Code #3577
Industry Overview
A bogie is the structure underneath a railway vehicle body that supports the axles and wheels through bearings. The CASNUB bogie is designed for freight wagons and consists of cast iron side frames, a floating bolster, mild steel spring plank, nested springs, and friction snubbers. The bolster is supported on the side frames through two nested sets of springs, while the side frames are connected by spring planks. Friction snubbers provide damping action to control oscillations, with damping proportional to the load.
The CASNUB bogie was initially fitted in BOXN wagons and designated CASNUB 22W. It was subsequently modified as CASNUB 22W(M) to address high wheel wear. Further variants, including CASNUB 22NL, CASNUB 22NLB, and CASNUB 22HS, were developed for different operational requirements. The CASNUB 22HS was developed for high-speed operation with a maximum permitted speed of up to 100 km/h. The various versions are used across freight wagons including BOXN, BOBR, BCN, BOBRN, BCNA, BOBY, BRN, BOBYN, BTPN, BFK, and BTPGLN.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 12 Nos/Day |
| Land & Building (50000 sq.mt) | Rs. 35.16 Cr |
| Plant & Machinery | Rs. 7.73 Cr |
| Working Capital for 2 Months | Rs. 10.67 Cr |
| Total Capital Investment | Rs. 63.81 Cr |
| Rate of Return | 38% |
| Break Even Point | 42% |
Content Index
- INTRODUCTION
- A BOGIE IS A STRUCTURE UNDERNEATH A RAILWAY VEHICLE BODY TO WHICH AXLES AND WHEELS ARE ATTACHED THROUGH BEARINGS.
- THESE BOGIES ARE NOW USED IN THE FOLLOWING WAGONS:-
- CONSTRUCTIONAL DETAILS
- THE CASNUB BOGIE ASSEMBLY CONSISTS OF THE FOLLOWING COMPONENTS:
- CASNUB BOGIE – TOP VIEW
- CASNUB BOGIE – FRONT VIEW
- A) WHEEL SET WITH CARTRIDGE BEARING
- B) AXLE
- C) AXLE BOX ADAPTER, RETAINER BOLT & SIDE FRAME KEY ASSEMBLY
- D) SIDE FRAMES WITH FRICTION PLATES
- E) BOLSTER WITH WEAR LINERS
- F) SPRING PLANK, FIT BOLTS & RIVETS
- G) LOAD BEARING SPRINGS AND SNUBBER SPRINGS
- H) FRICTION SHOE WEDGES
- I) CENTRE PIVOT ARRANGEMENT
- J) SIDE BEARER
- K) ELASTOMERIC PAD
- L) BOGIE BRAKE GEAR
- M) BRAKE BEAM (CASNUB 22W, 22NL, 22NLB & 22HS) AND BRAKE WEAR PLATES
- N) RECLAMATION OF BRAKE BEAM ON ACCOUNT OF WORN OUT BRAKE HEADS
- I) CASNUB 22W BOGIE
- II) CASNUB 22 W(M) BOGIE
- III) CASNUB 22 NL, 22NLB & 22HS BOGIE
- USES AND APPLICATION
- THESE BOGIES ARE NOW USED IN THE FOLLOWING WAGONS
- B.I.S. SPECIFICATION
- PROCESS FLOW CHART FOR CASTING
- PROCESS FLOW CHART FOR CO2 SAND CORE
- PROCESS FLOW CHART FOR CHEMICAL SAND CORE
- PRODUCTION PROCESS OF CASNUB BOGIE
- RAW MATERIAL
- CHEMICAL COMPOSITION (%)
- MECHANICAL PROPERTIES
- (A) SAND CASTING PROCESS OF SIDE FRAME
- STEEL SAND CASTING PROCESS
- RAW MATERIAL
- MOULDING
- SAND PREPARATION & SAND LAB
- CORE-MAKING
- MELTING
- POURING
- FETTLING
- HEAT TREATMENT
- I) PROCESS OF NORMALIZING SHALL BE FOLLOWED IN FOLLOWING ORDER
- II) PROCESS OF NORMALIZED AND TEMPERED SHALL BE FOLLOWED IN FOLLOWING ORDER:
- INSPECTION AND TESTING
- VISUAL EXAMINATION
- TESTS FOR CHEMICAL COMPOSITION AND MECHANICAL PROPERTIES
- NON-DESTRUCTIVE TESTS
- (A) RADIOGRAPHIC TESTS:
- (B) MAGNETIC PARTICLE TEST
- MICROSTRUCTURE
- WEIGHT
- LOAD TESTING
- PROOF LOAD TESTING
