`1

INTRODUCTION

1. COMPANY PROFILE
A) GENERAL : COMPANY INTRODUCTION

INDIA METALS, was established in 1967 for manufacturing track items, started in own
premises at 21, Industrial Area, Phase -1, Chandigarh.

Business works

The business practice of M/s INDIA METALS, is to improve the quality of its products up to
the entire satisfaction of customer. We always try to achieve our works on time and also
achieving. Production level with minimum rejection.

Quality policy

We, INDIA METALS, committed to satisfy our customers by supplying quality products through
continual improvement.

Quality objective

To give better quality at lower rates

To increase on time delivery by 90% to 95%

Implementation method

System is implement to the staff & trained labor for quality product through continuous and
effective training programmers from time to time.
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ORGANISATION CHART

NAME OF KEYPERSONNEL

Name Designation Qualification Experienc

S.N e
o

1 Mrs. Aarti Singal Proprietor Graduate 16 Years

2 Mr. Sunil Kumar Manager/Engineer Mech. Engineer 18 Years

3 Mr. R. S. Kabarwal Manager Graduate 25 Years

4 Mr. Ankuar Bhasit Quality Control Diploma Mech. 3 Years

Engg.

5 Mr. Raman Kumar Tech. Asstt. Graduate 4 Years

6 Mr. Khem Chand Clerk Graduate 23 Years

7 Mr. Sanjay Kumar Executive Graduate 16 Years

8 Mr. Sanjeev Tandon Clerk 10+2 16 Years

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2. FACTORY KEY PLAN ALONG WITH OUTER DETAILS OF INDIA

METALS
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3. FACTORY LAYOUT WITH INSIDE DETAILS OF INDIA METAL

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4. QUALITY CONTROL PERSONNEL

S.No Name Responsibility Qualification Experience

.

1. Mrs. Aari Singal Prope rioter Graduate 16 years

2. Mr. Sunil Kumar Manage/Engineer Administrator & 18 years
QC Head
3. Mr. R.S. Kabarwal Marketing Graduate 25 years
4. Mr. Ankur Bhashit Work shop Diploma Mech. 03 years
In-charge
5. Mr. Raman Kumar Tech. Asstt. Graduate 04 years
 `6

5. LIST OF PLANT & MACHINERY

Sr. Name of the Manufactured Quantity/ Capacit Unique SI No. Year of Documents Year of
N Equipment/ By/ Model No. No.s y Of Machine(IM) Procurement Established Manufacture
o Machine ownership
Mechanical Basant 2 Nos 100 Ton 14,15 1973 Owned 1973
1. Power Press
(Bar Cutting)

2. Mechanical Basant 4 Nos 200 Ton 16,17,18,19 1973 Owned 1973

Power Press
(Slotting)

3. Mechanical Basant 3 Nos 75 Ton 20,21,22 1973 Owned 1973

Power Press
(Notching)

4. Mechanical Basant 2 Nos 100 Ton 23,24 1973 Owned 1973

Power Press
(Stamping)

5. Mechanical Basant 2 Nos 50 Ton 25,26 1973 Owned 1973

Power Press
(Cross Cutting)

6. Mechanical Basant 1 Nos 50 Ton 27 1973 Owned 1973

Power Press
(Rejection
Cutting)

7. Grinding 5 Nos 18 Dia of 60,61,62,63,64 1975 Owned 1975

Machine 2800rpm

8. Bench 1 No. 10 Dia, 65 1975 Owned 1975

Machine 2800rpm

9. Lathe 1 No. 1-10Ft. 01 1973 Owned 1973

Machine
2-12Ft. 02

3-8Ft. 03

10. Shaper 2 Nos. - 04,05 1973 Owned 1973

Machine

11. Milling 1 No. - 06 1973 Owned 1973

Machine

12. Drill Machine 2 Nos. - 10,11 1973 Owned 1973

13. Surface 2 Nos. - 07,08 1973 Owned 1973

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Grinder

14. Nose Grinder 1 No. - 3 1973 Owned 1973

15. Power 1 No. - 12 1973 Owned 1973

Hacksaw

16. Heat Treatment 1 No. - 13 1973 Owned 1973

or Die
Tempering
 `8

1. POWER PRESS

A Power press is a special kind of machine that can bend any sheet metal into a specific shape.

