& y COMPANY PROFILE BEML Limited (formerly Bharat Earth Movers Limited) was established in may 1964 as a public sector undertaking for manufacture of Rail coaches and Spare Parts and mining equipment at its Bangalore complex. The has partially disinvested and presently government of India owns 54% of total equity and rest 46% is held by public, financial institutions , foreign institutional investors , banks and employees. a m = a 2 3 2) 3S BEML Limited a ‘Miniratna-category-1’, palys a pivotalrole and serves india’s core sectors like Defence, Rail, Power, Mining and Infrastructure. The Company started with a modest turnover of Rs.5 Cr during 1965 and today, thanks to its diverse business portfolio, the company has been able to achieve a turnover of more than rs.3,500 Cr. Its three major business verticals viz., Mining and construction, defense and rail and metro are serviced by its nine manufacturing units located at Bangalore , kolar gold fields(KGF), Mysore, Palakkad and Subsidiary- Vignyan Industries Ltd, in Chikmangalur district. BEMIL’s products are sold and serviced through its large marketing network spread all over the country. BEML’s products are exported to more than 56 countries. AS part of company’s globalization strategy, the company has expanded its global reach by opening local company at Indonesia and Brazil recently in addition to Malaysia and china offices. on | The company operates under three major verticals — viz . Mining and construction, Defense and Rail and Metro. Each of the above Business is headed by a director who acts as CEO of the Business and reports to the chairman and managing director of the company. In addition to the above trading division deals in non-company products. BEML manufactures and supplies Defense ground support equipment such as Tatra abased high mobility trucks, recovery vehicles , bridge systems, vehcles for missile projects, tank transportation trailers, milrail wagons, mine ploughs, crash fire tenders, snow cutters, Aircraft Towing tractors, Aircraft Weapon loading trolleys. The : company also plans to take up overhaul and upgradation of battle tanks with a view to 3 assemble and roll out the products. Under mining and construction business like bull 5 dozers, excavators, dumpers, shovels, loaders and motor graders to various user " segments and under rail and metro business, manufactures and supplies rail coaches , ¥ metro cars . AC EMUs , OHE cars , steel and aluminium Wagong to the rail sector.€ 4 e © SV QA7wapds3adcre The company has a dedicated R & D infrastructure and team in line with consistent policy of the company to meet the technological demands through in-house R&D and strategic technical tie-ups with global players. FMI operates an three major husiness verticals for associated equipment manufacturing: © Mining & Construction * Defense © Rail & metro In addition to the above there are two strategic units (SBUs): © Trading Division for dealing in non-company products © International business division for export activities The company has 9 manufacturing units spread over the following locations: Kolar gold field (KGF) complex ( around 100km from Bangalore ) © Carth moving division © Rail coach unit Il © Heavy fabrication unit © Hydraulic and powerline division Mysore complex ( around 130km from Bangalore) © Truck division © Engine division Bangalore complex rail and metro d Palakkad complex Vignyan industries , 2 subsid Bangalore )- steel catsings ry located at larikere (cruund 300k from BEML’s nation wide network of sales offices enables buyers with ready access toits wide range of products. Also, the full fledge service centers and parts depots offer tatal equipment care, maintenance contracts and rehabilitation services. The company has drawn up VISION-2013 with an ambitious growth rate of 12% CAGR for crossing rs.5,00 er turnaver by 2013-14 coinciding with BEMUs Golden Jubilee year. With this emerging prospects, BFMI. has plans tacross rs.S000Cr in the next twoer es years and is poised to achieve rs.10000 Cr markby 2016-17 and the company is gearing up with necessary infrastructure for achieving the same. Vision : lo become a market leader , as a diversified company supplying products and services to mining & construction, railway& metro and defense services and emerge as. an international player. OO Bz_PIOdQAo: Mission: eS Improve competitiveness Unvugl urganizativnal Uansformation and collaboration/strategic alliances/joint ventures in technology. Grow profitably by aggressively purs & international markets. iB Opportunities in national and Attract and build people in a rewarding and inspiring environment by fostering creativity and innovation. Objectives: & To maintain a dominant position in design, development, manufacture and marketing of defense, Earthmoving & construction and rail £ metro equipments To diversify and grow. To provide total engincering solutions to its customers. To internationalize operations by enhancing exports. To improve profitability. To maintain state of art technology for all products. Re-orientation of business operations to match present scenario. Continuous building of skills and compet effectiveness for management succession. ie> lv bring about executiveMATERIAL PREPARATION In the material preparation hanger, the metal sheets they receive are cut into proper geometry as e drawings received by them, by using various machines such as plasma cutter, flame cutter, shearing machines etc.. Plasma cutter: This machine