is connected with engine and
placed at the top of generator. It is also help in filtering.
Coupling: We use coupling to joint engine and alternator’s rotor. So both engine and
Alternator can rotate together.
Alternator: It is used to produce electricity. In DG, brushless alternator is used. There are
two main windings in it, a stator and a rotor winding.
Automatic Voltage Regulator: It is very important and used to regulate voltage and helps
to remain it in a fix level.
Figure 6 Diesel Generator Part

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Exciter: AVR commands exciter to regulate voltage in for a specific level and exciter
works to make it on a specific level.
Battery: Normally 2 batteries are used in series in Diesel Generator. And usually it is
used in couples for example 2, 4 or 6. They are connected in series to produce a 24v
supply. It is used to supply crank motor in starting.
Crank Motor: Crank is used to rotate DG’s rotor in starting. It works until rotor picks up
90% of the speed. After that motor get stops and engine’s rotor rotates alternator’s rotor.
By the use of crank motor and battery, engine will be self start.
Governor: Governor is used to maintain speed of the rotor even if the load is changing
so it prevents the effects of changing RPM speed which is required to produce 50Hz
frequency.
Flywheel: Flywheel is connected on rotor. When rotor rotates on a specific RPM
(normally 1500 is required), even if there is changing in load, flywheel is used to maintain
the speed of the rotor.
Control Panel: Control Panel is used to open and close the circuit of the diesel generator
to turn on and off its supply. It is also used to use generators in series in case of overload
and change of generator A to B in case of emergency or any fault.
It is mainly consisting of a display on which voltages, amperes, frequency, output voltage
and other measure
Can also e seen consisting of alarm circuit which can help to notify a signal in case of any
fault
Figure 7 Control Panel

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Circuit Breaker:
Circuit breaker is used as a protection device and helps to break
the circuit in case of overload. Air circuit breaker is used for this
purpose here. Normally 800A circuit breaker is used in 500
KVA diesel generators.
Circuit Breaker
4.1.2 MOTOR SHOP
The responsibility of motor shop in carriage and wagon is to repairing and overhauling
of cars, buses, trucks, fork lifter and cranes use for Pakistan railways. This shop consists
of mainly two sections
 Petrol section
 Diesel section
Automobile vehicles owned by Pakistan Railway are being fixed and overhauled at the
petrol division. Different types of buses, lorries, and other diesel vehicles such as cranes
and fork
lifters are overhauled in the diesel area.
4.1.2.1 Working of Diesel and Petrol Engines
The diesel and petrol engines that are used in most cars are highly similar. In essence, they
are internal combustion engines that work using a two or four-stroke cycle. In an internal
combustion engine, the power cycle is made up of four phases: intake, compression, power
and exhaust. In the intake phase, air is drawn into cylinder through the opening intake
valve. In the compression phase, the intake valve closes and air is compressed with fuelAt
this point, the mixture of fuel and air is ignited to cause an explosion. It is this explosion
that causes the piston to downwards and drive the crankshaft to produce motion. This isthe
power phase. The final phase is exhaust where the spent air-fuel mixture is expelled out
of the cylinder through the opening exhaust valve so that a new cycle may begin.
Figure 8 Circuit Breaker

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4.1.2.2 Difference
The main difference between diesel and petrol engines is that petrol engines use spark
plugs to ignite the air-fuel mixture, while diesel engines rely solely on heavily compressed
air.
As mentioned earlier, Rudolf Diesel found that the temperature of air could be made to
increase high enough if it was heavily compressed. The temperature would rise so high to
the point where it could cause the ignition of diesel fuel.
Therefore in diesel engines, air in cylinder would be very heavily compressed, typically
to around 14 to 23 times its original volume. In petrol engines, the compression ratio is
generally much lower, because they rely more on the spark plug to begin the power phase.
The compression
ratio is petrol engines is typically around only around 7 to 10, with high performance
vehicles having higher compression ratios of up to 13.
Figure 9 Engine Working

45
4.1.2.3 DIESEL ENGINE OVERHAULED
A diesel engine, which is an internal combustion engine that uses heat to ignite fuel, has
an average service life of about 10 years Diesel engines deliver both power and a high
level of performance. But wear and tear over time on the engine components can lead to
mechanical problems and performance failure. As you start to notice problems occurring
with your diesel engine, the best way to address them might be by getting an engine
overhaul. This procedure involves taking apart the engine, identifying faulty parts and
replacing them, cleaning all the engine components, and then rebuilding the engine. An
overhaul can increase the performance, power, and longevity of your vehicle. Use this
guide to help you decide when to have your diesel engine overhauled.
If you notice any of these problems, it is very likely time to bring your vehicle in to get an
overhaul immediately:
Your engine has spun a rod bearing.
Your engine has very low or no oil pressure.
Your engine has dropped a valve.
If you notice these symptoms, it is a good idea to talk to a mechanic about the possibility
of getting an overhaul:
Your engine has high blow by.
Figure 10 Diesel Engine Overhauling

46
Your engine is consuming a lot of engine oil or coolant.
You have put a lot of miles on your diesel and are getting lower fuel efficiency
4.1.2.4 Signs Your Diesel Engine May Be In Need Of An Engine Overhaul
 Oil Sludge
 Metal Shavings
 Increased Oil Or Coolant Consumption
 Excessive Exhaust
 Knocking Sounds
 Compression Loss
 Hitting Milestones
 Spun Rod Bearings
 Dropped Valve.
 Turbocharger Failure
 Extreme Blow-By
 Rough Idle Or Runaway

