CHAPTER 1

INTRODUCTION
The Bharat Wagon & Engg. Co. Ltd Muzaffarpur unit is engaged in manufacture of goods wagon for
INDIAN RAILWAYS. It also manufacture and supplies sugar machineries. Agriculture implements and
other mechanical and structural jobs
The company was started an English man Mr. Arthur Butler around 1870, when industrial revolution
was taking place. In the starting period the company did not have more than 120 workers. During this the
business expanded greatly and the number of employees increased tremendously. The company has 600
employees during the period
Upto the april 1996 the company was managed by M/S jubilee agents limited on 1 st may 1946. After
that british management sold the same to Indians and since 1948 the management was in the hands of
Indian businessman. The production of company was renamed as BHARAT WAGON & ENGG. CO.
Ltd. Muzaffarpur
Presently more than 400 employees are contributing their services to this unit of BWEL.

1. Total area of factory is 196200ft

2. Covered Area of factory is 164691ft

Page 1

CHAPTER 2
SECTIONS IN PLANT
THERE ARE NINE SHOPS NAMELY:

1.
2.
3.
4.
5.
6.
7.
8.
9.

Press and smithy shop

Template shop
Cutting and welding shop
Drilling shop
Structural shop
Machine shop
Foundry shop
Wagon assembly shop
Finalizing shop

Page 2

CHAPTER 3
ABOUT THE SECTIONS
3.1 PRESS & SMITHY SHOP
3.1.1 INTRODUCTION
In this shop there are seven small open hearth furnaces where coal burns on the bed.
On these furnaces various types of parts are heated. The heated parts is kept is kept on the anvil & with
the help of hammer the required shape is formed. In this shop mere than 50 components are pre pared as
like.

1.
2.
3.
4.
5.
6.
7.

Head stock pressing

Anchor plate pressing
Foot step
Pull rod
Head stock
Hand wheel
Bolster

3.1.2 List and Numbering of M/C:NAME OF MACHINE

CAPACITY

NO. OF MACHINES

Hydraulic Press

400T

01

Hydraulic Press

250T

02

Press Machine

600T

01

Power Hammer

400kg

01

Power Hammer

250kg

01

Power Hammer

100kg

01

Power Hammer

80kg

01

Coal Fired Forged

01

Oil Fired Furnace

01

Blower

02

Page 3

3.1.3 PRESS AND PRESS WORK

The press is a metal forming machine tool designed to shape or cut metal by applying mechanical formed
into desired shape without removing chips. The presses are exclusively intended in mass production work
and they present the fastest & most efficient way to form a sheet metal into finished product.
3.1.3.1 POWER PRESS

The constructional features of power press is almost similar to the hand press the only difference being
the arm instead of driven by power. The power press may be designed as mechanical or hydraulic
according to the type of working mechanism is used to transmit power on the ram. In a mechanical press,
the rotary motion is obtained from electric motor is obtained from an electric motor is converted into
reciprocating moment of the arm by using different mechanical device. In a hydraulic press the fluid
under high pressure is pumped on one side of piston and then on the other in a hydraulic cylinder to drive
the reciprocating movement. Power press is driven by a crank and connecting rod mechanism. The
working of power press is similar to as that of hand press. The punch is fitted on the end of the ram and
die is attached on the bolster plate. The flywheel is mounted at the end of the crank shaft stores up the
energy for maintaining a constant downward speed of ram when the sheet metal is pressed between punch
and the die.
POWER PRESS PARTS

The Different parts of power press are described below:

8. BASE
9. FRAME
10. BOLSTER PLATE
11. RAM OR SLIDE
12. PITMAN
13. CRANKSHAFT
14. FLYWHEEL
15. BRAKE
16. CLUTCH
3.1.3.2 HYDRAULIC PRESS
The hydraulic press is used to manufacture anchor plate. For this the plate is heated in a oil furnace. The
Heated plate is kept horizontally on the machine table and the arm is allowed to press the plate due to
downward moment and the U-shaped anchor plate is manufactured.

