DESIGN AND FABRICATION OF WELDING FIXTURE FOR I.C.F BOGIE FRAME A PROJECT REPORT Submitted by R.PERUMAL N.R.SARAVANAN S.

SUBBURAJ N.ASHWIN 41407114030 41407114038 41407114045 41407114007

In partial fulfillment for the award of the degree Of

BACHELOR OF ENGINEERING
In

MECHANICAL ENGINEERING

PRINCE SHRI VENKATESHWARA PADMAVATHY ENGINEERING COLLEGE PONMAR, CHENNAI 48

ANNA UNIVERSITY :: CHENNAI 600 025 APRIL 2011

ANNA UNIVERSITY : CHENNAI 600 025

BONAFIDE CERTIFICATE Certified that this project report DESIGN AND FABRICATION OF WELDING FIXTURE FOR I.C.F BOGIE FRAME is the bonafide work of R.PERUMAL (41407114030) who carried out the project work under my supervision .
SIGNATURE SIGNATURE

Mr.B.Brucelee,M.E. ASSISTANT PROFESSOR HEAD OF THE DEPARTMENT DEPARTMENT OF MECHANICAL ENGINEERING PRINCE SHRI VENKATESHWARA PADAMAVATHY ENGINEERING COLLEGE CHENNAI - 48

Mr.A.Baskar,M.E.,MBA,(PhD) ASSISTANT PROFESSOR SUPERVISOR DEPARTMENT OF MECHANICAL ENGINEERING PRINCE SHRI VENKATESHWARA PADMAVATHY ENGINEERING COLLEGE CHENNAI - 48

SUBMITTED FOR PROJECT VIVA HELD ON _________________

INTERNAL EXAMINER

EXTERNAL EXAMINER

ACKNOWLEDGEMENT

We

express

our

deep

gratitude

to

our

honorable

chairman

Dr.K.VASUDEVAN M.A.B.Ed.PhD., for rendering the technical staffs in completing this project. We convey our sincere gratitude to honorable principal

Dr.T.SOUNDERARAJAN M.Tech.PhD., for his moral support . Special thanks to our project coordinator Mr.B.BRUCELEE, M.E., for the help and support rendered to us . We sincerely our project guide Mr.A.BASKAR,M.E.,MBA,(PhD) for his constant encouragement and technical guidance . His inspirational and moral support have been inestimable in increasing our knowledge . We also express our deep gratitude to all other faculty members for their moral support rendered to us. Our sincere thanks to Mr.P.ETRAJ , Chief Instructor , Locoworks , for giving us constant encouragement and perceptive advice. He has been a constant source of inspiration. My special gratitude for Mr.P.R.SATHYAPAUL , Senior Section engineer , Coach Repair Shop, Locoworks , for having guided us in every sense , especially in obtaining various results in the design process. We would like to express our sincere gratitude to family members for their loving support and encouragement. Many thanks to our friends for the support and considerations rendered to us while doing project.

TABLE OF CONTENTS CHAPTER NO. TITLE PAGE NO.

ABSTRACT LIST OF FIGURES LIST OF SYMBOLS LIST OF TABLES

I II III IV

1.

INTRODUCTION

2.

LITERATURE REVIEW 2.1 THE BOGIE

2 2 2 3 4 5 5 7 7 8

2.1.1 Details About Bogie 2.1.2 Brief Description of Bogies 2.1.3 Attention of Bogie Components 2.2 2.2.1 WELDING DETAILS Flux Cored Arc Welding 2.2.2 2.2.3 2.2.4 Process variables Advantages Disadvantages

2.3 2.3.1 2.3.2 2.3.3 2.3.4 3.

BOGIE FRAME Parts of Bogie Frame Parts to be Welded Welding by Existing Method Disadvantages of Existing method

8 9 9 10 12 13 13 14 14 15 15 16 16 16 19 22 22 22 24 25

NEED OF PROJECT WORK 3.1 3.2 Ultimate Advantage Scope of Project Work

3.2.1 Problem Analysis 3.2.2 Limitation 3.3 3.3.1 3.3.2 3.3.3 3.4 4. THE FIXTURE Difference between a Fixture & a jig Advantage of Fixture Design Principles of fixtures Materials used in Fixture

FABRICATION OF ROTARY FIXTURE 4.1 PROPOSED ROTARY FIXTURE 4.2 PARTS DESCRIPTION 4.3 FABRICATION PROCEDURE 4.4 ADVANTAGES OF PROPOSED METHOD

5.

