Detailed Project Report on casting setup for railway bogie manufacturing
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CASTING SETUP FOR RAILWAY BOGIE MANUFACTURING [3577]
A bogie is a structure underneath a railway vehicle body to which axles and wheels are attached through bearings. CASNUB Bogie is used in Freight wagons. CASNUB bogie consists of two cast iron frames, floating bolster, mild steel spring plank, nested springs, and friction snubbers. Bolster is supported on the side frames through two nested of springs.Two cast iron steel frames are connected by spring planks. Frictional snubber acts as a frictional damper, which dampens the oscillations. Frictional snubbers provide damping action proportional to load. This bogie was first fitted in BOXN wagons and was designated as CASNUB 22W. This was later modified as CASNUB 22W(M) to take care of high wheel wear reported on earlier version. Subsequently CASNUB 22NL (Narrow jaw) and CASNUB 22 NLB (Narrow jaw with fish belly bolster) versions were introduced. The CASNUB 22 HS bogie has been developed for high-speed operation with maximum permitted speed up to 100 km/h. All CASNUB 22W bogies are to be converted to CASNUB 22W (Retrofitted) by the maintenance depots and workshops. The various bogie versions developed areas under. • CASNUB -22W, • CASNUB -22W (Retrofitted), • CASNUB -22W(M), • CASNUB -22NL, • CASNUB -22NLB, • CASNUB -22HS. These bogies are now used in the following wagons:- • BOXN BOBR, • BCN BOBRN, • BCNA BOBY, • BRN BOBYN, • BTPN BFK, • BTPGLN. The bogie comprises of two cast steel frames and a floating bolster. The bolster is supported on the side frame through two nests of springs. This also provides a friction damping proportional to load. A fabricated mild steel spring plank connects the side frames.
COST ESTIMATION
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%
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 – A:
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)
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