47
4.1.3 Heat Treatment Shop
Heat treatment is defined as an operation involving the heating and cooling of a metal or
an alloy in the solid-state to obtain certain desirable properties without change
composition. The process of heat treatment is carried out to change the grain size, to
modify the structure of the material and to relive the stresses set up the material after hot
or cold working.
The heat treatment is done to improve the machinability.
To improve magnetic and electrical properties.
To increase resistance to wear, heat and corrosion and much more reason.
Heat treatment consists of heating the metal near or above its critical temperature, held
for a particular time at that finally cooling the metal in some medium which may be air,
water, brine or molten salts. The heat treatment process includes annealing, case
hardening, tempering, normalizing and quenching, nitriding, cyaniding etc. Heat
Treatment Process Flow Chart Shown in figure13
Steps in Heat Treating Operation
Figure 11 Steps Of Heat Treatment

48
4.1.3.1 Types of Heat Treatment Processes
Eight different types of heat treatment processes are as follows:
 Annealing
 Normalizing
 hardening
 Tempering
 Nitriding
 Cyaniding
 Carburizing
 Flame Hardening
Types Of Heat Treatment
Annealing
Annealing is one of the most important
processes of heat treatment. It is one of
the most widely used operations in the
heat treatment of iron and steel and is
defined as the softening
process.Heating of from 30 - 50°C
above the upper critical temperature
and cooling it at the very slow rate by
seeking it the furnace. The main aim of
annealing is to make steel more ductile and malleable and to remove internal stresses. This
process makes the steel soft so that it can be easily machined.
Normalizing
Figure 12 Anealing Process

49
Normalizing: The main aim of
normalizing is to remove the internal
stresses developed after the cold
working process. In this, steel is heated
30 - 50°C above its upper critical
temperature and cooling it in the air.It
improves mechanical and electrical
properties, machinability & tensile
strength. Normalizing is the process of
heat treatment carried out to restore the structure of normal condition.
Hardening
Hardening: The main aim of the
hardening process is to make steel hard
tough. In this process, steel is heated
30° - 40°C above the upper critical
temperature and then followed by
continues cooling to room temperature
by quenching in water or oil. It is the
opposite process of annealing.
Tempering
Tempering: When the hardening process hardens a steel specimen, it becomes brittle and
has high residual stress. It is an operation used to modify the properties of steel hardened
by quenching for the purpose of increasing its usefulness.
Tempering or draw results in a reduction of brittleness and removal of internal strains
caused during hardening. Steel must be tempered after the hardening process.
Figure 13 Normalizing Process
Figure 14 Hardening Process

50
The tempering is divided into three categories according to the usefulness of steel
required.
Low-temperature tempering.
Medium temperature tempering.
High-temperature tempering.
Nitriding
Nitriding is the process of the case or
surface hardening in which nitrogen gas is
employed to obtain hard skin of the metal.
In this process, steel is heated in the
presence of ammonia environment.
Figure 15 Tempring Process
Figure 16 Nitriding Process

51
Due to this, a nitrogen atom is deposited and makes material hard. Induction hardening
and Flame hardening objects are heated by an oxy-acetylene flame.
Purpose of Nitriding
To harden the surface of the steel to a certain depth.
Increase resistance to wear and fatigue.
To increase corrosion resistance.
Cyaniding
Cyaniding: In this process, steel is heated in the presence of sodium cyanide environment.
Due to this, carbon and nitrogen atoms are deposited on the surface of steel and make it
hard.
Purpose of Cyaniding
This method is effective for increasing the fatigue limit of medium and small-sized parts
such as gears, shafts, wrist pins etc.
To increase surface hardness.
increase wear resistance.
To give the clean, bright and pleasing appearance to the hardened surface.
Carburizing
Carburizing: In this process, steel is heated in the presence of carbon environment. Due
to this carbon atom are deposited on the metal surface and make it hard.
Case hardening or surface hardening
The main aim of this process is to make the only external surface of steel hard and inner
core soft. It is the process of carburization i.e., saturating the surface layer of steel with
carbon, or some other process by which case is hardened and the core remains
soft.Purpose of Heat Treatment of Steel

52
The following are the purposes of heat treatment.
 To improve mechanical properties such as tensile strength, hardness, ductility,
shock resistance and resistance to corrosion.
 Improve machinability.
 To relieve the internal stresses of the metal-induced during cold or hot working.
 To change or refine grain size.
 Improve magnetic and electric properties.
 Increase resistance to wear, and corrosion.
 To increase the surface hardness.
4.1.3.2 Furnaces
Furnaces used for heat treatment can be split into two broad categories: batch
furnaces and continuous furnaces. Batch furnaces are usually manually loaded and
unloaded, whereas continuous furnaces have an automatic conveying system to provide a
constant load into the furnace chamber Railway loco heat treatment shop
Figure 17 Process Of Carburizing

53
Batch furnaces
Batch systems usually consist of an insulated chamber with a steel shell, a heating system,
and an access door to the chamber. Schematic Diagram of Batch Furnaces
Box-type furnace
A Box Furnace features a vertical lift or swing out door allowing the various sized
product(s) to be placed in the furnace. Box Furnaces are utilized for heat-treating,
calcining, curing, annealing, stress relieving, preheating, tempering, and other high
temperature thermal processes.

