Beruflich Dokumente
Kultur Dokumente
BWEL
BHARAT WAGON & ENGINEERING COMPANY LTD.
(A Govt. of India Undertaking, Ministry of Railways)
MUZAFFARPUR
SUBMITTED TO :- SUBMITTED BY :-
ER.SATISH KUMAR NAME : FAIZ AHMAD
(HOD, MECHANICAL DEPARTMENT) ROLL NO. - 1714654
TO DEC 2017 SEMESTER: - 7TH
SESSION : AUG. 2017
DEPARTMENT OF MECHANICAL
ENGINEERING
HCTM TECHNICAL CAMPUS, KAITHAL
ACKNOWLEDGMENT
FAIZ AHMAD(1714654)
CONTENTS
4. Template Shop
5. Drilling Shop
6. Machine Shop
8. Finishing Shop
9. refrences
CHAPTER 01 INTRODUCTION
The Bharat Wagon & Eng. Co. Ltd muzaffarpur unit is engaged
in manufacture of goods wagon for INDIAN RAILWAYS. It also
manufacture and supplies sugar machineries. Agriculture
implements and other mechanical and structural jobs.
The company was started an English man Mr. Arthur Butler
around 1870, when industrial revolution was taking place. In the
starting period the company did not have more than 120 workers.
During this the business expanded greatly and the number of
employees increased tremendously. The company has 600
employees during the period
Up to the april 1996 the company was managed by M/S jubilee
agents limited on 1st may 1946. After that british management
sold the same to Indians and since 1948 the management was in
the hands of Indian businessman. The production of company
was renamed as BHARAT WAGON & ENGG. CO. Ltd.
Muzaffarpur
Presently more than 400 employees are contributing their
services to this unit of BWEL.
POWER PRESS
The constructional features of power press is almost similar to the
hand press the only difference being the arm instead of driven by
power. The power press may be designed as mechanical or
hydraulic according to the type of working mechanism is used to
transmit power on the ram. In a mechanical press, the rotary
motion is obtained from electric motor is obtained from an
electric motor is converted into reciprocating moment of the arm
by using different mechanical device. In a hydraulic press the
fluid under high pressure is pumped on one side of piston and
then on the other in a hydraulic cylinder to drive the reciprocating
movement. Power press is driven by a crank and connecting rod
mechanism. The working of power press is similar to as that of
hand press. The punch is fitted on the end of the ram and die is
attached on the bolster plate. The flywheel is mounted at the end
of the crank shaft stores up the energy for maintaining a constant
downward speed of ram when the sheet metal is pressed between
punch and the die.
POWER HAMMER
On this machine the
part, which is to be
manufactured, is kept
on the die after heating
in the furnace and the
arm is allowed to strike
the component on the
die. Due to strike of the
ram the component
takes the shape of that
of the die.
TEMPLATE SHOP
TEMPLATES:-
Template shop forms the layout of the wagon and the structure
of wagon. Template shop give the required dimension of metal to
all shop special metal cutting.
CHAPTER 05 CUTTING AND WELDING SHOP
SHEARING MACHINE
On the shearing machine the plate to be cut should be flat and the
thickness should not be
more then 8mm for
cutting the flat plate is
kept on the bed of the
machine and is moved
manually. It is done with
the help of crane. It
consists of cutting blade
and no. of pressing bolts.
Which holds the plate.
CHIPPING MACHINE
This machine has a vertical column and two horizontal arm. One
arm consist of template and consist of the welding torch and the
small driving motor. It can cut the plate upto 35mm to 40mm,
through the welding torch oxygen and acetylene gas supplied.
This machine requires extra
amount of oxygen gas so
two oxygen pipe are
connected to the torch. To
cut the plate in desired
shape, the same shaped
template is fixed to the
upper arm and the magnetic
roller of the second i.e.
lower arm is touched to the
template. The torch moves
through the profile of the
template and the plate cuts
in the desired shape
KANGAROO MACHINE
CHIPS
INTRODUCTION
The arm is made of high class cast iron, arm slide is under strike
heat treatment and grinding 2HP motor can be provided diven
sped section under heavy duty cutting. The main spindle is
balanced by special spring. The overload protective devices can
secure the operator against injury.
SPECIFICATION
PARTS:
BASE
COULMN
RADIAL ARM
DRILL HEAD
UNIVERSALDRILLING MACHINE
SENSATIVE DRILLING MACHINE
DRILLING OF JOB
The following are the drill size & which are used for drilling in
this shop is 5mm, 6mm, 11mm, 13.5mm, 17.5mm, 21.5mm and
23.5mm. These
are the drill size
which are used here
for drilling marking
takes a lot of time
and it requires
more skilled
person for marking. So drilling of component by marking is used
for a few, cases.
For mass production of components jig is used for drilling .
The thickness of the jig plate, which is in practice, is 12mm. To
manufacture jig a hole greater dia. is done in the jig plate and
bush of required drill size is fitted in the hole . The material of the
jig bush is class IV and IS:1875 .
