BOGIE SHOP

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 subassembly of wheels and axles. Bogies take various forms in various modes of transport. A bogie may remain normally attached (as on a railway carriage/car or locomotive, or on a semi-trailer) or be quickly detachable (as the dolly in a road train); it may contain a suspension within it (as most rail and trucking bogies do), or be solid and in turn be suspended (as most bogies of tracked vehicles are); it may be mounted on a swivel, as on a railway carriage/car or locomotive, or additionally jointed and sprung (as in the landing gear of an airliner).

Railway Bogie:

Key components of a bogie include: 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.

 Suspension to absorb shocks between the bogie frame and the rail vehicle body: Common types are coil springs. Wheelset composed of an axle with a bearings and wheel at each end. Axle box suspensions absorb 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. A more modern design uses solid rubber springs. Brake equipment: Two main types are used: brake shoes that are pressed against the tread of the wheel, and disc brakes and pads. Usually, two bogies are fitted to each carriage, one at each end with the help of a central pivot pin fixed on the bogie bolster.

Purposes:
Bogies serve a number of purposes: Support of the rail vehicle body. Stability on both straight and curved track. Absorbing vibration and minimizing the impact of centrifugal forces when the train runs on curves at high speed. Minimizing generation of track irregularities and rail abrasion.

WORKING AT BOGIE SHOP(COACH REHABILITATION WORKSHOP, BHOPAL)

The coaches from all zones of Indian railway are brought in the workshop at Bhopal for midlife rehabilitation. The coaches are 12 to 15 years old and after rehabilitation in which almost 70-75% of the coach is rebuilt, the average life of the coach is increased by about 5 years. The first step in the workshop is separating the bogie from the coach. This process is done at Lifting Shop. Lifting Shop: Lifting is done to separate bogie from the carriage. A lift(crane) is used for this purpose it is attached to the rear and front part of the carriage. Two workers enter the bottom of the coach and remove both the central pivot pins from the bolster and then the crane lifts the carriage while the carriage is still in the air, the bogie is sent

directly to the bogie shop for working(inspection and further working) while the carriage is put on a dummy bogie and further work is proceeded which we will deal in this report later. Bogie Shop: The bogie is sent to the shop, the first step that is done in the shop is dismounting all the components of the system or stripping the bogie. After stripping all the components are individually inspected. The bogie frame is visually inspected, if the frame is found to be damaged or corroded beyond repair the bogie is condemned. After visual inspection the bogie frames are loaded in a mini truck in a group of 6 and sent for sand blasting. Sand blasting is a technique by which any component being blasted is cleaned from any impurity whatsoever. After sand blasting the frames are sent back to the bogie shop and the frame is again inspected and if the frame is found to be square or corroded or damaged the bogie is either condemned or if slightly square could be rearranged to make a dummy bogie, as per decided by senior engineer. The other components include wheel system, suspension system and air brake system. Air brakes are sent to air brake shop for testing the distributer valve. Wheel-mechanism is sent to wheel shop. Suspension and bearings are sent to their units respectively. Wheel Shop: In CRW, Bhopal the wheel axel mechanism is stripped from the bogie and sent for inspection. Firstly visual inspection of the wheel is done, if any part of the wheel is corroded or damaged which cannot be repaired that wheel is condemned, if not measurement of the wheel is taken it should be more than 837mm and less than 915mm, if not it is condemned and new wheel is used in its place. Axle dimensions are Whole length: 2191 mm Journal diameter: 150mm Wheel seat diameter: 210mm Axle diameter: 184mm.

A tolerance of 0.20 to 0.24 mm is made b/w the inner diameter of wheel and outer diameter of wheel seat so as to make interference fit. New wheels are not manufactured in CRW,Bhopal instead they are imported(both disc and axles) from RWF(Rail Wheel Factory), Bangalooru. Although the discs and the axles are not machined and they are machined here in CRW,Bhopal. The discs are kept inside a vertical turret lathe machine which machines the inner diameter of the discs. The inner diameter of the disc is kept 0.2 to 0.24 mm less than the wheel seat's diameter. In a vertical turret lathe simple lathe machine mechanism is followed, just the difference is the cutting tool moves in the vertical direction. The axle is mounted on the Bombay lathe machine for machining purpose.