There are various products made of metal which we use in our day to day life like automobiles,
electronic gadgets etc. Sheet metal is required to be cut, bended and pressed to form a particular
shape. In ancient times, these jobs were done manually but now to make the process quick, it is
used which can cut, bend and press metals to form shapes with accuracy. A forming press,
commonly shortened to press, is a machine tool that changes the shape of a workpiece by the
application of pressure. Presses can be classified according to-

their mechanism: hydraulic, mechanical, pneumatic;

their function: forging presses, stamping presses, press brakes, punch press
A simple frame, fabricated from steel, containing a bottle jack or simple hydraulic cylinder.
Good for general-purpose work in the auto mechanic shop, machine shop, garage or
basement shops, etc. Typically 1 to 30 tons of pressure, depending on size and expense.
Classed with engine hoists and engine stands in many tool catalogs.
 `9

2. SURFACE GRINDER

Surface grinding is used to produce a smooth finish on flat surfaces. It is a widely used
abrasive machining process in which a spinning wheel covered in rough particles (grinding
wheel) cuts chips of metallic or non-metallic substance from a workpiece, making a face of
it flat or smooth. Surface grinding is the most common of the grinding operations. It is a
finishing process that uses a rotating abrasive wheel to smooth the flat surface of metallic or
non-metallic materials to give them a more refined look or to attain a desired surface for a
functional purpose.
 `10

3. LATHE MACHINE

A lathe is a machine tool which rotates the workpiece on its axis to perform various
operations such as cutting, sanding, knurling, drilling, or deformation, facing, turning, with
tools that are applied to the workpiece to create an object which has symmetry about an
axis of rotation. Lathes are used in woodturning, metalworking, metal spinning, Thermal
spraying/ parts reclamation, and glass-working. Lathes can be used to shape pottery, the
best-known design being the potter's wheel. Most suitably equipped metalworking lathes
can also be used to produce most solids of revolution, plane surfaces and screw threads or

helices. Ornamental lathes can produce three-dimensional solids of incredible complexity.

The material can be held in place by either one or two centers, at least one of which can be
moved horizontally to accommodate varying material lengths. Other work-holding methods
include clamping the work about the axis of rotation using a chuck or collet, or to a
faceplate, using clamps or dogs. Examples of objects that can be produced on a lathe
include candlestick holders, gun barrels, cue sticks, table legs, bowls, baseball bats, musical
instruments (especially woodwind instruments), crankshafts, and camshafts.
 `11

4. DRILLING MACHINE
Radial drilling machine, also known as cross arm drill. Spindle box can move around on the
rocker, and with the rocker arm around Column The rotary 180 Drilling machine (see
photo). The rocker arm can lift along the outer column, in order to adapt to different
workpiece height. The smaller The workpiece Can be installed on the work table, the larger
workpieces can be directly placed on Machine tool A base or on the ground. Radial drilling
machine widely used in single piece and small batch production, processing of large volume
and weight of the workpiece hole. Radial drilling machine processing range, can be used for
drilling screw holes, cut large parts of the thread bottom hole and the hole. Radial drilling
machine's main forms a slide block and a universal type two. Slide type radial drilling
machine is the base type radial drilling machine to slide to slide along the bed, Guide
Mobile, to expand the processing Range , suitable for boiler, bridge, vehicle and ship,
Machining Industry, etc.. Universal radial drilling machine Rocker except for vertical and
rotary Movement Outside, and can move horizontally, the spindle box can tilt adjustment in
the rocker arm, to adapt to different parts of the processing
 `12

5. MILLING MACHINE
Milling is the machining process of using rotary cutters to remove material[1] from a
workpiece by advancing (or feeding) in a direction at an angle with the axis of the tool. It
covers a wide variety of different operations and machines, on scales from small individual
parts to large, heavy-duty gang milling operations. It is one of the most commonly used
processes in industry and machine shops today for machining parts to precise sizes and
shapes.

Milling can be done with a wide range of machine tools. The original class of machine tools
for milling was the milling machine (often called a mill). After the advent of computer
numerical control (CNC), milling machines evolved into machining centers (milling
machines with automatic tool changers, tool magazines or carousels, CNC control, coolant
systems, and enclosures), generally classified as vertical machining centers (VMCs) and
horizontal machining centers (HMCs). The integration of milling into turning environments
and of turning into milling environments, begun with live tooling for lathes and the
occasional use of mills for turning operations, led to a new class of machine tools,
multitasking machines (MTMs), which are purpose-built to provide for a default machining
strategy of using any combination of milling and turning within the same work envelope.
 `13