54
4.2 Locomotive Workshop
Pakistan's Moghalpura Lahore workshop was built in 1912. In the railway workshop, all
repair departments are working on the revitalization of Pakistan Railways trains. Most of
them were HGMU30 EMD trains and some were ZCU30 Made in China locomotives, the
whole repair process was done by the locals as the first arrival policy.
These are the following shops in which we have worked in Locomotive works:
 Rehabilitation Shop Locomotive Shop
 Diesel Classified Repair Shop
 Engine Block Shop Locomotive
 Machine Shop Loco Shop
 Tool Shop Loco Shop
Figure 18 Locoshop
Figure 19 Steam Engine

55
4.2.1 Project Carried Out
During our internship our projects is to maintain the initial working reports of all shops of
workshop.
There are following shops to cover during projects.
 Rehabilitation shop
 Diesel classified
 Machine shop
 Tool shop
 E&DC Shop
 Engine block shop
 Machine shop Carriage and wagon
 Tool shop Carriage and wagon
4.2.1.1 Rehabilitation shop
The first shop I visited was the Rehabilitation shop. Apart from repairs there are also
occasional maintenance
Supervisory Work in the Rehabilitation Shop.
My duties at the repair shop are to look at loco motivation engine repair tests and to check
out the cart frame and other different tests After a crash and a train accident all the
replacement trains are in a repair shop.
I am working is this shop under the supervision of Sir Ahmad who is the CIR in the
Locomotive Workshops. They guide me through my internship period which I spend in
this shop are:
Scheduling Process of Pakistan Railway Engines
 Inspection and checking of I beam

56
 Inspection and welding of Welded spots in engines
 Inspection of Batteries use in Loco engines
Two different sections are working for diesel classified Rehabilitation shop.
 Assemble and Disassemble Section of Steam and Diesel Locomotivess
 Maintenance/Repair Section
Disassemble Section:
In the section nut and bolts that connect the body and the trucks are open then bogie and
rail body disassemble and lifted by crane. lifting Crane can bear 150 tone wight. Two
crane-lift lift the body together.
Bogie of Locomotive
Bogie is play an important rolls for the link of rail body and track for the safety and
comfort purpose of passenger. In technical terms bogie called chassis or framework
consisting a wheel attach to a rail vehicle.
Bogies serve a number of purposes-
 To support the rail vehicle body.
 To run stably on both straight and curved tracks.
 To ensure ride comfort by absorbing vibrations and minimizing centrifugal forces
when the train runs on curved tracks at high speeds.
 To minimizes generation of track irregularities and rail abrasion
Main Component of bogie are fellow
 Bogie is frame itself.
 Brake components
 Suspension to absorb shocks between bogie frame and rail body.
 Two Wheel set with axle at each end and one at the center.
 Traction Motor

57
Central Pivot
The central pivot is located on the front side of the frame to allow for a certain level of
rotation of the train. Pivot carries about 60% of direct load and acquires and transmits
gravity and braking.
The pivot bowel and loading area are lined with grease for its line. The middle pivot is
checked for appearance. The central pivot pin connects the body to the bogie and transmits
the bogie 'gravity and brakes. It has silent rubber trees that help keep bogies in line with
the body and control and reduce angular oscillations of the bogies to some degree.
Traction Motor:
Traction motor is one of the key features of a diesel train, which plays a key role in the
smooth running of the train. The function of the locomotive engine is to convert
electrical energy into mechanical power around the train wheel. The transfer of
equipment is not recommended / incorrect on the train due to the size and weight of the
train, the gears large enough to control it can be too large and too large to operate.
Hand on Skills In Rehabilitation Shop
 Pre-Inspection:
 It is the inspection in which all the pipe fittings, brake equipment are properly
fitted and in placed before starting of testing the following:.
 Test for Pressure switch.
 Emergency Application
 Reservoir Charging.
 Release full Brake Application Full
Brake Application.
 Sealing Test
 Test for Pressure switch.
 Device
 Release emergency Brake applicati Figure 20 Traction Motor

58
If there is any part is missing or is in damaged condition then it is reported on the
inspection form
Final Inspection
Final testing is one of the most important parts of a bogie and coach care because if there
is a disagreement, the wrong combination or size is gone or a little tolerable so it can be a
big risk. To avoid such an accident, a final examination should be done carefully.
4.2.1.2Project Carried Out in the Rehabilitation Shop
Rehabilitation Maintenance Loco Engines
Rehabilitation maintenance of loco engines has two major schedule types:
 Preventation Maintenance
 Schedule shed Maintenance
Preventive Maintenance of the PR Locomotives
The efficiency of trains depends on the reliability and availability of trains. Proper and
efficient train maintenance is the foundation of cost-effective train operations. Care
procedures have emerged from the basic principle that the necessary attention should be
paid to all assets before they deteriorate due to aging which makes them prone to failure.
This is known as maintenance retention. Train block maintenance can be broadly divided
into two headings, namely, periodic adjustments and schedule adjustments.
PR Steam and Diesel Locomotives
The life expectancy of steam and diesel trains is 40 and 36 years, respectively. Due to the
longevity of life, it is important that both assets are stored properly and periodically to
ensure that there is no deterioration in their condition. The maintenance of steam and
diesel trains is done as follows.