uses plasma for cutting the metals. It uses a principle of ionization, in which the gases ionized at high temperature hecames a cutting matter of a metal. The machine which is present in a BEML can cut over up to a thickness of 6-15mm.the current of 130A should be supplied and the main voltage supplied to the hangar is 220- 240V, It Is stepped down to get a required current. The pressure around 8.3 is used, a compressor is used to obtain a required pressure. Generally a plasma can go up toa lemperature of 15000°C, which Is necessary to cut most of the metals they use. Hence plasma cutter can be used to cut any metal, generally it is used to cut mild steel and slainless steel. The components of plasmia Is No, O2, H20, C2H2, All. Flame cutter: There are different kinds of flame cutter used in the BEML, which can be automated, can cut required geometry by feeding its CAD drawing, manually operated and magnetic ( metal template machine). The flame used can be oxy acetylene flame or just an LPG flame. These flames are chosen according to the cutting conditions or a material to be cut.3 a es a a @ a @ oy @ a a Promecan shearing machine: This machine is used for shearing the material ina desired way to get a proper geometry on the metal. The thickness the machine can cut is around 5-30mm. it is a German made machine. The maximum dimensions it can cut is 3150mm width and 1000mm length and it can bevel up to 45° angle. Generally mild steel and stainless steel is cut in this machine. There are many other types of presses and dies with different cutting capacities. Similarly a proper machine is chosen for a required metal and the geometry. Why stainless steel preferred over others. In metallurgy, stainless steel also known as inox steel or inox from French “inoxydahle”, is steel allay with a minimum of 10.5% chromium content by mass. Stainless steel doesnot really corrode, rust or stain with water. Despite the name it is not fully stain proof, most notably under low-oxygen, high-salinity, or poor-circulation environment. stainlesssteel is used where both the properties of steel and corrosion resistance are required.Surface grinding machine: Surface grinding is the most common of the grinding operations. It is a finishing process that uses a rotating abrasive wheel to smooth the flat surface of metallic or nonmetallic materials to give them a more refined look or to attain a desired surface for a functional purpose. The surface grinder is composed of an abrasive wheel, a work holding device known as a chuck, and a reciprocating or rotary table. The chuck holds the material in place while it is being worked on. It can do this one of two ways: ferromagnetic pieces are held in place by a magnetic chuck, while non-ferromagnetic and nonmetallic pieces are held in place by vacuum or mechanical means. A machine vise (made from ferromagnetic steel or cast iron) placed on the magnetic chuck can be used to hold non-ferromagnetic work pieces if only a magnetic chuck is available. Factors to consider in surface grinding are the material of the grinding wheel and the material ot the piece being worked on. The grinding wheel is not limited to a cylindrical shape and can have a myriad of options that are useful in transferring different geometries to the object being worked on. Straight wheels can be dressed by the operator to produce custom geometries. When surface grinding an object, one must keep in mind that the shape of the wheel will be transferred to the material of the object like a reverse image.Punch press 40-1000T: A punch press is a type of machine press used to cut holes in material. It can be small and manually operated and hold one simple die set, or be very large CNC operated with a multi-station turret and hold a much larger complex dic sets. sa 5 fe a Similarly there are many other punch presses of different cutting or shearing capacities. Cec eeceeeaagxasi, i c c » e e e 3 : Tere ee eg se & Different types of welding used in BEML: TIG welding: ELECTRODE HOLDER TUNGSTEN ELECTRODE TINSULAING SHEAH WORKPIECE SHIELDING GAS, Gas tungsten arc welding (GTAW), also known as tungsten inert gas (1IG) welding, is an arc welding process that uses a non-consumable tungsten electrode to produce the weld. The weld area Is protected from atmospheric contamination by an inert shielding gas (argon or helium), and a filler metal is normally used, Unvugh suine welds, known as autogenous welds, do not require It. A constant- current welding power supply produces electrical energy, which is conducted across the arc through a column of highly ionized gas and metal vapors known as a plasma. GTAW is most commonly used to weld thin sections of stainless steel and non- ferrous metals such as aluminum, magnesium, and copper alloys. The process grants the operator greater control over the weld than competing processes such as shielded metal arc welding and gas metal arc welding, allowing for stronger, higher quality welds. However, GTAW is comparatively more complex and difficult to master, and furthermore, it is significantly slower than most other welding techniques. A related process, plasma arc welding, uses a slightly different welding torch to create a more focused welding arc and as a result is often automated.AOC -OCC CER SESE MHP IR 9OU MIG welding: Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert gas (MIG) welding or metal active gas (MAG) welding, is a welding process in which an electric arc forms between a consumable wire