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BWEL
BHARAT WAGON & ENGINEERING COMPANY LTD.
(A Govt. of India Undertaking, Ministry of Railways)
MUZAFFARPUR UNIT,
MUZAFFARPUR-842001
BIHAR
Submitted to
In Partial fulfillment of
The requirements for the degree of
Diploma in Mechanical Engineering
CERTIFICATE
My sincere thanks go to Mr. A.K. Verma (Press & Smithy Shop), Mr.
T. Ahmad (Cutting & Welding Shop), Mr. H. Kr. Shrivastava
(Template Shop), Mr. O.P. Singh (Drilling Shop), Mr. O.P. Singh
(Machine Shop), Mr. A.K. Varun (Structural Shop), Mr. A.K. Tiwari
(Maintenance Shop), Mr. S.N. Singh (Wagon Assembly Shop), & Mr.
Ranjeet Kumar Singh (Finishing Shop).
ALOK RANJAN
CONTENTS
PARTICULARS
Company Profile
Introduction
Template Shop
Drilling Shop
Machine Shop
Structural Shop
Finishing Shop
INTRODUCTION ABOUT THE PLANT
The Bharat Wagon & Engg. 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
Upto the april 1996 the company was managed by M/S jubilee agents limited on 1 st
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.
INTRODUCTION:-
In this shop there are seven small open hearth furnaces where coal burns
on the bed.
On these furnaces various types of parts are heated. The heated parts is
kept is kept on the anvil & with the help of hammer the required shape is
formed. In this shop mere than 50 components are pre pared as like.
POWER PRESS
POWER HAMMER
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.
CUTTING AND WELDING SHOP
This is one of the shop in which the basic work is performed as the name
indicates of this shop. This shop mainly involved in cutting the plates of
different thickness in the desired shapes and size.
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 consist 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
The form and dimension of a chip metal machining indicates the nature
and quality of a particular machining process. But the type of chip formed
in generally influenced by the properties of the material cut and various
cutting conditions.
In this shop there are different types of drilling machines. The drilling
Machine one of the important machine tool in the workshop. As reguards
its importance is secondary to thethe lathe. Although it was preliminary
designed to originate a hole, it can be perform a number of similar
oprations. In a drilling machine holes can be generated quickly and at a
low cost. The holes is generated by rotating edge of a cutting tool known
as a drill which exerts large force on the work clamped on the table. As the
machine tool exerts vertical pressure to originate the holes it is loosely
called the ”drill press”
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,
component where it is difficult to set a jig. 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
COULMN
RADIAL ARM
DRILL HEAD
SENSATIVE
DRILLING
MACHINE
DRILLING OF JOB
In this shop drilling is done by two methods:
By marking
By jig
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
MACHINE SHOP
This is the biggest
shop of this
organization. In this
shop there are
various types of
machines. Such as.
The lathe is a machine tool used principally for shaping articles of metal,
wood, or other material. All lathes, except the vertical
turret type, have one thing in common for all usual machining operations;
the workpiece is held and rotated around a horizontal axis while being
formed to size and shape by a cutting tool. The cutter bit is held either by
hand or by a mechanical holder, then applied to the workpiece. Principal
capabilities of the lathe are
CENTER LATHE
CONSTRUCTION:
The design of lathes can vary greatly depending on the intended application;
however, basic features are common to most types. These machines consist of (at the
least) a headstock, bed, carriage, and tailstock. Better machines are solidly constructed
with broad bearing surfaces (slides or ways) for stability, and manufactured with great
precision. This helps ensure the components manufactured on the machines can meet
the required tolerances and repeatability.
LATHE PARTS
BED
HEAR STOCK
TAIL STOCK
CARRIAGE
FEED MECHANISM
SCREW MECHANISM
THE BED
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, leadscrew of accurate pitch, or feedscrew.
FEED MECHANISM
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.
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.
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 tool’s 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
This machine is used for the boring purpose of big components. This
machine is driven by electric motor & with the help of gear mechanism the
main shaft is rotated. The sail, which is to be machined, is kept on the bed.
Before it, a ring is inserted over the sail to rigidly damp it. The main shaft
consists of two heads, which has groove in which cutting tool is fitted &
fightened with the bolts. The cutting head starts cutting from opposite
sides. Both the cutting tools rotate in opposite direction.
After assembling the wagon is sent to the finishing shop. In this shop the
wagon is brought to the shot blaster chamber. In this chamber small iron
particle is allowed to strike on the wagon to remove the extra welding
deposit and the rust formed on it . The high pressure air helps the iron
particle to come out from the gun and to strike rapidly . In this chamber the
working condition are very hazardous . So The worker wears oxygen mask
before doing work inside the chamber .
In this shop painting of wagon are done. The wagon is painted in
three coating.
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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