zeeshan_(1) (1)

8/13/2019 zeeshan_(1) (1)

http://slidepdf.com/reader/full/zeeshan1-1 1/45

A

PROJECT REPORT

AT

BRAITHWAITE & COMPANY L.T.D

( A GOVT. OF INDIA UNDERTAKING)

MINISTRY OF RAILWAY REGISTERED & HEADOFFICE:5 HIDE ROAD,

KOLKATA-700043 WEST BENGAL INDIA

WITH EFFECT FROM 5.6.2013 TO 15.7.2013

8/13/2019 zeeshan_(1) (1)


8/13/2019 zeeshan_(1) (1)


ACKNOWLEDGEMENT

My Industrial Training at Braithwate & co.Ltd Clive Work) Was a very different Leaning

experience of my life. I enjoyed this time duration because I have never exposed myself to such

experience before in short this company helped me bridge the gap between theory and

practice.

I would like to express my sincere gratitude for the personal and professional support provided

by Sr. Manager(Personal & Adm.).Manager works (CW/ VW),Production Executive Engineer.

Without their help the project would never have been complete. I would also like to thank

themfor assigning me project supervisor and constantly keeping in touch with our progress despite

their tight schedule

I would also like to thank all the operator and the manager, staff manager who helped us a lot

and provided the information with patience

Lastly, I would like to thank my parents and all other who motivated me throughout my training

period as without them this report would not have seen the light of the day and all mighty God

who was and is my leading light

Date:

Place: Signature:

8/13/2019 zeeshan_(1) (1)


INDEX

TOPIC

1. INTRODUCTION OF BCL

2. COMMERCIAL ASPECT OF BCL AND THEIR BUSINESS PROCEDURE

3. DIFFERENT WAGON IN BCL

4. MANUFACTURE OF BOXN-HL(MBS)

5. DETAIL OF BOXN-HL(MBS)

6. DETAIL OF BRN22.9

7. DETAIL OF MACHINE & TOOLS

8. DETAIL OF WELDING

9. EXPLANATION OF JIGS & FIXTURE

10. CTRB BEARING SYSTEM

11. EOT CRANE

12. FINISHING, PAINTING & LETTERING

13. TESTING & INSPECTION

14. MAINTAINANCE

15. SAFETY & PRECAUTION

16. FACTORY LAYOUT

17. PRODUCT LAYOUT

18. CONCULUSION

8/13/2019 zeeshan_(1) (1)


HOW MUCH THIS TRAINING WAS HELPFUL TO ME

The Training at Braithwaite & co. Ltd.(Clive work) was very much helpful to

me.Before the training at this premier plant, I just had the theoretical

knowledge of various equipment, device and machines. After coming here

and getting the supervisory hand and guidance of various senior and junior

engineers, technicians, workers. I get a good knowledge of what the

production & fabrication really stand for the equipment, apparatuses &

machines available here were just beyond the imagination until one can see

it practically, to watch them in practically was the main purpose of having the

training and which was really helpful for me. I gone through the different

processes of production & fabrication field. On, some apparatus I had the

opportunity to work under the guidance and that was really a big advantage

for me while studying. One of the aspect of this training was managerial

aspect. The co-ordination provided by the technical staffs and department of

training was very appreciable. So I thankful to the company to allow me to

train under such guidance

8/13/2019 zeeshan_(1) (1)


INTRODUCTION OF BRAITHWAITE & CO.LTD.

The company was established as BRAITHWAITE in 1913 as the Indian subsidiary of

BRAITHWAITE & CO. Engineers Limited (U.K.), for undertaking fabrication of structural

steel works. In 1930 it was incorporated as Braithwaite & co. (India) Ltd at Calcutta. In

1960 Braithwaite’s gnus Works located at Bhadreswar was set up for manufacture of

cranes, foundry products, machinery components etc.

The project division at Calcutta was established in 1978 to execute turnkey project for

material handling pants. In 1987 Victoria work was

taken over, which is equipped with all facilities for manufacture of Heavy structural’s for

Bridges and other engineering application. In 1976

company was taken over by Government of India, as fully owned public sector company.

Braithwaite & company ltd (BCL Company) is a public sector company under the

administrative jurisdiction of the Department of Heavy Industry, Ministry of Heavy

industry and public enterprise, Government of India.

The company (BCL) was incorporated in west Bengal as Braithwaite &

Co. ltd on 28 th February, 1930. The management of the company was taken by

India on 6 th March,1971. And the company was subsequently nationalised w.e.f.

on 1 st December 1976. BCL

became wholly owned by subsidiary of holding company “BH RTI BH RI UDYOG

LTD.(BBUNL)” , upon its formation in September, 1986. BCL is one of the largest manufacturers of wagon in India with an installed capacity

of 4350FWUS. It has composite

infrastructure for manufacturing. BCL deliver Wagon work, Structural work, Steel

Foundry work, etc. Previously they were accompanied with Tanks special Wagon,

Cranes, Jute curding M/C , and others.