Page 4

Fig 1 HYDRAULIC PRESS

3.1.3.3 POWER HAMMER

Fig 2 POWER HAMMER

On this machine the part, which is to be manufactured, is kept on the die after heating in the furnace and
the arm is allowed to strike the component on the die. Due to strike of the ram the component takes the
shape of that of the die.

Page 5

3.2 TEMPLATE SHOP

Mechanical template is used to cut and shape a product .
17. A die manufacturing
18. A mold
19. A jig (tool)
3.2.1 JIG AND FIXTURES
Jig and fixtures are production tool used to accurately manufacture duplicate and interchangeable
parts. Jig and fixtures used speciality to ensure interchangeablity of compounds.
Both Jigs and Fixtures position components accurately and hold component rigid and prevent movement
during working in order to import greater productivity and parts accuracy.
Fixtures are only holding the job during working but jigs are hold the job as well as guide the tool.
3.2.2 TEMPLATES:Template shop forms the layout of the wagon and the structure of wagon. Template shop give the
required dimension of metal to all shop special metal cutting.
3.3 CUTTING AND WELDING SHOP
This is one of the shop in which the basic work is performed as the name indicates of this shop. This shop
mainly involved in cutting the plates of different thickness in the desired shapes and size.
Machine which are involves in metal cutting are given below:
S.No.
1.
2.
3.
4.
5.

Name Of The Machine

Shearing Machine
Cropping Machine
Chipping Machine
Profile cutting Machine
Kangaroo Machine

No. Of Machine
01
02
01
03
01

3.3.1 SHEARING MACHINE

On the shearing machine the plate to be cut should be flat and the thickness should not be more then 8mm
for cutting the flat plate is kept on the bed of the machine and is moved manually. It is done with the help
of crane. It consist of cutting blade and no. of pressing bolts. Which holds the plate

Page 6

FIG 3 SHEARING MACHINE

3.3.2 CHIPPING MACHINE

This machine is used to used to produce an incline shape at tha end of plate, which is necessary in the
end-to-end welding. This machine has a gun through which high pressure air comes. This machine holds a
chisel. The high pressure pushes the chisel which causes to cut the plate.

3.3.3 PROFILE CUTTING MACHINE

This machine has a vertical column and two horizontal arm. One arm consist of template and consist of
the welding torch and the small driving motor. It can cut the plate upto 35mm to 40mm, through the
welding torch oxygen and acetylene gas supplied. This machine requires extra amount of oxygen gas so
two oxygen pipe are connected to the torch. To cut the plate in desired shape, the same shaped template is
fixed to the upper arm and the magnetic roller of the second i.e. lower arm is touched to the template. The
torch moves through the profile of the template and the plate cuts in the desired shape
3.3.4 KANGAROO MACHINE
One another plate-cutting machine in the shop is kangaroo machine. This is the biggest cutting machine in
the shop. This machine consist of two welding torch. The torch moves in all the co-ordinate axis, i.e. X, Y
&Z-axis. This is fully electronic controlled machine. This consists of an electric sensor and a horizontal
plate. The drawing of the required shape is kept on the horizontal plate and the sensor moves through the
black lines of drawing. This machine can also move manually. The amount of oxygen and acetylene gas
can be controlled with the knob.

