The document details a presentation by students from JK Lakshmipat University about their practical training at the Carriage and Wagon Repair Workshop in New Bongaigaon, Assam, focusing on various repair and maintenance activities for railway coaches and wagons. Key areas covered include wheel repair, manufacturing processes, and preventive maintenance, along with descriptions of specific machinery used such as lathes and slotting machines. The document also addresses corrosion issues in coaches and current measures taken to prevent it.

1. PS 1 FINAL PRESENTATION
Prepared By: Pramit Kumar Munshi (2013BtechMe027)
Rajesh Kumar Sah (2013BtechMe033)
Diptanshu Keshote (2013BtechMe008)
JK Lakshmipat University

2.  For our Practice School-1, we went to Carriage and Wagon Repair Workshop, New
Bongaigaon, Assam.
 It is an Indian state owned enterprise, owned and operated by the government of
India through the Ministry of Railways.
 We were assigned to Wheel Repair Shop, Machine Shop, Bogie Repair Shop,
Carriage Lifting Shop and Corrosion Repair Shop.
JK Lakshmipat University

3. COACH
 POH (Periodic Overhauling) of BG AC, Non-AC and DEMU Coaches.
 Repair of Accident involved damaged Coaches and Special Repair Coaches.
 Modification as recommended by Railway Board & RDSO to improve the
reliability of safety and better passenger’s amenities.
 Rehabilitation of BG Coaches.
 Conversion of conventional air brake coaches to Bogie Mounted Air Brake coaches.
JK Lakshmipat University

4. WAGON
 POH of BTPN, all types of BCN Wagons, DBKM, BRN, BOBYN and Brake Van.
MANUFACTURING & REPAIRING
 Manufacturing and fabrication of components and subassemblies of BG Coach and
Wagon.
 Manufacturing of new wheel set for BG & NG Coaches.
 Heat treatment, reclamation and testing of critical safety items like screw
coupling, suspension system, draw gear equipment and testing of chain and Rope.
 Shot Blasting, Magnaflux testing to detect crack and load testing of all types of
C&W springs.
 Phosphating of In-house manufactured component like Long beam, Bottom side
wall sheet etc.
JK Lakshmipat University

5. METALLURGICAL & CHEMICAL LABORTORY
 Non-destructive testing including ultrasonic testing of axles & wheels.
 Hardness testing of wheel.
 Chemical analysis, micro & macro analysis and physical testing of ferrous and
non-ferrous components and materials.
 Testing of oils, paints, lubricant, varnishes, coal etc.
MAINTENANCE
 The workshop undertakes in house preventive maintenance and brake down
attention of machinery, plants and equipment both for Electrical and Mechanical.
 Power supply for workshop and colony.
JK Lakshmipat University

6. Wheel Turning Shop
JK Lakshmipat University

7.  Train Wheels have a conical geometry, which is the primary means of keeping the train’s motion aligned
with the track.
 Train wheels have a flange on one side to keep the wheels, and hence the train keeps running on the rails,
when the limits of the geometry based alignment are reached.
JK Lakshmipat University

8. JK Lakshmipat University
Why Conical Train Wheels?
The conical shape allows the wheels to shift and slide across the tracks, thus
effectively varying their radii and allowing them to cover different distances
while rotating at the same angular velocity.

9. JK Lakshmipat University

10. Machines used in Wheel Turning Shop
 Wheel Turning Lathe
 CNC Wheel press machine
 Vertical Turret Lathe.
JK Lakshmipat University

11. Wheel Turning Lathe
 A lathe machine for turning wheel set having a common
axis, comprising two headstock fitted with one four jaw
hydraulic chuck on each headstock.
 It has two tool posts for holding two tools for turning the
two disc on the wheel set simultaneously.
 It has two control panels which facilitates to control the
two tool post separately. The machine is hydraulically
operated.
 Work done: Turning of wheel set.
 Tool used: Carbide tip tool.
JK Lakshmipat University

12. Wheel Press Machine
 It is used for removing wheels that are already fitted to axles and also for fitting wheels in axles, whose
wheel seat diameter is greater than wheel bore diameter.
 For different axle types different force for pressing is needed.
 Work done: Demounting of disc from axles.
JK Lakshmipat University

13. Vertical Turret Lathe:
Vertical Turret Lathe is one which allows the headstock to seat on the floor and the face plate to become a
horizontal rotating table, analogous to a huge potter’s wheel.
Here the rotating table are bigger in size to hold the disc of all size of the wheel set.
It has the facility of Programmable Logic Control (PLC).
Work done: Boring of bore diameter on the wheel disc.
Tool used: Square tip tool.
JK Lakshmipat University