- (A) STATIC PROOF LOAD TEST FOR BOGIE BOLSTER:
- A) TRANSVERSE LOAD FOR DEFLECTION
- B) TRANSVERSE LOAD FOR PERMANENT SET
- C) VERTICAL – SIDE BEARING LOAD FOR DEFLECTION
- D) VERTICAL – SIDE BEARING LOAD FOR PERMANENT SET
- E) VERTICAL – CENTRE PIVOT LOAD FOR DEFLECTION
- F) VERTICAL – CENTRE PIVOT LOAD FOR PERMANENT SET
- G) ULTIMATE LOAD
- (B) STATIC PROOF LOAD TEST FOR BOGIE SIDE FRAME:
- A) TRANSVERSE LOAD FOR DEFLECTION
- B) TRANSVERSE LOAD FOR PERMANENT SET
- C) & D) VERTICAL LOAD FOR DEFLECTION & FOR PERMANENT SET
- E) VERTICAL LOAD FOR DISTRACTION TEST PERMANENT SET
- SAMPLE SIZE FOR PROOF LOAD TESTING:
- SECTIONING TEST:
- FOLLOWING ITEMS ARE TO BE SPECIFICALLY CHECKED:
- PERMITTED VARIATION IN WALL THICKNESS OF THE CASTINGS IS AS GIVEN BELOW:
- INSPECTION AND TESTING OF BRAKE BEAM
- LOAD TEST OF BRAKE BEAM:
- ASSEMBLY PROCESS OF CAS NUB BOGIE
- (A) GAUGING OF BOLSTER & SIDE FRAME:
- (B) WELDING OF LINERS:
- (C) RIVETING
- (D) GAUGING OF H-FRAME
- (E) DIMENSION CHECK
- LOAD TESTING OF BOGIE ASSEMBLY
- SCALE OF THIS TEST SHALL BE DONE AS DETAILED BELOW:
- PAINTING:
- DISPATCH:
- MARKET POSITION
- FREIGHT CAN SPEED UP ECONOMIC GROWTH
- SUPPLY CONSTRAINTS HIT INDIAN RAILWAYS’ INDUCTION OF FREIGHT WAGONS
- RAILWAY MINISTER SAYS INDIA FACING SHORTAGE OF WAGONS
- INDIAN RAILWAYS INTENDS TO PURCHASE 38,000 WAGONS
- SUPPLY CONSTRAINTS HIT INDIAN RAILWAYS’ INDUCTION OF FREIGHT WAGONS
- RAILWAYS MULLS BUYING NEW WAGONS WORTH RS 9,000 CRORE IN 3 YEARS
- PLANT LAYOUT
- MANUFACTURERS/SUPPLIERS OF COMPELETE CAS NUB BOGIE ASSEMBLY
- APPROVED VENDORS FOR COMPLETE ASSEMBLY
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF CARBON STEEL BILLET
- MIG WELDING WIRE ELECTRODE
- COATING POWDER
- PACKING MATERIALS
- FIRE CLAY
- BENTONITE POWDER
- COAL DUST
- FIRE BRICKS
- SOAP STONE
- GRAPHITE POWDER
- SILICA SAND
- SUPPLIERS OF LIME STONE
- SUPPLIERS OF PLANT AND MACHINERIES
- SUPPLIERS OF INDUCTION FURNACE
- HEAT TREATMENT FURNACE
- SUPPLIERS OF INTENSIVE SAND MIXTURE AND MULLER
- SUPPLIERS OF SAND SIEVING MACHINE
- SUPPLIERS OF SQUEEZE MOLDING MACHINE
- SUPPLIERS OF SHAKEOUT MACHINE
- SUPPLIERS OF SHELL MOLDING MACHINE
- SUPPLIERS OF CORE SHOOTER MACHINE
- SUPPLIERS OF DRYING OVEN
- SUPPLIERS OF FOUNDRY TOOLS
- SUPPLIERS OF SHOT BLASTING MACHINE
- SUPPLIERS OF MOLDING BOXES
- SUPPLIERS OF ALUMINIUM PATTERNS
- SUPPLIERS OF METAL TESTING MACHINE
- SUPPLIERS OF PRECISION MEASURING TOOLS
- NDT INSPECTION EQUIPMENT
- EOT CRANE
- POWER TRANSFORMER
- ELECTRICAL PANEL
- ELECTRIC MOTOR
- COOLING TOWER
- EFFULENT TREATMENT PLANT
- AIR POLLUTION CONTROL EQUIPMENTS
- AIR CONDITIONING EQUIPMENTS
- AIR COMPRESSORS
- PLATFORM WEIGHING MACHINE
- MATERIAL HANDLING EQUIPMENTS
- FIRE FIGHTING EQUIPMENTS
- SHOT BLASTING MACHINE
- JIGS AND FIXTURE
- SUBMERSIBLE WATER PUMP
Appendix
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
A CASNUB bogie is a freight wagon bogie designed to support the wagon body and provide controlled wheel and axle movement. It incorporates side frames, a floating bolster, spring plank, nested springs, friction snubbers, and associated brake and bearing components. The friction snubbers provide damping to reduce oscillations during operation. Different CASNUB variants have been developed to address operational requirements such as wheel wear, structural configuration, and higher-speed service.
