Rail Coach Factory

Kapurthala

TRAINING REPORT
(6 WEEKS)

SUBMITTED TO:
Dr. H.K.Kansal

SUBMITTED BY:
Sukhjit Singh
Roll No.- UE109073
Mechanical/5th Sem.

OBJECTIVES OF TWO MONTH INDUSTRIAL

TRAINING
The main objective of the Training was to get first hand technical and

practical knowledge about the industry.

The main purpose was that the students would become familiar with

industrial environment so that they can take up future challenges when

they turn up in an industry with good confidence.
The students will thus understand the flow of control and information in

an industry.
This two-month Industrial Training has been introduced in Degree

Engineering Courses for the enhancement of students administrative

and professional knowledge about their respective fields.

After completion of their Degree Courses, this training experience will

help them to make their workplace stronger in the ever-competitive job

fields.

INTRODUCTION
RCFs Origin:

Taking into account countrys large population, a proper system of transportation

is inevitable.

The demand of more and more passenger trains is the result of the countrys
ever increasing prosperity and population.

The decision to set up a Rail Coach Factory at Kapurthala, Punjab in August85

was a timely step towards making good shortfall and complementing the coach
manufacturing capacity of Railways other manufacturing units.

Location:

The foundation stone of this factory was laid by the honorable Prime Minister
(Late Shri Rajiv Gandhi) of India on 17th August 1985.

It is located 9 kms. From Kapurthala, near the JalandharFerozepur railway line

and state highway, near the Hussainpur village.

Growth of RCF:

During year 2001-02, RCF has manufactured 1250 coaches having 974 non-AC
and 276 AC.

During recent development RCF is now started manufacturing the new series of
L.H.B coaches with the help of agreement of German Technology in design and
manufacturing.

OBJECTIVES OF RCF
DESIGN IMPROVEMENT: The emphasis is on light-weight Passenger

Coaches with higher passenger capacity, improved safety and comfort and
high speed.
TECHNOLOGY: Keeping pace with latest technological developments.
PRODUCTIVITY: Improvement in productivity vis--vis the existing coach

unit.
QUALITY: Maintaining workmanship of higher International standards.
MANPOWER DEVELOPMENTS: Development of an effective organization

with pride in their work and faith in the organization.

NATIONAL OBJECTIVES:

Self sufficiency
Energy conservation
Increased employment
Pollution free environment

VARIOUS SHOPS IN RCF

Sheet Metal Shop

Fabrication Shop
Shell Assembly Shop
Paint Shop

Bogie Shop
Furnishing Shop
Finishing Shop

SHEET METAL SHOP

In sheet metal shop, all the raw material is transported which is

1.

2.

3.
4.

required for the coach manufacturing of components. This material

is either brought from steel authority of India or is imported from
Japan.
Commonly used sheet for the part is carbon steel and the SAIL
supplies mild steel.
The carbon steel can be divided in to four groups or categories: Low Carbon Steel: It has the composition of carbon ranging from
0.05to0.25%. These are use only when moderate strength is
required together with considerable plasticity. These are generally
used for sheets, strips, tubing, wire nails, rivets, screws and parts
to be case hardened.
Structure Steel: This type of carbon steel has carbon contents
between0.2 to 0.35%. They have high yield point (3300 kg/sq.cm.)
and are best suited for both welding and riveted operation.
Forging Steel: These contain carbon between 0.30 to 0.40% and
are used for axles, bolts, pins, connecting rods, crank shaft etc.
Tool Steel: Steel containing 0.6 to 1.30% carbon is called tool
steel and is used for the manufacture of tools due to its property of
hardness and roughness.

FABRICATION SHOP

It consists of sections including under frame, side wall, roof & end

wall.
1.

Under Frame:

Under-frame constitutes the chassis

of the coach.

Four jigs are used to make the

assembly of under-frame.

The assemblies are placed in the jigs

and then welded together.

After this, it is lifted with the help of

overhead cranes and placed on the
tracks for the 2nd stage on the other
side of the frame.

The components, which are located

on this side, are welded and after
final welding, the frame is painted in
black paint and transferred to the
transfer bay for main assembly of the
shell.

2.

Side Wall:

The sidewall is assembled in the

pneumatic operated jigs.

The major parts of the sidewall are

body side pillar, sidewall sheet, light
rail, waist rail and stiffeners.

All these components are placed in the

jig and welded together.

The sidewalls are of eight window

sheets and lavatory sidewall sheet.

A number of other components like

window ceiling angel etc. are welded
after the wall is taken out of the jig.

3.

Roof:

The main roof is assembled on a rotary

jig on which the basic components i.e.
car line is located and after location, Ustiffener is welded to hold them.

After welding of these components, the

roof sheets that are eight in no. are
located together and tied properly with
the help of stainless steel fasteners.

The Jig is then turned round to position

and the roof sheet is welded together.

The roof is then removed from the jig &

put on trestles for providing other
components like fan brackets, lamp,
brackets etc.

4.

End Wall:

This is the end portion of the coach.