59
Schedule shed maintenance of PR Locomotives
Various test schedules have been developed as part of protective care so that specific
sections and parts of trains can be given need-based attention from time to time. Test
schedules list all the various aspects that need to be taken into account during repair,
depending on the aging and tear parts. The total number of kilometers that should have
been done before these tests were also specifie
Type of schedule km covered by WP/WG km covered by YP/YG
Schedule I 1600 950-1100
Schedule II Every month -
Schedule III 24,000 20,000
Schedule IV 48,000 40,000

60
Steam locomotives outlines the various types of schedules approved for the maintenance
of steam locomotives based on the total distance in kilo meters covered by the
locomotives.
Diesel locomotives A trip (or weekly) schedule, a fortnightly schedule, a monthly
schedule, a three-month schedule, a six-month schedule, a yearly schedule, a three- year
schedule, and a six-year schedule (POH) have been drafted for diesel locomotives. These
repair programs are based on experience and informed investigations into the causes of
train crashes. Compared to a railroad track, the diesel pump unit is much more complex,
often incorporating an indirect control system with many additional components. As a
result of this great complexity, there is a great deal of inefficiency on the failure of a
particular component. Therefore, in order to ensure a high level of reliability, various
schedules have been developed for testing and maintenance. The 'service' of small
schedules, that is, travel, two weeks, monthly, etc., which includes routine tests, a little
attention, and the like, takes about 4 to 12 hours. Larger schedules take longer, lasting 6
to 14 days, as they require major repairs and replacement.
Electric Locomotives
The schedules for inspection and checks given in Table 24.7 are generally followed on
Pakistan Railways to ensure the proper maintenance of electric locomotives.
Figure 21 Generator

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Schedule of maintenance of electric Locomotives
Frequency Code Time period alloted
for completion
Nature of attention
Weekly/trip
(within 1500 km)
Trip 1 hr Weekly or trip inspection
15 days Fortnightly 1 to 2 hrs Fortnight inspection
Monthly IA 2 hrs Incidental inspection
Two months IB 8 hrs Complete/partial inspection
Four months IC 8 hrs Complete inspection
Every third IC AOH 16 hrs Annual inspection
At 300,000 km or
after 3 years
IDH 15 days General inspection or intermediate
overhauling
At 600,000 km or
after 6 years
POH 30 days Through overhauling or periodical
overhauling
The frequency and duration of the various schedules are defined after considering the
failure of several trains, the presence of indigenous parts, and the air and dust temperatures
in the country have been considered. Compared to steam and diesel trains, electric trains
include more contacts, relays, and appliances / equipment. Electrical values and changes
in the locomotive state are not physically visible. Therefore, it is important to check
equipment, contacts, and relays periodically to determine the condition of various
equipment without much disruption. Most machines are tested during a four- month test,
therefore, these devices are not included in the annual test. During such inspections,
equipment is disconnected from mechanical equipment, assemblies are stripped and
cleaned, and worn or damaged parts are replaced and reconnected.

62
Travel or weekly or bi-weekly assessments are conducted in outdoor work areas, and all
other schedule assessments, with the exception of POH, are conducted in sheds. POH,
however, is practiced in workshops.
Rolling Stocks
Rolling stock includes locomotives, passenger coaches, goods wagons, and all other
types of coaches & wagons such as electric multiple units (EMUs), diesel rail cars, and
special wagons such as BOX wagons. This section gives some of the details of
passenger coaches and goods wagons.
Classification of railways locomotives
Pakistan Railways classifies locomotives according to horse power, and each locomotive
has its own code number assigned by P.R.
Following is a list of locomotives, along with their numbers.
3000 H.P V-type 16 cylinders’ locomotives
8200 two stroke engine • 4700 two stroke engine • 6000 two stroke engine • 6100 two
stroke engine
2000 H.P V-type 12 cylinders’ locomotives
5001 four stroke engine • 4800 four stroke engine • 4000 two stroke engine • 8000 four
stroke engine • 6200 two stroke engine
1200 H.P V-type 6 cylinders’ locomotive
EMD 645
The EMD 645 is a diesel engine series developed and built by General Motors' Electro
Motive Division. One 16-cylinder v type engine was included in the 645 series, which
was designed primarily for locomotive, marine, and stationary engine applications

64
ENGINE CONTROL UNIT
In the Power Device Section, the Engine Control Unit (ECU) is available (PDC). The
ECU is in charge of the diesel engine under various conditions. When required or ordered
by an engine management system, the ECU also protects the diesel engine from serious
damage by using speed protection and power reduction.
The key functions of the ECU are as follows
 Engine speed control
 Acceleration and reduction of the limit
 High fuel limit
 Engine mode control (screaming, running, shutting down, idleness, suspension,
stopping and over speed)
 Favorite speed of engine protection, overcrowding, smoke, low oil pressure and
low water pressure)
 Time management
Diagnosis.
If certain engine parameters are found outside of the Locomotive Diesel and are
operational, the ECU monitors and detects them. The diesel train is an independent electric
train. Diesel trains operate on the same basis as electric trains in that the crank shaft of a
diesel engine rotates the alternator. They also have electric drive in the form of traction
motors that drive axles and are controlled by electronic controls. Many auxiliary train
systems for cooling, lighting, heating, and braking are also available. It can be called by
the same people. The power station is made up of a large diesel engine and an alternator
that produces the required electricity. A capacity of 1000 liters of fuel is required. Because
a diesel engine cannot pull a train without a large number of gears and collision losses, it
is not possible to drive a train without the use of electric motors. Pakistani railways use
trains.
LOCOMOTIVE EVERSPEED
If the train exceeds the maximum allowable speed (122 kph), a Penalty brake application
is initiated until the train speed is sufficiently reduced.
Problems Encountered