DESIGN CALCULATION 5.1 5.2 5.3 BILL OF MATERIALS SPECIFICATIONS DESIGN CALCULATION

26 27 27 27 27 27 28 30 31 32 34 35 35 35 37 39 39 40 43

5.3.1 Power Calculation 5.3.2 Diameter of Shaft 5.3.3 Design for Column 5.3.4 Design for Clamping Plate 5.3.5 Design for Rotating Disk 5.3.6 Design for Journal Bearing 5.3.7 Design for Shaft 5.3.8 Design for Gear box 5.3.9 Motor Specification 5.3.10 Speed Reduction 5.4 6. CASE STUDY

DRAWINGS AND IMAGES 6.1 AUTO-CAD DIAGRAM 6.2 PRO-E DIAGRAM 6.3 PHOTOGRAPHIC IMAGE

7. 8.

CONCLUSIONS REFERENCES

47 48

ABSTRACT

The Passenger coaches of Indian railways are uniquely designed for comfort as well as safety of the train journey. Considering the speed , safe and jerk free operation, the coach wheels are not directly mounted on the frame of the coach. The wheels are assembled in pairs and fixed to a sub assembly called Bogie. Each coach is provided with two numbers of such bogies in the bottom which are joined by welding. The vertical load of the coach is directly transmitted to these bogies equally . As such ,the bogies are of vital in nature which also take care of the suspension system . These bogies are manufactured in loco works to meet their own requirements as well as for the replacements of the old damaged ones in other railway zones. During the fabrication of these bogies, loco works does not have a suitable fixture for carrying out the welding operation . As such, we decided to design and fabricate one such welding fixture for the use of loco works which will improve the accuracy of welding and also reduces the operation time.

LIST OF FIGURES FIGURE NUMBER 2.1 2.2 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 DESCRIPTION Flux Cored Arc Welding Overhead Crane setup of Existing Method Welding Fixture set up in Auto-CAD Bogie Frame in Pro-E Welding Fixture set up1in Pro-E Welding Fixture set up2in Pro-E Photographic Image of Bogie Frame Photographic Image 1 of the Welding Fixture Photographic Image of Gear Setup Photographic Image 2 of the Welding Fixture 46 45 44 43 42 40 41 39 PAGE NO. 6 11

II

LIST OF SYMBOLS SYMBOL T P Fs Wcr Wc I M Fcr Fb EXPLANATION Torque Power Shear Stress Crippling Load Crushing Load Moment of Inertia Bending Moment Crippling Stress Bending Stress Angle of Contact K Degrees of Freedom Co-Efficient of Friction m a Module Center Distance UNIT N-mm KW N/mm2 KN KN mm4 N-mm N/mm2 N/mm2 Degree No unit No unit mm mm

III

LIST OF TABLES

S.No. 1 2

DESCRIPTION Parts Description Bill of Materials

PAGE NO. 22 26

IV

CHAPTER - 1 1. INTRODUCTION

The theoretical aspects of practical oriented industrial training in loco works Indian railway , Chennai helped me to acquire the additional skill irrespective of the proceeses involved in manufacturing techniques , not forgetting the quality to be achieved and economy of the manufacturing cost. This expense to the shop floor gave me practical approach to the day to day problems very much similar to a normal shop floor production . The need for increasing productivity by reducing the unnecessary and difficult work to weld on the side frame in coach bogie in the prescribed position with the help of unskilled labour . It leads to motivates us to design such that to avoid monotony to the worker by emphasizing quick method of rotating and guiding method for welding a side frames in coach bogie. This project work of manufacturing a Welding Fixture for side frame in coach bogie been selected with a view to provide immense opportunity and expose to the solution of the day to day shop floor problems.

CHAPTER - 2 2.LITERATURE REVIEW

2.1 THE BOGIE 2.1.1 DETAILS ABOUT BOGIE Railway coaches and wagon are designed to carry passengers and cargo respectively . The upper portion of coach wagon is mounted on a fabricated structure is called bogies. The bogie consists of 1. Bogie frame 2. Bogie bolster 3. Brake 4. Brake frame wheel suspension coils IRS BG BOGIE In BG bogie the weight is taken at the center pivot, which is one of the bolster through coil bolster coil springs. From here the weight is passed over to the bogie frame by means of rocker bar and plate assembly . From bogie frame the weight is transmitted to the auxillary spring through bogie brackets . From here the bearing springs the weight goes to the axle box , brass , journals and wheel. IRS MG BOGIE In MG bogie weight is taken at the pivot top of the bolster . This weight is transmitted to the bottom springs planks through elliptical bolster spring. 2