It is the first manufacturing company to poses ISO 9002 certification for their

management system & marketing management. There Crane manufacturing unit

received ISO 9001 and their Foundry product (Angus) poses 9002 certification. Now

8/13/2019 zeeshan_(1) (1)


this industry is under ministry of

railway.

*It is one of the largest manufacture having all necessary infrastructure in the company.

*Export wagon to many country of the world.

*The company possess 9000 certificates for their of product.

*It offers a wide range of Engineering product and services.

*There is adequate supply of Electric power.

*Large number of experienced and skilled man power working.

*Economical location near Kolkata Port, Rail route , etc.

* “Enterprise Resources Planning” (ERP) package is implemented to increases the costeffective economics.

*It has capacity to develop necessary products within a short learning time such as

Bogie, Coupler, Dished end, LPG Bullets etc. LPG Bullets

which were installed under the supervision PDIL sindri and IOCL Digboi by Braithwaite

and company ltd.

8/13/2019 zeeshan_(1) (1)


PLANNING

After getting the ord er the organization informs it s drawing office for deleted design

and drawing. Then calculation of raw material involvement is done. Costing of raw

material is being informed to accounts department. Advice purchase to procure

material accordingly. To calculate man-hour involvement & machine involvement

behind the job. To select suitable area in the workshop where the job will be done. In

this case tonnage of job handle, capacity of EOT (Electrical overhead traction)

Crain(S) available. Bay width & length suitable route of incoming & outgoing

material, loading & despatch of material etc. are consider. To fix product target

schedule. Time of inspection & dispatch.

Details Of The Product :

Clive Works :-

1 .Bogie Covered Non Transitional coupling type High Speed railway wagon, with Air brake orBCNA-HS

2 .Bogie Alumina Tank Wagon, High Pressure railway wagon(for BALCO), BATW-HP or

BTAP-HP

3 .Bogie Open Special Type with Non Transitional coupling Light Weight railway wagon orBOXN-HL

4 .Bogie Open Special Non Transitional coupling type High Speed railway wagon or BOXN-HS

5 .Bogie Rail Non Transitional coupling type High Speed railway wagon with Air

brake or BRN22.9 Victoria works :-

6 .Bogie Tank Petrol Non Transitional coupling type railway wagon, BTPN (oil

tank), BTFLN (oil tank) Angus Work :- Bogie, Coupler, Striker Casting & other

Foundry products

The facilities provided are capable of producing high quality casting of approximately 3000 MT.

8/13/2019 zeeshan_(1) (1)


COMERCIAL ASPECT OF BCL & THEIR BUSINESS PROCEDURE

The marketing procedure in BCL follow the steps below:

1. Contract & Order

2. Planning

3.Design & Drawing

4. Purchase

MARKETING & COMMERCIAL

Main Objective:

1) To receive the order after opening of tender , Techno-commercial evaluation of the

tender is done for assignment of price according to terms and condition.2) After the manufacturing of wagons, Dispatch memo (DM) and inspection

certificate (IC) is prepared and the final bill is prepared for receiving the residual

amount of money

STEPS FOR IMPLEMENTATION & EXECUTION OF A RAILWAY BOARD WAGON

CONTRAC:

8/13/2019 zeeshan_(1) (1)


DIFFERENT WAGON IN BCL

1. BOXN-HL

BOGIE OPEN SPECIAL NON TRANSTIONAL COUPLING TYPE HIGH SPEED

RAILWAY WAGON (BOXN-HL) IS A HIGH CAPACITY WAGON. ITS

CARRYING CAPACITY IS 70.30T AND ITS TARE WEIGHT IS 21.3T AND AREA

OF BOXN-HL IS 30.32M. IT IS HIGH SPEED AND HIGH LOAD WAGON. IT HAS

TWO SIDE BODY AND TWO END BODY ATTACHED TO ITS AT SIDE AND

END BODY OF WAGON. IN THESE CTRB IS USE IT STAND FOR CARTRIDGE

TAPERED ROLLER BEARING. IH HAS A HIGH CAPICITY DRAFT GEAR WITH

FOLLOWER AND ALSO HAVING FOUR FLAP DOOR BOXN-HL

WAGON FITTED WITH CASNUB HS HIGH SPEED BOGIES RAISING THE

MAX. SPEED TO 100KM/H

8/13/2019 zeeshan_(1) (1)


2.BRN22.9

BOGIE RAIL NON TRANSITIONAL COUPLING TYPE HIGH SPEEDRAILWAY WAGON BRN22.9 Is a high speed wagon. Its carrying capacity is

68.90T and tare weight is 22.90T. It has

two end body and ten stanchion channel are fixed in both side of the wagon. Air braked wagon with CASNUB bogies for rail and steel product.as shown in FIG(1)

FIG(1) FIG(2)

