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A SUMMER TRAINING REPORT AT DIESEL LOCOMOTIVE WORKS VARANASI

A SUMMER TRAINING REPORT AT DIESEL LOCOMOTIVE WORKS VARANASI Submitted by-Sanjeev Kumar Course-IDD (Part-III)

Submitted by-Sanjeev Kumar Course-IDD (Part-III) Department-Mechanical engineering Roll no-14134013 Institue-IIT BHU

ACKNOWLEDGEMENT

I would sincerely like to thank the employees and the officers of DLW, VARANASI for their help and support during this training. Despite their busy schedules, they took time out for us and explained to us the various aspects of the working of the plant from the production shops.

This training provided me immense knowledge not only in the field of mechanical engineering but I also got to learn about the prestige that DLW has in our country.

Their logo “Our locos moves the nation” explains the whole story of their importance in this country. People working in DLW work their best to provide us the most comfortable locomotives.

PREFACE

The objectives of the practical training are to learn something about industries practically and to be familiar with the working style of a technical person to adjust simply according to the industrial environment. It is rightly said practical life is far away from theoretical one. We learn in class room can give the practical exposer real life experience no doubt they help in improving the personality of the student, but the practical exposure in the field will help the student in long run of life and will be able to implement the theoretical knowledge. As a part of academic syllabus of four year degree course in Mechanical Engineering, every student is required to undergo a practical training. I am student of third year mechanical and this report is written on the basis of practical knowledge acquired by me during the period of practical training taken at Diesel Locomotive Works, Varanasi.

CONTENTS

[1].Introduction to DLW……………………………………….

[2].Tool Room ………………………………………………….

[3]. Heavy Welding Shop……………………………………….

[4]. Light Machine Shop………………………………………

[5]. Machine Shop……………………………………………….

INTRODUCTION TO DLW

Diesel Locomotive Works (DLW) is a production unit under the ministry of railways. This was setup in collaboration with American Locomotive Company (ALCO), USA in 1961 and the first locomotive was rolled out in 1964. This unit produces diesel electronic locomotives and DG sets for Indian railways and other customers in India and Abroad.

Subsequently a contract for transfer of technology of 4000 HP Microprocessor Controlled AC/AC Freight (GT 46 MAC) / passenger (GT 46 PAC) locomotives and family of 710 engines has been signed with electro motive division of GENERAL MOTORS of USA for manufacture in DLW. The production of these locomotives has now started and thus DLW is the only manufacturers of Diesel Electric Locomotives with both ALCO and General Motors technologies in the world

History of diesel locomotives

In the early 1960s Indian Railways began conversion of its mainline from steam to diesel locomotives. For this conversion General Motors Electro-Motive Division (EMD) and the American Locomotive Company (ALCo) were asked to submit designs for new diesel locomotives. Each company submitted prototypes. Indian Railways designated these prototypes the WDM-4 class and the WDM-2 class respectively.

Technologically the General Motors WDM-4 was superior to ALCO's WDM-2, but Indian Railways required a transfer of technology agreement that would allow these locomotives to be manufactured in India. General Motors did not agree to the transfer of technology agreement so the ALCo prototype was selected for production. The first few prototype WDM-2 were imported. After Diesel Locomotive Works (DLW) completed construction of its factory in Varanasi, production of the locomotives began in India. The first 12 locos were built using kits imported from ALCo in the United States. After that DLW started manufacturing the WDM-2 locomotives from their own components. Since then over 2,800 locomotives have been manufactured and the WDM-2 has become the most popular locomotive in India.

However, even before the arrival of WDM-2 another type of diesel locomotive was imported from ALCo beginning in 1957. This locomotive was classified as WDM-1

.

Later a number of modifications were made and a few subclasses were created. This includes WDM-2A, WDM-2B and WDM-3A (formerly WDM-2C).

The WDM-2 is the diesel workhorse of the Indian Railways, being very reliable and rugged.

Introduction to Tool Room

Tool shop had 6 sections for carrying out different operations.

1.Machine section- Universal CNC machine which worked on 6 axis x,y,z,a,b and w.

Had tool of various sizes rangign from T1 to T24

Tool used in the machine was high speed steel.

Fluid used was soluble oil which is 1:20 ratio of oil and water

Universal CNC milling machine

is 1:20 ratio of oil and water Universal CNC milling machine 2.Grinding section- grinding operations. Universal

2.Grinding section-

grinding operations.