The swing link bolt assembly takes up this weight from the bottom springs plank and transmits to the bogie frame . From the frame the weight is passed over to the equalizing beam through the coil springs kept on this beam . since the ends of the equalizing beams are resting at the crown of the axle boxes , the box , the brass, the journal and the wheel take up the weight . 2.1.2 BRIEF DESCRIPTION OF BOGIES The bogies being manufactured by ICF and RCF which have been accepted as standards on the Indian railways all welded light weight construction . the axle in these bogies with their self aligning spherical roller bearing mounted inside the cast steel axle box are rigidly guided by telescopis dashpots and axle guide assembly. Helical springs working in parallel with dashpots/hydraulic shock absorber are used for both primary and secondary suspension . The coach body is supported on two pairs of helical springs supported on a two side bearer located 1600mm apart on a floating bolster which in turn , rests on two pairs of helical springs supported on asprings plank swung from the bogies frame. The side bearer consists metal slides (wearing piece & bronze piece) Immersed in oil bath , well protected from oil dust ingression . no weight is transferred through the bogie pivot which is located in the center of the bolster . The pivot acts merely as a center of rotation and serves to transmit acceleration and retardation forces and incorporates a resilient silent bloc bush , which isolates noise from the track and offers a certain amount of constraint for noising of the bogies. To floating bolster is secured in the longitudinal direction to the bogies frame by means of two anchor links with silent 3

block bushing located diagonally opposite to each other and transmit draw and breaking forces between the bogie and body. Rigid wheel base 2896 mm 915mm 813mm

Wheel diameter(New ) Wheel diameter(Old ) -

2.1.3 ATTENTION OF BOGIE COMPONENETS The following attention should be paid to bogie components during POH before reassembling them. 1. The bogie frame should be checked thoroughly after cleaning for any possible cracks particularly at places where the bolster suspension brackets are welded and at the welding joints of top and the bottom flanges of side frame . Normally squareness and alignment of dashpots does not require checking . 2. Dismantle the bogie frame from bogie assembly and place it upside down with the guides up on a suitable stand . In the modified axle box arrangement, a guide closing plate to be welded. 3. The misalignment of the axle box guides should be measured with reference to the bolster spring suspension(BSS) bracket. 4. Center punch marks should be made at the center of each BSS brackets and the measurements taken. 5. The wear on the bush bolster suspension brackets should also be limited to 0.5mm and changed when worn beyond this limit. 4

2.2 WELDING DETAILS 2.2.1 FLUX CORED ARC WELDING Flux-cored arc welding (FCAW or FCA) is a semi-automatic or automatic arc welding process. FCAW requires a continuously-fed consumable tubular electrode containing a flux and a constant-voltage or, less commonly, a constant-current welding power supply. An externally supplied shielding gas is sometimes used, but often the flux itself is relied upon to generate the necessary protection from the atmosphere. The process is widely used in construction because of its high welding speed and portability. FCAW was first developed in the early 1950s as an alternative to shielded metal arc welding (SMAW). The advantage of FCAW over SMAW is that the use of the stick electrodes used in SMAW is unnecessary. This helped FCAW to overcome many of the restrictions associated with SMAW. TYPES OF FCAW One type of FCAW requires no shielding gas. This is made possible by the flux core in the tubular consumable electrode. However, this core contains more than just flux, it also contains various ingredients that when exposed to the high temperatures of welding generate a shielding gas for protecting the arc. This type of FCAW is attractive because it is portable and generally has good penetration into the base metal. Also, windy conditions need not be considered. Some disadvantages are that this process can produce excessive, noxious smoke (making it difficult to see the weld pool); under some conditions it can produce 5

welds with inferior mechanical properties; the slag is often difficult and timeconsuming to remove; and operator skill can be a major factor.

Fig.2.1 Flux Cored Arc Welding Another type of FCAW uses a shielding gas that must be supplied by an external supply. This is known informally as "dual shield" welding. This type of FCAW was developed primarily for welding structural steels. In fact, since it uses both a flux-cored electrode and an external shielding gas, one might say that it is a combination of gas metal (GMAW) and flux-cored arc welding (FCAW). This particular style of FCAW is preferable for welding thicker and out-of-position 6

metals. The slag created by the flux is also easy to remove. The main advantages of this process is that in a closed shop environment, it generally produces welds of better and more consistent mechanical properties, with fewer weld defects than either the SMAW or GMAW processes. In practice it also allows a higher production rate, since the operator does not need to stop periodically to fetch a new electrode, as is the case in SMAW. However, like GMAW, it cannot be used in a windy environment as the loss of the shielding gas from air flow will produce visible porosity (small craters) on the surface of the weld. 2.2.2 PROCESS VARIABLES  Wire feed speed (and current)  Arc voltage  Electrode extension  Travel speed and angle  Electrode angles  Electrode wire type  Shielding gas composition (if required) Note: FCAW wires that don't require a shielding gas commonly emit fumes that are extremely toxic; these require adequate ventilation or the use of a sealed mask that will provide the welder with fresh air. 2.2.3 ADVANTAGE  FCAW may be an "all-position" process with the right filler metals (the consumable electrode). 7

