INTEGRAL UNIVERSITY

DEPARTMENT OF MECHANICAL ENGINEERING

LUCKNOW

One month Industrial Training atBharat Wagon & Engineering Corporation limited(Govt. of india undertaking-ministry of Railway)

Training Period: June 02 to June 29

Belal Bin Neyaz (1200116029)

PERSENTATION ON

PRESENTED BY:

BWECLMUZAFFARPUR, BIHAR

• COMPANY PROFILE• RAW MATERIAL• ORGANISATIONAL STRUCTURE• PRESS & SMITHY SHOP• CUTTING & WELDING SHOP• DRILLING SHOP• MACHINE SHOP• FOUNDRY SHOP• TEMPLATE SHOP• WAGON ASSEMBLY SHOP• FINISHING SHOP• SCRAP & SCRAP MANAGEMENT

CONTENTS

COMPANY’S PROFILE Bharat Wagon is an engineering Industry commanding very good reputation and having decades of experience with two manufacturing units in Mokama & Muzaffarpur in the state of

Bihar. Its both units have been accredited with ISO-9001:2000 Quality management System Standards for manufacturing of wagons. The product profile of Bharat Wagons and the enriched experience reveal the credibility of the company and the capability of skilled personnel that have brought laurels to the

organization.

The wagons are catered to the Indian Railways and Ministry of Defence. Some special purpose wagons

are also produced according to specific customer requirements. The unit at Muzaffarpur is equipped to produce both Broad gauge and Metre gauge units. In

addition to railway wagons the unit is capable of producing all relevant wagon components. BWEL

diversified into turnkey project in 1979 as part of its diversification strategy and a separate Project Division was set up in 1995. This division has

successfully executed a number of turnkey projects.

COMPANY’S PROFILE

Raw materials in wagon manufacturing can be

broadly divided into two categories: (a) DM components, being components, which

are inspected by the RDSO before they are supplied to BWEL and

(b) Non-DM components, being low value components, which are the procured locally and do

not require RDSO inspection.

RAW MATERIALS

• Common DM components include steel, coupler sets, air brake equipment, air brake pipe, wheel sets, slack adjuster, nylon bush, door check spring, bearing, twist lock, draw gear (quick draw) and draw bar.

Principal raw materials are flat steel products, such as steel plates. They normally source their entire requirement from suppliers such as SAIL and TISCO.

They have an arrangement with komatsu Mining Germany (Demag) for supply of components and spares. They import components such as hydraulics and gear boxes from komatsu Mining Germany, Rexroth, Carraro and also several other reputed companies in India and abroad.

RAW MATERIALS

• Bharat Wagon and Engineering Company Limited is divided into following department :-

• (i) Personnel Department - The personnel department is hereby in charged (Personnel and Administration) assistant who is also looking after the job of welfare officer.

• (ii) Finance Department – Finance department is headed by a Manager (finance). The work of finance department is to fix the price of the product by costing methods and other allied works related to the employees for which they are entitled.

• (iii) Stores and Purchase Department - Stores and purchase department is headed by Material Manager. The department conducts the supplies and purchase of all materials and products. This department receives the order for the supply of products.

• (iv) Work Department – Work department is headed by Deputy Manager (Works). The main function is to take care about wagon assembly, cutting and welding, Press and smithy, machine shop, finishing and painting shop.

• (v) Planning and Civil Department – Deputy Manager (planning and inspection) headed this department. The main function of the department is to get the civil work done and capital budgets etc.

ORGANISATIONAL STRUCTURE

1. Fabrication and assembling of railway goods. 2. Manufacturing of wagon components. Fabrication of component of railway bridges/ road bridges.

WORKS & PRODUCTION DEPARTMENT

The Function of the maintenance Dept. is as follow:• Mechanical Maintenance of all machineries and

equipments.• Electrical maintenance of all machineries and

equipments.• Vehicle maintenance.• Generator operations and maintenance.• Erection and commissioning of equipments.

MAINTAINANCE DEPARTMENT

• Material Department of Bharat Wagon & Engineering Company Limited, Muzaffarpur is very important as it is primarily intended to assist in the production, maintenance and other allied function of all departments in respect of

• To make available balance flow of raw materials components, equipments and other materials necessary to meet operational requirements.

• To provide maintenance of materials, spare parts and general stores as required.

