STANDARD SPECIFICATION NO.

TM/HM/6/169 FOR CARDON

SHAFT OF CONTINUOUS TAMPING MACHINE CSM 09-32
(PROVISIONAL)

1.0 GENERAL
To transmit power from the engine to ZF gearbox, distribution gearboxes and
driving bogie, Cardon Shafts are used in Continuous Tamping Machine CSM 09-
32 and Point & Crossing Tamping Machine 08-275. The Cardon Shafts transmit
power between two points having different positions in vertical and horizontal
planes. Therefore, the Shafts are provided with universal joints at both ends.
The variation in length of the cardon shaft is possible through spline joints
provided in central portion of shaft. In general Cardon shaft consists of three
parts - Central Shaft, Universal joints at the ends and a spline joint. The cardon
shaft is made of a strong steel barrel because it has to withstand torsional
stresses while transmitting torque and it should be light and well balanced.
This specification covers the requirements of Cardon Shaft of Continuous
Tamping Machine (CSM 09-32). The specification is detailed into three sections
as mentioned below:
 Spline Portion
 Hollow Barrel Portion
 Coupling Portion
For dimensional details of the cardon shaft covered under this specification, refer
to RDSO's drawing No.TM/9905(Rev.), TM/9930, TM/9931, TM/9932 and
TM/9933.
This specification may be treated as provisional subject to modifications based
on the service performance.

2.0 MATERIAL AND PHYSICAL PROPERTIES

2.1 Splines Portion:

2.1.1 Recommended Material:

Steel Grade 20Ni2Cr2Mo2 conforming to IS:4432-1988 (Indian Standard
Specification for Case Hardening Steel).The composition of the material
shall be as under:

Constituent Percent (Max. ) Constituent Precent (Max.)

C 0.190 P 0.014
Si 0.210 Ni 0.085
Mn 0.440 Cr 0.100
S 0.015 Mo 0.024

2.1.2 Mechanical Properties:

Tensile Strength : 7500-10500 Kg/cm2
Yield Strength : 5200 Kg/cm2 (min)
Hardness (BHN) : 220 (max).
2.1.3 Heat Treatment:
The spline portion is to be case hardened to a depth of 1.0+0.2 mm at a
temperature of 780-8200 C. The quenching media may be oil/thermal-bath or
Polyquench.
Full length of spline is to be coated from inside and outside with non-metallic
coating.

2.1.4 Micro Structure:

The micro structure shall consist of fine ferritic grains with pearlite at places.
Grain size shall be ASTM 7-8.

2.2 Hollow Barrel Portions

2.2.1 Recommended Material :

Material conforming to ASTM-A-106 Gr. It shall consist of low carbon semi killed /
rimming steel. However, the recommended composites of the material shall be
nearer to:
Constituent Percent Constituent Percent
C 0.23 (max) P 0.01 (max)
Si 0.06 (min) Ni -
Mn 0.49 Cr -
S 0.01 (max) Mo -

2.2.2 Mechanical Properties:

 Tensile strength : 3300 Kg/cm2 (min)
 Yield Strength : 2050 Kg/cm2 (min.)
 Hardness (BHN) : 165

2.2.3 Heat Treatment:

The barrel shall be hot rolled, extruded and self normalised.

2.2.4 Micro Structure:

Rolled structure shall consist of ferrite grains and pearlite grains shall have
directionality. Grain size shall be ASTM 7-8.

2.3 Coupling Portion

2.3.1 Recommended Material :

Steel designated as 45C8 conforming to IS: 2004 -1991 (Indian Standard
Specification of Carbon Steel Forging for General Engineering Purposes-Third
Revision). The composition of the material shall be as under:
 Constituent Percent (Max.) Constituent Percent(Max.)
C 0.44 P 0.018
Si 0.20 Ni 0.10
Mn 0.62 Cr 0.13
S 0.03 Mo 0.01

2.3.2 Mechanical Properties:

 Tensile Strength : 6200 Kg/cm2 (min.)
 Yield Strength : 3200 Kg/cm2 (min.)
 Hardness (BHN) : 242
 Elongation(%age) : 15 (min.)

2.3.3 Heat Treatment:

The Component shall be supplied as forged or as forged and normalised
condition.

2.3.4 Micro Structure:

The component shall consist of fine pearlite within thin network of ferrite. Grain
size shall be ASTM 7-8.

3.0 MANUFACTURER
Manufacturer should have the essential facilities required for manufacture of the
component as appended below. In case steel making facilities is not available
with the manufacturer, he should furnish a certificate having obtained raw
material of requisite quality from a reputed source.

3.1 Splines

3.1.1 Steel Making

a) Type of furnace: Open hearth, Electric Arc, Basic-Oxygen or any other
approved process, which will meet the requirements of the
specified standard. The raw material for the production of
carbon steel forging shall be in accordance with IS
1875:1991.

b) Capacity : 5 tonne (Min).

c) Heavy duty hydraulic press should be used for straightening the casting.

3.1.2 Heat Treatment:

The forging shall be suitably heat treated and cooled to avoid cracks or flakes
and shall be wel1 finished as nearly as possible to the dimensions of the drawing
No.TM/9905(Rev.), TM/9930, TM/9931, TM/9932 and TM/9933.
3.1.3 Condition of supply :
Forging shall be forged, normalised, hardened and tempered. The spline portion
to be case hardened to a depth of 1.0+0.2mm. Minimum hardness in the
hardened and tempered condition shall be 50-54 HRC.