 No shielding gas needed making it suitable for outdoor welding and/or windy conditions.  A high-deposition rate process (speed at which the filler metal is applied) in the 1G/1F/2F.  Some "high-speed" (e.g., automotive applications)  Less precleaning of metal required.  Metallurgical benefits from the flux such as the weld metal being protected initially from external factors until the flux is chipped away. 2.2.4 DISADVANTAGES  Melted Contact Tip happens when the electrode actually contacts the base metal, thereby fusing the two.  Irregular wire feed typically a mechanical problem.  Porosity the gases (specifically those from the flux-core) dont escape the welded area before the metal hardens, leaving holes in the welded metal.  More costly filler material/wire as compared to GMAW.  Less suitable for applications that require painting, such as automotive body works. 2.3. BOGIE FRAME Bogie frame sustain the whole coach body weight and rest on axle box coil springs. In each coach two bogie frame is placed, one in front and other in rear. It

acts as a housing for wheels, brakes, batteries, brake frame, bolster, brake cylinder and various auxiliaries. The bogie bolster weight and auxiliaries weight are transmitted over to the bogie frame by corresponding links. By which bogie frame is a very important in coach. 2.3.1 PARTS OF BOGIE FRAME  Side frame  Transom  Head stock  Longitudinal  Web  Channel  Rib 2.3.2 PARTS TO BE WELDED  Wire rope brackets  Transom brackets  B.S.B(Bolster Suspension Brackets)  Anchor link bracket  Brake cylinder fixing brackets 9

2.3.3 WELDING BY EXISTING METHOD At present the bogie frame is being rotated with the help of six men and a bridge crane nearly eight times to carry out continuous run weld.The various steps which are involved in the rotation of bogie frame are given below :

 After the tag welding of top and bottom piece along with ribs and webs, the bogie frame is carried to fixture, which is stationary.  The bogie frame welding is carried through continuous run weld at one side.  Then the bogie frame is taken out with the help of bridge crane and placed down.The bogie frame is rotated with the help of bridge crane and placed in the fixture.  After fixing continuous run welding is carried out.  The bogie frame is then moved in vertical position by using bridge crane.  The welding is carried out in the channels, outer webs and ribs.

10

Fig 2.2 Overhead Crane setup of Existing Method

11

2.3.4 DISADVANTAGES OF EXISTING METHOD :  Inventory cost is more.  Machining cost is more.  Idle time of worker is increased.  Accident prone.  Decreased productivity.  Fatigue to labour.  Labour cost is more.  Fixing cost is more.  Waiting for crane, so time is lost.  Welding accuracy is lost.  Need of skilled labours.

12

CHAPTER - 3 3. NEED OF PROJECT WORK

There is a new innovation made if there is a need. The need is due to disadvantages of the existing method. The disadvantages in the manufacture of bogies made us to undertake brainstorming analyses and find an optimal design and fabrication for rotation of bogie frame. Bogie frame is one of the main parts in the coach, there must not be any kind of problems incurred in its manufacturing and functioning during welding and smaller process also. The ultimate aim of our project is to provide Loco Works with a rotary fixture which cannot be seen in either ICF or Carriage Works. 3.1.ULTIMATE ADVANTAGE  Production rate is increased.  Time taken for production is reduced.  Cost of manufacturing is reduced.  Worker idle time is reduced.  Worker motivation is increased.

13

3.2 SCOPE OF THE PROJECT WORK Present and future scenarios are dealing with reduced time, reduced cost, reduced in number of labour and complexity. As our project has taken into account the present scenarios and it has risen up with a best solution to overcome the problems faced by existing method. The project has got a wider scope, as it is user friendly and and doesnot involve much cost. This project deals with the design and fabrication of welding fixture of bogie frame using worm wheel mechanism. The fixture is used in all types of industries wherever there is need for increase in production when the heavy object is to be tilted and welded. The project will enumerate various problems and various parameters identification and analysis using problem solving technique. Brainstorming and arriving at a comprehensive design of the fixture. The calculation and cost analysis of the fixture is done. This fixture considerably decreases the inaccuracy in welding and increases the production rate which in return will reduce the fatigue. 3.2.1 PROBLEM ANALYSIS In this existing method, no fixture is used for welding of side frame in coach bogie. Every time a crane is used to turn it. Since side frame is in I in cross section if it has to be run welded 4times and the best position for welding is down hand welding and the workpiece mount be at 60* so it has to be in turned on swing by 60* on turn it upside down. In the current method the work piece is placed on a 14