The main component of end wall is end

sheet, side sheet, end stanchions and
center stiffeners.

All these components are positioned in

the jig located and weld together.

When welded, these are taken out and

placed on trestles for fixing pipes and
other fittings.

All the components are welded with

MIG welding.

SHELL ASSEMBLY SHOP

In the shell assembly shop, sidewall, end wall, roof, under-frame is

assembled and other necessary operation for making shell is done.

Shell assembly operations are done in five stages:
Stage 1:
In first stage, under-frame is placed on the jig.
Then setting of camber is done to avoid bending of under-frame downward.
Then sidewalls and end walls are placed on shell jig along with under-frame and are

fully welded.
Afterwards roof is placed and full welding is done, the sidewalls and roof are made

tight for welding by using tie rods.

After welding all clamps and tie rods are removed and checking for final camber is

done.
Cables pipes are also attached.

Stage 2:
In this stage End walls and Sidewalls are welded to each other.
Residual welding for shell integral from first stage is also done.
Door corner fitting, Conditioning of under-frame, junction box and cable box are fitted,

flooring work is also done in this stage.

Stage 3:
In this stage, vestibule doorsill, alarm tube bends; ceiling support angle and window bar

fitting is done.
Skin tensioning is also done in this stage.
In Skin tensioning heating on spots at some distances is done and then hammering is done
to remove any deformations.

Stage 4:
In this stage partition framing of lavatory and seating is done.
Besides this, door fitment operations are also performed.

Stage 5:
Buffer and draw Gear assembly is done at this stage.
Components of Buffer are:

CASING

STEEL ROD

PLUNGER

RUBBER PAD

SPRINGS

PLATE

PAINT SHOP
In this shop, the shell is painted manually or with automatic

painting plants with different coats of chemical and paint etc.

Various operations done in paint shop are:1. Shot Blasting:

Small steal balls are made to strike against the external surfaces of the shell with
great speed.

Firstly marking is done to render steel balls to enter inside the shell.

It is done with wooden boards size of shots are 170mm,230mm,280mm.

Centrifugal machines are used in plants.

2.

Primer Application:

After that shot blasting primer is

applied with automatic machines with
nozzles which moves up down and
side ways are used for this purpose
in primer plant.

There are mainly two type of primer:

1.Internal Primer 2.External Primer

3.

Putty Application:

To obtain uniform thickness, putty

cutting is done.

It is done with silicon water Emory

paper.

Putty cutting is done by applying

water at the required place.

This cutting is called wet cutting.

4.

Surface Application:

After putty, surface is applied to the

external.

The surface are applied with the help

of air less spraying machines.

When it become dry than cutting of

surface is done with Emory papers.

5.

Top Coat Application:

After drying surfaces top coat is

applied on the external surface with
the help of automatic and air less
spraying machines as used while
primer application.

The thickness of paint on coaches is

200-250mm.

In paint shop, air film transversal is

used for shifting of coaches.

BOGIE SHOP
Bogie is the part on which the coach

rests and due to which the coach runs

on the rail line Thats why it is
manufacture under strict precision so
that the dimensions do not vary too
much from drawing.
In the bogie shop the bogies of different

coaches are manufacture in the various

stages.
The various parts of the bogie are not

manufactured in that shop, only bogie

frame is manufactured in this shop and
the rest of the parts are imported from
out side sources. These parts are only
assembled here.
The coach consists of eight wheels and

these eight wheels are divided into two

sets of two wheels with suspension
frame, springs and dampers when
assembled properly then these two
sets are known as BOGIE.

 The main parts of the bogie are: 1.

Frame:

In this part of the bogie, shell is placed.

It is made of Leo Fein steel sheet.

The thickness for general coaches and high-speed coaches is 8 mm and 12 mm

respectively.

Its parts are Head stock, transverse, Longitudinal and side frames

These parts are machined in this shop and at last are assembled in this shop with
the help of jigs.

2.

Wheels:

These are the casting of Mild Steel and are flanged from inner side.

The diameter of the wheel is 890 mm and its thickness is 120 mm.

Two wheels are joined with frame by AXLE.

Each Bogie contains two wheels and a coach contains four wheels.

3.

Bearing:

In this section Bearing are fixed on journal.

The types of bearing used are roller bearings.

The diameter of wheels, journals & axles are 915mm, 130mm, and 155mm.

The distance between wheels is 1600mm.

4.

Brake System:

Air Brake system is used for braking action.

For high speed coaches such as L.H.B and IRY coaches the disc brakes are used
and for other coaches block brake are used.
The band blocks are used for breaking and the braking is system is basically of liver
pulley system.
The pressure is applied on the pipes from the cylinder to the liver and then the
brakes are applied.

5.

Alternator:

It is a source of electricity when the train is moving.

For AC coaches two alternators of 25KW power each are used in a single coach.
For general coaches an alternator of 4.5 KW power per coach is used.
V Belts and Pulleys, connects the shaft of the alternator to axle.

6.

Suspension System:

a)
b)

It is used for absorbing shocks.