The main components of a CASNUB bogie include wheel sets with cartridge bearings, axles, axle box adapters, side frames, friction plates, bolster and wear liners, spring plank, load-bearing and snubber springs, friction shoe wedges, centre pivot arrangement, side bearers, elastomeric pads, and bogie brake gear. Brake beams and brake wear plates are also included in the assembly. These components work together to provide structural support, suspension, damping, guidance, and braking functions for freight wagon operation.
CASNUB bogies are used in a range of Indian railway freight wagons. The report identifies BOXN, BOBR, BCN, BOBRN, BCNA, BOBY, BRN, BOBYN, BTPN, BFK, and BTPGLN among the wagons using these bogies. Their application supports freight transportation by providing a robust bogie arrangement capable of carrying wagon loads while accommodating suspension, wheelset movement, braking, and damping requirements.
The report identifies CASNUB-22W, CASNUB-22W (Retrofitted), CASNUB-22W(M), CASNUB-22NL, CASNUB-22NLB, and CASNUB-22HS as the principal variants. The CASNUB-22W(M) was developed to address high wheel wear reported with an earlier version, while the narrow-jaw variants introduced different design configurations. The CASNUB-22HS was developed for high-speed operation, with the report specifying a maximum permitted speed of up to 100 km/h.
CASNUB bogie components are manufactured through processes that include moulding, sand preparation, core-making, melting, pouring, fettling, heat treatment, assembly, and finishing. The report also covers casting and steel sand casting processes. Quality control includes visual examination, chemical composition and mechanical property testing, radiographic testing, magnetic particle testing, microstructure examination, weight checks, dimensional inspection, proof load testing, and load testing of the bogie assembly and brake beam.
Proof load testing is important because it verifies the structural performance of critical bogie components under specified loading conditions. The report includes static proof load tests for both the bogie bolster and side frame, covering transverse and vertical loading conditions, deflection, permanent set, and ultimate load. Such testing helps identify unacceptable deformation or structural deficiencies before components are placed into service and forms an important part of quality assurance for railway bogie manufacturing.
A CASNUB bogie manufacturing plant requires equipment covering foundry, casting, heat treatment, fabrication, inspection, assembly, material handling, utilities, and environmental control. The report lists equipment such as induction furnaces, heat treatment furnaces, sand mixers and mullers, moulding and core-making machines, shakeout and shot blasting machines, testing equipment, precision measuring tools, NDT equipment, EOT cranes, compressors, electrical systems, cooling towers, effluent treatment and air pollution control equipment, fire-fighting equipment, and material handling systems.
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