Industrial Training Report Diesel Locomotive Works Varanasi: Mechanical Engineering Department
Industrial Training Report Diesel Locomotive Works Varanasi: Mechanical Engineering Department
Industrial Training Report Diesel Locomotive Works Varanasi: Mechanical Engineering Department
By
Ramu Verma
(Roll No- 1673440044)
Bachelor of Technology
We also take the opportunity to acknowledge the contribution of Mr. Saurabh Tripathi,
Head, Department of Mechanical Engineering for his full support and assistance during
the development of the project.
Signature:
Date: 16/10/2019
TABLE OF CONTENTS
1. Introduction
2. History
3. Product of DLW
4. Workshops
Heavy Welding Shop
Heavy Machine shop
Sheet Metal Shop
Truck Machine Shop
5. Conclusion
6. References
INTRODUCTION TO TRUCK MACHINE SHOP:
The shop deals with the matching various small component such
as pinion, Axial wheel, collar, gearing, gear etc.
1. Truck frame machine section
2. Centre lathe machine section
3. U.T.L section
4. Axial wheel machine section
5. Miscellaneous machine section
6. Axial wheel and box assembly section
7. Truck frame sub assembly section
8. Truck frame fabrication section
9. Truck frame assembly section
3.WHEEL SHOP:-
In this shop, repair work of the wheel and axel is under taken. As it is known that,
the wheel wears throughout its life. When at work the profile and diameter of the
wheel constantly changes. To improve it’s working and for security reason, it is
repaired and given correct profile with proper diameter.
Type Wheel dia. Distance b/w journal Journal Axel wheel seat
center (mm) size(mm) dia. (mm)
Wheel can be used certain minimum diameter after which it is discarded. The
diameter
FIG:(2).WHEEL
5.HEAT TREATMENT SHOP:-
Heat treatment is the process of heating and cooling of a material to change its
physical and mechanical properties without changing the original shape and size. Heat
treatment of steel is often associated with increasing its strength, but can also be used
to improve machinability, formability, restoring ductility, etc. Basic heat treatment
process for steels are described in the following subsections.
1. Hardening.
2. Tempering.
3. Austempring.
4. Martempring.
5. Annealing.
6. Stress relieving.
7. Spheroid zing.
8. Normalizing
9. Case hardening.
10. Cyaniding.
11. Flame hardening.
13. Nitriding.
1. Air-Braking system.
2. Vacuum-brake system
1. Brake cylinder.
2. Brake pipe.
3. Feed pipe.
4. Distributer pipe.
5. Angle lock.
6. House pipe.
7. Auxiliary reservoir.
8. Guards van valve & pressure gauge.
9. Isolating cock.
FIG:(5).BREAKING SYSTEM
BRAKE PIPE-This is charged from the locomotive at 5 kg/cm3 and causes
application and release of brakes due to change in its pressure through the
FEED PIPE- It having 6kg/cm3 pressure, and keeps the auxiliary reservoir
charge at fuel pressure even when brakes are applied. Feed pipe are also
connected to the distributor valve.
HOUSE COUPLING- Both the brake-pipe and feed pipe are fitted to the
angle cock outlet for the passage of compressed air from one coach to another
ISOLATING COCK- Use for isolating the air from one point to the other
point.
CHOKE- It is device for restricting the flow of air from one point brakes circuit to
other point. The handle of this cock is kept parallel to the pipe to indicate that it is in
open conditions .
7.SPRING SHOP:-
In this section the helical and leaf spring are prepared. For this purpose there certain
machine for testing, grading and repairing it.
FIG:(6).SPRING
[3] D’ buckling
Visual and magnetic crack detection. The visual test with the help of magnifying lens
and glass the spring the is inspected of-
Corroded--------------- Fail
In the magnetic testing a mixture of kerosene oil and magnetic red ink is sprayed on the spring and
inspected for the clinging of the oil droplets. If oil clings at same place if present the presence of crack.
There are variation reasons for the failure of the helical spring such as free height load test, dent
mark, corrosion and breakage.
CAUSE PERCENTAGE OF FAILURE
Free of height 8.93%
Load test 82.08%
Dent mark, corrosion &breakage 08.39%
After the buckling test, the spring should be put on scraping machine and the camber
should be measured. In this test, the spring should be pressed quickly and camber
should be measured 2 times. The spring should be test such as, it should not be more
than ½ of the plate. In helical spring scraping, the spring is kept on the machine and
its free height us measure. Now the spring is compressed, under certain and its
compression is noted down. The compression is matched from the table provided for
springs. If the compression matches, the spring is passed otherwise rejected
D’ BUCKLING
On this machine, buckling is performed on laminated spring. The leaves of the springs
are assembled and pressed. Now it is put on the buckling machine axial and
longitudinal forces are applied.
8.PAINTING SHOP:-
After the coach body is fully repaired and the flooring work completed, it should be
swept and cleaned of all dust, shavings, etc., before the coach is placed in the Paint
shop for painting and polishing.
The condition of the paint on the inside and outside surfaces should be examined to
decide whether the old paint should be removed to the bare metal. Usually, extensive
corrosion repair work necessitates removal of old paint to bare metal and complete
repainting of the coach.
ii) Flat brushes nos. 25 mm, 38 mm, 50 mm, 63 mm, 75 mm, 100 mm
iv) Stencil brushes v) Cleaning brushes for LP sheets with soda ash
2. Scrapers
i) Shave tukes
ii) Triangular
iii) Semi circular
iv) Diagonal
3. Safety apparel
i) Goggles
ii) Helmet
4. TRACTION MOTOR
A traction motor is an electric motor used for propulsion of a vehicle, such as
an electric locomotive or electric roadway vehicle.
Traction motors are used in electrically powered rail vehicles such as electric
multiple units and other electric vehicles such as electric milk floats, elevators,
conveyors, and trolleybuses, as well as vehicles with electrical transmission
systems such as diesel-electric, electric hybrid vehicles and battery electric
vehicles.
5. TRACTION MOTORS as DRIVES IN LOCOMOTIVES
Transverse drives
Longitudinal drives
11. REFRENCE:-
[1] Kuře, G. Railway technical handbook. Axleboxes, wheelset bearings, sensors,
condition monitoring, subsystems and services. Volume 1, SKF (2011). ISBN 978-91-
978966-3-4
.
[2] Hudzikowski, J.Bearings for drive systems for railway vehicles – an outline. SKF
science report, Development Centre Steyr (2005–2006), pp. 79–84
[3] www.irieen.indianrailways.gov.in/view_section.jsp/lang=0,296,437
[4] www.irieen.indianrailways.gov.in/view_section.jsp/lang=0,296,438
[5]