Rail Coach

Factory
Kapurthala
TRAINING REPORT ON
MACHINE SHOP

Submitted To: -
Submitted By:-

NIHAL KUMAR

V.T NO - 5869

Acknowledgement
Rail Coach Factory, Kapurthala is considered one of the best manufacturing
firms in entire Asia. The technology used here is considered most advanced. So
training at R.C.F has been a great experience of our life .We are exposed to new
and advanced technology and right kind of industrial training and industrial
atmosphere.

I am highly thankful to Mr. R K Sharma (Chief Instructor, Technical

Training Centre) to assist me with their knowledge and continuous help
extended by them.

I am further grateful to Mr.R.K KHANNA and all the shop superintendents

workers of various shops for their knowledge, unforgettable support and
professionals guidance.

And last but not least I am very thankful to all friends and fellow trainees for
intending their corporation during the completion of the training.

OBJECTIVE OF 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 one-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.
 TECHNICAL TRAINING CENTRE

Technical training center is the centralized training center for technical

aspects of coach building, prototype development. Railway administrative rules,
budget, accounts and computers etc.
This center arranges training for probationers, trainee from different
colleges/ institutes crash courses for staff, staff from other railways for new
design of coaches built at rail Coach Factory, Kapurthala. Center has its own
small workshop to provide hands on practical sessions other than the production
shop. Faculty members with different exposure expertise are there for providing
deep and through guidance in different field.

For effective visual demonstration center has its own video film room and
samples of equipment and systems like air brake, air conditioners coach cress
section modules etc has been kept in assembled stage along with its loose
components for working demonstration.

Senior staff (Chief Instructor) of TTC set schedule for the trainees having
close watch and co-ordination with different production shops for complete
awareness and knowledge of modern manufacturing process, stages, latest
machinery, tools and techniques involved coach industry with high quality
standards as per ISO9001.

In net shell TTC is a unique combination of technical educational

institute and production shops.
MACHINE SHOP
 LAYOUT OF MACHINE SHOP

CHIEF
INSTRUCT0R 1.UNIVERSAL
OFFICE OF M/C MILLING
SHOP MACHINE

10.SHEARING
MACHINE
11.SCRA
P
3.PEDESTAL
GRINDER MACHINE
ENTRY
4.SHAPER

9.BENCH VICE

6.LATHE MACHIN
E

8.POWER HACK
SAW

MACHINE SHOP
1.Lathe Machine :-

A lathe is
a machine
tool which
turns
cylindrical
material,
touches a
cutting
tool to it,
and cuts
the
material.
The lathe
is one of the machine tools most well used by machining .
A material is firmly fixed to the chuck of a lathe. The lathe is
switched on and the chuck is rotated. And since the table which
fixed the byte can be moved in the vertical direction, and the
right-and-left direction by operating some handles.

It touches a byte's tip into the material by the operation, and

make a mechanical part.

The purpose of a lathe is to rotate a part against a tool whose

position it controls. It is useful for fabricating parts and/or
features that have a circular cross section. The spindle is the
part of the lathe that rotates. Various workholding attachments
such as three jaw chucks, collets, and centers can be held in
the spindle. The spindle is driven by an electric motor through a
system of belt drives and/or gear trains. Spindle speed is
contolled by varying the geometry of the drive train.

The tailstock can be used to support the end of the workpiece

with a center, or to hold tools for drilling, reaming, threading, or
cutting tapers. It can be adjusted in position along the ways to
accomodate different length workpices. The ram can be fed
along the axis of rotation with the tailstock handwheel.

The carriage controls and supports the cutting tool. It consists

of:

A saddle that mates with and slides along the ways.

A cross slide that controls transverse motion of the tool

(toward or away
from the operator).

A tool compound that adjusts to permit angular tool

movement.

A toolpost T-slot that holds the toolpost.

CAUTIONS!

When we use a lathe, the following things must take great care.
(1) Don't keep a chuck handle attached by the chuck. Next, it
flies at the moment of turning a lathe.
(2) Don't touch the byte table into the rotating chuck. Not only
a byte but the table or the lathe are damaged.

Three Important Elements

In orger to get an efficient propcess and beautiful surface at the

lathe machining, it is important to adjust a rotating speed, a
cutting depth and a sending speed. Please note that the
important elements can not decide easily, because these
suitable values are quiet different by materials, size and shapes
of the part.