MATERIAL DEPARTMEMT

• Open Type Freight Wagon (BOXN)• Covered Type Freight Wagon (BCNA)• Flat Type Freight Wagon (BRNA)

TYPES OF WAGONS MANUFACTURED

• BOXN – 8 Wheeler Broad Gauge Bogie Open Type Wagons fitted with Cast Steel Casnub Bogies, High Tensile Centre Buffer Couplers (NT) with single air brake system, Tare Wt. 22.47 MT,

Pay Load – 58.81 MT and Gross Load – 81.28 MT. • BRNA – 8 Wheeler Broad Gauge Flat Wagons with

fixed ends but fitted with single air brake, Casnub bogies and HT CBC coupler

• BCNA – 8 Wheeler Broad Gauge Bogie covered wagons fitted with cast Steel Casnub Bogie with Air Brake and CNC(NT) couplers

DESCRIPTION OF WAGONS

• PRESS & SMITHY SHOP• CUTTING & WELDING SHOP• DRILLING SHOP• MACHINING SHOP• FOUNDARY SHOP• WAGON ASSEMBLY SHOP• FINISHING SHOP

DIFFERENT SHOPS ENGAGED IN MANUFACTURING OF

WAGONS

• In this press and smithy shop there are seven open hearth furnaces where coal burns on the bed. On these famous various of parts are heated. The heated part is kept on the anvil with the help of hammer the required shape is formed. In this shop more than 50 components are manufactured :-

• Head Stock pressing• Anchor plate pressing• Anchor support pressing• Foot Step• Pull Road• Head Stock• Hand Wheel• Bolster etc.

PRESS & SMITHY SHOP

The press is metal forming machine tool designed to shape of cut metal tool by applying mechanical force or pressure. The metal is formed the desired shape without removal of clops. The presses are exclusively intended for mass production work and they present the fastest and most efficient way to form a sheet metal in a finishing products.

PRESS & SMITHY SHOP

As the name indicates this shop is mainly involved in cutting the plates of different thickness in the desired shape & size and in the profile cutting and welding them into components.

In the welding section mainly bolster and cross bars are manufactured.

CUTTING & WELDING SHOP

• List of machines involved in cutting & welding shop

• 1. Shearing Machine• 2. Cropping Shearing Machine• 3. Chipping Machine• 4. Profile Cutting Machine• 5. Kangaroo Machine

CUTTING & WELDING SHOP

• Shearing Machine :-On the shearing machine the to be cut should be flat & the thickness should not be more than 8 min. For cutting the flat plate is kept on the bed of the held of crane. The machine consists of a cutting blade & no. of pressing bolts press the plate and keep it rigidly fixed the downward movement of the cutting plate.

• Cropping Machine :-On the cropping machine number of works are performed. This machine can cut the flat plate of small sizes, angles, plates, square hollow rod & circular hollow rod. Also this machine can be used as punching machine.

• Chipping Machine :-This machine is use to produce an inclined shaped at end of plate which is necessary in the end to end welding. This machine has a gun through which high pressure air comes. This machine holds a chisel. The high-pressure air pushes the chisel. Which causes to cut the plate?

ABOUT MACHINES

• Profile Cutting Machine :-This machine consists of a vertical column and two horizontal arms. The one arm consists of the template and another arm consists of the welding torch and the small driving motor. This machine can cut the plate of thickness of 35 to 40 mm. Through the welding torch acetylene and oxygen gas is supplied. This machine requires extra amount of oxygen gas. So two oxygen pipes are connected to the torch. To cut the plate in the desired shape. The same shape template is fitted to the upper arm and the magnetic roller of the second i.e. lower arm is toughed to the template. The driving motor drives the torch. The torch moves through the profile of the template and plate cut in the desired shape.

• Kangaroo Machine :-One another plate cutting machine in this shop is Kangaroo Machine. This is the biggest cutting machine. This machine consists of two welding torch. The torch can move in all the three coordinate axis i.e. X,Y and Z axis. This is fully electronic controlled machine. This machine consists of an electronic sensor and a horizontal plate. The drawing of the required shape is kept on the horizontal plate and the sensor moves through the black lines of the drawing this machine can be moved manually. The amount of acetylene and oxygen gas can be controlled with the knobs.