V-block like stand and no fixture is used in holding it to a position and frame is fixed to position by its own weight. 3.2.2 LIMITATIONS  To turn the work piece, crane is involved which may be in need to other parts of the shop.  It takes more time for turning the side frame each time using crane.  More risk is involved when overhead cranes are used to rise and turn the workpiece.  Once the welding is started on the side frame, handling it using crane is difficult. Hence to overcome the above limitations we have suggested, designed, manufactured and implemented a WELDING FIXTURE which helps coach in coach bogie side frame welding. 3.3 THE FIXTURE A fixture may be defined as a device which holds and locate a workpiece during an inspection or for a manufacturing operation. The fixture does not guide the tool. In construction the fixture comprises different standards or specially designed work holding devices which are clamped on the machine table to haold the work in position . The tools set at the required position on the work by using gauges or by manual adjustment.

15

3.3.1 DIFFERENCE BETWEEN THE FIXTURE AND A JIG  Fixture holds and positions the work but does not guide the tool, whereas a jig holds, locates and guides the tool  Fixture are generally heavier in construction and are bolted rigidly on the machine table, whereas the jigs are made lighter for quicker handling and clamping with the table is often unnecessary.  The fixture are employed for holding work in milling, grinding, planning or turning operation whereas the jigs are used for holding the tool and guiding the tool particularly in drilling, reaming or tapping operations. 3.3.2 ADVANTAGES OF FIXTURE  Increases productivity.  Enable production of identical work.  Reduce operator fatigue.  Enable semi skilled labour to perform task.  Increases machining accuracy.  Cost reduction 3.3.3 DESIGN PRINCIPLES OF FIXTURES:  Before planning of the toll, compare the cost of production of the work with the present tools with the expected cost of production using the tool to be made and see that the cost of building is not excess of expected gain.  Before laying out the fixture decide the outline points and outline a clamping arrangement. 16

 Make all clamping and binding devices as quick acting as possible.  In selecting locating points, see that these component part of the machine can be located from the corresponding points and surfaces.  Make the fixture tool proof so that no work in other hand the required job cannot be inserted.  Locate the clamps so that they will be in the best position to resist the presence of the cutting tool when at work.  Make if possible, all clamps integrated part of fixture.  Avoid complicated clamping which are fixable to weak or get out of order.  Place all clamps as nearly as possible opposite to some bearing parts of work to avoid impinging.  Carry out all unnecessary metal, making the tools as lighter as possible , consistent with rigidity and stiffness.  Rounded all corners.  Provide handle whenever these will make the handling of the fixture more convenient.  Make if possible all the locating points visible to the operator when placing the work in position. LOCATING ELEMENT These Position the workpiece accurately with respect to tool setting or tool guiding elements in fixture.

17

CLAMPING ELEMENTS These hold the work piece securely in located position during operation. TOOL SETTING ELEMENT This aid in setting the tool in correct position with respect to workpiece. PROPERTIES  Fool proofing  Clearance  Rigidity  Safety  Economical FOOL PROOFING It is defined as the incorporation of design in the fixture , which prevents wrong loading of workpiece in fixture. This is provided by a fool proofing pin. CLEARANCE It is provided for two reason to allow any variation in component sizes. To allow any hard movements so that the workpiece can easily be placed in the fixture. RIGIDITY Fixture must be rigid enough to withstand all vibration while machining.

18

SAFETY  Sharp corner must be avoided.  Slight surfaces must be cleared.  Bolts and nuts should not protrude on the outside. ECONOMICAL The fixture should be rigid and light in weight. It should also be very economical in cost. 3.4 MATERIALS USED IN FIXTURE This is mainly used for cutting tools. These can hold be oiled as air hardened to 64-66 R.C.18% tungsten and also contains 4.3% chromium , 1.7% vanadium and smaller quantities of carbon,molybdenum etc. CARBON STEELS This can be used for standard cutting tools .They contain 0.85% carbon 0.5% to 0.8% manganese and a small quantity of silicon. These can be water hardened to 62.63 hardness . These can be used for drill bushes, locators and other parts , which are subjected top wear and need to be hardened. MILD STEEL It is used for most of the parts in the jigs and fixture . Mild steel contains less than 0.3% of carbon and 0.1% to 0.8% of manganese steel En 32 falls in this category . This can be case hardened to 56RC free cutting steels caontains less than 0.15% carbon and cannot be hardened . Generally all parts, which require 19