1. Rotating
Speed:-
It
expresses
with the
number of rotations (rpm) of the chuck of a lathe. When the
rotating speed is high, processing speed becomes quick, and a
processing surface is finely finished. However, since a little
operation mistakes may lead to the serious accident, it is better
to set low rotating speed at the first stage.

2. Cutting Depth:-
The cutting depth of the tool affects to the processing speed
and the roughness of surface. When the cutting depth is big,
the processing speed becomes quick, but the surface
temperature becomes high, and it has rough surface. Moreover,
a life of byte also becomes short. If you do not know a suitable
cutting depth, it is better to set to small value.

3.Sending Speed (Feed):-

The sending speed of the tool also affects to the processing
speed and the roughness of surface. When the sending speed is
high, the processing speed becomes quick. When the sending
speed is low, the surface is finished beautiful. There are
'manual sending' which turns and operates a handle, and
'automatic sending' which advances a byte automatically. A
beginner must use the manual sending. Because serious
accidents may be caused, such as touching the rotating chuck
around the byte in automatic sending.

Cutting
Tools for
Lathe

There are
vrious
kinds of
the cutting
tools for a
lathe. We must choose them by the materials and shape of a
part. Three typical cutting tools are introduced in follows. Then
we consider what is an easy process or a hard process.

(a)Side Tool :- It can process to cut an outside surface and an

edge surface. Since the material is set at the right of lathe,
then this tool can only cut the right of the material.

(b)Cutting-Off Tool:- The cutting tool is used at parting and

grooving processes. Its pointed end is slim, then it is too weak.
Don't add a strong side-force to the tool. This tool must send
vertical direction only.
(c)Boring Bar:- The boring bar is used to cut at an inside
surface. It can make a big hole, which cannot be process by a
drill, and an high accurate hole.

Cutting Tool Terminology

Setting of a Cutting Tool

In case
a
cutting
tool is
fixed to
a table, thin metal plates are put between the tool and the
table, and the height of the edge is adjusted to the center of
material.

In the case of using the general cutting tool, when the edge is
higher than the center of material, the edge of a blade does not
hit the material, and it cannot cut at all. Conversely, if the edge
is low, it becomes impossible to cut the center of material.
Moreover, the scale of a handle does not have correct value,
then accurate processing becomes impossible.

Though the height of the cutting tool is adjusted in careful, we

cannot unite with the center of material completely. Therefore,
we have to set the tool to the direction, that the edge is easy to
touch the material. The general cutting tool and the parting tool
have to be set a few low position. The boring bar has to set a
few high position.

Standard Cutting Tools

Accessories

Live center (top)

&Dead center
(bottom)
Lathe operations

1. Turning

The lathe can be used to reduce the diameter of a part to a

desired dimension.The part should not extend more that three
times its diameter. Then install a roughing or finishing tool
(whichever is appropriate). If you're feeding the saddle toward
the headstock use a right-hand turning tool. Move the tool off
the part by backing the carriage up with the carriage
handwheel, then use the cross feed to set the desired depth of
cut.

2. Facing

A lathe can be used to create a smooth, flat, face very

accurately perpendicular to the axis of a cylindrical part. First,
clamp the part securely in a lathe chuck Then, install a facing
tool. Move the tool outside the part and adjust the saddle to
take the desired depth of cut. Then, feed the tool across the
face with the cross slide. Be careful clearing the ribbon-like
chips; They are very sharp. Do not clear the chips while the
spindle is turning. After facing, there is a very sharp edge on
the part.

3. Parting

A parting tool is deeper and narrower than a turning tool. It is

designed for making narrow grooves and for cutting off parts.
Ensure that the parting tool is perpendicular to the axis of
rotation and that the tip is the same height as the center of the
part. A good way to do this is to hold the tool against the face
of the part. Set the height of the tool, lay it flat against the face
of the part, then lock the tool in place. When the cut is deep,
the side of the part can rub against sides of the groove, so it's
especially important to apply cutting fluid. In this clip, a part is
cut off from a piece of stock.

4. Drilling
A lathe can also be used to drill holes accurately concentric
with the centerline of a cylindrical part. First, install a drill chuck
into the tail stock. Withdraw the jaws of the chuck and tap the
chuck in place with a soft hammer.