65
Following Problems, we face in this shops are:
 Not properly doing scheduling of the engines
 Not properly welded of the battery racks (where batteries are fitted inside the
locomotives)
 If it is not properly welded, then battery is not working properly or not be fitted.
 Not proper Levelling of the Beam facing problem
Problems Solving
 In-time scheduling maintenance of the engines.
 Proper welded of the Battery racks
 Proper Levelling of I beam under manufacturing methods.
How Productivity can enhance in a given system
The Pakistan Railways workshop is a very useful organization. One of the best and most
profitable things is that the workshop is completely independent. It does not require any
external vendor or product. This section is full of the power of the Railway Workshop.
The main motivation for the train workshop is to maintain the train, doing its maintenance
from time to time. The organization does its job very well but in a very old way. In the
process of increasing productivity, there are some points raised,
Time management and team communication are very important in all areas. Rail systems
are good but need some upgrades to improve their production and craftsmanship.
The workplace has a very large working and production space as well. Manufacturing
stores such as forging, blacksmith, spring and casting shop. It can be used for external
projects and components. This can increase their profits and popularity.
Productivity can be improved by making a careful assessment of your company’s
(Pakistan Railway) greatest productivity challenges.
For example: High productivity ensures low production costs, high productivity and
efficient use of available resources. The concept of production is gaining popularity
among manufacturers, workers, and consumers.

66
Quality Management system in PR
The quality management system of the Pakistan Railway workshop is excellent. The
workshop has ISO 9001: 2008, which means that the performance is perfectly standard.
They use old techniques but they work to the fullest. They have a proper testing and
evaluation system. This can be further developed through the use of modern techniques.
Safety at Work
The Pakistan Railway workshop is not following any OSHA rules and other safety
procedures. Workers working in during welded without using any helmet and proper
gloves.
In this shop they are not sun glasses for workers to prevent the eyes from metal chips.
There is no fire extinguishers and emergency exit in the rehabilitation shop
Workers are working without safety shoes and gloves.
many their points that can cause of harm of persons and the property also. The safety at
work is very important.
Work Experience in Rehabilitation shop
The main task of the rehabilitation shop is to repair or rehab damaged locomotives so that
they may be used again. We work with Mr. Mansoor, the foreman, who informs us about
all of the primary functions of the rehabilitation shop and its sections. We also visit some
of the accident locomotives and study the locomotive engine's traction motor and cooling
system. We see how they separate the locomotive's pivots from its bogie and elevate the
locomotive's body using a 40-ton horizontal puller crane before resting it on ground fixed
jacks.

67
4.2.2 Diesel Classified Repair Shop
Diesel Classified Repair Shop C.C. 7026
This workshop was about the repairing, mending and over allying of an entire Diesel
Engine along with its corresponding systems. As our project with China also contained
the over allying procedure of their Engines along with bringing new ones. China Engine
needs a complete over allying procedure at least after 3 years in order to meet the proper
running condition of the engine. Chinese were called upon the site for this process.
Diesel classified shop
The responsibility of diesel classified work shop is overhauling of all locomotives of
Pakistan Railways after every 5 years. In diesel classified shop there are different section
that perform preventive maintenance of different parts.
Figure 22 Engine Overhauling

68
Diesel locomotive
A diesel locomotive is a type of railway locomotive in which the prime mover is a diesel
engine. Several types of diesel locomotive have been developed, differing mainly in the
means by which mechanical power is conveyed to the driving wheels.
Figure 24 Diesel Injection Pump
Figure 23 Specification of Engine

69
4.2.2.1 SECTIONS OF DIESEL CLASSIFIED
 There are following sections of diesel classified shop. Each section performs its
respective operation.
 The Power Assembly Section
 Nozzle Section
 Crank Shaft Section
 Radiator Section
 Electric Section
 Engine Governors Section
Schedule of maintenance
Each of these locomotives having different class of power range from 1500HP to 3000HP,
but now Pakistan railway adds a new class of locomotives which having power up to 4000
HP known as (GE-40) Purchased from US America. Most of these locomotives are 4
stroke diesel enginess and GMCU-15 is only a 2 stroke diesel engines.
Figure 25 Schedule Maintenance
Supervisory Work in Diesel Shop Types of Diesel Engine
Diesel engine is divided into two types
 Vertical engine

70
 V-type engine
 Vertical engine
In this types the engine is fitted in the verticle direction. Each connecting rod is clamp
with a separate journal. These engines are:
ALCO-95 6 cylinder four stroke
ALCO-12 6 cylinder four stroke
HAU-10 6 cylinder four stroke
V-type engine
The cylinder of these engines are mounting on a same journal like v shape at a angle of
45 degree.
Following engines are v-type engine
1. AG-30
GMU-30
ALU-24
ZCU-30
Parts of diesel engine
Diesel engine is consist on following parts
 Crank Case
 Cylinder block
 Crank Case motor
 Crank shaft
 Connecting rod
 Main bearing
 Piston and piston rings
 Cam shaft

71
Parts of Locomotive
There are the several different parts of Locomotive as given below and demonstrated in
given below figure:
 Diesel Engine
 Lubricating System
 Main Generator
 Battery
 Cooling System
 Air Compressor
 Compressed-air reservoir
 Sandbox
 Ventilator
 Radiator
 Air Filter
 Fuel tank of the engine
 Dynamic Brake
 Driver’s Car