Page 7

FIG 4 KANGAROO MACHINE

Page 8

3.4 DRILLING SHOP

3.4.1 INTRODUCTION
In this shop there are different types of drilling machines. The drilling Machine one of the important
machine tool in the workshop. As reguards its importance is secondary to thethe lathe. Although it was
preliminary designed to originate a hole, it can be perform a number of similar oprations. In a drilling
machine holes can be generated quickly and at a low cost. The holes is generated by rotating edge of a
cutting tool known as a drill which exerts large force on the work clamped on the table. As the machine
tool exerts vertical pressure to originate the holes it is loosely called the drill press
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. These are the drill size which are used here
for drilling marking takes a lot of time and it requires more skilled person for marking. So drilling of
component by marking is used for a few, component where it is difficult to set a jig. For mass production
of components jig is used for drilling . The thickness of the jig plate, which is in practice, is 12mm. To
manufacture jig a hole greater dia. is done in the jig plate and bush of required drill size is fitted in the
hole . The material of the jig bush is class IV and IS:1875
In this drilling shop there are universal drilling machine, radial drilling 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 .
3.4.2 RADIAL DRILLING MACHINE
The radial drilling machine intended for drilling medium to large and heavy work pieces. The
machine consist of a hevy, round vertical column mounted on a large base. The coulmn support a radial
arm, which can be raised or lowered to accommodate work piece of different heights. The drill head
containing mechanism for rotating and feeding the drill is mounted on a radial arm and can be moved
horizontally on the guide ways and clamped at any desired position. As it is possible to swing the arm
relative to the machine's base, a radial drilling machine is able to operate over a large area without having
to reposition the work piece. This saves considerable time because it is much faster to reposition the drill
head than it is to unclamp, move, and then re-clamp the work piece to the table. When several holes are
drilled on a large work piece, the position of the arm and drill head is altered so that a drill spindle may
be moved from one position to another after drilling the hole without altering the setting of the work. The
work may be mounted on the table or when the work is very large it may be placed on the floor or in a pit.
The radial drilling machines are used in small and big workshops, engineering industries, dies, tools,
and mould manufacturing, machine tool builders, automobile and ship building industries, railway,
defense, fabrications shops etc.

Page 9

RADIAL DRILLING MACHINE PARTTS WITH SPECIFICATION:

FIG 5 RADIAL DRILLING MACHINE

The arm is made of high class cast iron, arm slide is under strike heat treatment and grinding 2HP motor
can be provided diven sped section under heavy duty cutting. The main spindle is balanced by special
spring. The overload protective devices can secure the operator against injury.
SPECIFICATION
TPR-720A

TPR-820A

TPR-920A

TPR-100

Distance from column surface to 750mm

spindle Centre maximum

850mm

950mm

1100m

Travel of spindle head

530mm
Distance from base surface to 1060mm
spindle end

630mm
1210mm

730mm
1210mm

855mm
1280mm

Evaluating height of arm

650mm

650mm

600mm

605mm

Page 10

PARTS:

1. Base
2. Coulmn
3. Radial arm
4. Drill head
5. Spindle head & feed mechanism

There are also many types of drilling machines such as:

1. Universal drilling machine

2. Semi universaldrilling machine
3. Sensitive drilling machine
4. Gang drilling machine, etc
3.4.3 UNIVERSAL DRILLING MACHINE :
This is one of the important drilling machine. It can produce a hole in any direction at any angle. The
universal drilling machine consist 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.

FIG 6 UNIVERSAL DRILLING MACHIN

Page 11
3.4.4 SIMPLE RADIAL DRILLING MACHINE :
This type of driling machine move horizontal, vertical and rotate. This machine consists
of one electric motor, which is used for the operation of drilling. This machine can work by both
manually and automatic. In this machine water is used as coolant the chip which comes out from the
operation is continuous chips.

FIG 7 SIMPLE RADIAL

DRILLING MACHINE

DRILLING OF JOB
In this shop drilling is done by two methods:

1. By marking
2. 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. These are the drill size which are used here for drilling marking takes a
lot of time and it requires more skilled person for marking. So drilling of component by marking is used
for a few, cases.
For mass production of components jig is used for drilling . The thickness of the jig plate, which is
in practice, is 12mm. To manufacture jig a hole greater dia. is done in the jig plate and bush of required
drill size is fitted in the hole . The material of the jig bush is class IV and IS:1875 .

Page 12
FORGING PROCESSES

Fig 8 FORGING PROCESS

3.5 MACHINE SHOP
This is the biggest shop of this organization. In this shop there are various types of machines. Such as.