It consists of springs and shockers.
Springs are made of steel.
Suspension system has two parts:
Primary parts: It takes the load of shell only and restricted its vibrations.
Secondary parts: It takes the load of shell as well as the thrust from wheels.

 Testing of Final Bogie:

STATIC TESTING MACHINE:

Static testing machine is used to test the bogie frame by applying same amount of
load as in actual service condition.

Purpose of this testing is to check the strength and correctness of different Bogie parts
under the application of load on it.

Load is applied by hydraulic system at the center of bogie.

Under this load the deflection in spring is noted down and the deflection is compared
with specified deflection for particular spring.

If the deflection is with in the safe limit or with in the specified limit and the other parts
also behaved in specified way then the Bogie gets the OK signal. Otherwise, the
defective part is replaced and then again the testing is done, until it gets OK.

FURNISHING SHOP
The furnishing shop is working for decoration of coaches. So all the decorative

work is done here in this shop.

In this shop seats, birth, electrical applications, portions, flooring, bogie

installation and many more other goods are fitted here.

The shop consists of no. of sections and these sections are:-

1.

Flooring & PVC Section:

In this section flooring is done on the metal under frame.

First of all, the plywood flooring is done on the under frame.

The plywood is screwed to the metal floor of the coach, then after this the
water sealing compound ISOPATHIC PUTTY is applied on plywood joints and
is rub by emery paper later on for the uniformity of the flooring.

2.

Electrical Stage:

In this stage, all the electrical wiring

is done for the electrical equipment.

D.C batteries are also loaded on the

coaches.

For A.C, S.G and general coach,

wires used are 1.5mm.

Equipment for which these batteries

and invertors are provided is Fans,
Lights, Air Conditioner, etc.

3.

Window and Ceiling

Section:

After electrical wiring, windows and

ceiling covers are mounted on the
coach in window and ceiling stage.

These windows are not manufactured

in this factory. These are
manufactured by vendors as the
design recommended by R.C.F.

These windows consist of a

4.

Panel Section:

After providing the windows and

ceiling covers the work of paneling is
done.

In this stage all the inner walls of

coach are covered with thin-mica
sheets, this is known as paneling.

These mica sheets are fastened with

help of screws.

5.

Moulding Section:

After paneling the work of molding is

done.

In this stage aluminum strips cover

all the joints of paneling.

The molding is done for better out

look of inner walls of coach.

Screws fasten these strips.

6.

Lavatories Section:

In this stage, all the accessories of

lavatories are mounted such as
flushes, washbasins, water tanks.

7.

Plumbing Section:

In this section, the fitting of pipes

from water tank to lavatory and to
wash basins is done.

8.

Seat and Berth Section:

In this section, following work is done:

Fixing of chairs angels and sleeve for

single seats.
Fitting of luggage racks and back rests

arrangements.
Fitting of guard compartment.
Fitting of designation board.
Fitting on no. plates of seats and

berths.
Stench works indicating type of zones

and type of coach.

9.

Lowering Section:

Fixing of bogies to the coaches is the

main function in this shop.

The procedure followed in this section

is given below:

Fixing of center pivot pin.

Adjustment of buffer height.

Fitting of bearing plates in Bogie.
Taking bearing frame to the center.
Lowering of coach on bogie.
After lowering, the fitting of cotter and

split pin.
Buffer point adjustment.

10. Electrical Stage-1:

In this stage all the electrical

equipment are mounted on coaches.

This electrical equipments are fans,

lights, electrical switches and air
conditioner units.

The wiring is attached to these

equipments.

11. Air Brake Section:

After lowering of coach all the

connections of air brake are completed.

In early days Vacuum Brakes were

used but now-a days air pressure
brakes are used.

There are two types of pipes Feed pipe

and Brake pipe. Feed pipe is of white
color and Brake pipe is of green color.

Pressure in Feed pipe and Brake pipe

is 6Kg/cm and 5Kg/cm.

These two pipes are connected to a

diaphragm. With the help of this
diaphragm air pressure is released to
piston cylinder arrangement, with the
help of which brake is applied.

12. Finishing Stage:

In this stage, all the work that is

completed in furnishing, is checked
i.e. all equipments are switched on by
connecting to electric supply to the
coach.

FINISHING SHOP

Following operations take place in this shop:

1.

Installation of Air Brake

System and Testing:

Air brake system is installed in the

coach and is being tested by passing
the compress air in pipelines.

Generally two-pipe line exists in which

one is white and another is green.

2.

Shower Testing:

In this the coach is placed below

water shower and then the shower is
started.

This inspection is done to check

whether the leakage is there in roof
or not.

This testing is mainly done to check

3.

AC Generation Test:

This can be tested with the help of motor and belt.

After checking the electricity generation, the performance of the AC unit is also
checked by glowing number of high wattage bulbs and with AC unit ON.

So after all this a final inspection is done and after getting OK signal from inspectors,
the coach is sent to Delhi headquarters, from there they will sends to the various
railway zones according to their demand.