72
Barriers to Learning in the Locomotive Cabinet
 The driver of Locomotive noted the following readings to ensure the proper
working of the Pakistan Railway Trains
 Pressure Gage (brake)
 Pressure Gage (cylinder)
 Status Indicator
 Unloaded, Total overflow, Grounding, Aux Convertor Cabinet Fault
 The water level is too low
 Alarming diesel engine
 Computer alarming
 Self-load
 Too much low brake pipe pressure
 Compressor is running
 R brake alarming
 Sliding of wheel
 Engine speed
 Accu. generator voltage
 Current/active main generator
 Main generator voltage
Here are some of the things that cause a functioning engine to stumble / stop working if
they are not notified. Therefore, they should be regularly inspected to ensure the proper
operation of the Engine. In addition, the driver sitting in the cupboard also recognizes
these limitations in his journey. These features are provided below:
Coolant temp
 Lubricating oil pressure Fuel Capacity

73
Maintenance of a Locomotive is a complete job. Here, is a table in which there is a
complete schedule of its inspection, time taken to complete and the parameter which are
inspected during this process.Project Carried out in Diesel Classified Shop Loco
Inspection and Maintenance Schedule

76
4.2.3 Project Carried Out Dismantling of Locomotive
After the train was delivered, for the first time, the nut bolts connected to the body and the
trucks were opened. Then the locomotive body is lifted and the bogies are separated. The
body of the train is lifted over the stand and trucks are dismantled. The motor breaks the
wheels and is sent to a rear shop for engine repairs. Separate the train wheels and send
them to the tire shop for equipment and testing inspectin
Figure 26 Dismantling of Engine
The responsibility of the diesel classified workshop is overhauling all locomotives of
Pakistan Railways after every 5 years. 5 different sections are working for diesel
classified.
 Power assembly section.
 Nozzle, fuel Injection & pump section.
 Governor section.
 Electrical section.
 Air compression section.
 Bogie assembly section

77
LUBRICATING SYSTEM
One branch line from the lubricating
system of the
engine is connected to the turbo
supercharger. Oil from the lube oils
system circulated through the turbo
supercharger for lubrication of its
bearings. After the lubrication is over,
the oil returns to the lube oil system
through a return pipe. Oil seals are
provided on both the turbine and blower
ends of the bearings to prevent oil
leakage to
the blower or the turbine housing.
Engine Fuel injectors
Diesel fuel from the injection pump enters the mechanical injector body and starts to build
pressure. Once the pressure is high enough
(about 4,000 psi), a check valve in the
injector is lifted off its seat, and fuel sprays
through. Diesel fuel injectors are quite
complicated; the injector has a high micron
filter on the top inlet side which
corresponds to small hypodermic-sized
holes on the bottom for the atomizing of
the diesel fuel.
Traction motor
Traction motors are powered by electricity and generate the power to rotate the wheels
of the train. The turning force produced by traction motors is transmitted to the wheels
via the driving gear unit and axle. Traction motors are typically mounted in the trucks
where the wheels are housed.
Figure 28 Injection System
Figure 27 Lubrication System

78
Cooling system of PR Loco
A locomotive radiator system primarily cools the air, water, and oil. The air is used in
the combustion process; the water for cooling the engine and turbo (if equipped); and oil
for lubricating the engine components.
Figure 29 Traction Motor
Figure 30 Cooling System Of generator

79
Prime Mover
The combustion of diesel fuel pushes pistons connected to an electric generator. The effect
of electric power on engines connected to train wheels. The internal combustion engine
“diesel” uses heat generated by air pressure during high-stroke cycles to fuel system
Locomotive and Diesel Engine Parts
 Wheel for Locomotives Pistons
 Piston Connection Rod
 Piston Assembly
 Piston Ring
 Engine Bearing
 Crankshaft Exhaust
 Valve Engine
 Gears
 Fuel Injectors
Figure 37 Prime Mover
Figure 31 Locomotive Part

80
Bogie assembly section
Loco is offered a bogie made. This is a three-dimensional, two-phase suspension with
helical coil springs in the first phase and rubber springs for the second phase suspension
and a pivot of the middle floating type pivot. The bogie frame will be made of a type of
construction box, made from steel plate to IS.2062 grade C.
The body weight of the train car is transferred directly to the bogie frame through the four
"Rubber" "Compression" spring assemblies. The bogie frame is supported by a “soft
basic” suspension consisting of eight pairs of helical coil springs (inside and outside). Two
springs are included in each scale, providing ride quality and balance of tire loads.
Figure 38 Assembly Section
Figure 39 Boggie System

81
Supervisory works in Diesel Shop
 I am working is this shop under the supervision of Sir Zahid who is the Chargemen
in the
 Diesel Classified Workshops. They guide me through my internship period which
I spend in diesel shop are:
 Visualize inspection of Diesel Locomotives
 Locomotives Overhauling
 Checking and inspection of Diesel Engine Parts
 Dismantling of Locomotives
 Testing of Traction Motor
 Locomotives for overhauling
Periodic and accidental maintenance of locomotives
Wheel Assembly
This is the part of a rake that is just adjacent to the tracks. It consists of four main parts:
 Axle
 Wheel
 Bearing and Housing
Components Of Axle And Wheel Assembly
 Two brake disks (4), diameter 640 mm and width 110 mm.
 Inbuilt slack adjusting brake cylinder fitted
 Two-wheel disc of tread die 915 (New), 845(worn).
Figure 32 Maintenance Chart