Sr. No.

Name of machine

Total no. Of machine

1.

Lathe

11

2.

Drilling machine

02

3.

Shaper machine

03

4.

Boring machine

02

5.

Planner

02

6.

Milling machine

02

3.5.1 LATHE MACHINE

The lathe is a machine tool used principally for shaping articles of metal, wood, or other material. All
lathes, except the vertical
turret type, have one thing in common for all usual machining operations; the work piece is held and
rotated around a horizontal axis while being formed to size and shape by a cutting tool. The cutter bit is
held either by hand or by a mechanical holder, then applied to the work piece. Principal capabilities of the
lathe are forming straight, tapered, or irregularly outlined cylinders, facing or radial turning cylindrical
sections,
.

cutting

screw

threads,

and

boring

or

enlarging

internal

diameters.
Page 13

FIG 9 LATHE MACHINE

3.5.1.1 CENTER LATHE
CONSTRUCTIONAL FEATURES OF CENTRE LATHE:
The Centre Lathe is used to manufacture cylindrical shapes from a range of materials including; steels
and plastics. Many of the components that go together to make an engine work have been manufactured
using lathes. These may be lathes operated directly by people (manual lathes) or computer controlled
lathes (CNC machines) that have been programmed to carry out a particular task. A basic manual centre
lathe is shown below. This type of lathe is controlled by a person turning the various handles on the top
slide and cross slide in order to make a product.
CONSTRUCTION:
The design of lathes can vary greatly depending on the intended application; however, basic features
are common to most types. These machines consist of (at the least) a headstock, bed, carriage, and
tailstock. Better machines are solidly constructed with broad bearing surfaces (slides or ways) for
stability, and manufactured with great precision. This helps ensure the components manufactured on the
machines can meet the required tolerances and repeatability.

Page 14

LATHE PARTS

1.
2.
3.
4.
5.
6.

BED
HEAR STOCK
TAIL STOCK
CARRIAGE
FEED MECHANISM
SCREW MECHANISM

THE BED
The bed is a robust base that connects to the headstock and permits the carriage and tailstock
to be aligned parallel with the axis of the spindle. This is facilitated by hardened and ground ways which
restrain the carriage and tailstock in a set track. The carriage travels by means of a rack and
pinion system, leadscrew of accurate pitch, or feedscrew.

Types of beds include inverted "V" beds, flat beds, and combination "V" and flat beds. "V"
and combination beds are used for precision and light duty work, while flat beds are used for heavy duty
work.

FIG 10 THE BED

Page 15

THE HEAD STOCK

FIG 11 THE HEAD STOCK

The headstock houses the main spindle , speed change mechanism , and change gears . The headstock is
required to be made as robust as possible due to the cutting forces involved, which can distort a lightly
built housing, and induce harmonic vibrations that will transfer through to the workpiec
reducing the quality of the finished workpiece.
The main spindle is generally hollow to allow long bars to extend through to the work area. This
reduces preparation and waste of material. The spindle runs in precision bearings and is fitted with some
means of attaching workholding devices such as chucks or faceplates. This end of the spindle usually also
has an included taper, frequently a Morse taper, to allow the insertion of tapers and centers. On older
machines the spindle was directly driven by a flat belt pulley with lower speeds available by manipulating
the bull gear. Later machines use a gear box driven by a dedicated electric motor.
THE TAIL STOCK
The tailstock is a tool holder directly mounted on the spindle axis, opposite
the headstock. The spindle does not rotate but does travel longitudinally under the action of a lead screw
and hand wheel. The spindle includes a taper to hold drill bits, centers and other tooling. The tailstock can
be positioned along the bed and clamped in position as required.
Page 16

There is also provision to offset the tailstock from the spindles axis, this is useful for turning small tapers.