Move the saddle forward to make room for the tailstock. Move
the tailstock into position, and lock the it in place (otherwise it
will slide backward as you try to drill). Always use a centerdrill
to start the hole. You should use cutting fluid with the
centerdrill. A hole is drilled with a drill.

5. Boring

Boring is an operation in which a hole is enlarged with a single

point cutting tool. A boring bar is used to support the cutting
tool as it extends into the hole. Because of the extension of the
boring bar, the tool is supported less rigidly and is more likely
to chatter. This can be corrected by using slower spindle speeds
or by grinding a smaller radius on the nose of the tool.

6. Single Point Thread Turning

External threads can be cut with a die and internal threads can
be cut with a tap. But for some diameters, no die or tap is
available. In these cases, threads can be cut on a lathe. A
special cutting tool should be used, typically with a 60 degree
nose angle. To form threads with a specified number of threads
per inch, the spindle is mechanically coupled to the carriage
lead screw. Procedures vary for different machines.

Hearing the Sound

In the case of the lathe process, sharpness is known from

scraps of the material or a processing surface. In addition, it is
also important to hear the sound. For example, when the sound
is too high, the processing is not suitable. It is caused by the
bad edge of the tool, too higher rotating speed of the lathe, or
vibrating of a thin material.
Technical Specifications of Center Lathe Machine:-

1. Make : HMT VIKRAM.

2. Plant no : 1203-001.
3. Total bed length : 1800 mm.
4. Distance b/w centre to centre : 1200 mm.
5. Distance b/w centre to bed : 200 mm.
6. Swing : 300 mm.
7. Spindle Bore : 50 mm.
8. Type of Head stock : Geared.
9. Type of L/S thread : ACME,Angle-290
10. Thread pitch of L/S : 6 mm.
11. Speed : 25-2000 rpm.
12. Feed : 0.04-1.00 mm.
13. Gap bed length : 200 mm.
2. CAP ASTIAN LATHE:

It carries the hexagonal turret on a ram or short slide. The ram

slides longitudinally on a side positioned and clamped on lathe
bed ways. This machine is used for smaller work piece due to
its lighter construction. The feeding movement is obtained
when ram moves from left to right and vice versa. In turret
lathes, turret is directly mounted on saddle while in capstan
lathe turret is mounted on the ram, which is mounted on the
saddle.

TECHNICAL SPECIFICATIONS of Cap astian lathe:-

Turning length : 346mm.

Speed range : 40-1000rpm.
Spindle bore : 54mm.
Feed range mm/min. : 5-63
Spindle drive motor : 5.6Kw.
Dia. Of spindle flange : 190.5mm.
Max. Longitudinal traverse : 348mm.
Max. Longitudinal cross : 193mm.
Swing over bed : 375 mm
3. RADIAL DRILLING MACHINE: -
It consists of vertical column with a radial arm that can be
swing trough an arc of 180 degrees or more on the radial arm,
which is power driven for vertical movement. Is an
independently driven head fitted with power feed? The drilling
head can be moved along the arm by hand or by gear
mechanism. On a single fitting of work piece number of holes
can be drilled by rotating the arm or sliding the dr1l1 head
along the arm.

TECHNICAL SPECIFICATIONS OF RADIAL DRILLING

MACHINE :-
Max. Drill diameter : 100m.
Max. Job thickness : l2.5mm.
Drilling capacity : For CI 60 mm
Cutting speed : 1520mm/rev
Feed : 6 feed ranges 0.125-1.25
mm/rev.
Tapping capacity : For metric system M70
For British system
2.5"(BW)
Min. /Max Drilling radius : 550/23P50 mm.
Min. / Max Distance between : 380/1645
Base plate and spindle nose.
Swing arm : 360 degrees:

4.Power hacksaw

A power hacksaw is a type

of hacksaw that is powered
either by its own electric motor (also known as electric hacksaw)
or connected to a stationary engine. Most power hacksaws are
stationary machines but some portable models do exist.
Stationary models usually have a mechanism to lift up the saw
blade on the return stroke and some have a coolant pump to
prevent the saw blade from overheating.