electrode and the workpiece metal(s), which heats the workpiece metal(s), causing them to melt and Join. Along with the wire electrode, a shielding gas feeds through the welding gun, which shields the process from contaminants in the air. The process can be semi- automatic or automatic. A constant voltage, direct current power source is most commonly used with GMAW, but constant current systems, as well as alternating current, can be used. There are four primary methods of metal transfer in GMAW, called globular, short-circuiting, spray, and pulsed-spray, each of which has distinct properties and corresponding advantages and limitations. Originally developed for welding aluminum and other non ferrous materials in the 1940s, GMAW was soon applied to steels because it provided faster welding time compared to other welding processes. The cost of inert gas limited its use in steels until several years later, when the use of semi-inert gases such as carbon dioxide became common. Further developments during the 1950s and 1960s gave the process more versatility and as a result, it became a highly used industrial process. Taday, GMAW is the mast common industrial welding process, preferred for its versatility, speed and the relative ease of adapting the process to robotic automation. Unlike welding processes that do not employ a shielding gas, such as shielded metal are welding, it is rarely used outdoors or in other areas of air volatility. A related process, flux cored arc welding, often does not use a shielding gas, but instead employs an electrode wire that is hallaw and filled with flux “Ww.Spot welding: Spotting =] i a Resistance spot welding (RSW) is a process in which contacting metal surfaces are joined by the heat obtained from resistance to electric current. Work-pieces are held together under pressure exerted by electrodes. Typically the sheets are in the 0.5 to 3 mm (0.020 to 0.118 in) thickness range. The process uses two shaped copper alloy electrodes to concentrate welding current into a small “spot” and to simultaneously clamp the sheets together. Forcing a large current through the spot will melt the metal and form the weld. Ihe attractive feature of spot welding is that a lot of energy can be delivered to the spot in a very short time (approximately 10-100 milliseconds). That permits the welding to occur without excessive heating of the remainder of the sheet. The amount of heat (energy) delivered to the spot is determined by the resistance between the electrodes and the magnitude and duration of the current. The amount of energy is chosen to match the sheet's material properties, its thickness, and type of electrodes. Applying too little energy will not melt the metal or will make a poor weld. Applying too much energy will melt too much metal, eject molten material, and make a hole rather than a weld.Another feature of spot welding is that the energy delivered to the spot can be controlled to produce reliable welds. Robotic spot welding is majorly used in there, it ic an automated spot welding used for various welding purposes. Series spot welding: the working is exactly similar to the above mentioned process, but in series spot welding there will be more than one welding spots at a time.CCC E SHSM Hs eIVGVECE Resistance seam welding is a process that produces a weld at the faying surfaces of two similar metals. The seam may be a butt joint or an overlap joint and is usually an automated process. It differs from butt welding in that butt welding typically welds the entire joint at once and seam welding forms the weld progressively, starting at one end. Like spot welding, seam welding relies on two electrodes, usually made from copper, to apply pressure and current. The electrodes are disc shaped and rotate as the material passes between them. This allows the electrodes to stay in constant contact with the material to make long continuous welds. The electrodes may also move or assist the movement of the material. A transformer supplies energy to the weld joint in the form of low voltage, high current AC power. The jaint of the work piece has high electrical resistance relative to the rest of the cit it and is heated to its melting point by the current. The semi- molten surfaces are pressed together by the welding pressure that creates a fusion bond, resulting in a uniformly welded structure. Most seam welders use water cooling through the electrode, transformer and controller assemblies due to the heat generated. Seam welding produces an extremely durable weld because the joint is forged due to the heat and pressure applied. A properly welded jaint farmed by resistance welding is typically stronger than the material from which it is formed.A common use of seam welding is during the manufacture of round or rectangular steel tubing. Seam welding has been used to manufacture steel beverage cans but is no longer used for this as modern beverage cans are seamless aluminum. There are two modes for seam welding: Intermittent and continuous. In intermittent seam welding, Ue wheels advance lo the desired and stop to make each weld. This process continues until the desired length of the weld is reached. In continuous seam welding, the wheels continue Lu rull as each weld Is made. ~ 136Aw a BS is a a a ceo a « w w ws Machine shop Computer Numerical Control (CNC): Numerical control (NC) is the automation of machinc tools that are operated by precisely programed commands encoded on a storage medium, as opposed to