FIG 12 THE TAIL STOCK

The image shows a reduction gear box between the hand wheel and spindle, this is a feature found only in
the larger center lathes, where large drills may necessitate the extra leverage. The tool bit is normally
made of HSS, cobalt steel or carbide.
CARRIAGE
In its simplest form the carriage holds the tool bit and moves it longitudinally (turning) or
perpendicularly (facing) under the control of the operator. The operator moves the carriage manually via
the hand wheel or automatically by engaging the feed shaft with the carriage feed mechanism. This
provides some relief for the operator as the movement of the carriage becomes power assisted. The hand
wheels on the carriage and its related slides are usually calibrated, both for ease of use and to assist in
making reproducible cuts.
It consist of following parts:

1.
2.
3.
4.
5.

Saddle
Cross slide
Compound rest
Tool post
Apron

Page 17

FIG 13 THE CARRIAGE

FEED MECHANISM
Various feed mechanisms exist to feed material into a lathe at a defined rate.
Bar feeder-A bar feeder feeds a single piece of bar stock into the cutting machine. As each part is
machined, the cutting tool creates a final cut to separate the part from the bar stock, and the feeder
continues to feed the bar for the next part, allowing for continual operation of the machine.
Bar loader-A bar loader is a variation on the bar feeder concept in that multiple pieces of bar stock may
be fed into a hopper, and the loader feeds each piece as necessary.
3.5.1 HEAVY DUTY LATHE
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 motor,
which is required to rotate the chuck has the following specification. This is 3 phase induction motor and
require 415 volts . The type is delta connection. The horsepower of the motor is 50 H.P. & the output shaft
of this motor can rotate speed of 1460 rpm. The tail stock of the lathe consists of a separate electric motor
to move it self on the lathe bed.

3.5.2 SHAPER MACHINE

Shapers have been largely superseded by milling nachines or grinding machines in mordern industrial
practice.
Page 18

The basic function of the machine is still sound and tooling for them in minimal and very cheap to
reproduce.
They can invaliable joiing or repair shops where only one or few pieces are required to be produce and
the alternative methods are cost or tooling intensive. The mechanically operated machines are simple and
simple and robust in construction, making their repair and upkeep easily achievable.
TYPES
Shapers are mainly classified as standard, draw cut, horizontal, universal, vertical geared, crank,
hydraulic, contour and travelling head. The horizontal arrangement is the most common. Vertical shapers
are generally fitted with a rotary table to enable curved surfaces to be machined. The vertical shaper is
essentially the same thing as a slotter (slotting machine), although technically a distinction can be made if
one defines a true vertical shaper as a machine whose slide can be moved from the vertical. A slotter is
fixed in the vertical plane.
Small shapers have been successfully made to operate by hand power. As size increases, the
mass of the machine and its power requirements increase, and it becomes necessary to use a motor or
other supply of mechanical power. This motor drives a mechanical arrangement (using a pinion gear, bull
gear, and crank, or a chain over sprockets) or a hydraulic motor that supplies the necessary movement via
hydraulic cylinders
OPERATION
The drive arm revolves less for the return stroke than for the cutting stroke, resulting in a quicker return
stroke and more power ful cutting stroke.
A shaper operates by moving a hardened cutting tool backwards and forwards across the work
piece. On the return stroke of the ram the tool is lifted clear of the workpiece, reducing the cutting action
to one direction only.
The work piece mounts on a rigid, box-shaped table in front of the machine. The height of the
table can be adjusted to suit this work piece, and the table can traverse sideways underneath the
reciprocating tool, which is mounted on the ram. Table motion may be controlled manually, but is usually
advanced by automatic feed mechanism acting on the feed screw. The ram slides back and forth above the
work. At the front end of the ram is a vertical tool slide that may be adjusted to either side of the vertical
plane along the stroke axis.
Page 19

This tool-slide holds the clapper box and tool post, from which the tool can be positioned to cut a straight,
flat surface on the top of the work piece. The tool-slide permits feeding the tool downwards to deepen a
cut. This adjustability, coupled with the use of specialized cutters and tool holders, enable the operator to
cut internal and external gear tooth profiles, splines, dovetails, and keyways.
The ram is adjustable for stroke and, due to the geometry of the linkage, it moves faster on the
return (non-cutting) stroke than on the forward, cutting stroke. This action is via a slotted
link or Whitworth link.
Cutting fluid may be employed to improve the finish and prolong the tools life.