Universal cnc grinding machine to perform the

water Universal CNC milling machine 2.Grinding section- grinding operations. Universal cnc grinding machine to perform the

3.New development-In this the new parts were manufactured.

4.Breakdown section-Here the older components were machined to put to use again.

5.Pneumatic section-Compressed air pressure was used to clean the surfaces of componenets.

INTRODUCTION OF HEAVY WELDING SHOP:

In the DLW there are basically three type of welding used in HWS. The welding quality of DLW is very high quality. After the machining process we can’t say that this piece is not single piece.

1. Submerged arc welding

2. Manual metal arc welding

3. MIG welding

piece is not single piece. 1. Submerged arc welding 2. Manual metal arc welding 3. MIG

SUBMERGED ARC WELDING:

In submerged arc welding the welding process will be covered with the flux so that it will not react with oxygen and nitrogen. Because of the versatility of the process and the simplicity of its equipment and operation, shielded metal arc welding is one of the world's most popular welding processes. It dominates other welding processes in the maintenance and repair industry, and though flux-cored arc welding is growing in popularity, SMAW continues to be used extensively in the construction of steel structures and in industrial fabrication. The process is used primarily to weld ironand steels (including stainless steel) but aluminium, nickel and copperalloys can also be welded with this method.

GMAW COMPONENTS:

1. DC or Direct Current power supply

2. Electrode or wire feed controller

3. Wire drive roller assembly

4. Shielding gas source (cylinder) & regulator

5. Manually held Gun & ground clamps

6. Wire reel

roller assembly 4. Shielding gas source (cylinder) & regulator 5. Manually held Gun & ground clamps

MIG WELDING:

MIG welding can be used for most types of metals; steel, stainless steel, as well as aluminium. But welding aluminium is very different from welding mild steel because aluminium is a metal that is different from steel. So when we weld aluminium, we have to use other parameters, other settings. Aluminium has a lower melting temperature than mild steel, for example, so you should expect that we should use a lower heat input but in spite of this. So we have to use a higher local heat-input but a faster welding speed than with steel to get good fusion and penetration. This sounds as if aluminium welding is difficult, but it's not. The welding sets that we use adjust the welding parameters automatically, so the welder can concentrate on the welding operation, the movement of the welding gun and the weld pool.

INTRODUCTION TO LIGHT MACHINE SHOP

This shop deals with the matching of various small components required for the power pack unit such as, cam shaft, connecting rod, liners, gears,levers, F.P. Support, Piston pin, nuts and bolts bushes, various shafts etc.

as, cam shaft, connecting rod, liners, gears,levers, F.P. Support, Piston pin, nuts and bolts bushes, various

INTRODUCTION TO MACHINE SHOP

Machine shop work is generally understood to include all cold-metal work by which an operator, using either power driven equipment or hand tools, removes a portion of the metal and shapes it to some specified form or size. It does not include sheet metal work and copper smithing. The function of all machine tools is to produce metal parts by changing the shape, size, or finish of a piece of material. The shape of a part made with a machine tool is limited by the types of motion the tool can apply. Standard machine tools are grouped in six basic classes:

1. LATHES

2. DRILLING MACHINES

3. SHAPERS

4. PLANERS

5. MILLING MACHINES

6. GRINDING MACHINES

SAFETY RULES FOR MACHINE TOOLS:

The following are general safety rules for any machine tool:

1. Gears, pulleys, belts, couplings, ends of shafts having keyways, and

other revolving or reciprocating parts should be guarded to a height

of 6 feet above the floor. The guards should be removed only for repairing or adjusting the machine and must be replaced before operating it.

2. Safety setscrews should be used in collars and on all revolving or

reciprocating members of the machine tool or its equipment.

3. Do not operate any machine tool without proper lighting.

4. Never attempt to operate any machine tool until you fully understand how it works and know how to stop it quickly.

5.

Never wear loose or torn clothing and secure long hair, since these

items can become caught in revolving machine parts. Ties should be removed and shirt sleeves should be rolled up above the elbow.

6. Gloves should never be worn when operating machinery except

when absolutely necessary.

7. Always

measurements of the work piece. 8. Do not lubricate a machine while it is in motion. Injury to the operator and damage to the machine may result from this practice.

9. Always wear safety glasses or goggles while operating machine

tools. Also, wear respiratory protection if operation creates hazardous dust. All persons in the area where power tools are being operated should also wear safety eye protection and respirators as needed.

10. Know where tire extinguishers are located in the shop area and

how to use them.

taking

stop

the

machine

before

cleaning

it

or