JOGINPALLY B.

R ENGG
COLLEGE
DEPARTMENT OF MECHANICAL ENGG
A SUSPENSION SYSTEM OF A TRAIN BOGIE
GUIDED BY
MR. A.V.RAO
ASSOCIATE PROFESSOR

ABSTRACT
THIS PROJECT INVOLVES A DETAILED STUDY ON THE
SUSPENSION SYSSTEM OF TRAIN BOGIE ICFARE OF
TWO TYPES ONE IS PRIMARY SUSPENSION SYSTEM AND
OTHER ONE IS SECONDARY SUSPENSION SYSTEM.AS A
APART OF PROJECT WORK INDIVIDUAL PARTS ALONG
WITH DETAILS HAVE BEEN DONE.THE
FUNCTIONINGASPECTS OF SUSPENSION SYSTEM HAVE
BEEN STUDIED AND PRESENTED.

INTRODUCTION TO
SUSPENSION SYSTEM
SUSPENSION SYSTEM IS A TERM GIVEN TO THE
SYSTEM OF SPRINGS ,SHOCK ABSORBERS AND
LINKAGE THAT CONNECTS A VEHICLE TO ITS
WHEELS.IT IS BASSICALLY CUSHION FOR PASSENGERS
PROTECTS THE LUGGAGE OR ANY CARGO AND ALSO
ITSELF FROM DAMAGE AND WEAR.

SIR WILLIAM BRUSH IS THE

FATHER OF SUSPENSION SYSTEM
IN AUTOMOBILES

SUSPENSION OF ICF(ALL COILED) BOGIE

IT CONSISTS OF TWO SUSPENSIONS NAMLEY:
PRIMARY SUSPENSION SYSTEM.
SECONDARY SUSPENSION SYSTEM.

PRIMARY SUSPENSION
SYSTEM
IT CONSISTS OF FOLLOWING COMPONENTS:
AXLE BOX GUIDE WITH DASHPOT

ARRANGEMENT.
AXLE BOX HELICAL COMPRESSION SPRING.
DERLING WASHERS AND HYDRAL WASHERS.
PACKING RINGS.

AXLE BOX GUIDE DASHPOT

ARRANGEMENT
AXLE BOX GUIDE WITH DASHPOT ARRANGEMENT

IS
MAINLY A CYLINDER PISTON ARRANGEMENT USED
ON PRIMARY SUSPENSION SYSTEM OF IR.
THE LOWER SPRING SEAT ACTS AS A CYLINDER
AND THE AXLE BOX GUIDE ACTS AS PISTON

AXLE BOX HELICAL COMPRESSION

SPRING
HERE HELICAL COMPRESSION SPRINGS ARE

USED
IN PRIMARY SUSPENSION SYSTEM MADE UP
OF
CHROME VANADIUM/CHROME MOLYBDENUM.
THE DIAMETER OF THE COIL IS
APPROXIMATELY
245MM.

DERLING AND HYDRAL WASHERS

THEY ARE USED IN PRIMARY SUSPENSION

SYSTEM IN ORDER TO ISOLATE THE

MIGRATIONS CAUSED BY WHEELS AND IT
GIVES PERFECT SEATING FOR AXLE BOX
GUIDE COMPRESSION.
THEY ARE MADE UP OF HIGH DENSITY
MOLECULAR POLY UTHARANE.

PACKING RINGS
THEY ARE USED IN PRIMARY SUSPENSION

SYSTEM TO GET EQUAL BUFFER HEAD.

SINCE ALL WHEELS HAVE DIFFERENT
DIAMETERS
IN ORDER TO GET SAME BUFFER HEAD THE
PACKING RINGS OF DIFFERENT DIMENSIONS
ARE TO BE USED IN PRIMARY SUSPENSION
SYSTEM.

SECONDARY SUSPENSION SYSTEM

COMPONENTS OF SECONDARY SUSPENSION:
BOLSTER
LOWER SPRING BEAM
BOLSTER COMPRESSION SPRINGS
BSS HANGERS
BSS PIN
EQUALISING STAY ROD
ANCHOR LINK
SHOCK ABSORBER

BOLSTER
THE BODY BOLSTER IS A BOX TYPE FABRICATED

MEMBRANE MADE UP OF CHANNELS AND WELDED

TO THE COACH.
IT IS FREE FLOATING MEMBRANE.
THE BODY BOLSTER TRANSFERS THE DEAD
WEIGHT OF THE COACH BODY TO THE BOGIE
FRAME.
THEY TWO TYPES OF BOLSTER IA AN ICF BOGIE:
BODY BOLSTER AND THE BOGIE BOLSTER.