3.BCNA-HSBOGIE COVERED NON TRANSITIONAL COUPLING TYPE HIGHSPEED RAILWAY WAGON BCNA-HS wagon are modified design of BCNAwagon with CASNUB HS High speed bogie rising the max. Speed upto100km/h. These wagon are characterised by a patch of red white horizontalstripes on the top left. as shown in FIG(2)

8/13/2019 zeeshan_(1) (1)


8/13/2019 zeeshan_(1) (1)


IDEAL UNDERFRAME FOR WAGON

The whole process of fabrication of a wagon mean fabrication of different

parts,

assemble them together also with important parts, finishing, painting, and

lettering. BCNA wagon is made of one under frame, which is the spinal cord. Ofthe whole, two side Bodies, and covering of the whole i.e. the roof, and bogies and

wheels. Different parts of the wagon are fabricated in different places and after that

they are assembled together in assembly shop. Some of the component like bogies,

wheels, axle, etc. are bought from outside. The assemblies are also an assembled

from other sub-assemblies. The main components of wagon are:

1. Under frame (1 no.)2. Side body (2 no.)

3. End Body (2 no.)

4. Bolster (4 no.)

5. Cross bar (8 no.)

6. Sole bar (2 no.)

UNDER FRAME ASSEMBLY AND ITS SUB - ASSEMBLIES

It is the main frame or main structural and functional element of wagon. It

consists of several subs - assemblies. The process will follow:

1). Sub - assemblies (canter sill, sole bar, bolster, cross bar, stiffener box ,etc.) are

manufactured. (Discussed later)

2). Assembled together on fixture, welded by upside down on bottom side. 3). Trunion Welded.

4). Floor plates are tack welded at bottom side, then stitch welded (thinner

(3mm) plates may distort or there may be a problem of undercut or

penetration during continuous welding) at bottom.

5). Brake system assembled.

6). Striker casting, back stop, couple, centre pivot on the retainer ring etc. arewelded or riveted where necessary.

7). After completion of the under frame fabrication it is send for boxing.

8/13/2019 zeeshan_(1) (1)


UNDER FRAME COMPONENTS:

Center sill, sole bar and bolster are the main load carrying components of an under frame.

Cross bar, carrier brackets, string channels and headstock are load distributing components that

provides rigidity to the structure. The two gusset plate provides rigidity to the joints ( betweencross bar-centre sill & bolster) & prevents bending at the joints. Coupler acts as the linkage

between the two wagons,& receives tensile stress, compressive stress & testing. These

stresses are transported to the draft gear (consists of a rubber compressed at high pressure) by

yoke that absorbs the stress & twisting. Yoke connect coupler path.

Retaining ring acts as a support to the centre pivot pin that connect the body of the wagon

with the bogies attached to the wheels. Auxiliary reservoir supporting bracket acts as a

support to the auxiliary air cylinder that provides air during its insufficient supply for proper

functioning of brake system.

8/13/2019 zeeshan_(1) (1)


COUPLER & ITS COMPONENET

It is a part os wagon in one wagon two coupler is used. A coupler is a mechanisim for

connecting rolling stork in the train. The design of the coupler is standard and it play a vitalrole it is basically use to join and pulling another wagon.

Component of Coupler

1. Striker casting

2. Draft gear

3. Follower

4. York 5. York pin

6. York supporting plate

7. Knuckle

8/13/2019 zeeshan_(1) (1)


8/13/2019 zeeshan_(1) (1)


DETAIL OF BOXN-HL WAGON

UNDERFRAME:

It is a part of wagon. In boxn-hl it is used. It play a vital role in wagon and it may also called back bone of the wagon. It carry the entire load of the wagon. To making the under frame

there are various part are attached such as, center sill, sole bar, head stock, bolster, cross bar,

stringer channel, gussets, coupler, brake assembly etc.as shown in fig(5)

SIDE BODY:

It is a part of boxn-hl. In boxn-hl two side body is use. It locate in side part of the wagon.In side body stanchion channel and door are fitted.as shown in fig (6)

END BODY:

It is a part of boxn-hl. In boxn-hl two end body is used. It locate in end part of the wagon.

In end body stanchion channel are fitted.as shown in fig(7)

fig(5) fig(6) fig(7)

8/13/2019 zeeshan_(1) (1)


BOGIE WITH WHEEL:

It is a part of wagon. In BOXN-HL CTRB Bearing are use (cartridge Taper Roller

Bearing) are mounted on wheels and onto bearing adapters are placed. Now one Bogie

(casnub 22 nlb) is placed on two sets of wheel and axle ( one set consists of two wheels

and their connecting axel weighs about 1480 kg). Before mounting the bogie, theelectrometric pads should be placed at the proper places. After bogie wheeling is done the

boxed wagon is placed on it. As shown in fig(8)

fig.(8) fig.(9) fig(10)

BOLSTER:

It is a part of BOXN-HL. In boxn-hl four bolster is used. It locate in between of center sill

and sole bar. In Bolster four plate is

use one is in top, and bottom and two is in middle. To making the under frame various

part are attached with bolster are center sill, sole bar and sanction channel. as shown in

fig(9).