FORGING PROCESSES
CHAPTER 07 MACHINE SHOP
INTRODUCTION
This is the biggest shop of this organization. In this shop there are
various types of machines. Such as.
LATHE
CENTER LATHE
CONSTRUCTION:
BED
HEAR STOCK
TAIL STOCK
CARRIAGE
FEED MECHANISM
SCREW MECHANISM
THE BED
The bed is a robust base that connects to the headstock
and permits the carriage and tailstock to be aligned parallel with
the axis of the spindle.
This is facilitated by
hardened and
ground ways which
restrain the carriage and
tailstock in a set track.
The carriage travels by
means of a rack and
pinion system, lead
screw of accurate pitch,
or feed screw.
FEED MECHANISM
SHAPER MACHINE
Shapers have been largely
superseded by milling
nachines or grinding machines
in mordern industrial practice.
The basic function of the
machine is still sound and
tooling for them in minimal and very cheap to reproduce. They
can invaliable joiing or repair shops where only one or few pieces
are required to be produce and the alternative methods are cost or
tooling intensive. The mechanically operated machines are
simple and simple and robust in construction, making their repair
and upkeep easily achievable.
TYPES
Shapers are mainly classified as standard, draw cut, horizontal,
universal, vertical geared, crank, hydraulic, contour and travelling
head. The horizontal arrangement is the most common. Vertical
shapers are generally fitted with a rotary table to enable curved
surfaces to be machined. The vertical shaper is essentially the
same thing as a slotter (slotting machine), although technically a
distinction can be made if one defines a true vertical shaper as a
machine whose slide can be moved from the vertical. A slotter is
fixed in the vertical plane.
Small shapers have been successfully made to operate by hand
power. As size increases, the mass of the machine and its power
requirements increase, and it becomes necessary to use a motor or
other supply of mechanical power. This motor drives a
mechanical arrangement (using a pinion gear, bull gear, and
crank, or a chain over sprockets) or a hydraulic motor that
supplies the necessary movement via hydraulic cylinders.
OPERATION
The drive arm revolves less for the return stroke than for the
cutting stroke, resulting in a quicker return stroke and more
power ful cutting stroke.A shaper operates by moving a hardened
cutting tool backwards and forwards across the work piece. On
the return stroke of the ram the tool is lifted clear of the
workpiece, reducing the cutting action to one direction only.
The work piece mounts on a rigid, box-shaped table in front of
the machine. The height of the table can be adjusted to suit this
work piece, and the table can traverse sideways underneath the
reciprocating tool, which is mounted on the ram. Table motion
may be controlled manually, but is usually advanced by
automatic feed mechanism acting on the feed screw. The ram
slides back and forth above the work. At the front end of the ram
is a vertical tool slide that may be adjusted to either side of the
vertical plane along the stroke axis. This tool-slide holds
the clapper box and tool post, from which the tool can be
positioned to cut a straight, flat surface on the top of the work
piece. The tool-slide permits feeding the tool downwards to
deepen a cut. This adjustability, coupled with the use of
specialized cutters and tool holders, enable the operator to cut
internal and external gear tooth profiles, splines, dovetails, and
keyways. The ram is adjustable for stroke and, due to the
geometry of the linkage, it moves faster on the return (non-
cutting) stroke than on the forward, cutting stroke. This action is
via a slotted link or Whitworth link.Cutting fluid may be
employed to improve the finish and prolong the tools life.
USES
The most common use is to machine straight, flat surfaces, but
with ingenuity and some accessories a wide range of work can be
done. Other examples of its use are:
Keyways in the boss of a pulley or gear can be machined
without resorting to a dedicated broaching setup.
Dovetail slides
Internal splines
Keyway cutting in blind holes
INTRODUCTION
CENTRE SILL
This is manufactured in the sub-assembly shop. To manufacture
two Z channels are welded after welding the supporting plate is
welded to require position and then it is sent for marking. After
marking, drilling is done and coupler cashing is fitted at both the
ends and riveting 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. The length of the center sill should be 9784mm and the
width should be 2960 mm. The centre seal is placed on the fixture
and cross bar and bolster is welded to it . After welding these two
seal bars are attached and is welded . Now this is known "Under
frame ". Now riveting is done. The head stock is also welded to
the centre sill at both the ends. The gusset plate and the cross bar
bottom plate is welded to bolster and cross bar respectively . The
strenger is welded to the under frame throughout 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 riveted
and welded to the under frame . This complete box is kept on the
wheel assembly and then it is sent for finishing.
CHAPTER 09 FINISHING SHOP
INTRODUCTION
After this the wagon is painted and the specifications are written
on the wagon and then dispatched to INDIAN RAILWAY .
FLOW CHART OF WAGON (BOXNHL MBS)
WHEEL SET BOGIE FROM
& STROKE
OTHER COMPONENT
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