Page 1 of 7

TECHNICAL SPECIFICATION
INDEX No. 4DMW/SPEC---
DIESEL LOCO MODERNISATION WORKS PATIALA

PURCHASE SPECIFICATION FOR SHEET

PROCUREMENT OF CRANKSHAFT GEAR
FORGINGS PROOF MACINED THROUGH
HARDENING
DATE
DRG. NO. 3DCW/SK-258

1 GENERAL:This specification covers manufacture and supply of Gear crankshaft

forgings proof machined to drawing no. 3DCW/SK-258 for ALCO Locomotives

2 APPLICATION
Gear Crank shaft is a forged component using high quality steel conforming to AISI
A86 B45 grain size 5 to 8 or finer without any carbon segregation.
These are critically loaded engine components. These are responsible for
transmitting the forces from crankshaft to camshafts and related
components.Therefore, both its physical strength as well as its geometrical accuracy
is of utmost importance to ensure reliability in engine performance.

3 COMPLIANCE WITH STANDARDS:The gears shall comply with the following

specifications
i) D93300 (Materail Specification)
ii) D 93300 ac (Heat treatment note)
iii) FGS 0010 (Forging Standard)
iv) 4DMW/Spec-037 (Inspection standard for forging items)
v) Any other standard as per relevant drg./specification.
4 SUBMISSION OF TENDER QUOTATIONS
4.1 The supplier shall submit the quote for Gear crank shaft forgings (proof machined)
covering the requirements as laid down in para 3 above ,Drawing no.3DCW/SK-258
and related drawing no.10140475
4.2 The supplier shall submit the clause wise comments on :
i) Detailed list of machines/equipments as mentioned in Para 6.1 and 6.2 of the
specification.
ii) Past performance as per Para 6.11
iii) Quality Assurance Program including machines/equipment to be used in the
manufacture as per Para 5.
 Page 2 of 7

TECHNICAL SPECIFICATION
INDEX No. 4DMW/SPEC---
DIESEL LOCO MODERNISATION WORKS PATIALA

PURCHASE SPECIFICATION FOR SHEET

PROCUREMENT OF CRANKSHAFT GEAR
FORGINGS PROOF MACINED THROUGH
HARDENING
DATE
DRG. NO. 3DCW/SK-258

5 QAP:
The QAP shall be treated as one of the basis for the approval of the firm for
manufacture of gears. The firm shall have a well-defined Quality Assurance Plan
(QAP) for manufacture of the gears and shall submit the same for approval to DMW
as a part of compliance of this STR.

The QAP must include source of procurement of raw material, test procedure /
standards followed for acceptance of raw material and criteria of stage inspection /
final inspection of the product during the process of manufacturing. Further, it shall
be a comprehensive document covering the following major aspects:

5.1 Complete process Flow Chart covering all steps of manufacture of the product (or for
a family of product, if the process is same) shall be clearly listed.

5.2 Details of machines used for all the steps involved in manufacturing operations of
gears shall be included as per format given below:
i) Date of commissioning.
ii) Machine capacity, accuracy & status of calibration.
iii) Details of operations involved in complete manufacturing process.

iv) Details of UT test and MPI test facility.

5.3 Firm shall have to declare details of the manufacturing operations to be conducted in
house or by outside agencies. Details of the outside agencies shall be indicated and
prior approval shall be taken from DMW, which reserves the right to inspect these
firms also.
A general format for guidance is given below:

6 SPECIAL INFRASTRUCTURE CONDITIONS

 Page 3 of 7

TECHNICAL SPECIFICATION
INDEX No. 4DMW/SPEC---
DIESEL LOCO MODERNISATION WORKS PATIALA

PURCHASE SPECIFICATION FOR SHEET

PROCUREMENT OF CRANKSHAFT GEAR
FORGINGS PROOF MACINED THROUGH
HARDENING
DATE
DRG. NO. 3DCW/SK-258

6.1 FORGING FACILITIES:

6.11 Firm should be QS 9000/ISO 9000 certified company and should have past
experience in forging Gear blanks of size 400 mm dia (or higher) weighing 55 kg.
(approx.)
Tenderer must attach proof in this regard along with the offer.

