I had my training at

BHARAT WAGON & ENGG.

CO. LTD. MUZAFFARPUR

for : 4 weeks

in my training period i
have learned

1) production of wagons
2)management of a
industry
 The Bharat Wagon and Engg. Co. Ltd. Muzaffarpur Unit is
engaged in manufacture of goods wagon for Indian railways.
It also manufactures and supplies Sugar Machineries,
Agricultural implements and other mechanical and structural
Jobs.
The company was taken over by the government of India with
effect from 15th Dec. 1973 and ultimately it was nationalized on
8th Dec. 1978.
Presently more than 800 employees are contributed their
services to this unit of BWEL. Total area of factory 196200
ft2Covered area of factory 164691 ft2 THERE ARE TEN SHOPS
NAMELY:- (1) Press & smithy shop. (2) Electrical maintenance
shop (3) Cutting and welding shop. (4) Template shop. (5)
Drilling shop. (6) Structural shop. (7) Machine shop. (8) Foundry
shop. (9) Wagon Assembly shop. (10) Finishing shop

 Vision: to provide the road map of business

development, diversification and capacity
building in respect of all group companies

Mission: to enter into new technologies in

respect of its core strength areas

Values: loyalty and pride in company

 THERE ARE TEN SHOPS NAMELY:-

(1) Press & smithy shop.

(2) Electrical maintenance shop
(3) Cutting and welding shop.
(4) Template shop.
(5) Drilling shop.
(6) Structural shop.
(7) Machine shop.
(8) Foundry shop.
(9) Wagon Assembly shop.
(10) Finishing shop
 This shop is working the guidance of Mr. A.K.Barun. In this
press and smithy shop there are seven small open hearth
furnaces. These furnaces are connected with blower is driven
by induction motor

LIST OF MACHINE IN PRESS AND SMITHY SHOP:

NAME CAPICITY NO. SPECIFICATION CAPICITY OF OF MOTOR
MOTOR
(1) Hydraulic press (400T) 1 I.M 20HP
(2) Hydraulic press (250T) 2 I.MS 16HP
(3) Press machine (600T) 1 I.M 25HP
(4) Power Hammer (400kg) 1 I.M
The hydraulic press is used to
manufacture anchor plate. For
this the plate is heated in the
oil furnace. The heated plate is
kept horizontally on the machine
table and the ram is allowed to
press the plate, due to downward
movement the U shaped
anchor plate is manufactured. The
specification of this machine is as follows:-
Nominal pressure 250 tons
. Working pressure 200 atm.
Speed - 0.020 m/sec.
Motor capacity 50hp
 On this machine the part which is to be manufactured is kept
on the die after heating on the furnace and the ram is allowed
to strike the component on the die . Due to the strike of ram
the component takes the shape that of the die.
 As the name indicates this shop is mainly involved in cutting the
plates of different thicknesses in the desired shape & size and in the
profile cutting In this shop there is one shearing machine and two
cropping shearing machine for the cutting purpose.
In this shop there is one
shearing machine and two
cropping shearing machine
for the cutting purpose. On
the shearing machine the
plate to be cut should be
flat & the thickness should
not be more than 8 mm
 In this shop there are different types of drilling machines. In
this shop drilling is done by two method, i e. by marking and
by jig. The following are the drill size & which are used for
drilling in this shop is 5mm, 6mm, 11mm, 13.5mm, 17.5mm,
21.5mm and 23.5mm.

In this drilling shop there is one universal radial machine ,

two semi universal radial drilling machine and a few ordinary
radial drilling machine . There is one gang drilling machine
and one sensitive drilling machine .
 The universal drilling machine is
one of the important drilling machine .
The drilling machine can produce a
hole in any direction at any angle .
The universal drilling machine consists
of a vertical column and a horizontal
arm. The horizontal arm can move in
any direction i.e. horizontally, vertically,
and at any inclination. The drilling can
be done by automatic feed mechanism
and by manual operation.
 The shop works under the supervision of Mr. S. N.
Singh. This is the biggest shop of this organization.

In this shop there are various types of machines.

Such as
lathe, Drilling m/c, shaper, slotter milling m/c grinder,
boring m/c, planer etc. There are seven heavy duty
lathe machine, 11 lathe machine, 2 capstan lathe, 2
shaper machine, one double shaper machine, 2 milling
machine one vertical and one radial drilling machine , 3
slotter m/c and two boring machine .
The heavy duty lathes have 4 jaw
chuck and can hold a job of 1 m. dia.
The chuck can rotate up to a maxm
speed of 315 rpm.

