STANDARD SPECIFICATION NO.

TM/HM/6/142 FOR CUTTER BAR OF

BALLAST CLEANING MACHINE (PROVISIONA) - 1997

1.0 This specification covers requirements of the cutter bar of Ballast Cleaning
Machine. The cutter bar is used in the Ballast Cleaning Machine to guide
the cutter chain while excavating the caked up ballast beneath the
sleepers. There is a guiding notch in the cutter bar through which the
scraper shovel of cutter chain moves. During machine working the cutter
bar remains embedded in the ballast bed under the track. The bottom
flared portion of the cutter bar wears very fast due to continuous rubbing
action of the sub grade and ballast.
For dimensional details of the cutter bar covered by this specification,
refer to RDSO's drawing No. TM/9616
2.0 The specification may be treated as provisional subject to modification
based on service performance.
3.0 MATERIAL AND PHYSICAL PROPERTIES:
(a) Recommended : Steel Grade 2 to IS: 4896 -1976 (specification for
Material one percent Chromium steel casting for
resistance to abrasion).
(b) Physical Properties :
i) BH Hardness : 400-420 (3000 kg/ 10mm/ 15 sec)
ii) Tensile Strength - 900 N/mm 2 (min.)
iii) Elongation % - 6.0 (min.)

(c) Heat Treatment : The material shall be annealed, hardened and

tempered so as to achieve tempered martensite
structure.

4.0 MANUFACTURE
Manufacturer should have the essential facilities required for manufacture
of the Cutter bar as mentioned below. In case Steel making facilities if not
available with the manufacturer, he should furnish a certificate having
obtained raw material of requisite quality from a reputed source.
4.1 Steel Making
i) Type of furnace - Electric arc or electric induction.
ii) Capacity - 5 MT (min.)
4.2 Overhead cranes of suitable capacity.
4.3 Pattern shop equipped with the facilities of making patterns for moulds &
cores.

4.4 Foundry
i) Moulding facility (hand/machine)
ii) Core making
iii) Mould & Core drying with temperature indicating-cum-recording
facility.
iv) Decorning & dressing.
4.5 Heavy duty hydraulic press for straightening the castings.
4.6 Heat Treatment
Oil fired/electric furnace equipped with temperature indicating-cum-
recording facility.
4.7 Quality Control Facilities
i) Following facilities should be available with the manufacturer: -
a) Chemical analysis (instrumental/wet method).
b) Brinell hardness testing machine.
c) Tensile strength testing machine.
ii) Further if agreed to between the purchaser and manufacturer, the
following non-destructive testing facilities should also be available:-

a) Ultrasonic examination.
b) Magnetic particle examination.
c) Liquid penetration examination.
d) Radiographic examination.
5.0 PRODUCT ANALYSIS
The product analysis may be carried out from a test piece or from a
casting representing each melt. Drillings for analysis shall be taken from
not less than 6 mm beneath the cast surface and in such a manner as not
to impair the usefulness of any casting selected.
6.0 WORKMANSHIP AND FINISH
6.1 The casting should be accurately moulded in accordance with pattern or the
working drawings supplied by the purchaser with the addition of such
letter, and marks as may be specified.
6.2 The purchaser shall specify the tolerances on all important dimensions.
7.0 FREEDOM FROM DEFECTS
7.1 All casting shall be free from defects that will adversely affects machining
or utility of casting.
7.2 When necessary to remove risers or gates by flame or arc or
combination thereof, or by any other process involving intense heat, care
shall be taken to make the cut at sufficient distance from the body of the
casting so as to prevent any defect being introduced into the casting due
to local heating. Any such operation is preferably done before heat
treatment.
7.3 In the event of any casting proving defective from foundry course in the
process of preparation, machining or erection, such casting may be
rejected not withstanding any previous certification of satisfactory testing
and/or inspection.
8.0 FETTLING AND DRESSING
All casting shall be properly fettled and dressed and all surfaces shall be
thoroughly cleaned.
9.0 HEAT TREATMENT
9.1 The casting shall be heat-treated in a properly constructed furnace,
having adequate means of temperature control and which shall permit the
whole of the castings being uniformly heated to the necessary
temperature.
The material shall be annealed, hardened and tempered so as to achieve
tempered martensite structure.

9.2 The test piece shall also be treated along with casting they represent.
10.0 TESTING AND INSPECTION

10.1 The components offered by the manufacturer shall be visually inspected

individually for their finish and freedom from defects viz pits, porosity,
cracks, improper edges etc.
10.2 Each component found suitable after visual inspection shall be checked for
their dimensional characteristics as per drawing no. TM/9616. The
components found satisfactory with regard to all the dimensional
characteristics shall be accepted subject to testing as per para 10.3 below.
The manufacturer shall provide necessary gadget required for dimensional
checks.
10.3 The component found to be free from defects during visual
and dimensional checks, shall be subjected to following tests:-
i) Mechanical Tests
The following tests shall be carried out:-
a) Brinell Hardness
b) Tensile strength
 c) Elongation percentage.
The samples for testing are to be taken from test bars cast either
separately from or attached to the castings to which they refer.

ii) Chemical Analysis:

The selected sample shall be tested for chemical analysis in

accordance with IS:228-1959 `Methods of chemical analysis for steel'
and shall conform to the chemical requirement of composition stipulated
for Steel Gr 2 to IS:4897-1976.

Constituent Percent Permissible variation

over specified limit(%)
C 0.55 to 0.70 + 0.04
Mn 0.50 to 1.00 + 0.06
Si 0.75 + 0.05
Ni 0.40 (Max) + 0.03
Cr 0.80 to 1.50 + 0.06
Mo 0.20 to 0.40 + 0.03
iii) Non-destructive Tests
If agreed to between the purchaser and the manufacturer the following
types of non-destructive tests shall be applied to examine the defects:-

a) Ultrasonic examination as per IS:7666-1975.

b) Magnetic particle examination as per IS:3703-1980.
c) Liquid penetration examination as per IS:3658-1981.
d) Radiographic examination as per IS:2595-1978.
11.0 ACCEPTANCE CRITERIA
The samples from test bar or any one of the casting in the lot, shall be
subjected to chemical analysis and mechanical tests. If the results of
the chemical analysis do not meet the specified requirements, given
in paras 3.0 and 10.3 above, two new samples shall be taken on different
pieces from the same lot. Should both the samples satisfy the
requirements, the lot represented may be accepted. Should either of the
samples fail, the material shall be taken as not complying with the
specification.
12.0 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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