After machining of axle on Bombay lathe it is followed by machining on Cylindrical Axle Turning Machine in which the axle is finalised. Both axles and discs are sent to hydraulic Press working machine in which the axles and disc are lifted with the help of a motorised mini crane and the operator fixes disc to one side and axle hangs to the middle of the machine. Before starting of press work a solution of lead carbonate and linseed oil is applied on the wheel seat, for the first 24 hours it works as heat absorbent while after 24 hours it itself works as adhesive. When lifted at proper height the press working starts since it is interference fit very high power is applied which is b/w 78 to 108 tonnes. After this process on both sides of the axle wheel is kept for 48 hours before it could be remounted on the bogie.

BEARING CENTRE
The bearing is dismounted from the wheels by applying hydraulic oil machine in which oil rushes by application of hydraulic pressure and forms a film b/w bearing and discs and due to the oil film it slips and is released out from the rest of the wheel set. After removal of bearings they are sent to the bearing centre where they are firstly visually inspected by an inspector which separates out fit bearings and condemns the rest. After visual inspection bearings are UV inspected by firstly putting in a dye and then inspected under a microscope in Ultra Violet Lighting. Bearings fit for use are forwarded while others are condemned. Before mounting the bearings, they are put in a induction heater for 8-10 minutes due to which their size increases. After heating they are arranged and mounted on the wheel, on cooling they get strongly attached to the wheel.

SUSPENSION CENTRE
The primary suspension in an Bogie is through a dashpot arrangement. The dashpot arrangement consists of a cylinder (lower spring seat) and the piston (axle box guide). Axle box springs are placed on the lower spring seat placed on the axle box wing of the axle box housing assembly. A rubber washer is placed below the lower spring seat for cushioning effect. The axle box guide is welded to the bogie frame. The axle box guide acts as a piston. A washer is placed on the lower end of the axle box guide. The end portion of the axle box guide is covered with a guide cap, which has holes in it. A sealing ring is placed near the washer and performs the function of a piston ring. The axle box guide moves in the lower spring seat filled with dashpot oil. This arrangement provides the dampening effect during the running of the coach. Dashpot arrangement: The dashpot arrangement is mainly a cylinder piston arrangement used on the primary suspension of Indian Railway coaches. The lower spring seat acts as a cylinder and the axle box guide acts as a piston. The dashpot guide arrangement has the following main components:

 Lower Spring Seat Lower Rubber Washer Compensating Ring. Guide Bush Helical Spring Dust Shield. Circlip. Dust Shield Spring. Protective Tube Upper Rubber Washer. Axle Box Guide Screw with sealing washer The axle box guide (piston) is welded to the bottom flange of the bogie side frame. Similarly, the lower Spring seat (cylinder) is placed on the axle box housing wings forms a complete dashpot guide arrangement of the coaches. Axle box guides traditionally had a guide cap with 9 holes of 5mm diameter each; however, in the latest design, the guide cap is made an integral part of the guide. Approximately 1.5 liters of dashpot oil is required per guide arrangement. Air vent screws are fitted on the dashpot for topping of oil so that the minimum oil level is maintained at 40mm. Suspension is firstly tested in a spring testing machine after which if spring is reusable it is used else they are condemned. New springs in bogeys are not manufactured in Bhopal Plant, they are imported from RSK(Rail Spring Karkhana), Gwalior. After testing they are dipped in paint after drying out lubrication is done by filling lubricant on the spring for 2-3 hours.

AIR BRAKES
Air Brakes are sent to Air Brake Shop for testing if they give positive results in all of 6 tests they are kept if not they are condemned.

REMOUNTING OF COMPONENTS ON BOGIE

After completing all the tests on the bogie components and replacing or repairing of components on the bogie , the components are mounted on the bogie and the finished bogies are sent to the finishing shop where the finished carriage is mounted on the bogie.