CENTER SILL

It is a part of boxn-hl. In boxn-hl one center sill is used. It locate in the center of the under

frame. In center sell stiffer box and rib are fatted. To making the under frame there are

various part are attached to center sill and they are cross bar, sole bar, bolster, head stock

and stanchion channel. as shown in fig(10).

SOLE BAR:

It is a part of BOXN-HL. In boxn-hl two sole bar is used. It locate in side portion of

under frame where the side body get fitted. To making the under frame: head stock,

stanchion channel, bolster, cross bar, is attached to sole bar. as shown in fig(11).

8/13/2019 zeeshan_(1) (1)


CROSS BAR:

It is a part of BOXN-HL. In boxn-hl eight cross bar is use. It lacate in between to center sill

and sole bar. In cross bar three

plate are fitted one is in top and bottom, and middle. To making the under frame various

part are attached with cross bar are stanchion channel, sole bar and center sill. as shown infig(12).

HEAD STOCK:

It is a part of BOXN-HL. In boxn-hl four head stock is use. It locate at the end of boxn-hl.

To making the under frame head stock is attached with sole bar, center sill, and stanchion

channel. as shown in fig(13).

fig(11) fig(12)

STRINGER CHANNEL:

It is a part of BOXN-HL. In boxn-hl stringer channel fitted across the head stock &

bolster &cross bar or between the two cross bar is known as stringer channel. In boxn-hl

sixteen channel is used

CARRIED BRACKETS:

It is a part of BOXN-HL. In boxn-hl carried bracket are use it is similar to cross bar it also

consist of supporting plate which provides support to the brake pipes.

8/13/2019 zeeshan_(1) (1)


FLAP DOOR:

The flap

door ishinged at

the

underframe.

The door is

fitted to the

side body by

hinge

which is

riverted to it

by a

rimming

machine.

There are four flap doors in the wagon.

8/13/2019 zeeshan_(1) (1)


DETAIL OF BRN22.9 WAGON

UNDERFRAME: It is a part of wagon. In BRN22.9 it is used. It play a vital role in wagon

and it may also called back bone of the wagon. It carry the entire load of the wagon. To

making the underframe there are various part are attached such

as,center sill, sole bar, head stock, bolester, center gidder web, inner cross bar, cross bar

web, stringer channel, gussets plate, coupler, brake assembly etc.as sown in fig(a)

fig.(a fig.(b)

SIDE BODY:

It is a part of BRN22.9. In brn22.9 ten stanchion post are fitted in stanchion bracket which isattached with side rail.as shown in fig(b)

END BODY:

It is a part of boxn-hl. In boxn-hl two end body is used. It locate in end part of the wagon. In

end body stanchion channel are fitted.as shown in fig.(c)

8/13/2019 zeeshan_(1) (1)


BOLSTER:

It is a part of BRN22.9. In brn22.9 two bolster is used. It locate in between of center sill and

center girder web. In Bolster four plate is use one is in top, and bottom and two is in middle.

To making the under frame various part are attached with bolster are center sill, sole bar,

sanction channel, and center girder web.

CENTER SILL:

It is a part of BRN22.9. In brn22.9 two center sill is used. It locate in the both end of the

under frame. To making the under frame there are various part are attached to center sill

and they are , bolster, head stock, and stanchion channel. as shown in fig(c).

SOLE BAR:

It is a part of BRN22.9. In brn22.9 two sole bar is used. It locate in side portion of under

frame where the side rail get fitted. To making the under frame: head stock, stanchion

channel, cross bar web, is attached to sole bar. as shown in fig(d).

fig.(c) fig.(d)

CROSS BAR WEB:

It is a part of BRN22.9. In brn22.9 eight cross bar is use. It locate in between , sole bar and

center girder web. In cross bar web three plate are fitted one is in top and bottom, and

middle. To making the under frame various part are attached with cross bar web are

stanchion channel, sole bar, and center girder web. as shown in fig(e).

fig.(e)

8/13/2019 zeeshan_(1) (1)


HEAD STOCK:

It is a part of BRN22.9. In brn22.9 four head stock is use. It locate at the end of brn22.9.

To making the under frame head stock is attached with sole bar, center sill, and

stanchion channel. as shown in fig(f).

SIDE RAIL:

It is a part of BRN22.9. In brn22.9 two side rail is use. It locate at side part of the wagon. In

side rail ten stanchion post are fitted. as shown in fig.(g)

fig.(f) fig.(g) fig.(h)

CENTER GIRDER WEB: It is a part of BRN22.9. In brn22.9 two center girder web is use.