6.12 Firm should have following forging & heat treatment facilities inhouse or can have
tender specific tie-ups with ISO Certified firms having fallowing facilities subject to the
dispensation given in para 7.4 of the specifications :

i) Billet heating electrical/oil-fired furnace with multipoint temperature control and

recording facilities.
ii) Oil quenching tank with agitating, cooling and multipoint temperature control
system.
iii) Stress relieving/tempering furnace (up to 650°C min.) with continuous multipoint
automatic temperature recording and control system. The time-temperature
graph should have proper scaling arrangement or software controlled.

iv) Forging machine/ hammer (5 ton or higher) to suit job requirement

v) Trimming machines
vi) Ultrasonic testing machine with scanning saving facility.
vii) Metallurgical lab testing facility with Microscope facility for taking microstructure
photographs.
viii) Shot blasting facilities of apropriate capacity (more than 700mm job diameter)
and to achieve surface finish of Sa 2 1/2 with suitable conveyor alongwith shot
separator.
ix) Rockwell hardness tester fixed type suitable for job requirement.
x) Digital and portable hardness tester
xi) Micro hardness tester
xii) Magna particles / Magna flux testing machine along with dark room

6.2 MACHINING FACILITY:Tenderer should have cutting,turning and milling facilities to

suite the requirements of the tendered item inhouse or can have tender specifictie-
ups with a QS 9000/ISO9000 CERTIFIED Company for their limited requirements.

7 HEAT TREATMENT PROCESS:

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TECHNICAL SPECIFICATION
INDEX No. 4DMW/SPEC---
DIESEL LOCO MODERNISATION WORKS PATIALA

PURCHASE SPECIFICATION FOR SHEET

PROCUREMENT OF CRANKSHAFT GEAR
FORGINGS PROOF MACINED THROUGH
HARDENING
DATE
DRG. NO. 3DCW/SK-258

7.1 Before going for heat treatment of the job, it is necessary to punch identification
marks with 5-8 mm letter height on the job. It is also necessary to punch heat number
and date of heat treatment on the job’s test piece.
7.2 Punching identification marks shall be provided on gear and test piece (identification
by etching is not allowed).
7.3 Gear vendor shall submit forging supplier’s certificate regarding forging ratio,
inclusion rating, chemical composition and grain size on each lot of gears supply.

7.4 The firm shall, preferably, have its own heat treatment facility. In case, such facility is
not available with the firm, the heat treatment can be sub-contracted to an external
agency which has all relevant, ISO & other quality control certifications.
7.5 A heat treatment furnace for stress relieving capable of handling the entire production
shall be available. The furnace shall be either oil fired / Electric type. At least two
thermocouples shall be available on each furnace for confirmation of temperature.
Firm shall have adequate stand by power generation to avoid breakdown of power
during heat treatment.
7.6 Following guidelines shall be followed for process control & shall be incorporated in
QAP:
i) The furnace shall have multi-point automatic continuous temperature recording
arrangement with digital indicator for each point. The heat treatment recorder for
time– temperature graph shall have sealing arrangement.

ii) Proper numbering and maintenance of record shall be kept for items under
stress relieving for traceability with time–temperature curve and date.
iii) Proper sealing arrangement of heat treatment furnace doors shall be available to
avoid oxidation / scale formation on the surface of beams being heat-treated.
There shall be arrangement for positive pressure inside the furnace to avoid
entry of air from outside.
iv) Positioning of the nozzles of oil fired furnace, if used, shall be such that the
flames do not make direct contact with the beams/ charge.
v) The heat treatment furnace shall be calibrated using thermocouples for
assessing temperature at different zones at various temperature ranges. The
calibration shall be done at least once in a year & proper records shall be
maintained.
vi) Thermo-couples & temperature indicators shall be calibrated at least once in six
months.
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TECHNICAL SPECIFICATION
INDEX No. 4DMW/SPEC---
DIESEL LOCO MODERNISATION WORKS PATIALA

PURCHASE SPECIFICATION FOR SHEET

PROCUREMENT OF CRANKSHAFT GEAR
FORGINGS PROOF MACINED THROUGH
HARDENING
DATE
DRG. NO. 3DCW/SK-258

vii) Records of heat treatment indicating loading item’s sr. no. & quantity, charging
items, date, starting time, soaking time and stopping time shall be available in
logbook.
viii) The firm shall have qualified person to carryout for heat treatment and must have
a qualified Metallurgist on its permanent roll. The qualification certificate of the
person shall be submitted to DMW alongwith QAP.

8 LABORATORY FACILITIES:The firm shall also have certified persons for carrying
out visual testing, Magnetic Particle Testing, Ultrasonic Testing, Radiographic
Interpretation and Liquid Penetrant testing etc. Such a person shall be on permanent
roll of the company and certificate of qualification shall be submitted to DMW
alongwith QAP.
Physical test (i.e. Ultimate tensile strength, yield stress and % elongation) shall be
conducted at the works of the gear manufacturer. This is necessary for testing of the
coupon (test piece).