6. POWER HACKSAW
Power hacksaws are used to cut large sizes (sections) of metals such as steel. Cutting
diameters of more than 10/15mm is very hard work with a normal hand held hacksaw.
Therefore power hacksaws have been developed to carry out the difficult and time
consuming work.
The heavy arm moves backwards and forwards, cutting on the backwards stroke
The metal to be cut is held in a machine vice which is an integral part of the base. Turning
the handle tightens or loosens the vice. The vice is very powerful and locks the metal in
position. When cutting is taking place, the metal and especially the blade heats up quickly.
Coolant should be fed onto the blade, cooling it down and lubricating it as it cuts through
the metal.
Without the use of coolant the blade will over heat and break/snap. This can be dangerous
as the blade can break with powerful force, shattering. When the metal is placed and fixed
in the vice, the blade is lowered onto its top surface. The diagram below shows the arm
being lowered with the adjusting handle
 `14

7. LIST OF TESTING/MEASURING INSTRUMENTS

S. no. Name of Manufact Quanti Capaci Unique Year of Documen Year Calb. Calb.
equipment/ma ured ty/ ty S.I. No. procurem ts of Date Due
chine by/Model No.s of ent establishe Man
No. machine d u.
ownershi
p
1. Computerized FIE 1 No. 40 Ton 76/111 2011 TM/64/I 2011 10.03. 10.03.
Universal UTN-40 M/2010- 14 15
Testing TO 11
Machine UTN-ES-
40
2. Vernier Mitutoya 1 No. 0 to 0607878 NA NA NA 04.01. 04.01.
caliper Japan 150 6 14 15
mm
3. Computerized FIE 1 No. 3000K 04/2011- 2011 TM/64/I 2011 11.05. 11.05.
Brinell B-3000PC gf 131 M/2010- 14 15
Hardness 11
Tester
Machine
4. Standard Test BLUE 1 No. 140 - 2012 Invoice 2012 - -
Block STAR BHN
140BHN
5. Metallurgical Radical 1 No. Slide RXM 7D 2014 M720 2014 Dec Dec
microscope 1/100 2014 2015
6. Polishing Radical 1 No. 12 RXM 7D 2014 M720 2014 Dec Dec
Machine 2014 2015
7. Approved sets RDSO 2 set - - 2012 QA/CT/ 2012 Gauge Next
of gauges approved for ML approv approv
each al al due
Drg. letter 31.12.
No. dt. 15
T- 09.10.
3738 12
T-
For 3740
internal T-
used 3741
T-
3742

1 set
for
each
Drg.
No.
T-
3738
T-
 `15

3740
T-
3741
T-
3742
 `16

1. COMPUTERISED UNIVERSAL TESTING MACHINE

A universal testing machine (UTM), also known as a universal tester,[1] materials testing
machine or materials test frame, is used to test the tensile strength and compressive
strength of materials. The "universal" part of the name reflects that it can perform many
standard tensile and compression tests on materials, components, and structures (in other
words, that it is versatile).The set-up and usage are detailed in a test method, often published
by a standards organization. This specifies the sample preparation, fixturing, gauge length
(the length which is under study or observation), analysis, etc. The specimen is placed in the
machine between the grips and an extensometer if required can automatically record the
change in gauge length during the test. If an extensometer is not fitted, the machine itself can
record the displacement between its cross heads on which the specimen is held. However,
this method not only records the change in length of the specimen but also all other
extending / elastic components of the testing machine and its drive systems including any
slipping of the specimen in the grips. Once the machine is started it begins to apply an
increasing load on specimen. Throughout the tests the control system and its associated
software record the load and extension or compression of the specimen.
 `17

2. VERNIER CALLIPER
A vernier Scale also known as vernier calliper is a device that lets the user measure more
accurately than could be done by reading a uniformly-divided straight or circular
measurement scale. It is scale that indicates where the measurement lies in between two of the
marks on the main scale.

MANUAL CALLIPER- Verniers are common on sextants used in navigation, scientific

instruments used to conduct experiments, machinists' measuring tools (all sorts, but especially
calipers and micrometers) used to work materials to fine tolerances, and on theodolites used
in surveying. The vernier, dial, and digital calipers give a direct reading of the distance
measured with high accuracy and precision. They are functionally identical, with different
ways of reading the result. These calipers comprise a calibrated scale with a fixed jaw, and
another jaw, with a pointer, that slides along the scale. The distance between the jaws is then
read in different ways for the three types. The simplest method is to read the position of the
pointer directly on the scale. When the pointer is between two markings, the user can
mentally interpolate to improve the precision of the reading. This would be a simple
calibrated