It locate at the center of under frame. To making the under frame center girder web is

attached with sole bar, bolster, cross bar web, inner cross bar and stanchion

channel. As shown in fig.(h)

fig.(j)

8/13/2019 zeeshan_(1) (1)


8/13/2019 zeeshan_(1) (1)


TYPES OF WELDING:

Manual Metal arc welding(MMAW): One of the most common types of arc welding is

shielded metal arc welding (MMAW);it is also known as manual metal arc welding (MMA)

or stick welding. Electric current is used to strike an arc between the base material and

consumable electrode rod, which is made of filler material (typically steel) and is coveredwith a flux that protects the weld area from oxidation and contamination by producing carbon

dioxide (CO2) gas during the welding process. The electrode core itself acts as filler material,

making separate filler unnecessary. Shielded metal arc welding. The process is versatile and

can be performed with relatively inexpensive equipment, making it well suited to shop jobs

and field work. An operator can become reasonably proficient with a modest amount of

training and can achieve mastery with experience. Weld times are rather slow, since the

consumable electrodes must be frequently replaced and because slag, the residue from the

flux, must be chipped away after welding. Furthermore, the process is generally limited to

welding ferrous materials, though special electrodes have made possible the welding of cast

iron, nickel, aluminum, copper, and other metals. as shown in fig.(a)

fig.(a) fig.(b) fig.(c)

8/13/2019 zeeshan_(1) (1)


MIG WELDING: MIG welding was developed in the 1940 s and 60 years later the general

principal is still very much the same. MIG welding uses an arc of electricity to create a short

circuit between a continuously fed anode and a cathode. The heat produced by the shortcircuit, along with a non-reactive gas locally melts the metal and allows them to mix

together. Once the heat is removed, the metal beings to cool and solidify, and forms a new

piece of fuses metal. MIG welding is useful because you can use it to weld

many different types of metals: carbon steel, stainless steel, aluminum, magnesium, copper,

nickel, silicon, bronze and other alloys. As shown in fig.(b)

SUBMERGED ARC WELDING: SAW is a commend arc welding process. Originally

developed by the linde-union carbide company. It requires a non-continuously fed

consumable solid or tubular electrode. The molten weld and the arc zone are protected from

atmospheric contamination by being “submerged” unde r a blanket of granular fusible flux

consisting of lime, silica, manganese oxide, calcium fluoride, and other compounds. Whenmolten, the flux because conductive, and provides a current path between the

electrode and the work. This thick layer of flux completely covers the molten metal thus

preventing spatter and sparks as well as suppressing the intense ultraviolet radiation and

fumes that are a part of the shielded metal arc welding(SMAW) process. As shown

in fig.(c)

8/13/2019 zeeshan_(1) (1)


8/13/2019 zeeshan_(1) (1)


MACHINE & TOOLS

A machine is a tool that consists of one or more parts, and uses energy to achieve a particular

goal. Machines are usually powered by mechanical, chemical, thermal, or electrical means,

and are frequently motorized. Historically, a powered tool also required moving parts toclassify as a machine; however, the advent of electronics technology has led to the

development of powered tools without moving parts that are considered machines. A simple

machine is a device that simply transforms the direction or magnitude of a force, but a large

number of more complex machines exist. Examples include shearing machine, rolling

machine, drilling machine, cutting machine, bending machine, etc.

A machine tool is a machine for shaping or machining metal or other rigid materials, usually by cutting, boring, grinding, shearing or other forms of deformation. Machine tools employ

some sort of tool that does the cutting or shaping. All machine tools have some means of

constraining the work piece and provide a guided movement of the parts of the machine.

Thus the relative movement between the work piece and the cutting tool (which is called the

tool path) is controlled or constrained by the machine to at least some extent, rather than

being entirely "offhand" or "freehand".

TYPES OF MACHINE

Hydraulic Guillotine Shearing Machines:

This fully Hydraulic Guillotine Shearing Machines is very versatile, reliable and efficient,

designed and built to high standard to meet the requirement of precision sheet and plate

working applications. Fast and accurate motorized back gauge with front digital readout is a

standard with all models of this machine. The back gauge travels on precision lead screw.as

shown in fig.(b)

8/13/2019 zeeshan_(1) (1)


Fig.(b) fig.(c)

Gas cutting machine :

Gas Cutting Machine helps a Fabricator in cutting production costs and increases efficiency.

It is designed for heavy duty jobs and also for precision jobs. It works on single phase supply

and is operated by 1/12 H.P. single phase motor. Machine is designed to operate on magnetic

effect in the roller shaft of gear box. Movement of gas cutting nozzle is directly linked with

magnetic roller shaft which results in fine cutting of metal.