82
Wheels Dismounting Machine
Railteco's Type A Wheelset Press-Fitting (Mounting, Assembly, or Charging) Machine is
used for the unloading and assembling wheels, brake discs, and gear wheels. It can be
used on the passenger cas, wagons, electric multiple units, and city rails vehicles
Figure 34 Wheel Dismantling Machine
Hand on skills in Diesel Shop
 During this test we can get the following indicators for different measuring tests
and get the different testing results:
 We can check Bubbling test of wheel with the help of it.
 Grease or oil leakage
 We can check the temperature of traction motor during testing with the help of
temperature meter.
Figure 33 Wheel Testing Machine

83
 Temp test (should be atmospheric temp add 20+ to atmospheric temp). if the temp
is 20 meaning is that add 10 into 20=30
 We can check noise test during this process.
 We can get 450 rpm in this motor during testing.
 After one year of motor working the motor is dried then we repair it after 1 year
 Note: During this whole testing the maximum voltage is 130
 Note; During this whole method maximum amperes is 80
 Note: During this whole process. A hold type chemical is used to grips the nut
threads in this motor.
Problems facing
During the working in diesel shop we face many problems are:
Not excessive use of silicon during traction motor testing using inside the traction motor
facing problems.
Not properly welding of the center pivot if it is not properly welded and well finishing it
not properly fits in its position and if it is not fits its position train cannot move certain
and proper required amount of degree 60 because its helps to move the trains left or right.
Not properly using of the mega meter.
Problems Solving
Use required amount of silicon during testing according to the manufacturing
specifications
Properly welding and finishing of center pivots.
Properly use of mega meter (before using this meter adjust their difference which is zero).

84
How the productivity can be further enhanced in diesel shop?
Pakistan Railways workshop is very practical organization. The one of best and profitable
thing is that the workshop is totally independent. It does not need any external vendor or
productivity. This part is very power full for Railway Workshop. The main motive of
railway workshop is to maintain the locomotive, do their periodic maintenance. The
organization is doing their work very well but in very old technique way. In the way to
increase the productivity, there is some suggested points,
By using the modern equipment and techniques. For example, in the engine block shop
they
still using old telescope for the scoping and alignment. By using modern laser and
graphical techniques, the time and money both can save.
Time management and team coordination is very important in every field. The systems in
railway is good but need some improvement to enhanced their production and creativity.
The productions shops like forging, blacksmith, spring and casting shop. Can be used for
making external projects and parts. This can increase their profit and their popularity.
Quality management
Quality management system of Pakistan Railway workshop is very good. The workshop
has ISO 9001:2008, which means that the working is totally on standard.
They are using old techniques but working with complete standard. They have the proper
inspection and checking system. This can be further increase by applying modern
techniques.
Safety at work
In this shop they are not sun glasses for workers to prevent the eyes from metal chips
during welding or finishing
There is no fire extinguishers and emergency exit in the diesel shop
Workers are working without any safety shoes and gloves.

85
Many other points that can cause of harm of persons and the property also. The safety at
work is very important.
My Work Experience in Diesel Shop
My Work Experience I Supervised different repairing and testing sections in diesel
classified shop. I examine traction motor load testing. Firstly, they fill up the bogie wheel
and its fitting case with high quality grease. And then they run the motor at different load
and speed for specific time to check its vibration or any kind of leakage

86
4.2.4 Machine Shop
In this shop worked on mass production. Here marking and machining of different parts
of coaches and wagons. This shop has 5 different sections that’s work together and
machined lot of parts in a day.
The sections shown below:
 Marking Section
 CPL (Capstan Lath Section)
 CL (Center Lath Section)
 Press Section
 Drill Section
In the machine shop following machines are used to make the different parts like nuts,
bolts and caps.
 Lathe machine
 Milling machine
Project Carried Out in Tool Shop
Figure 42 CLP Laathe
Figure 35 Drill MAchine

87
Types of Lathe Machines
Lathe machine has other many types
 Centre Lathe
 Capstan Lathe
 Bench Lathe
 Turret Lathe
Centre Lathe
Center Lathe is used to make cylindrical shapes from a variety of materials including;
metals and plastics. Many of the components that go into making an engine work have
their own are built using lathes. These may be labels for direct human use (handmade
lathes)or computer-controlled lathes (CNC machines) designed to perform a specific task.
The basic institutional lathe is shown below. This type of lathe is controlled by a convert
various handles on the top slide and cut the slide to make a product / component.
Figure 36Lathe Machine

88
Bench Lathe
Lathe mounted on a workbench. lathe - machine tool for shaping metal or wood; the work
piece turns about a horizontal axis against a fixed tool.
Turret Lathe
The turret lathe is a form of metalworking lathe that is used for repetitive production of
duplicate parts, which by the nature of their cutting process are usually interchangeable.
It evolved from earlier lathes with the addition of the turret, which is an index able tool
holder that allows multiple cutting operations to be performed, each with a different
cutting tool, in easy, rapid succession, with no need for the operator to perform set-up
tasks in between, such as installing or uninstalling tools, nor to control the toolpath. The
latter is due to the toolpath's being controlled by the machine, either in jig-like fashion
via the mechanical limits placed on it by the turret's slide and stops, or via electronically-
directed servomechanisms for computer numerical control lathes.
Figure 37 Bench Lathe