While stationary electric hacksaws are reasonably uncommon

they are still produced but saws powered by a stationary
engines have gone out of fashion. The reason for using one is
that they provide a cleaner cut than an angle grinder or other
types of saw.
5. Shaper:-

A shaper is a
machine tool used
for shaping or
surfacing metal
and other
material.

Shapers have
been largely
superseded by milling machines or grinding machines in modern
industrial practice. The basic function of a shaper machine is
still sound and tooling for them is minimal and very cheap to
reproduce. They can be invaluable for jobbing or repair shops
where only one or a few pieces are required to be produced and
the alternative methods are cost or tooling intensive. The
mechanically operated machines are simple and robust in
construction, making their repair and upkeep easily achievable.

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
differs from a slotter (slotting machine), as the slide can be
moved from the vertical. A slotter is fixed in the vertical plane.

Very small machines have been successfully made to operate

by hand power. Once size increases, up to a potential 36 inch
stroke, the power needs increase and it becomes necessary to
use an electric motor. This motor drives a mechanical
arrangement (using a pinion gear, bull gear and crank) or a
hydraulic motor which supplies the necessary movement via
hydraulic cylinders
Operation:-

Shaper linkage.
Note the drive
arm revolves
less for the
return stroke
than for the
cutting stroke,
resulting in a
quicker return
stroke and
more powerful cutting stroke.A shaper operates by moving a
hardened cutting tool backwards and forwards across the
workpiece. On the return stroke of the ram the tool is lifted
clear of the workpiece, reducing the cutting action to one
direction only.

The workpiece mounts on a rigid, box shaped table in front of

the machine. The height of the table can be adjusted to suit
this workpiece, and the table can traverse sideways underneath
the reciprocating tool which is mounted on the ram, the table
motion is usually under the control of an automatic feed
mechanism which acts on the feedscrew. 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. This tool-slide holds the clapper box and toolpost from
where the tool can be positioned to cut the straight, flat surface
on the top of the workpiece. The tool-slide permits feeding the
tool downwards to put on a cut it or may be set away from the
vertical plane, as required.

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.
 may be employed to improve the finish and prolong
Cutting fluid
the tool's life.

Technical Specification of Shaper Machine:-

1. Make : Cooper CSH-63.

2. Plant no. : 1931-001.
3. Max length of stroke : 630 mm.
4. Max Horizontal traverse of table : 710 mm.
5. Max vertical traverse of table : 350 mm.
6. Max distance of table to ram : 450 mm.
7. Min distance of table to ram : 100 mm.
8. Range of speed to ram strokes/min : 8-125 mm.
9. Range of feed to table(in 10 steps) : 0.32-3.2 mm/min.
10. Max traverse of tool slide : 160 mm.
11.Can be swiveled through on either side of vertical : 45 0
12.Vice admits in length : 290 mm.
13.Width & depth of vice jaw : 330 mm.
6. Milling machine:-

A milling machine
is a machine tool
used for the
shaping of metal
and other solid
materials. Milling
machines exist in
two basic forms: horizontal and vertical, which terms refer to
the orientation of the cutting tool spindle. Unlike a drill press, in
which the workpiece is held stationary and the drill is moved
vertically to penetrate the material, milling also involves
movement of the workpiece against the rotating cutter, the
latter which is able to cut on its flanks as well as its tip.
Workpiece and cutter movement are precisely controlled to less
than 0.001 inches (.025 millimeters), usually by means of
precision ground slides and leadscrews or analogous technology.
Milling machines may be manually operated, mechanically
automated, or digitally automated via computer numerical control
(CNC).

Milling machines can perform a vast number of operations,

some very complex, such as slot and keyway cutting, planing,
drilling, diesinking, rebating, routing, etc. Cutting fluid is often
pumped to the cutting site to cool and lubricate the cut.

Comparing vertical with horizontal

In the vertical mill the spindle axis is vertically oriented. Milling

cutters are held in the spindle and rotate on its axis. The spindle
can generally be extended (or the table can be raised/lowered,
giving the same effect), allowing plunge cuts and drilling. There
are two subcategories of vertical mills: the bedmill and the
turret mill. Turret mills, like the ubiquitous Bridgeport, are
generally smaller than bedmills, and are considered by some to
be more versatile. In a turret mill the spindle remains stationary
during cutting operations and the table is moved both
perpendicular to and parallel to the spindle axis to accomplish
cutting. In the bedmill, however, the table moves only
perpendicular to the spindle's axis, while the spindle itself
moves parallel to its own axis. Also of note is a lighter machine,
called a mill-drill. It is quite popular with hobbyists, due to its
small size and lower price. These are frequently of lower quality
than other types of machines, however.