. The tail stock of the lathe consists

of a separate electric motor
to move it self on the lathe bed.
This machine is used
to produce good surface
on rough work piece. Also
it can be used to cut a key
way & for many other
operations too .
 This is also very important shop of this plant.

In this shop casting is done. The various parts of the wagon are
manufactured in this shop. The casting is divided into three groups Low,
Medium & High casting . The low & medium castings are again divided into
sub-group Green and Dry and loam casting or sweep moulding.

For moulding clay is mixed with sand to improve binding strength. Normaly
Bentonite & cow dung improves the porous nature of sand. Normally 3 % clay
is mixed with sand. For casting first mould is prepared with help of moulding
box. As per the requirement core is used in moulding. For preparing core
reinforcement is used which supports the core. The core is bitted rigidly to
perment the displacement of core due to the pressure of the molten metal.
Green casting is used for mass production. For Dry casting, the core and the
prepared mould is heated from inside the coal oven to reduce the moisture &
to improve the strength & reduces the shrinkage allowances
 CUPOLA ZONES

The cupola furnace is divided in various zones. A number of chemical

reactions take place in this zone, which are as follow as: -
1. WELL
It is the space between the bottom of tuyers and the sand bed. The
metals are trickles down after melting and collects in this space before it
is tapped out.
2. COMBUSTION ZONE
It is also known as oxidizing zone . It is located between top of tuyers
and theoretical level above it. The actual combustion takes place in this
zone. More heat is evolved due to oxidation of silicon & manganese. A
temperature about 15400 C to 1870 0 is produced. The exothermic
reaction taking place in this zone. C + O2 ---------------> CO2 +
HEAT Si + O2--------------- > SiO2 + HEAT 2Mn + O 2 -----------
---- > 2MnO + HEAT
3. REDUCING ZONE
It is also known as protective zone . It is located between the top of the
combustion zone and the top level of the coke bed . CO2 is reduced in
Co in this zone through an endothermic reaction , as a result of which
the temperature falls from combustion zone, temperature is about
12000 C of this zone . CO 2 + C ( of coke) -------------------------
> 2CO - HEAT
 4. MELTING ZONE

The first layer of metal charge above the coke bed. The solid metal
changes to state in this zone. 3Fe + 2CO ----------------> Fe3C +
CO2
5. PREHEATING ZONE
It extends from above the melting zone to the bottom level of the
charging door and contains a number of alternate layer of coke and
metal charges. The function of this zone is to preheat the charges from
atmospheric temperature to about 10930C before the settle downward
to enter the melting zone. This preheating takes place due to the
upward advancing hot gases.
6. STACK ZONE
The empty portion of Cupola above the preheating zone. Which provides
the passage to hot gases to go to atmosphere, is known as Stack zone.
CUPOLA EFFICIENCY Th thermal efficiency of cupola is given by the ratio
of heat actually utilized in melting zone and superheating the metal to
the heat involved in it through various means. The ratio can express
mathematically :- npercent cupola = Heat utilize in melting and
superheating the metal x 100 Calorific value of coke + Heat involved
due to oxidation of iron, Si and Mn
In this shop the various
components which are
manufactured in the
different shops are
assembled and the wagon
is completed and then set
to the finishing shop . First
of the assembly of wagon,
the centre sill is kept on the
fixture .
 After assembling the wagon is sent to the finishing shop. In this
shop the wagon is brought to the shot blaster chamber. In this
chamber small iron particle is allowed to strike on the wagon to
remove the extra welding deposit and the rust formed on it .
After this the wagon is painted and the specifications are written on
the wagon and then dispatched to Indian Railway
 SUPPLIERS OF MAIN WAGON COMPONET
COMPONENT SUPPLIERS

(1)WHEEL W.A.P. BANGLORE

(2)BOGIE BESCO KOLKATA
(3)HIGH TENSION COUPLER H.D.C. KOLKATA
(4)AIR BRAKE EQUIPMENT
1.ESCORT Ltd. FARIDABAD
2. STONE INDIA Ltd. DELHI
3. BHARAT BRAKES & VALVE Ltd. KOLKATA

(5) STEEL
1. BOKARO STEEL PLANT
(6) BEARING
2. TISCO. INDIA THMKEN INDIA JAMSHEDPUR