1. Outside jaws: used to measure external diameter or width of an object

2. Inside jaws: used to measure internal diameter of an object
3. Depth probe: used to measure depths of an object or a hole
4. Main scale: scale marked every mm
5. Main scale: scale marked in inches and fractions
6. Vernier scale gives interpolated measurements to 0.1 mm or better
7. Vernier scale gives interpolated measurements in fractions of an inch
8. Retainer: used to block movable part to allow the easy transferring of a measurement
caliper; but the addition of a vernier scale allows more accurate interpolation, and is the
universal practice; this is the vernier caliper. Vernier, dial, and digital calipers can measure
 `18

internal dimensions (using the uppermost jaws in the picture at right), external dimensions
using the pictured lower jaws, and in many cases depth by the use of a probe that is attached
to the movable head and slides along the centre of the body. This probe is slender and can get
into deep grooves that may prove difficult for other measuring tools

The vernier scales may include metric measurements on the lower part of the scale and inch
measurements on the upper, or vice versa, in countries that use inches. Vernier calipers
commonly used in industry provide a precision to 0.01 mm (10 micrometres), or one
thousandth of an inch. They are available in sizes that can measure up to 1,829 mm (72 in).

DIGITAL CALLIPER- A refinement now popular is the replacement of the analog dial
with an electronic digital display on which the reading is displayed as a single value. Some
digital calipers can be switched between centimeters or millimeters, and inches. All provide
for zeroing the display at any point along the slide, allowing the same sort of differential
measurements as with the dial caliper. Digital calipers may contain some sort of "reading
hold" feature, allowing the reading of dimensions even in awkward locations where the
display cannot be seen.
 `19

3. BRINELL HARDNESS TESTING MACHINE

The Brinell hardness test method consists of indenting the test material with a 10 mm diameter
hardened steel or carbide ball subjected to a load of 3000 kg. For softer materials the load can
be reduced to 1500 kg or 500 kg to avoid excessive indentation. The full load is normally
applied for 10 to 15 seconds in the case of iron and steel and for at least 30 seconds in the case
of other metals. The diameter of the indentation left in the test material is measured with a low
powered microscope. The Brinell harness number is calculated by dividing the load applied by
the surface area of the indentation.

The diameter of the impression is the average of

two readings at right angles and the use of a Brinell
hardness number table can simplify the determination of
the Brinell hardness. A well structured Brinell hardness
number reveals the test conditions, and looks like this,
"75 HB 10/500/30" which means that a Brinell Hardness
of 75 was obtained using a 10mm diameter hardened steel
with a 500 kilogram load applied for a period of 30
seconds. On tests of extremely hard metals a
tungsten carbide ball is substituted for the steel ball.
Compared to the other hardness test methods, the
Brinell ball makes the deepest and widest indentation, so the test averages the hardness over a
wider amount of material, which will more accurately account for multiple grain structures and
any irregularities in the uniformity of the material. This method is the best for achieving the
bulk or macro-hardness of a material, particularly those materials with heterogeneous structures
 `20

4. METALLURGICAL MICROSCOPE
Metallurgical microscope is the optical microscope, differing from other microscopes in the
method of the specimen illumination. Since metals are opaque substances they must be
illuminated by frontal lighting, therefore the source of light is located within the microscope
tube. This is achieved by plain glass reflector, installed in the tube.
The optical scheme of metallurgical microscope is shown in the picture.

The image quality and its resolving power are mainly determined by the quality of the objective.
The objective magnification depends on its focal length (the shorter focal length, the higher
magnification). The eyepiece is the lens nearest the eye. The image is magnified by eyepiece in
x6, x8 or x10.

The total magnification of the microscope may be calculated by the formula:

M = L*E/ F
Where

L- the distance from back of objective to eyepiece;

F the focal length of the objective;
E- the magnifying power of the eyepiece.
 `21

9. IS Reference Code Number

S.no CODE

1. IS: 2062:2011 Hot rolled low, medium and high tensile structural steel.

2. IS: 1608-2005 Metallic materials tensile testing at ambient temperature.

3. IS: 1599-1985 Method for bend test.

4. IS: 228 (Part - 8)- 1989 Determination of silicon by gravimetric method (for Si 0.05% -
5.0%).

5. IS: 228 (Part - 3)- 1989 Determination of phosphorus by alkalimetery method.

6. IS: 228 (Part - 12)- 2001 Determination of manganese by periodate spectrophotometric

method in plane carbon,low alloy and high alloy steels (for
manganese 0.01 to 5.0%).

7. IS: 228 (Part - 20)- 2003 Determination of carbon and sulphur by infrared absorption
method (for carbon0 .005 to 2.0% and sulphur 0.001 to 0.05%).

8. `IS: 1500-2005 Method for Brinell hardness test for metallic materials.

