TRAINING PRESENTATION

Ajmer Group of Workshops,

North Western Railways,
INDIAN RAILWAYS

Submitted To :
Prof. R.O. Rustogi
Dept. of Mechanical Engg.
Mechanical Engg.

Submitted By:
Ayush Jain
B.Tech
JECRC, Jaipur

INDIAN RAILWAYS

Indian Railways is an enterprise, owned and operated by the

Government of India through the Ministry of Railways.

It is one of the world's largest railway networks comprising 115,000 km

of track over a route of 65,000 km and 7,500 stations.

AJMER WORKSHOP
Ajmer Diesel Loco & Wagon Workshop
Carriage Workshop

S
No.

Ajmer(Carriage)

Ajmer(Loco)

1.

Strength

3494

2308

2.

No. of Officers

3.

No. of supervisors

254

237

4.

Total area

250000 sq. mpp.

160000 sq. mpp.

5.

Covered area

66100 sq. m.

71363 sq. m.

6.

Power Consumption

176000 units/month

140000 units/month

7.

Annual Budget

Rs. 130 Cr.

Rs. 138 Cr.

AJMER DIESEL LOCO AND WAGON

Wagon: POH/NPOH/RSP Works
Periodic Overhauling of BG Wagons.
Periodic Overhauling of MG Wagons.

Retro fitment of Casnub bogie & Air brake system .

Repair of UIC Bogies.

AJMER DIESEL LOCO AND WAGON

Diesel POH shop:
Periodic Overhauling of YDM4MG Diesel Locomotive.
Periodic Overhauling of DPC/DTC of DEMU

Periodic Overhauling of DHMU

POH of MG/BG Track Machine

Rewinding of Traction Motor/Traction Generator Armatures (BG

and MG).

AJMER CARRIAGE WORKSHOP

POH of BG AC Coaches.

Corrosion repair of BG Coaches .

This workshop under takes POH of prestigious trains Palace on Wheels

(BG), Royal Oriental Express (MG).

In addition, there are various manufacturing activities. Emphasis has

been given on quality of outturn. Regular quality audits are being

conducted in vital section/Shops.

SHOPS
1. Welding shop
2. Heat treatment shop:
It is done to relieve them from internal stresses and improving their
mechanical properties. Generally internal stresses developed during
various cold and hot working operations.

3. Spring section:
Inspection and Testing of Coil Spring:
Dismantle springs are obtained.
Sand Blasting is done for cleaning and stress relieving.
Visual inspection of spring :
If found any crack, seam, dent, pitting or broken coil than

reject immediately the spring if not then pass.

o Checking on magnetic crack detection machine by
ultra violet light and reject the defective springs.
o Load Testing
Check free height of spring.
Apply the load on the spring by load testing machine

4. Black smithy shop

Inspection and tensile testing of screw coupling, draw
bar etc.
Inspection and testing of draw bar, coil spring, leaf
springs etc.
Forging of different Jobs.
Heat Treatment
Stress relieving of draw bar, draw hooks etc.
5. Machine shop
6. Wheel shop
7. Jigs and fixtures
8. Mill right shop
9. Paint shop

BOGIE AND WHEEL SHOP

Bogie is very important part of the coach. It has to carry the
motors, Brake system and suspension system, all within a tight
envelope. It is subjected to several stresses and shocks and may
have to run at in a high-speed application.

BOGIE SECTION BLOCK DIAGRAM

LOCOMOTIVE

BOGIE
SPRING
SHADDLE

EQUALIZING
BEAM
AXLE
WHEEL
RAILWAY LINES

ROLLER BEARING
Bearings are used to reduce friction between the wheels

and the axle. There are two types of bearings used in

wheel axle:
1. Cylindrical Bearing
2. Taper Bearing
In Loco wheel axle Cylindrical Bearings are used.
In Wagon wheel axle Taper Bearings are used.
These are made up of alloy steel.
In Cylindrical Bearings outer race is rolled, while in
Taper Bearings inner race is rolled.

BEARING DEFECT
Excessive Clearance
Inner Race Crack
Roller Damage
Roller Pitted
Outer Race Pitted
Outer Race Crack

Procedure for Opening of Roller Bearing

Bring Journal (Axle box removed) at the bearing opening work

place.
Open end locking nuts using proper key wrench and remove end
locking plate and locking nut.
Remove roller bearings using Inventom Bearing Extractor
(Hydraulic machine uses oil at a pressure of 4 Kg./cm2)
Take roller bearings for cleaning.
Remove distance ring with ring cover and felt ring from journal
and take them at their respective cleaning places.
Ensure end lock nut and plates should not be used again.
Also take retaining ring to the cleaning place.
After the bearing is sent to the bearing washing plant.

CLEANING OF ROLLER BEARING

Cleaning of roller bearing is done by PROCECO

Machine and is carried out in three steps basically. Three

tanks are provided there in the machine. Pressure of
these tanks is kept 5.3 Kg./cm2.
Processes included are mentioned in table below:

S.NO

1.

PROCESS USED

Cleaning of Grease and Oil stuck on roller

bearings assembly

PROCESS
USED IN
PROCECO
MACHINE

TEMPRATURE

Washing by
123 C
hot water (In
Pre-Wash tank)

2.

Cleaning of Grease and Oils using Alkali

Chemical Reaction

Performed in
Wash tank

3.

Washing of Chemicals stuck during Chemical Performed in

Reaction
Rinse tank

165 C

105 C

INSPECTION OF ROLLER BEARING

The inspection of roller bearings is done in following steps:
After washing roller bearing in PROCECO washing plant,

wash roller bearing either in kerosene or in petrol and put in

on for inspection process.
Inspect all parts of bearings like inner race, outer race rollers,

and cage.
Measure bearing radial clearance taking help of filler gauges.

The standards limit of this clearance is as given in the

table.
S.No. BEARING
TYPE

RADIAL CLEARANCE FOR UPPER LIMIT OF

NEW BEARING (In mm.)
RADIAL CLEARANCE
FOR USED BEARINGS
(In mm.)
BROAD GAUGE METER
GAUGE

BROAD
GAUGE

METER
GAUGE

1.

NEI / FEG /
NORMA

0.145 0.190

0.1 0.135 0.27

0.25

2.

SKF /
NACHI

0.145 0.190

0.1 0.135 0.195

0.25

ZYGLO TESTING OF ROLLER BEARINGS

Dip the bearing in the fluorescent emulsified dye for 10

minutes.
Excessive dye to be drained.
Excessive dye to be washed off with water.
Put the bearing in the oven for dryness.
Apply developer powder (BaSO4) on the dried bearing for the

contrast.
Examine the bearings (Inner race only) under Ultra Violet

light for any crack and mark the rejected bearings by a red
mark.

ASSEMBLY OF ROLLER BEARINGS

In assembly section roller bearing is assembled on the

journal by using various processes. Induction heating is

done for expanding inner race of the bearing of so that it

can be mounted on the journal of the wheel without any
problem.
Induction heating includes following features :
Temperature is maintained at 120 C.

Minimum time for heating between induction coils is 5

to 7 minutes.

THANK YOU