89
Capstan Lathe
A capstan machine is a processing machine used to make the same parts again and again.
The cutting bits are mounted on a rotatable turret known as a capstan, which permits the
client to rapidly change the introduction of the bits for slicing without needing to take off
the first bit and afterward mount the second. A bit of crude material, off and on again
known as a clear, is mounted into the capstan machine and is then spun at high velocity.
The cutting apparatuses, some of the time known as blades, are then used to slice into the
clear to make another shape or outline.
Specifications
 Swing
 Distance between centers
 Length of bed
 Radius (one of swing)
Operations on Lathe Machine
 Turning
Figure 38 Turret Lathe

90
 Facing
 Boring
 Drilling
 Threading
 Knurling
Milling Machine
Milling is the machining process of using rotary cutters to remove material from a
workpiece by advancing (or feeding) in a direction at an angle with the axis of the tool. It
covers a wide variety of different operations and machines, on scales from small
individual parts to large, heavy-duty gang milling operations. It is one of the most
commonly used processes in industry and machine shops today for machining parts to
precise sizes and shapes.
Figure 39 Turet Lathe

91
Milling can be done with a wide range of machine tools. The original class of machine
tools for milling was the milling machine (often called a mill). After the advent of
computer numerical control (CNC), milling machines evolved into machining centers
(milling machines with automatic tool changers, tool magazines or carousels, CNC
control, coolant systems, and enclosures), generally classified as vertical machining
centers (VMCs) and horizontal machining centers (HMCs). The integration of milling into
turning environments and of turning into milling environments, begun with live tooling
for lathes and the occasional use of mills for turning operations, led to a new class of
machine tools, multitasking machines (MTMs), which are purpose-built to provide for a
default machining strategy of using any combination of milling and turning within the
same work envelope.
Types of Milling Machine
There are three types of milling machine
 Vertical Milling
 Horizontal Milling
 Universal Milling
 Vertical Milling
In the vertical mill the spindle axis is vertically oriented. Milling cutters are held in the
spindle and rotate on its axis. The spindle can generally be extended (or the table can be
raised/lowered, giving the same effect), allowing plunge
cuts and drilling. There are two subcategories of vertical
mills: the bed mill and the turret mill.
A turret mill has a stationary spindle and the table is moved
both perpendicular and parallel to the spindle axis to
accomplish cutting. The most common example of this
type is the Bridgeport, described below. Turret mills often
have a quill which allows the milling cutter to be raised and
lowered in a manner similar to a drill press. This type of
machine provides two methods of cutting in the vertical (Z)
direction: by raising or lowering the quill, and by moving
the knee
Figure 40 Vertical Miling

92
In the bed mill, however, the table moves only perpendicular to the spindle's axis, while
the spindle itself moves parallel to its own axis
Horizontal Milling Machine
A horizontal mill has the same sort but the cutters are mounted on a horizontal spindle
(see Arbor milling) across the table. Many horizontal mills also feature a built-in rotary
table that allows milling at various angles; this feature is called a universal table. While
end mills and the other types of tools available to a vertical mill may be used in a
horizontal mill, their real advantage lies in arbor-mounted cutters, called side and face
mills, which have a cross section rather like a circular saw, but are generally wider and
smaller in diameter. Because the cutters have good support from the arbor and have a
larger cross-sectional area than an end mill, quite heavy cuts can be taken enabling rapid
material removal rates. These are used to mill grooves and slots. Plain mills are used to
shape flat surfaces. Several cutters may be ganged together on the arbor to mill a complex
shape of slots and planes. Special cutters can also cut grooves, bevels, radii, or indeed any
section desired. These specialty cutters tend to be expensive. Simplex mills have one
spindle, and duplex mills have two. It is also easier to cut gears on a horizontal mill. Some
horizontal milling machines are equipped with a power-take-off provision on the table.
This allows the table feed to be synchronized to a rotary fixture, enabling the milling of
spiral features such as hypoid gears.
Figure 41 Horizontal Milling

93
Universal Milling Machine
The universal machine can be fitted with various attachments such as the indexing fixture,
rotary table, slotting and rack cutting attachments, and various special fixtures The basic
difference between a universal horizontal milling machine and a plain horizontal milling
machine is the
addition of a table swivel housing between the table and the saddle of the universal
machine. This permits the table to swing up to 45° in either direction for angular and
helical milling operations.
Milling Cutters
 Plain milling cutter
 Side milling cutter
 Form milling cutter
 End milling cutter
 Face milling cutter
 T-slot cutters
 Shaper Machine
A shaper is a type of machine tool that uses linear relative motion between the work piece
and a single-point cutting tool to machine a linear tool path. Its cut is
analogous to that of a lathe, except that it is (archetypal) linear instead of helical.
A wood shaper is a similar woodworking tool, typically with a powered rotating cutting
head and manually fed work piece, usually known simply as a shaper in North America
and spindle molder in the UK.
A metalworking shaper is somewhat analogous to a metalworking planer, with the cutter
riding a ram that moves relative to a stationary work piece, rather than the work piece
moving beneath the cutter. The ram is typically actuated by a mechanical crank inside the
column, though hydraulically actuated shapers are increasingly used. Adding axes of
motion to a shaper can yield helical tool paths, as also done in helical planning
Figure 42 Miling Cutter

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