9. IS: 2500 (Part - 1) 1992-2000 Sampling inspection procedure attribute, sampling plans indexed
by acceptable quality level for lot by lot inspection.

10. IS: 1153-2000 Specification for temporary corrosion preventives hard, film,
solvent deposited.

11. IS: 4163:2004 Steel-Determination of inclusions contents by mirrographic

method.

12. IS: 4748:2009 Steel-Determination delivery requirements for Steel & Steel
product

13. STR: IRS Specification for metal liners for use with ERC (prov.)2013

14. ISO: 9001-2008 Quality management systems requirements

 `22

10. CALIBRATION AND INSPECTION OF TESTING EQUIPMENT

a. CALIBRATION OF TESTING EQUIPMENTS

Up to date calibration of testing equipment i.e. UTM & vernier is maintained at a frequency
of 1 year, calibration stickers indicating the date of calibration and the due date of calibration
is pasted on the respective equipments. These calibration certification are submitted to the
inspecting engineer with every inspection.

b. GAUGES AND ITS CALIBRATION

We have 3 sets of gauges for Drg. i.e. for metal linear to Drg. No. RDSO/T-3738, RDSO/T-
3740, RDSO/T-3742. Two set of each Drg. is sent to RDSO for approval and 1 set of each Drg
are for internal use. These gauges are hardened by heat treatment to have minimum wear and
tear while using it. The gauges approved by RDSO is kept for inspection ( 1 set for inspecting
engineer and 1 set as master gauge ) as advised by RDSO.
 `23

11. MANUFACTURING AND TESTING PROCESS OF METAL LINERS

11.1 INCOMING RAW MATERIAL

11.1.1 For procuring Raw Material/section of metal liners it is ensured that for rolling of
Section/raw material has been procured from the market so as to match With Chemical &
rnechanical properties to confirm to grade designation F 250 Quality C as I laid in Table
1&2 of IS: Billets is procured with the specification that if the steel is killed by silicon
alone , the silicon content should not be less than 0.1% when steel is killed by Aluminum
alone. the Aluminum content not be less than 0.02% when the steel is killed by silicon-
Aluminium, the silicon content should not less than 0.03% and total Aluminum content
should not less than 0.01% . we procure certified copy of Original Invoice and test
certificate from the re-rollers. Traceability of billets to rolled section is maintained by the
manufacturer. The billets is re-rolled into desired metal liners bars and the rolling is done at
following firms.

1. M/s AVDESH TRACKS Ltd. ,VILL. JAWAHARPUR,DERABASSI PUNJAB

The re-roller firm is having facilities of normalizing liner bars through heat treatment in a
separate normalizing furnace by properly soaking in appropriate authentic state for a
suitable period followed by cooling in still air.

11.1.2 Raw material received at work premises is identified/checked by matching the derails
provided in the original invoice.
11.1.3 After proper identification of raw material the raw material unloaded at the work
premises.
11.1.4 The unloaded raw material is Stacked in raw material stock yard heat wise/section
wise.
11.1.5 To ensure that the different heats of raw material do not get mixed up following
information is displayed on each bays of raw material:-
a) Heat no
b) Drawing no./Section
c) Quantity
d) Source of raw material
e) P.O Placing Railway
f) Supplier of billets/bloom
 `24

11.2 CHECKING OF RAW MATERIAL

To demonstrate the achievement of desired quality of raw materials as rolled section are checked
for various properties as per IRS specification metal liners use with Elastic Rail Clips (ProvisionaI)
2013 each heat/section separately for the following:-

1) Visual and from surface defects: In this test raw material is checked visually as hot
rolling in involved in the manufacturing of raw material, hence visual check is required to
check that no over heating not have occurred. Mill scale is also removed from shape &
Section bars with help Of emery paper as for Iron & Steel, All bars are thorough checked
any die marks occur during rolling. Samples are cut randomly from bars & dipped In acid to
test for seam or any other surface defect and details recorded in the Annexure-I. If any seam
is occurred 1 particular heat then the whole heal is rejected & rejection is returned back to
the manufacturing source. After the material is found satisfactory then we go for
dimensional check.

Dimensions :- In this process the raw material is checked dimensionally with the help of
RDSO approved gauges (G-2 & G-6) and drawings. In metal liners all the dimensions are
to be maintained as per RDSO Drg.

for above properties of the rolled section at least 2% bars for each heat are checked. The
dimensions are checked with RDSO approved gauges (G2 & G6) and the observations are
recorded in a Performa given in annexure-1 and same checked with respect to their
acceptability as per specifications and respective drawing.