no hardening , are made of mild steel because it is cheapest material available among the steels. NYLON AND FIBRE These are used as soft lining for clamps top denting of damage to workpiece due to clamping pressure . Nylon or fibre pads are screwed or struck to mild steel clamps. CAST IRON Used for odd shapes to save machining and laborious fabrication, cast iron usage requires a pattern for casting . Pattern cost should be compared with cost of machining and fabrication . Cast iron contains 2 to 2.5% carbons . It can withstand vibrations well and it is suitable for bases and bodies if milling fixtures . Self lubricating properties of cast iron make are suitable for machine slides and guide ways. PHOSPHER BRONZE When screw operated clamps is worn out the screw as well as the nuts needs to be replaced . Generally screw are longer and costlier than nuts . So nuts are made or phosphor which has tensile strength . As phosphor bronze is softer than mild steel it wear out before the mating screw without causing much wear of the steel screw . Phosphor bronze nut bushes can be replaced periodically and thus , the life of the steel screw can be prolonged . Nuts for lead screws of most of the machine tools are made of phosphor bronze. 20

HIGH TENSILE STEELS Used mainly for fasteners such as high tensile screw these contain 0.4 to 0.6 to 1% Manganese . These can be oil hardened to 45 to 50 RC.

21

CHAPTER 4 4. FABRICATION OF ROTARY FIXTURE 4.1 PROPOSED ROTARY FIXTURE In order to avoid the disadvantages of existing method we have designed a fixture which has greater advantage when compared to the existing method. The proposed method consists of well suited rotary fixture that is capable of rotating the bogie frame and guides the same for operation to be performed. During this all the necessary design calculation is taken care. Even though we have got various method of operation, fixture is capable of rotating the bogie frame comfortably. The main advantage of selected fixture is that it is workers friendly and at the same time it saves the money and increase the productivity. 4.2 PARTS DESCRIPTION The various assembly components in the rotating fixture are SNo Parts 1 Base plate Description This is the lower most part, which form the base and the entire components rest on it. 2 Pillar This is column pair which rest on the base plate. A standard ISMI channel is used of length 1135mm.

22

Supporting plate

This is a additional plate, which is generally provided inorder to place housing arrangement about it. It is just like a stand for placement on it.

Bearing housing

Shaft

It is just like a roller or rod in bearing which rotate the rotating disc through the motor drive.

Rotating disc

This is one rotating part which rotates the rotating disc through motor drive.

Clamping plate

This is a U type channel to clamp the bogie frame according to the position. HL bolts, which are used in worm wheel are used to sustain the partial.

Bolt(HL)

9 10

Worm wheel Gear box

This has a diameter of 800 mm and number of teeth is 46. It is used to reduce the speed according to the requirements. It transmits the power to the worm wheel through worm.

11

Motor

This is a 7.5 hp motor with a rated speed of 1445 rpm.

23

4.3 FABRICATION PROCEDURE The various steps involved in fabrication are  Initially the entire sub components are made during assembly.  All the components are first applied with chalk powder and the centre point is marked using scriber,measuring tape,divider,try square etc.,  Place the two pillar on the top of the base plate at the centre position between according to the distance by using welding.  Take the supporting plate amd tag weld it over the pillar.  The whole assembly 0f housing and journal bearing is placed at the centre of supporting plate through tag weld.  Now take a rotating disc and tag weld to the shaftin either one supporting place on either disc through tag weld.  Apply grease in the bearing and then insert the shaft with the disc.  Place the work wheel at the right end of other side of the shaft through tag weld.  To provide the table arrangement according to the position for sustaining the worm wheel and gear box and to the motor arrangement.  Worm is fixed to the worm wheel.  Worm is mounted on the shaft through key and keyway arrangement tightly. 24

 Gear box connects to the sprocket wheel through the small shaft.  Sprocket wheel connects the pinion through standard drive.  Pinion attach to the motor shaft through the key and keyway arrangement.  Paint the fixture and this completes our fabrication procedures successfully. 4.4 ADVANTAGES OF PROPOSED METHOD  Semi skilled labour can do the work.  Idle time of the worker is reduced.  Reduced fatigue.  Increased productivity.  Once after fixing there is no use of bridge crane.  Setting and fixing time is reduced.  Welding accuracy is obtained.  Maintenance cost is low.  Less labour cost as less labour is involved.