controlled manually via. Hand wheels or levers or mechanically automated via. cams’alone. Most NC today is a CNC, in computers play an integral part of the control. In modern CNC systems, end to end component design is highly automated using CAD and CAM programs. The program produces a computer that is interpreted to extract the commands needed to operate a particular machine via post processor and then loaded in to the CNC machines for production. Since any particular component might require the use of number of different tools drills saws etc. modern tools often combined multiple tools into a single “cell”. In other installations, a number of different machines are used with an external controller and human or robotic operators that move the component from machine to machine . in either case, the series of steps needed ta produce any part is highly automated and produces a part that closely matches the original CAD design. Other CNC machines including milling, drilling, lathes, plasma cutters ete. HORIZONTAL BORING MACHINE: A horizontal boring machine or horizontal boring mill is a machine tool which bores holes in a horizontal direction. There are three main types — table, planer and floor. The table type is the most common and, as it is the most versatila, it is also known as the universal type. A horizontal boring machine has its work spindle parallel to the ground and work table. Typically there are three linear axes in which the tool head and part move. Convention dictates that the main axis that drives the part towards the work spindle is the Z axis, with a cross-traversing X axis and a vertically traversing Y axis. The work spindle is referred to as the C axis and, if a rotary table is incorporated, its centre line is the B axis.€é€ OO 6 3:3! ecg ¢ Drilling machine: A drill is a tool fitted with a cutting tool attachment or driving tool attachment, usually a drill bit or driver bit, used for boring holes in various materials or fastening various materials together with the use of fasteners. The attachment is gripped by a chuck at one end of the drill and rotated while pressed against the target material. The tip, and sometimes edges, of the cutting tool does the work of cutting into the target material. This may be slicing off thin shavings (twist drills or auger bits), grinding off small particles (oil drilling), crushing and removing pieces of the workpiece (SDS masonry drill), countersinking, counterboring, or other operations. Drills are commonly used in woodworking, metalworking, construction and do-it-yourself projects. Specially designed drills are also used in medicine, space missions and other applications. Drills are available with a wide variety of performance characteristics, such as power and capacity. (t — Hota tink Chesatee S08eH sears Shaping machine: A shaper is a type of machine tool that uses linear relative motion between the workpiece and a single-point cutting tool to machine a linear toolpath. Its cut is analogous to that of a lathe, except that it is (archetypally) linear instead of helical.A. wood shaper is a similar woodworking tool, typically with a powered cutting head and manually fed workpiece, usually known simply asa shaper in North America and spindle moulder in the UK.A metalworking shaper is somewhat analogous to metalworking planer, with the cutter riding a ram that moves relative to a stationary workpiece, rather than the workpiece moving heneath the cutter. The ram is ~15~typically actuated by a mechanical crank inside the column, though hydraulically actuated shapers are increasingly used. Adding axes of motion to a shaper can yield helical toolpaths, as also done in helical planing.Shapers are mainly classified as standard, draw-cut, horizontal, universal, vertical, geared, crank, hydraulic, contour and traveling head,[1} with a horizontal arrangement most common. Vertical shapers are generally fitted with a rotary table to enable curved surfaces to be machined (same idea as in helical planing). 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 ta operate hy hand pawer 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. TOOL FEED HANDLE GRADUATED COLLAR — RAM CLAMPING NUT CLAPPER BOX TOU Post —__, PIE RBIONO® a) ell CWICH HANDLE TABLE 5 ~~a a } ‘ADJUSTABLE SLIDING ° SUPPORT —- ‘CROSS TRAVERSE ae HANDLE= Milling machine: Milling is the machining process of using rotary cutters to remove material from a workpiece by advancing (or feeding) in a direction at an angle with the axis of the tool. It covers a wide variety of different operations and machines, on scales from small individual parts to large, heavy-duty gang milling operations. It is one of the most commonly used processes in industry and machine shops today for machining parts to precise sizes and shapes.Milling can be done with a wide range of machine tools. The original class of machine tools for milling was the milling machine (often called a mill). After the advent of computer numerical control (CNC), milling machines evolved into machining centers (milling machines with automatic toni changers, tani magazines ar carousels, CNC control, coolant systems, and enclosures), generally classified as vertical machining centers (VMCs) and horizontal machining centers (HMCs). The integration of milling into turning environments and of turning into milling environments, begun with live tooling for lathes and the occasional use of mills for turning operations, led to a new class of machine tools, multitasking machines (MTMs), which are purpose-built to provide for a default machining strategy of using any combination of milling and turning within the same work envelope.The milling process removes material by performing many separate, small cuts. This is accomplished by using a cutter with many teeth, spinning the cutter at high speed, or advancing the material through the cutter slowly; most often it is some combination of these three approaches.