(1) Chemical composition: From the raw material small pieces are cut & prepared as specified
with the help of shape & surface grinding machine. Three samples from each heat is drawn
for chemical test for ensuring better quality & practically no chance for any type of error.
These polished samples are chemically tested at Govt. approved lab or RDSO approved lab
Indiana Ferro Alloys, Mohali . Chemical composition of 6 elements is checked i.e. Carbon,
Manganese, Sulphur, Phosphorous, Silicon & Aluminum. Raw material test certificate is also
procured from the raw material supplier & to ensure that no human error has been occurred
the chemical test certificate received from the raw material supplier is compared with
chemical test report of the samples got tested internally by us. No raw material is used for
manufacturing of metal liner if it doesnt in the prescribed limit.
 `25

(2) Physical properties Like( Bend test, Yield, Tensile strength & % elongation etc. in this
test dumbles are prepared from bars from each heat for each section for bend test. These
pieces undergoes tensile test , yield and elongation test at 40 Ton capacity UTM machine.
Prescribed limit for yield test is 250 N/mm2 and tensile test I 410 N/mm2. And %elongation
is 23% Bend test pieces are also tested at UTM machine, if material is passed from the test
then the material is issued for production.

(3) Non Metallic Inclusion Contents & apparent Grain Size Determination: The
determination of contents of nonmetallic inclusion and Grain size is done by microscopic
method with the help of Trinocular Metallurgical Microscope having Grain Size Eyepiece
WF 10x with adjustable focusing calibration side 1/100 mm form the raw material small
pieces are cut & prepared as specified with the help of shaper & polishing machine. Two
samples from each heat are drawn and checked for inclusion contents in accordance with IS:
4163-2004 in longitudinal section with inclusion rating shall not be worse that 2.0. A.B.C.D.
for both thick and thin series when compared to the chart for determining the inclusion
content of secondary refined steels (Fig.) of IS 4163-2004. The microstructure of the samples
is checked with the fine grain ferrite and pearlite with grain size of ASTM-6 of finer.

Two Nos. of bars for each heat and for each section are checked for the above properties
results of observations are recorded in a pro-forma given in Annexure-2,3&4 and same are
seen for their acceptability as per specification and also compared with the test certificates.
If the variation is beyond the specified tolerance the heat section is rejected and stored
separetly till is disposed off. Only passes material in all parameters is used for manufacture
of the product.
 `26

12. MANUFACTURING PROCESS & INPROCESS CHECKS

After satisfactory acceptance of raw material the manufacturing process starts with first
cutting operation only one heat is cut at a time, material is cut into desired lengths as per
required. After cutting, slotting operation is done. After slotting , notching operation is done
followed by stamping, coining and parting operation. Gauging is done by RDSO approved
gauges only before oiling and packing. The material is packed and sacked in batches and
offered for inspection. We are checking the material during its manufacturing at various
stages and maintaining the values in Annexure number 5,6&7 are used for the purpose.
Detail of various operation as under ,

(1) CUTTING OPERATION: Cutting of raw material is done with Power Press of sufficient
capacity. The Die work is done with the help of stoppers engraved for dimension control.
The prescribed length for all types of metal liners is 107.5 to 109 mm. To check taper while
cutting angle gauge is used. The dies are checked regular intervals and faces are sharpened
at surface grinding machine if bluntness occurs. To demonstrate the achievements required
quality at least 20 samples of metal liners are checked every hour during the cutting
operation.

(2) SLOTTING OPERATION: After cutting the material undergoes slotting operation at
Power Press of sufficient capacity. Here also dies are operated with stoppers engraved as
per prescribed limit. These stoppers are made of Tank Plates having very low wear and tear.
The slotting operation is very important operation with tolerance is only 0.5mm. This
tolerance is as per area available between inserts and tracks while lying of metal liners at
railway track. This dimension is very crucial and important and is prescribed length is
77.5mm to 79mm which is designed as per tolerance of area between SGCI to rail foot. All
the die operation is done with the help of guide die which control press stocks so that the
force occurs on the material should be cut as per desired dimension. This slotting operation
is the basic operation for manufacturing metal liners. To demonstrate the achievements
required quality at least 20 samples of metal liners are checked every hour during the
cutting operation and the data are recorded as per per-forma given in the Annexure-5.