25

CHAPTER 5 5. DESIGN CALCULATION 5.1 BILL OF MATERIALS S.No Parts 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Base plate Pillar Supporting plate Bearing housing Journal bearing Shaft Rotating disc Bolt (HL) Clamping plate Worm and worm wheel arrangement Gear box Shaft Chain drive Motor Bolt small TOTAL 26 Nos Volume (cm3) 65550 19058 9000 869.227 9047.78 7539.82 11128.78 Weight (kgs) 514.57 149.68 70.65 6.82 71.02 59.19 87.36 Cost(Rs) 16466.24 4789.76 226.8 226.08 6000 2130.4 3144.96 400 1200 94.2 250 3014.4 4500 7500 861.123 8.759 121.67 1000 14000 250 62771.03

2 2 2 2 4 2 2 7 2 1 1 1 1 1 10

5.2 SPECIFICATIONS Material : Mild steel Density : 7.85 g/cc Total mass of the bogie frame = 800 Kg 5.3 DESIGN CALCULATION 5.3.1 POWER CALCULATION Torque(T) Where ,W R T = W*R = weight of the bogie frame in N. = centre distance in mm. = 7848*1182 = 9.276106 N-mm = = 9.276 N-m Power = (2* *N*T)/60 = (2* *3*9.276)/60 = 2.9 KW 5.3.2 DIAMETER OF THE SHAFT Torque(T) Fs = ( *p*Fs*d3)/16 = shear stress = 40N/mm2 (from PSG data book page no. 7.7) 27

T D

= ( *Fs*d3) /16 = 105.7mm

From PSG data book page no. 7.20 According to R20 series standard diameter is 100 mm Therefore diameter of shaft = 100 mm 5.3.3 DESIGN FOR COLUMN Rankines formula for column. Rankines formula for short column that fails by crushing the failure of the component is due to both direct and bending(Buckling stress). {1/{Wc}} Wcr Wc = = = { 1/Wc}+{1/We} crippling load by rankine formula. ultimate crushing load for the column.

= Fc x A We = crippling load obtained by Eulers formula = {( xexI)/L} L L = = = 2xI (one end fixed and other end free) 2x1135 2270mm. 28

= =

{(BH )-(bh )}/12 {(150x200 )}-{(150-10)x(200-20 )}/12 31.96X106 mm4 2.1x105 N/mm. (150x200)-(140x180) 4800 N/mm I/A 31.96X104/4800. 81.597mm.

Youngs modulus(E ) = A = = K = = =

ULTIMATE CRUSHING LOAD Wc Fc Fs Fs Wc = Fc xA = crushing stress = 3200kgf/cm = 320 N/mm = 320x4800 = 1536000N = 1536KN We = {PxExI}x{L} 29

= {Px2x2.1x105x31.96x106}/2270} We Wc = 12855059.66N = {1/Wc}+{1/We} = Wcr = = {1/5360000}+{1/12855059.66} 1372058.21N 1372.058 KN

Crippling stress = 1372058.216/4800. = 285N/mm.

Therefore design for column is safe. 5.3.4 DESIGN FOR CLAMPING PLATE As we are using two clamping plate and load acting on them is 7848 N. Distribution of load on each clamping plate will be each 3942 N. Bending moment (M) = {WL}/8 = {3924*0.8}/8 = 392.4 N-m = 392400 N-mm

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MOMENT OF INERTIA I = {bd3}/12 = {800*1503}/12 = 225106 N-mm Cripping stress = 1372058.216/4800 = 285 N/mm2 Cripping stress>crippling stress 5.3.5 DESIGN OF ROTATING DISC Bending moment Bending stress Moment of inertia M Fb I = 3924*340 = 1334160 N-mm = {M*Y}/I = { (D4-d4)}/64 = { (6804)}/64 I Fb = 1.04761010 = {M*Y}/I = {1334160340}/{1.04761010} = 0.04N/mm2 Safe bending stress Fb = 60 N-mm2 So design is safe. 31

5.3.6 DESIGN OF JOURNAL BEARING FULL JOURNAL BEARING: When angle of contact = 360 known as full journal bearing

Materials = cast iron (from R.S.Khurmi and Ghupta) Determine bearing length by choosing a ratio i/d from psg data book pg. no. 7.31 L/D = 1.97 for railway car L = 1.97x180 = 354.6 But length taken = 225mm Check bearing pressure p p = W/(LxD) = 7848/(225x180) = 0.1937 N/mm Allowable bearing pressure is 3.5 N/mm from data book. Therefore the value of p is safe, so the dimension of LxD is safe and standard. Assuming a lubricant from table 25.2 from R.S.Khurmi and Guptha operating temperature is 32

SAE 60 to = 50c absolute viscosity z = 0.17 Kg/ms (1kg/ms = 1000 centipoises) Determine the operating value (ZN/P) for assumed bearing temperature corresponding value is table 25.3 from R.S.Khurmi and Gupta to determine the possibility of determining fluid operation. = = = = (ZN/P) N (0.17x3)/0.1937 2.6319 3

The minimum value for bearing module at which the oil film will break is given 3K = (ZN/P)

Bearing modules at the point of friction: K = = 7/3 2.3

Since calculated value for bearing characteristic no is 3 or more than 2.3, it will operate in hydrodynamic condition From table 25.3 clearance C/D = 0.001 33