WELDING & CUTTING MACHINE:

which are available in different dimensions and specifications. Used in applications like

automatic or manual cutting & flame cutting of small vehicles, our range is portable and

have cutting capacity of range 1200 mm. Further, our products find application in steel plate

making in industries such as car, ship building, engineering machinery, petroleum and

chemical industry etc.as shown in fig.(c)

PLASMA CUTTING MACHINE:

Plasma cutting is a process that is used to cut steel and other metal of different thickness(or

sometime other material) using a plasma torch. In this process, an inert gas (in some units,

compressed air) is blow at high speed out of a nozzle; at the same time an electrical arc is

formed through that gas from the nozzle to the surface being cut, turning some of that gas to

plasma. The plasma is sufficiently hot to metal being cut and moves sufficiently fast to blow

molten metal away from the cut as shown in fig.(d)

8/13/2019 zeeshan_(1) (1)


ROLLING MACHINE :

It is used to roll or bend a plate by help of three rollers one on top and two below the plate.

The plate is straightened and depends upon the vertical distance between axis of top roller

and bottom two rollers and the bending upon top roller vertical movement. More the vertical

movement more will be the bending effect. as shown in fig.(e)

Fig.(d) fig.(e )

8/13/2019 zeeshan_(1) (1)


BENDING & PRESSING :

Bending is a manufacturing process that produces a V-shape, U-shape, or channel shape

along a straight axis in ductile materials, most commonly sheet metal. Commonly used

equipment include box and pan brakes, brake presses, and other specialized machine

presses. Typical products that are made like this are boxes such as electrical enclosuresand rectangular

STRAIGHTNER MACHINE:

This machine is use to straighten the metal plate which bend due to various defect. Here the

floor plate are straighten before placing it on the floor of the wagon.

Pneumatic Compressor Machine:

It is a type of machines which creates air pressure and is used in various machine for various

process. Altogether there eight pressure pump in the Braithwaite which supply pneumatic

pressure for various equipment for running. as shown in fig.(f)

fig.(f)

SHOT BLASTING MACHINE:

It is a type of machine which is requires giving finish touch to the product that is wagon. It

is designed in such manner that all the part and body are shaped properly.

8/13/2019 zeeshan_(1) (1)


RIVETTING MACHINE:

Riveting machines are used to automatically set (squeeze) rivets in order to join materials

together. The riveting machine offers greater consistency, productivity, and lower cost when

compared to manual riveting. It is a heavy machine which contain a piston inside which

presses the die to give the required shape to the metal piece which is heated near it melting point .so that it is easier to give a desire shape.

GRINDING MACHINE:

A grinding machine, often shortened to grinder, 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.

CNC MACHINE

CNC Machine is a process used in the manufacturing sector that involves the use of

computer to control machine tools. Tools that can be controlled in this manner include lathes,

mills, routers and grinders. The CNC in cnc machine stands for Computer Numerical

Control. On the surface, it may look like a normal PC controls the machines, but the

computer s unique software and control console are what really sets the system apart for use

in CNC machine. Under CNC Machining, machine tools function through numerical control.

A computer program is customized for an object and the machine are programmed with CNC

machining language that essentially controls all features like feed rate, coordination, location

and speeds. With CNC machine, the computer can control exact position ng and velocity.

CNC machining is used in manufacturing both metal and plastic parts.

There are many advantages to using CNC Machining. The process is more precise than

manual machining, and can be repeated in exactly the same manner over and over again.

Because of the precision possible with cnc machining, this process can produce complex

shapes that would be almost impossible to achieve with manual machining. CNC

Machining is used in the production of many complex three-dimensional shapes. It is

because of these qualities that CNC Machine is used in jobs that need a high level of

precision or very repetitive tasks.

8/13/2019 zeeshan_(1) (1)


COMPRESSOR MACHINE

Hydraulic Compressor Machine:A hydraulic compressor machine is used to run various machine for compressing the job

or for creating sheers on the blade to cut the material Its silent features are

1.More Economical & Easy To operate high Performance

2.Durability

3.Sale Service Support

4.Require Low Maintenance5.Cost Effective

6.Faster Than Single Pump

7.Long Life of High Pressure Pump

8.Continuous Process(Less labour Required)

8/13/2019 zeeshan_(1) (1)


LOCK BOLTING MACHINE:

This was an inspiration for later gas operated, semi-automatic or selective fire firearms (such

as the M1, M14, M16, the L85A1/A2 and the AK-47/74) in which the bolt, upon contact with

the breech, rotates and locks into place, being held in place by lugs attached to the breech or

barrel extension. Upon closing, the bolt passes through the slots cut in the front of the barrel

extension, and then rotates; at this point it is

locked in place. The bolt remains locked until the action is cycled, either manually by the

operator, or mechanically by the gas created by discharging the rifle pushing on the operating

rod or bolt carrier, which then rotates the bolt and unlocks it from the breech so that it can be

withdrawn in order to extract and eject the spent casing, and chamber a new round.

RIMMERING MACHINE:

It is a type of machine used to make the size of the drilling much accurate and slag free so

that lock bolting or riveting can be easily done without any problem.