ABOUT MACHINES

The drilling machine is one of the most important machine tools in a workshop. As regards its importance it is second only to the lathe. Although it was primarily designed to originate a hole, it can perform a number of similar operations. In drilling machines holes may be drilled quickly and at a low cost. The hole is generated by the rotating edge of a cutting tool known as the drill which exerts a large force on the work clamped on the table. As the machine tool exerts vertical pressure to originate a hole it is loosely called a “drill press”.

DRILLING SHOP

• RADIAL DRILLIGN MACHINE :-The radial drilling machine is indented for drilling medium to large and heavy work pieces. The machine consists of a heavy, round, vertical coulomb mounted on a large base. The column supports a radial arm which can be raised and lowered to accommodate work piece of different bights. The arm may be swung around to any position over the work bed. The drill head containing mechanism for rotating and feeding the drill is mounted on a radial arm and can be moved horizontally on the guide ways and clamped at any desired position. These three movements in a radial drilling machine when combined together permit the drill to be located at any desired point on large work piece for drilling the hole. When several holes are drilled on a drilled on provide guide ways on which the drill head may be made to slide. The arm may be swage bound the column. In some machine this movement is controlled by separates motor.

• Drill head :- The drill head mounted on the radial arm and drives the drill spindle . It encloses an the mechanism for driving the drill at multiple speeds and at different feed. At the mechanisms and control are may be made to slide on the guide ways of the arm for adjusting the position of drill spindle with respect to the work. After the spindle has been properly adjusted in position the drill head is clamped on the radial arm.

ABOUT MACHINES

• Universal Drilling Machine :- It is one of the important drilling machine. This drilling machine can produce a hole any direction at any angle. The universal drilling machine consists of a vertical i.e. horizontally, vertically and at any inclination. The drilling can be done by automatic feed mechanism and by manual operation.

• Semi Universal radial drilling machine :- It is same as universal radial drilling machine except this drilling machine cannot produce a hole in inclined direction. This machine consists of two electrical motors. One is used for the operation of drilling and the another is used for the vertical movement of horizontal arm is the feed. In these machine water is used as a coolant the chip which comes out from the operation is continues chip.

• Sensitive drilling machine :- On the machine small sized hole is drilled usually a drill of 5 mm and 6 mm is used for the machine has a very long bed and a gang of three drilling machine. This machine is used to produce a hole in the very long channel. For operation the channel is kept on the bed the jig is fitted to the channel and with the help jig bush the hole is produced at desired position.

ABOUT MACHINES

This is the biggest shop of this organization . In this shop there are various type of machines. :- Such as :- 1. Lathe 2. Drilling 3. Shaper 4. Slotter 5. Grinder 6. Planed 7. Milling

MACHINING SHOP

• This is also very important shop of this plant. In this shop casting is done. The various parts on the wagon are manufactured in this shop. This casting is divided into three groups Low & Medium casting are again divided in to sub group Green and dry and loam casting of sweep moulding. For moulding clay is mixed with send to improve binding strength. Normally Bentonite & cow dung improved the porous nature of sand. Normally 3% clay is mixes with sand. For casting first mould is prepared with help of moulding box.

FOUNDARY SHOP

• As per the requirement core is used in moulding . For preparing core reinforcement is used which supports. The pressure of the molten metal.

• Green casting is used for mass production. For dry casting, the core and the prepared mould is hearted from inside the coal oven to reduce the moisture & to improve the strength & reduce the shrinkage allowance.

FOUNDARY SHOP

• CUPOLA FURNACE :-This is very important type furnace. It has the bottom bed & air chamber. During operation the bottom bed is closed & the inclined sand bed is prepared on the bottom bed. The air chamber which is connected with the outlet of bower which supplies air to the coke is 12 to 36 inches above the air chambers. Improve the firing . The coke is fired air blown. As the coke produce heat nearly equal to 22000 C the ferrous metal starts melting.

• After melting the metal flows downward and get stored on the sand bed. Due to its high density the coke starts flowing. As the slag starts flowing outside it is confirmed that the metal is in the fully molten state condition the gate is opened and the molten metal is allowed , to blow in the ladle. In this system the hot air which tends to pass from top is recycled and again supplied to the air chamber. This reduces the cost of production.

FOUNDARY SHOP

Before describing the template is worth while to elaborate the word“template”. This is a pattern or gauge a time in mass scale. This savesa lot of time, as no marking is necessary when using template . Basicallytemplates are of two types :

– Marking Template– Checking Template

• The main objective of this shop is making templates of all the consigned wagon components where a certain profile cutting is necessary.