3.1.4 Quality Control Facilities:

3.1.4.1 Following facilities should be available with the manufacturer:
i) Chemical analysis (instrumental/wet method)
ii) Hardness testing (Brinell/ Rockwell).

3.1.4.2 If agreed to between the purchaser and manufacturer the following further
testing facilities should be available with the manufacturer.

i) Macrotech test in accordance with IS: 11371-1985 (Method for Macrotech

test of wrought steel products).

ii) Ultrasonic test in accordance with IS 3664-1981 (Code of Practice for

Ultrasonic pulse echo testing by contact and immersion methods, First
Revision).

iii) Hardenability test in accordance with IS:3848-1981 (Method for end quench
test for hardenability of steel, First Revision)

iv) Blank hardening test for core strength guarantee according to recommen -
dation of Table 7 of IS:4432-1988 for type of steel 20Ni2 Cr2 Mo2 should be:-

Blank Hardened Value : 34 HRC

Jominy Hardenability Values in HRC at a distance from the Quenched end

face should be :-

Distance Value
1.5 mm 41-48 HRC
5.0 mm 30-44 HRC
20 mm 20-32 HRC

Note 1: Blank hardening should be carried out on 30 mm dia turned specimen,

taken from the same location of the billet as recommended for tensile
test specimen and to be determined at the centre of such a specimen.

Note 2: Blank hardening temperature for the steel should be 870+10o C with 45
minutes soaking followed by oil quenching.

Note 3: Jominy hardenability test shall be carried out according to IS:3848-1981.

 v) Microstructure for Merchantability including bending, and

vi) Hot up-set test for forgeability.

3.2 Hollow Barrel

Material furnished to this specification shall conform to the requirements of the
current edition of ASTM standards A530 / A530M (Specification for General
Requirements for Specialized Carbon and Alloy Steel Pipe).

3.2.1 Steel Making :

The steel shall be killed steel made by one or more of the following processes :
 Open-hearth,
 Basic-oxygen, or
 Electric-furnace
Steel may be cast in ingots or may be strand cast. When steels of different
grades are sequentially strand cast, identification of the resultant transition
material is required. The producer shall remove the transition material by any
established procedure that positively separates the grades.

3.2.2 Heat Treatment :

Hot-finished pipe need not be heat treated. Cold drawn pipe shall be heat
treated after the final cold draw pass at a temperature of 120 o F (65 o C) or
higher.

3.2.3 Quality Control Facilities

3.2.3.1 Following facilities should be available with the manufacturer:

i) Chemical analysis (Instrumental/Wet method).
ii) Hardness testing (Brinell).

3.2.3.2 If agreed to between the purchaser and manufacturer, the following further
testing facilities should be available with the manufacturer:
i) Bend test
ii) Flattening test
iii) Hydrostatic test
iv) Non-destructive Ultrasonic test.

3.3 Coupling

3.3.1 Steel making

All forging shall be manufactured from killed steel produced by the open hearth,
electric, basic oxygen or any other suitable method which will meet the
requirements of this standard.
The raw material for the production of carbon steel forging shall be in accordance
with IS 1875:1991.
3.3.2 Quality Control Facilities
The supplier shall carry out the detailed cross check of the components for which
following facilities are required at his end:
i) Chemical analysis (Instrumental/ Wet method)
ii) Hardness testing (Brinell)

3.3.3 If agreed to between the purchaser and manufacturer, the following further
testing facilities should be available with the manufacturer.
i) Bend test
ii) Microscopic test
iii) Macroscopic test
iv) Magnaflux test and
v) Ultrasonic test

4.0 TESTING AND INSPECTION

4.1 The components offered by the manufacturer shall be visually inspected
individually for their finish and freedom from surface defects viz. pits, porosity,
cracks, improper edges etc.

4.2 Each component found suitable after visual inspection shall be checked for their
dimensional characteristics as per concerned drawing no.TM/9905(Rev.),
TM/9930, TM/9931, TM/9932 and TM/9933. Only those components to be
satisfactory with regard to all these dimensional characteristics shall be accepted
subject to testing as per para 5.0 below. The manufacturer shall provide
necessary gadgets required for dimensional check.

4.3 The component found to be free from defects during visual and dimensional
checks shall be subjected to following tests:
i) Mechanical Tests:

Brinell Hardness Test:

The sample for testing are to be taken from test bars cast either separately from
or attached to the casting to which they refer.

ii) Chemical Analysis:

The Chemical analysis shall be conducted on the sample by Vacum
Spectrometer.

iii) Micro Examination:

Micro pieces shall be cut from the three samples. The samples to be polished,
etched and viewed under microscope.

4.4 After complete assembly, the cardon shaft should be dynamically balanced to
ensure rotation of cardon shaft free from wobling.
5.0 ACCEPTANCE CRITERIA
The samples from test bars or any one of the casting in lot, shall be subjected to
chemical analysis and mechanical tests. If results of the chemical analysis and
mechanical tests do not meet the specified requirements given in para 2.0 and
4.3 above, two new samples shall be taken on different pieces from the same lot.
Should both the analysis satisfy the requirements, the lot represented may be
accepted. Should either of the tests fail, the material shall be taken as not
complying with the specification.

6.0 PROTECTION
The components shall be protected with one coat of boiled linseed oil to IS: 77-
1976 `Linseed oil for paints or any other rust preventive compound.

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