CUTTING AND CHIPPING MACHINE:

In Braithwaite various mechanical , hydraulic and pneumatic shear machine are presentwhich basically run manually and use to cut and make small chip for further production of

the components by giving shear.

8/13/2019 zeeshan_(1) (1)


DRILLING MACHINE:

A drill is a tool fitted with a cutting tool attachment or driving tool attachment, usually a

drill bit or driver bit, used for drilling holes in various materials or fastening various

materials together with the use of fasteners. The attachment is gripped by a chuck at one endof the drill and rotated while pressed against the target material. The tip, and sometimes

edges, of the cutting tool does the work of cutting into the target material. This may be

slicing off thin shavings (twist drills or auger bits), grinding off small particles (oil drilling),

crushing and removing pieces of the work piece (SDS masonry drill), countersinking,

counter boring, or other operations.

ig.(g) fig.(h)

8/13/2019 zeeshan_(1) (1)


JIGS &FIXTURE

In metalworking and woodworking, a jig is a type of custom-made tool used to control the

location and/or motion of another tool. A jig's primary purpose is to provide repeatability,

accuracy, and interchange ability in the manufacturing of products.[1] A jig is often confused

with a fixture; a fixture holds the work in a fixed location. A device that does both functions

(holding the work and guiding a tool) is called a jig. as shown in fig(h)

DRILL JIGS

A drill jig is a type of jig that expedites repetitive hole centre location on multiple

interchangeable parts by acting as a template to guide the twist drill or other boring device

into the precise location of each intended hole centre. In metalworking practice, typically a

hardened drill bushing lines each hole on the jig plate to keep the tool from damaging the jig.

Drill jigs started falling into disuse with the invention of the jig borer.

TYPES OF DRILL JIGS

1.Plate jigs or channel jig.

2.Angle plate jig.

3.Box jig.

4.leaf or latch jig.

5.Sandwich jig.

6.Trunnion jig.

7.Jig for multi spindle machines.

8. Template jig

9 Universal Jig

8/13/2019 zeeshan_(1) (1)


FIXTURE

A fixture is a work-holding or support device used in the manufacturing industry.[1][2]

Fixtures are used to securely locate (position in a specific location or orientation) and

support the work, ensuring that all parts produced using the fixture will maintain conformity

and inter changeability. Using a fixture improves the economy of production by allowing

smooth operation and quick transition from part to part, reducing the requirement for skilled

labour by simplifying how work pieces are mounted, and increasing conformity across a

production run.

CTRB BEARING:

A bearing is a machine element that constrains relative motion between moving parts to

only the desired motion. The design of the bearing may, for example, provide for free linear

movement of the moving part or for free rotation around a fixed axis; or, it may prevent a

motion by controlling the vectors of normal forces that bear on the moving parts. Bearings

are classified broadly according to the type of operation, the motions allowed, or to the

directions of the loads (forces) applied to the parts. CTRB is a special type of bearing used in

bogie wheel of wagon. It is a very costly bearing imported from America by themanufacturer name Benco. Altogether for a boxn-hl 16 bearing is mounted on the two side

of the wheel.

8/13/2019 zeeshan_(1) (1)


8/13/2019 zeeshan_(1) (1)


FINISHING, PAINTING AND LETTERING

Finishing & Painting: After manufacturing of BOXN-HL wagon complete testing &

inspection is done. If there is no objection, then it is go for finishing. The metallic surface may

have been damaged by several fabrication processes and rust. So one or more subsequent

polishing may be needed to get better surface. Shot blasting gives the necessary surface finish

to provide good adhesive property to paints. Within 30 to 60 minutes after shot blasting

painting is done. Painting gives the surface, corrosion resistant against all natural hazards.

There are three coats to protect the surfaces of the bodies (end-bodies, side-bodies &

under-frame) as these are manufactured with the thin steel sheet. Following paints are used for

brazing at finishing shop.

Lettering: This is the process of providing information about the wagon. The outer surface of

the wagon is inscribed with the letters which gives the relevant information such as no. of the

wag on, name of railways, its tare weight, carrying capacity, and other railway related

information regarding the wagon.

8/13/2019 zeeshan_(1) (1)


TESTING & INSPECTION

After manufacturing of BOXN-HL and BRN22.9 wagon, before dispatch an inspection

work is done by the company. A wagon is tested to check Brake Test: A brake is

mechanized device which offers an artificial Frictional resistance onto a moving body, in

order to slowdown (retard) or, stop it completely. The brake used in railway wagon is

mainly air brake. So the testing done by „ irbrake Testing Rig . During the testing, hose

pipe transfers the air from the Airbrake Testing Rig to the dirt collector where air became

clean (as dirt causes chocking of valves, piping & other internal equipments) and go to

control chamber; it allows air to go to distribution valve and distribute the air to brake

cylinder (generally 5 kg/cm 2) and the excess air to auxiliary reservoir. Auxiliary reservoir

will supply air to break cylinder if the air pressure falls below 5 kg/cm 2, within the

distributor valve. During testing, brake cylinder is connected to a pressure gauge which

records the pressure inside the cylinder and also the movement of the piston during

locking & unlocking of the brake- shoe with the wheel.