BOGIE BOLSTER
LOWERSPRING BEAM:
THE BOLSTER SPRINGS ARE SUPPORTED ON A LOWER
SPRINGS.
THE LOWER SPRING BEAM IS A FABRICATED MADE OF
STELL PLATE.
IT IS TRAPEZODIAL IN SHAPE WITH SMALL STEEL
TUBES ON EACH END.
THE LOCATION OF THE BOLSTER SPRING SEATING IS
MARKED BY TWO CIRCULAR GROOVES IN THE CENTRE.
A RUBBER WASHER IS PLACED AT THE GROOVED
CENTRE.
THE BOLSTER SPRING SITS ON THE RUBBER WASHER.

BOLSTER

BOLSTER COMPRESSION SPRING

SINCE IT IS A ALL COILED BOGIE, HELICAL COMPRESSION

SPRINGS ARE USED IN SECONDARY SUSPENSION.

THEY ARE MADE UP OF CHROME VANADIUM/CHROME
MOLBDENUM STEEL.
THE MEAN DIAMETER OF THE SPRINGS APPROX 324MM.

BSS HANGER,BSS BLOCK,BSS PINS

IN SECONDARY SUSPENSION SYSTEM, THE BOLSTER IS

SUPPORTED ON HELICAL COIL SPRING BEAM.

THE LOWER SPRING BEAM IS SUSPENDED FROM BOGIE
SIDE FRAME THROUGH BSS HANGERS ON BSS BLOCKS.
THIS BSS HANGER BLOCKS ARE SUPPORTED ON BSS
HANGER PINS WHICH ARE ATTACHED IN BOGIE FRAME.

EQUALISING STAY ROD

THE INNER SECTION OF THE LOWER SPRING BEAM IS

CONNECTED TO THE BOGIE BOLSTERWITH THE HELP OF

AN EQUALISING STAY ROD.
IT IS A DOUBLE Y-SHAPED MEMBRANE FABRICATED
USING STEEL TUBES AND SHEETS.
THE EQUALISING STAY ROD IS HINGED ON BOTH THE
ENDS WITH THE LOWER SPRING BEAM AS WELL AS THE
BOGIE BOLSTER WITH THE HELP OF BRACKETS WELDED
TO BOGIE BOLSTER.
THEY CONNECTED THROUGH A PIN MAKING IT A HINGED
ARRANGEMENT.

EQUALIZING STAY ROD

SHOCK ABSORBER
IN ORDER TO DECREASE THE UNWANTED OSCILLATIONS

DURING PITCHING,SHOCK ABSORBER ARE USED AS

DAMPER.
SINCE SECONDARY SUSPENSION OF ICF BOGIE HAS
HELICAL COIL SPRINGS,TO ISOLATE UNWANTED
OSCILLATIONS OF THIS SPRING A GABRIEAL OR ESCORT
SHOCK ABSORBERS ARE USED.

ADVANTAGES
COMFORT OF THE PASSENGERS.
GOOD HANDLING.
SHIELDS THE VEHICLE FROM DAMAGE.
INCREASE THE LIFE OF THE VEHICLE.
KEEP THE TYRES PRESSED FIRMLY TO THE GROUND.

SUGGESTION
SUSPENSION SYSTEM OF A ICF BOGIE MAINLY FAILS

DUE TO FAILURE OF SPRINGS AND IMPROPER

ASSEMBLEY.
SINCE FAILURE OF SPRING IS MAINLY DUE TO IMPROPER
HARDNESS,WE WOULD SUGGEST THAT TO INVOLVE A
HEAT TREATMENT PROCESS OF SPRINGS DURING OVER
HAULING IN ORDER TO GET DESIRE HARDNESS.
A SPECIAL CARE SHOULD BE TAKEN DURING ASSEMBLY
OF SUSPENSION SYSTEMIN ORDER TO AVOID FAILURE
DUE TO PROPER ASSEMBLEY.

CONCLUSION
FROM THE WHOLE DSCUSSION IN SUSPENSION SYSTEM.I
OBSERVE THAT SUSPENSION SYSTEM IS LIKE A WHITE
BLOOD CELL PROVIDES ENERGY TO OUR BODYTO FIGHT
AGAINST DISEASES OR VIRUSES WHICH TRY TO DESTROY
OR TRY TO DECREASE OUR LIFE,IN THE SIMILAR WAY
SUSPENSION SYSTEM PROVIDES ENERGY TO A VEHICLE
TO PROTECT ITSELF FROM DAMAGING INCREASING LIFE
OF THE VEHICLE AND INCREASES COMFORT OF
PASSENGERS AND MANY MORE.
SO ACCORDING TO ME IF YOU REMOVE SUSPENSION
SYSTEM,THEN YOU WILL FEEL LIKE IN BULL CART IN
AUDI,IN MERC TYPE LUXURIOUS CARS.THE ONLY
DIFFERENCE IS SPEED.SO THE SCOPE OF SUSPENSION
SPEED IS SO BRIGHT.

BATCH MEMBERS:
A.ROHIT REDDY
N.BHANU KIRAN
A.ANIL

(13J21A0303)
Y.RAHUL
(13J21A0388)

(13J21A0305)
(13J21A0316)

THANK YOU