14. MACHINE SHOP
JK Lakshmipat University

15. Machines used in Machine Shop
 Vertical lathe / Boring Machine
 Centre Lathe
 Slotting Machine
 Shaper Machine
JK Lakshmipat University

16. Vertical Lathe/ Boring Machine
 Vertical Lathe is one which allows the headstock to seat on the floor
and the face plate to become a horizontal rotating table, analogous to
a huge potter’s wheel.
 This is useful for the handling of large, heavy, short work pieces.
 Work done: Turning of face plate of the buffer body plunger.
 Tools used: Side cutting tool, V-tool and Square tool.
JK Lakshmipat University

17. Centre Lathe
 The centre lathe is used to manufacture cylindrical shapes from a
range of materials, including steels and plastics.
 This lathes may be operated directly by people (manual lathes) or
computer control lathes (CNC) that have been programmed to carry
out a particular task.
 Work done: Thread cutting.
 Tool used: Side cutting tool
JK Lakshmipat University

18. Slotting Machine
 A reciprocating machine in which the ram holding the tool reciprocates in the
vertical axis and the cutting action of the tool is only during the downward stroke.
It is also known as vertical axis shaper.
The work piece that cannot be held conveniently in shaper can be machined in
slotting machine.
The stroke of the ram is smaller in slotting machine than in shaper.
Work done: Machining of equalizing beam i.e. to flatten the two adjacent sides at
the end of the equalizing beam.
Tool used: Bottom tool.
JK Lakshmipat University

19. JK Lakshmipat University

20. Shaper Machine
In this machine the tool is clamped to the tool post mounted to a dapper
box which in turn is mounted to a reciprocating ram.
The ram, while under taking the cutting stroke, pushes the cutting tool
through the work piece to remove the material. Here the quick return
mechanism is employed.
Work done: Making of centre pin cross cutter by radius tool.
Tool used: Radius tool.
JK Lakshmipat University

21. BOGIE REPAIR SHOP
JK Lakshmipat University

22. BOGIE
A bogie is a wheeled wagon or trolley. In mechanics
terms, a bogie is a chassis or framework carrying
wheels, attached to a vehicle, thus serving as a modular
sub assembly of wheels and axels.
Parts Of Bogie:
Bogie Frame
Brake Equipment
Axle Box Suspension
Transmission
JK Lakshmipat University

23. THE BOGIE FRAME
 This can be of inside frame type where the main frame and bearings are between the wheels, or (more
commonly) of outside frame type where the main frame and bearings are outside the wheels.
JK Lakshmipat University

24. AXLE BOX SUSPENSION
Absorbs shocks between the axle bearings and the bogie frame. The axle box suspension usually consists of a
spring between the bogie frame and axle bearings to permit up-and-down movement, and sliders to prevent
lateral movement.
JK Lakshmipat University

25. POWER TRANSMISSION
JK Lakshmipat University

26. CARRIAGE LIFTING SHOP
JK Lakshmipat University

27. Lifting of Coach Body:
In this shop the body is separated from the bogie. This can be done only when the connecting pipes and the
lighting wires are disconnected or cut out from the bogie to the body.
Before lifting following components are removed and disengaged:
 Dynamo belt
 Brake pull rod
 Lavatory chute
 Centre pivot of cotter nut
 Air vent screws on bogie frame
JK Lakshmipat University

28. Corrosion Repair Shop
JK Lakshmipat University

29. Causes of Corrosion in Indian Railway Coaches:
Water seepage through the flooring to the top of trough floor.
Leakage of water through lavatory flooring.
Defective water pipe fittings.
Flushing the flooring with the water jet for cleaning.
The design of the window seal leaves the gap between the side panel to allow the rain
water flow through the panel and to drain out at the bottom.
JK Lakshmipat University

30. Area subjected to High Rate of Corrosion in Coaches
Body pillar: Bottom portion of pillar near doorways and
lavatory area.
Cross bearer : Joint between sole bar.
JK Lakshmipat University

31. Train Roof : Generally occurs due to Rain water.
 Trough floor : Adjacent to wash basin and lavatory
JK Lakshmipat University

32. Head stock: Outer head stock and tubular sections are
heavily corroded due to lavatory.
Battery box : Corrosion due to acid action
JK Lakshmipat University

33. Existing System
At present high carbon steels are not used for structural work due to its lack of ductility and weld ability.
To prevent corrosion, IRS M-41/97 steels are used which have high ductility, yield strength and weld ability.
These steels have good atmospheric corrosion resistance.
In order to Overcome Corrosion, the following steps are used:
 Improve surface coating
 Corrosion prevention design adapted
JK Lakshmipat University

34. JK Lakshmipat University