(3) NOTCHING OPERATION : In this operation notching /V-Cutting is done with help of
die guided plate and stoppers. Notching is done in such a manner that the upper dimension
 `27

is maintained equivalent to inner dimension of 77.5 to 79mm. This operation is done on

power Press. The compound die operation is such that it cuts two pieces from two sides in
single stroke. Edge of dies are sharpened at surface grinder daily before start of production
and periodical checks are made in the hexagonal cutting die edges.
(4) STAMPING AND COINING OPERATION : As the whole process of manufacturing of
metal liner is cold process and ther cutting are done with power press with single strokes
hence some times after slotting and notching operation there is slight twist in the material.
In coining operation dies are made in such a manner that the metal liner became straight
line and all twists are removed by press stroke i.e.coining operation. The two ends of ribs
with width of 14.5 to 15.5mm would be having stamp initial as one end as IM stands for
our firm's initial and 14 stands for the year of manufacturing 2014 and other end stamped
as RT-3738,RT-3741,RT-3742,dependig on the type of liner manufactured . The die is
working is such a manner that the lower end is fitted as per railway track on which the liner
is going to be fitted ultimately and press strokes guides it . As per the requirement RDSO
drawings the punching is done properly.

(5) PUNCH MARKING OF LOT NO: All liners shall be punch marked with lot no. along
with other requirement of respective drawing of liner.

(6) PARTING OPERATION : As the raw material is rolled in such a way that two pices of
liners are rolled together. Parting is done in such a way that ther vertical stroke of the
Power Press parts the product into two liners of equal dimenion . Here also the total die
operation is guided by the guide , if the cutting edges become blunt then the edges are
sharpened at surface grinding machine.

(7) GRINDING : To remove the burs & sharp edges of liners each metal liner grinded on
bench grinder s as per the requirement of respective drawing.

(8) SCREEN PRINTING : Screen Printing as per Drg. Is also marked to distinction between
GS T- 3741) & NGS(T-3742) liners. In case their purchaser desires to dispenser with screen
printing on the liners then either it is specifically mentioned in the purchase order/contract.

(9) GAUGING & INTERNAL TESTING OF FINISHED PRODCUTS : After 100% Visual
Test gauging is done with help of RDSO approved Gauges from Gauge No. G-1 to G-
8, G-1 Gauge is for to check the thickness of the rib. G-2 Gauge is for to check the
thickness of liner, G-3 Gauge is for to check the length of horns, G-4 is to check the
 `28

length between two horn. G-5 is to check the internal width ,G-6 is to check the overall
width of the liner , G-7 and G-8 are to check the overall fitting and sitting of liner Sampling
Plan IS-2500 Part-1-2000 with sampling size as per Table 1 GIL-II and
acceptance/rejection level of Table 2 A(Single sampling plan for normal inspection) AQL
2.5% is stricity followed .

(10) MACRO EXAMINATION AND HARDNESS TEST: If the material is within

acceptance range of the sampling plan IS: 2500 Part-I GIL-II AQI. 2.5% then 5% liners or
minimum 5 nos are taken for hardness test. In the macro examination test liners are
examined for surface flaws, laminations, rough jagged & imperfect edges etc. the other
harmful defects are checked by etching process in hot acid.If the liners are found OK &
free from all defects that the lot is considered as accepted lot in terms of macro
examination. Samples drawn for hardness test are tested for hardness on the middle portion
of the liner in accordance with IS:1500-2005. If the Macro examination (Freedom from
Defect) is satisfactory as per Annexure-XI & Hardness Test is not less than 115
BHW(BHN/HB/HBS) as per Annexure XIII, then said lot is accepted and offered for final
inspection after oiling and packing.

(11) INCLUSION CONTENT & GRAIN SIZE TEST: For each test 5% of the sample size or
Minimum 5 nos are checked for inclusion test the inclusion rating when determinate as per
IS: 4163-2004 should not be worse than 2.0 A,B,C,D both for thick & thin series when
compared to the chart in fig. 2 of IS: 4163-2004. The grain size is determined as per IS:
474-l998 and should be fine with grain size of ASTM-6 or finer. The record is maintained
as per Annexure XII

(12) CHEMICAL COMPOSITION: Chemical composition from the finished material is done
on small pieces cut & prepared as specified with the help of shaper & surface grinding
machine as described in clause 11.2.2 (i) shall be tested after manufacturing Three sample
per lot from each section is drawn for chemical test. Record is maintained as per Annexure-
IX 13.0 Physical Properties like (Bend test, Yield, Tensile Strength & % Elongation etc. as
described in clause 11.2.2 (ii) shall he tested after manufacturing. Three Sample per lot
from each section is drawn for physical test. Record is maintained as per Annexure X
 `29