The manufacturing of template is done with the help of the design and drawing provided by R.D.S.O. Lucknow . Also the allowances for different tools are taken into consideration during marketing the template. The varies machine to machine. The templates here are usually made of mild steel . They are of small thickness. Working in this shop needs greatest accuracy because shapes all the components made with the help of template depends upon the template. Thus a minor fault cans a great fault in the production.

TEMPLATE SHOP

• In this shop the various components which are manufactured in the different shops are assembled and the completed and then set to the finishing shop. First of the assembly of wagon, the centre sill is kept on the fixture.

• Centre Sill -This is manufactured in the sub assembly shop. To manufacture two Z channels are welder after welding the supporting plate is welded to require position and then it is sent for marking . After marking drilling is done by the air gun. Lastly it is checked whether it is true size or not. If not the length is reduced by gas cutting.

WAGON ASSEMBLY SHOP

• The length of the centre sill should be 9784 mm and width should 2960 mm. The centre sill is placed in the fixture and cross bar bolster welder to it. After welding these two seal are attached and is welded.

WAGON ASSEMBLY SHOP

• Now this known “Under frame”, now riveting is done . The head stock also welded to the centre still at the ends. The gusset plate and the cross bottom plate is welded to bolster and cross bar respectively . The stranger welded to the under frame through out the length. The under frame is placed on the manipulator for welding at the bottom side. Now the air brake cylinder and the pipe line is fitted and clamped . The side body and end body is attached and riverted and welded to the frame . This complete box is kept on the wheel .

WAGON ASSEMBLY SHOP

After assembling the wagon is sent to the finishing shop. In this the wagon is brought to the shot blaster chamber. In this chamber small iron particle is allowed to strike on the wagon to remove the extra welding deposit and the rust formed on it. The high pressure air helps the iron particle to come out from the gun and to strike rapidly. In this chamber the working condition are very hazardous. So the worker wears oxygen mask before doing work inside the chamber.

FINISHING SHOP

Components Suppliers1. Wheel W.A.P. Banglore2. Bogie BESCO Kolkata3. High Tension Couler H.D.C. Kolkata4. Air Brake Equipment 1. Escort Ltd. Faridabad

2. Stone India Ltd. Delhi 3. Bharat Brakes & Value Ltd.

Kolkata

5. Steel 1. Bokaro Steel Plant 2. Tisco6. Bearing Jamshedpur

SUPPLIERS OF MAIN WAGON COMPONENTS

After this the wagon is painted and the specification are written on the wagon is painted and the specifications are written on the wagon and then dispatched to Indian railway.

FINISHING SHOP

Broadly scrap is materials discarded from manufacturing operations that may be suitable for re processing. Scrap is a term used to describe the recycling of metal. Old unwanted metal such as left out iron sheets, building supplies, surplus materials, useless equipment, safety appliances, worn-out tools machine part etc.

FINALLY SCRAP AND SCRAP MANAGEMENT

Scrap from wagons shop :• Left out metal sheets after cutting out of required

shapes of sheets used in production of LHB FIAT wagons.

• Sheet portions left out after cutting by laser cutting machine.

• Iron pieces and bits that are of not suitable to be welded with wagons frame.

• Metal fillings and residue left out during machining of LHB wagons.

FINALLY SCRAP AND SCRAP MANAGEMENT

• Such a large quantity of scrap needs a proper way of management and disposal. Otherwise it would create wastage and environmental hazards.

• The proper utilization, processing, disposal and other type of related maintenance of various types of scraps is broadly termed as scrap management.

• Scrap management process differs from industry to industry. Scrap from large and big industry usually serves as raw materials for small scale industries and factories .

FINALLY SCRAP AND SCRAP MANAGEMENT

SCRAP MANAGEMENT IN BWEL MUZAFFARPUR• Scrap production in BWEL MUZAFFARPUR is one of largest

in the North India. Every year crores of scrap is produced in various workshops of BWEL MUZAFFARPUR, whose proper management and disposal is very necessary. That’s why scrap Management is very important aspect in proper functioning of BWEL MUZAFFARPUR.

• Specially for this purpose there is a scrap depot in the factory campus where all the scrap and waste material is dumped and whole process of scrap management is carried out from there.

FINALLY SCRAP AND SCRAP MANAGEMENT

ANY QUESTION

THANKS