A horizontal mill has the same sort of xy table, but the cutters
are mounted on a horizontal arbor (see Arbor milling) across the
table. A majority of horizontal mills also feature a +15/-15
degree rotary table that allows milling at shallow angles. While
endmills and the other types of tools available to a vertical mill
may be used in a horizontal mill, their real advantage lies in
arbor-mounted cutters, called side and face mills, which have a
cross section rather like a circular saw, but are generally wider
and smaller in diameter. Because the cutters have good
support from the arbor, quite heavy cuts can be taken, enabling
rapid material removal rates. These are used to mill grooves
and slots. Plain mills are used to shape flat surfaces. Several
cutters may be ganged together on the arbor to mill a complex
shape of slots and planes. Special cutters can also cut grooves,
bevels, radii, or indeed any section desired. These specialty
cutters tend to be expensive. Simplex mills have one spindle,
and duplex mills have two. It is also easier to cut gears on a
horizontal mill.

Technical Specification of Vertical Milling Machine:-

1. Make/type : BATLIBOI-
FA3V
2. Plant no. : 1310-
001.
3. Working table length & width :
1250x300 mm.
4. Longitudinal traverse : 800
mm.
5. Vertical traverse : 390 mm.
6. Cross traverse : 265
mm.
7. Distance b/w main spindle to table surface min & max :
0 & 450 mm.
8. Distance b/w main spindle centre to column slide :
300 mm.
9. Swivel of spindle head on either side : 450
10. Vertical movement of spindle : 75
mm.
Technical Specification of Universal Milling Machine:-

1. Make/type : BFW-UF-I
2. Plant no. : 1307-001
3. Table overall size : 1175x230
mm.
4. Table clamping area : 1000x230 mm.

5. Table longitudinal movement automatic : 560 mm.

6. Table longitudinal movement manual : 590
mm.
7. Table traverse movement automatic : 250
mm.
8. Table traverse movement manual : 270 mm.
9. Table vertical movement manual : 340 mm.
10. Table swivel to either side : 450
mm.
11. Distance of spindle centre to table surface :
0-330 mm.
12. Distance of spindle centre to left hand end of table :
250 mm.
7. Grinding machine:-

Rotating abrasive
wheel

A grinding machine
is a machine tool used
for grinding, which is a type of machining using an abrasive wheel as
the cutting tool. Each grain of abrasive on the wheel's surface
cuts a small chip from the work piece via shear deformation.

The grinding machine consists of a power driven grinding wheel

spinning at the required speed and a bed with a fixture to guide
and hold the work-piece

Grinding machines remove material from the workpiece by

abrasion, which can generate substantial amounts of heat; they
therefore incorporate a coolant to cool the workpiece so that it
does not overheat and go outside its tolerance. The coolant
also benefits the machinist as the heat generated may cause
burns in some cases. In very high-precision grinding machines
(most cylindrical and surface grinders) the final grinding stages
are usually set up so that they remove about 2/10000mm (less
than 1/100000 in) per pass - this generates so little heat that
even with no coolant, the temperature rise is negligible.

8. Surface grinding:-
Surface grinding is a widely used process of machining in which
a spinning wheel covered in rough particles cuts chips of
metallic or non metallic substance making them flat or smooth.

Spark out is a term used when precision values are sought and
literally means "until the sparks are out (no more)". It involves
passing the workpiece under the wheel, without resetting the
depth of cut, more than once and generally multiple times. This
ensures that any inconsistencies in the machine or workpiece
are eliminated.

As with any grinding operation, the condition of the wheel is

extremely important. Diamond dressers are used to maintain the
condition of the wheel, these may be table mounted or as the
first image shows, mounted in the wheel head where they can
be readily applied

Effects on work material properties

The high temperatures encountered at the ground surface
create residual stresses and a thin martensitic layer may form on the
part surface; this decreases the fatigue strength. In ferromagnetic
materials, if the temperature of the surface is raised beyond the
Curie temperature then it may lose some magnetic properties. Finally,
the surface may be more susceptible to corrosion.

*****************