QUALITY ASSURANCE: After manufacturing of BOXN-HL,BRN22.9 & before despatch

an inspection is done by the RDSO inspection, Ministry of Railway Board. The inspection

form contains: Running gear, bogie made & bogie no., air brake made, SAB (Slack adjustment

barrel) made, date of air brake testing units calibration, data of air brake testing, coupler made,

tare weight, date of water tightness testing,RAD availed, date of short blasting, DM issusing

date, IXR fit memo issue date. The last official formality of quality assurance is, the above

inspection from should be signed by works inspectors & RDSO inspection jointly.

8/13/2019 zeeshan_(1) (1)


MAINTAINANCE

Maintenance, repair, and operations (MRO) or maintenance, repair, and overhaul[2] involves

fixing any sort of mechanical, plumbing or electrical device should it become

out of order or broken (known as repair, unscheduled or casualty maintenance). It also

includes performing routine actions which keep the device in working order (known as

scheduled maintenance) or prevent trouble from arising (preventive maintenance).

MRO may be defined as, "All actions which have the objective of retaining or restoring

an item in or to a state in which it can perform its required function. The actions include the

combination of all technical and corresponding administrative, managerial, and supervision

actions." MRO operations can be categorised by whether the product remains the property of

the customer, i.e. a service is being offered, or whether the product is bought by thereprocessing organisation and sold to any customer wishing to make the purchase. (Gazette,

2002) The former of these represents a closed loop supply chain and usually has the scope of

maintenance, repair or overhaul of the product. The latter of the categorisations is an open loop

supply chain and is typified by refurbishment and remanufacture. The main characteristic of

the closed loop system is that the demand for a product is matched with the supply of a used

product. Neglecting asset write-offs and exceptional activities the total population of the product between the customer and the service

provider remains constant.

8/13/2019 zeeshan_(1) (1)


SAFETY& PRECAUTION

Engineering Workshop Safety Manual Custodian:

(a) Never adopt a casual attitude in the workshop and always be conscious of the potential

hazards.

(b) Ensure that personal clothing is suitable to the workshop conditions, e.g. Safety

footwear with steel capping. Thongs or open footwear should not be worn in the

workshop area. Singles, tank tops or similar clothing are not suitable for wearing in the

workshop.

(c) Always wear eye protection when using power operated hand or machine tools, or while

performing physical tests that could lead to eye damage.

(d) Use protective clothing and devices appropriate to the type of operation being carried out,giving due consideration to the work being carried out in the vicinity.

(e) Never run in the workshop or any laboratory.

(f) Never indulge in reckless behaviour in the workshop

(g) Always exercise care when opening and closing doors and entering or leaving the

Workshop.

(h) Do not carry out any work in isolation in the workshop; ensure that at least a second person is within call.

(i) Before any work is carried out in the workshop, permission must be obtained from the

Workshop Supervisor. Never undertake any work unless the potential hazards of the operation

are known as precisely as possible, and the appropriate safety precautions are adopted. Any

flame producing activity is not to commence until the immediate area has been cleared of

dusts. Many materials, which are non-flammable in a lump state, become quite volatile whenin

powdered or dust cloud form.

(j) Take additional care when carrying or moving any potentially hazardous

material or substance. Warning signs and barriers followed carefully.

8/13/2019 zeeshan_(1) (1)


PRODUCT FLOW

8/13/2019 zeeshan_(1) (1)


FACTORY LAYOUT OF BCL, CLIVE WORKS

8/13/2019 zeeshan_(1) (1)


CONCLUSION

I am highly obliged to the H.R Dept. of BRAITHWAITE & CO. LTD. who allowed me to

pursue my summer training in such a big reputed organisation. BRAITHWAITE & CO. LTD.is one of the leading manufacturer in wagon industry where production is in bulk along with

safety of environment and employee.

During the training I came to know the various application of the mechanical equipment which I

have gone through in my studies. Mechanical equipment like gear box, shaft motor, bearing,

shearing machine, welding and its type, different types of machine, etc.. working are best

understood in practical knowledge rather than book knowledge. Engineering students foundindustrial visit highly helpful to understand the working of the different huge machine which is

impossible to make understood by the faculty in an organisation.

In BRAITHWAITE & CO. LTD. I have learned the working environment of company in

different department. All department follow safety norms and rules for the safety of each other.

Here I have understood that how important is summer education in the career of engineering

student.

We have to join industry after our studies and summer training provide me to establish our self

conveniently in the industry.

zeeshan_(1) (1)

Documents

Transcript of zeeshan_(1) (1)