USES
The most common use is to machine straight, flat surfaces, but with ingenuity and some accessories a
wide range of work can be done. Other examples of its use are:

1. Keyways in the boss of a pulley or gear can be machined without resorting to a

dedicated broaching setup.

2. Dovetail slides
3. Internal splines
4. Keyway cutting in blind holes

3.5.3 HORIZONTAL BORING MACHINE

This machine is used for the boring purpose of big components. This machine is driven by electric
motor & with the help of gear mechanism the main shaft is rotated. The sail, which is to be machined, is
kept on the bed. Before it, a ring is inserted over the sail to rigidly damp it. The main shaft consists of two
heads, which has groove in which cutting tool is fitted & fightened with the bolts. The cutting head starts
cutting from opposite sides. Both the cutting tools rotate in opposite direction.

Page 20

3.7 WAGON ASSEMBLY SHOP

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.

3.7 CENTRE SILL

This is manufactured in the sub-assembly shop. To manufacture two Z channels are welded
after welding the supporting plate is welded to require position and then it is sent for marking. After
marking, drilling is done and coupler cashing is fitted at both the ends and riveting is done by the air gun.
Lastly it is checked whether it is true size or not. If not the length is reduced by gas cutting. The length of
the center sill should be 9784mm and the width should be 2960 mm. The centre seal is placed on the
fixture and cross bar and bolster is welded to it . After welding these two seal bars are attached and is
welded . Now this is known "Under frame ". Now riveting is done. The head stock is also welded to the
centre sill at both the ends. The gusset plate and the cross bar bottom plate is welded to bolster and cross
bar respectively . The strenger is welded to the under frame throughout the length. The under frame is
placed on the manipulator for welding at the bottom side . Now the air brake cylinder and the pipe line is
fitted and clamped . The side body and end body is attached and riveted and welded to the under frame .
This complete box is kept on the wheel assembly and then it is sent for finishing.

FIG 14 CENTRE SILL

Page 21

3.8 FINISHING SHOP

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 . The high pressure air helps the iron particle to come out from
the gun and to strike rapidly . In this chamber the working condition are very hazardous . So The worker
wears oxygen mask before doing work inside the chamber .
In this shop painting of wagon are done. The wagon is painted in three coating.
1. Each primer:- It is avoid the dust.
2. Zinc phosphate:- it is the second coating at the paint.
3. Firozy blue: it is the finishing coating of the painting.
After this the wagon is painted and the specifications are written on the wagon and then dispatched to
INDIAN RAILWAY .

Page 22

FLOW CHART OF WAGON (BOXNHL MBS)

WHEEL SETFROM
BOGIESTROKE
&
OTHER COMPONENT

AIR BRAKE AND OTHER

COMPONENT

Page 23

CHAPTER 4
CONCLUSION
The training period in BHARAT WAGON & ENGINEERING COMPANY LTD.,
MUZAFFARPUR, was a very knowledgeable and learning experience. I learnt new things
about the industry in this period of 6 weeks. This period was very fruitful and has cleared
many of my concepts.
The company has provided me an insight to the various practices carried out in a
manufacturing plant and provided me knowledge of the various policies adopted by any
company, right from the input of raw material to the output with final quality product.

Page 24

CHAPTER 5
References:

This report is completed by myself with the refrence of some medium which is as follows.

1. Workshop technology By P.S Pragyan

2. Workshop technology By K.C. John.
3. Bharat wagon library
4. Wikipedia.com
5. Google.com
And special help of Bharat Wagon family.

Page 25