Determine the coefficient of friction: = {33/108}X{ZN/P}X{D/C}+K From data book page no. 7.34 K = 0.002 = {33/108}x3x1000+0.002 = 0.0029

so <1 the design is safe 5.3.7 DESIGN OF SHAFT Bending moment M = W*L M = 3924*400 =156900 Nmm Moment of inertia I ={ *d4}/64 =4908738.521 mm^4 b =(32*Mb)/( *100^3) for solid shaft b = (32*1569600)/( *1003) B = 15.98781432 N Safe bending stress is 60 N So design is safe. 34

5.3.8 DESIGN OF GEAR BOX Speed No. of starts Speed ratio I z I = 20 =3 = z/Z = 3*20 = 60 mm Module m = 5 mm

Centre distance a = 180mm 5.3.9 MOTOR SPECIFICATION Rated speed of the motor Rated current Rated voltage Power 5.3.10 Speed Reduction Step 1 Speed of Motor = 1440 rpm = 1440 rpm = 11 amps = 415 volts = 5.5 kw or 7.5 hp

Reduction of Speed From motor shaft to sprocket wheel = Speed Of Sprocket Wheel 35 = 1440/2

= 720 rpm Input Output Step 2 Speed of Sprocket wheel = 720 rpm = 1440 rpm = 720 rpm

Reduction of Speed From sprocket wheel to worm & worm wheel = 1/20 Speed Of Worm Wheel 1 = 720/20 = 36 rpm Input Output Step 3 Speed of Worm Wheel = 36 rpm = 720 rpm = 36 rpm

Reduction of Speed From worm&worm wheel 1 to worm&worm wheel 2= 1/15 Speed Of Worm Wheel 2 = 36/15 = 2.4 rpm Input Output Thus in 3 Stages the speed is reduced from 1440 rpm to 3 rpm. 36 = 36 rpm = 3 rpm

5.4 CASE STUDY Labour cost per hour = Rs.50 60

Bogie frame per month = EXISTING METHOD

1.Required man power per bogie frame is 2.Total man hour per month 3.Number of man deployed 4.Labour cost per month 5.Labour cost per year TOTAL

= 12 mens = 60*12 = 4 to 5 = 60*12*50*3 = 60*12*50*3*12 = Rs.12,96,000

PROPOSED METHOD 1.Required man hour hour per bogie frame 2.Total man hour per month 3. Number of man deployed 4.Labour cost per month TOTAL = 7 = 60*7 = 1 to 2 = 60*7*5*1*12 = Rs.2,52,000

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COST SAVED CALCULATION Total cost saved = [cost of existing method]-[cost of proposed method] =Rs.12,96,000-Rs.2,52,000 =Rs.10,44,000 TIME SAVED CALCULATION Time saved per bogie frame Time saved per month Time saved per year = 5 hours = 5*30 = 5*30*12 =1800 hours

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CHAPTER 6 6 DRAWINGS AND IMAGES 6.1 AUTO-CAD DRAWING

Fig 6.1Welding Fixture set up in Auto-CAD 39

6.2 PRO-E DRAWING

Fig 6.2 Bogie Frame

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Fig 6.3Welding Fixture Set up 1 in Pro-E

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Fig 6.4 Welding Fixture Set up 2 in Pro-E

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6.3 PHOTOGRAPHIC IMAGE

Fig 6.5 Photgraphic Image of Bogie Frame

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Fig 6.6 PhotoGraphic Image 1 of Welding Fixture

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Fig 6.7 Photographic image of Gear setup

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Fig 6.8 PhotoGraphic Image 2 of Welding Fixture

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CHAPTER 7 7 . CONCLUSIONS JUSTIFICATION AND CONCLUSION : Our designed and fabricated fixture consists of simple assembled parts which is quite simple in design and fabricated. It has the reduced number of worker in existing method from four to two for the proposed method. The features of proposed method are as follows, y The total time saved is nearly three thousand six hundred hours per year. y The overall cost saved is ten lakhs ninety six thousand per year. y Productivity rate is increased. y Reduce the labour cost. The Future Scope of this project lies in replacing the induction motor to a stepper motor , in which the rotations would be in steps so that we could get the desired position of welding accurately than this set up. CONCLUSION : The workers use this fixture very easily and effortless and all the necessary steps are taken into consideration to ensure longer life with higher accuracy.

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CHAPTER 8 8. REFERENCES

1. PSG Design Data book 2. A TextBook of Machine design by R.S.Khurmi & J.K.Gupta 3. Theory of Machines by R.S.Khurmi & J.K.Gupta 4. Strength of Materials by R.K.Bansal 5. http://en.wikipedia.org/wiki/Bogie 6. http://en.wikipedia.org/wiki/Flux_cored_arc_welding

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