13. OILING & PACKING

After the material is found satisfactory the material is send for packing, before packing
screen-printing or oiling is done with rust preventive oil as specified or as required by the
purchasing agency. After oiling, packing of liner is done in old gunny bags (Containing 100
pieces of liner in each bag). Stacking is done in heat wise/batch wise with 100 bags per
batch. After this whole process the material is offered for final inspection the authorized
inspecting authority, inspection is done in our own premises and the sampling plan used by
the inspecting agency is as per inspection level II and AQL 2.5% shall be as per IS-2500 Part
1-2000. Every day record of raw material received, heat No. 1nvoice NO Production don
balance quantity of raw material, quantity dispatched along with rejection shall be
maintained.
 `30

14. GENERAL CLEANLINESS OF WORK SHOP

We follow the concept "Cleanliness is near to God" hence daily general cleanliness is done.
Before the start of the production lubrication and proper oiling is done on all the
machineries and after production the scrap so generated is stacked at the scrap stacking
store.
 `31

14.1 Quality Assurance System- Inspection and Testing Plan

Subject/ Parameters Sample Size & Mode of Acceptance Rejection details/
Product/ for inspection its frequency inspection/ Limit/Criteria/ Reprocesses/
Process Parameters for Equipment Specified Value Scraped
Inspection

Raw Surface defect 100% Visual Free from all Any bar found
Material Examination surface defects as defective return
mentioned in to supplier
specification

Dimension 2% Bars of By RDSO To be accepted by Rejected and

each section approved respective gauges return to
gauges supplier

Chemical 2 samples of Complete C=0.20% Max Rejected and

Composition each section chemical Mn=1.5% Max return to
analysis as per Si=0.4% Max supplier
S=0.040% Max
specification
P=0.040% Max
Physical tests 2 samples of On UTM Bend test=Internal Rejected and
each section dia min (3t) Yield= return to
(Bend test, Min 250N/mm sq) supplier
yield Tensile
strength & % Tensile Strength=
elongation) Min 410N/mm2

%Elongation=23%
min

Inclusion 2 samples of On trinocular Inclusion rating<2.0 Rejected and

Content & each section Metallurgical A,B,C,D both for return to
Grain size test per heat Microscope thick & thin as supplier
compared chart in
fig 2 of I.S 4163-
2004. Grain Size:
Fine grains ferrite
and Pearlite with
grain size if ASTM-
6 or finer

Product Slotting 10 samples By internal To be accepted by Rejected and

Control/ are checked gauges respective gauges scraped
internal every hour
testing while
mft. Stamping & 10 samples By internal To be accepted by Rejected and
are checked
 `32

Coining every hour gauges respective gauges scraped

Grinding Each liner On bench As per the Rejected and

grinded grinders requirement of scraped
respective drg.

Process Surface 100% Visual Free from all surface Any sample
Control/ defects Examination defects as mentioned found defective
Final testing in specification cut in two pieces
& scraped

Dimension 2% subject to By RDSO To be accepted by Rejected & cut in

min. of 20 approved respective gauges two pieces &
samples of gauge scraped
each section

Chemical 3 sample of Complete C=0.22% Max Rejected & cut in

Composition each section chemical Mn=1.55% Max two pieces &
of each lot analysis as per Si=0.43% Max scraped
specification S=0.045% Max
P=0.045% Max
Physical tests 3 sample of On UTM Bend test=Internal Rejected & cut in
(Bend test, each section dia min (3t) Yield= two pieces &
yield Tensile of each lot Min 250N/mm sq) scraped
strength & %
elongation Tensile Strength=
Min 410N/mm2

%Elongation=23%
min

Freedom 5% of the Macro Free from all surface Rejected & cut in
from surface samples size Examination defects as per clause two pieces &
defect or min. 5 6.3.1 of specification scraped
pieces per lot
of each
section

Inclusion 5% of the On Trinocular Inclusion rating<2.0 Rejected & cut in

content & samples size two pieces &
grain size test or min. 5 Metallurgical A,B,C,D both for scraped
pieces per lot thick & thin as
Microscope compared chart in
of each
section fig 2 of I.S 4163-
2004. Grain Size:
Fine grains ferrite
and Pearlite with
grain size if ASTM-
6 or finer

Hardness 5% of the On Hardness Minimum value 226 Rejected & cut in

samples size HBW (BHN/HB/ two pieces &
 `33

Test or min. 5 Tester HBS) scraped

pieces per lot
of each
section
 `34

Bibliography

1) www.google.co.in

2) Wikipedia.com

3) India metal executive

4) Yahoo.in

5) Manufacturing Process by R K Rajput

6) Manufacturing technology by R Ragwanshi