9 SUPPLIER'S SCOPE OF WORK

i) The contractor or the tenderer meeting the condition of special infrastructure as laid
down in para 6 & 7 of the specification shall be considered for Bulk supplies

ii) The contractor or successful tenderers shall submit QAP to CME/DMW for approval prior
to start of manufacturing activity. QAP is a part of vendor development process.

iii) Supplier to undertake the manufacturing activity after the approval of QAP by CME or his
authorosed representative.

10 PROTOTYPE INSPECTION: Prototype forging for the tendered item shall be

approved by RDSO.The supplier will provide following test certificates alongwith test
reports at the time of offering prototype to RDSO.
10.1 RAW MATERIAL
i) WTC from the source complying following operation in the steel making process:
Electric furnace melted
Vacuum degassed and argon bubbled
Ladle refined
Argon shrouded during pouring.

ii) Chemical composition as per Spec. No. D93300.

iii) Microstructure photographs of fine grain ASTM grain size 5 to 8 or finer without
any carbon segregation.
 Page 6 of 7

TECHNICAL SPECIFICATION
INDEX No. 4DMW/SPEC---
DIESEL LOCO MODERNISATION WORKS PATIALA

PURCHASE SPECIFICATION FOR SHEET

PROCUREMENT OF CRANKSHAFT GEAR
FORGINGS PROOF MACINED THROUGH
HARDENING
DATE
DRG. NO. 3DCW/SK-258

iv) The inclusion rating not exceeding: 2.OA, 2.OB, 2.OC and 2.OD for both thick
and thin series.
The worst field of each type of inclusion shall be determined in accordance with
IS:4163 (Latest).

v) Hardenability test in accordance with IS:3848. Firm shall submit hardness curve.

10.2 FORGINGS
i) Mechanical Properties ( as per D 93300 ac.): Normalised ,quenched and
tempered to fallowing mechanical properties:
Test specimen: Please refer FGS-0010 and tests shall be conducted as per
FGS-0010

mechanical Property min value

Tensile strength(psi) 165,000
Yeild point (psi) 135,000
Elongation 12%
Reduction area 40%
Hardness (Brinnel) 341-371
ii) Microstructure photographs of fine grain ASTM grain size 6 to 7 or finer

iii) Macrostructure (grain flow sample) as per Part No. 10141649. Firm shall submit
photograph of grain flow pattern.

iv) Heat treatment documentation with control for Normalise,quench and tempering
details as per Spec. D93300 ac alongwith Time-temperature curve.

v) Hardness 341-371 Brinell as per D 93300 ac and location as per respective

drawing.
vi) MPI test report as per Spec. 31PD 5672.
vii) Dimensional check sheet of the component as per Part No. 10140475.
viii) Test bar (additional).
*Test specimen shall be taken as per FGS-0010 and tests shall be conducted as per
FGS-0010.Firm have to conduct above tests at NABL approved lab.

10.3 After the prototype is approved by RDSO, the supplier shall undertake the
machining activity and offer the tendered item to DMW for final inspection as
part of prototype approval.
 Page 7 of 7

TECHNICAL SPECIFICATION
INDEX No. 4DMW/SPEC---
DIESEL LOCO MODERNISATION WORKS PATIALA

PURCHASE SPECIFICATION FOR SHEET

PROCUREMENT OF CRANKSHAFT GEAR
FORGINGS PROOF MACINED THROUGH
HARDENING
DATE
DRG. NO. 3DCW/SK-258

11 CONDITION OF CONTRACT
The supply shall be as per the standard IR / DMW conditions of contract.
12 REGULAR INSPECTION
i) Prototype inspection of forging shall be carried out by RDSO. Regular inspection
shall be done only after prototype approval by RDSO. The minimum sample size for
prototype inspection should not be less than 5 (five)
ii) Regular final inspection will be conducted by RITES for Bulk supplies.
iii) The supplier shall make available all necessary tools, gauges, fixtures, equipments etc. to the
inspecting official at his premises free of cost. The supplier shall also make available all
records concerned with manufacture and procurement of parts to the inspecting official.
Where the supplier does not have necessary facilities to conduct any required tests and
inspections at his premises, he shall arrange for such test and inspections elsewhere e.g. his
sub-vendor or sub contracted inspection agency/lab at his cost.

13 PACKING AND MARKING:

i) The components should be suitably applied rust preventive before dispatch and shall be
packed so as to prevent transit damage or deterioration during storage before use.The
component itself shall be marked “Electric Etch” with 3/16” letters for the following details

Part number & seriol no.

Vendor’s code
Year of manufacturing

ii) The component will be packed individually and shall be marked on the wooden packing box
with:

DMW order number

Manufacturer name
Batch/lot number
Year of manufacturing