[2] The speeds and feeds used are varied to suit a combination of variables. The speed at which the piece advances through the cutter is called feed rate, or just feed; it is most often measured in length of material per full revolution of the cutter. SorenLathe: Lathe is a machine tool that rotates the workpiece on ite axis to perform various operations such as cutting, sanding, knurling, drilling, or deformation, facing, turning, with tools that are applied to the workpiace to create an object with symmetry about an axis of rotation. Lathes are used in woodturning, metalworking, metal spinning, thermal spraying, parts reclamation, and glass-working. Lathes can be used to shape pottery, the best-known design being the potter's wheel. Most suitably equipped metalworking lathes can also be used to produce most solids ot revolution, plane surfaces and screw threads or helices. Ornamental lathes can produce three- dimensional solids of incredible complexity. |he workpiece is usually held in place by either one or two centers, at least one of which can typically be moved horizontally to accommodate varying workpiece lengths. Other work-holding methods include clamping the work about the axis of rotation using a chuck or collet, or to a faceplate, using clamps or dogs.BVO FOASrOMEeEE RS &FQOSOOBBIGOAGAH wo Honing machine: Honing is an abrasive machining process that produces a precision surface on a metal work piece by scrubbing an abrasive stone against it along a controlled path. Honing is primarily used to improve the geometric form of a surface, but may also improve the surface texture. Typical applications are the finishing of cylinders for internal combustion engines, air bearing spindles and gears. There are many types of hones but all consist of one or more abrasive stones that are held under pressure against the surface they are working on. In terms of sharpening knives, a honing steel does nat actually hone knives, but simply realigns the metal along the edge. Other similar processes are lapping and super finishing,Maeococet & O 8. 9(9 & S & & & & & PRETREATMENT SHOP Pretreatment ot metal involves removal ot various oxides and other and other impurities also provides a protective coating of zinc and phosphate for their better life. here are many tanks for this purpose such as given below. TANK 1 & 2: * Function: To remove oil and grease © Temperature : 85-90°C ° Time 210-15 min Chemical : sodium hydroxide, sodium carbonate, tri sodium phosphate, resin+water. TANK 3 & 4: * Tunction — : Washing * Temperature : 1-2 min + Time : roun temperature: * Chemical: water TANK 5: * Function — : To remove rust * Temperature : room temperature * Time 210-15 min * Chemical — : Rustodine Tank 6 & 7: Same as that of tank 3 and 4 Tank 8: Function —_: Phosphating 0-75°C 5-7 min Chemical = zinc phosphateSSB D9 FWA | S Or IAA eee ee & YG & TANK 9: Water rinsing TANK 10: Function —_: Acetylate( to neutralize) Temperature : 50-60°c Time 330-60 seconds Chemical =: chromic acid +water After this treatment the metal is allowed to dry for some time and then red oxide or yellow (zinc) oxide is coated. PHOSPHATING: It is a transformation of steel surface into new surface non-metallic and nonconductive properties. It protects the surface against corrosion and forms an excellent base to improve paint adhesion and prolongs the useful life of paint film.BOGIE Bogie Is the main part of the train which comes at the bottom ot the system. Here it is to carry motor, suspension system and brakes all in a tight envelope. The shape and material of the bogie depends on its application. It is tabricated using mild steel (for RC coaches) and stainless steel (for EMU’s). The parts of a bogie are:- eee ea ee Bogie frame Bogie transom Primary suspension Longitudinal canal Gear box a Motor VSS bracket Rolster a Sy Wc.ec? Cee C7 1. Bogie frame(side frame):- It can he made of steel plates and mild steel. In this case it is a modern design of welded steel hox format where the section is formed into hallaw section of the required shane frame of regular coaches is made fram MS and metra uses SS material which are welded into one. Generally employed welding processes are submerged arc welding, MIG welding, electric arc welding Specifications of submerged arc welding used here. OOORE eS ES ees & OO 89.9 * Temperature : 300-1000°c © Voltage :50v © Thickness of material : Smm-20mm SUBMERGED ARC WELDIN en DCPOWER ~23~IO BO0 ae & O 6 33 Cee « xt ¢ “y ¢ a 8 8 g a 2. Bogie transom: Transverse structural member of bogie frame which alsa supports the car body guidance parts and traction motors. 3. Primary suspension: Asteel coil spring’, two of which are fitted to each axle box in this design. They carry the weight of the bogie frame and anything attached to it. It also provides the comfort. 4. Gear box: This contains the pinion and gear wheel which connects the drive from the armature to the axle, 5. Motor: Normally each axle has its own axle. It drives the axle through the gear box. ” Some designs , particularly on tram cams use a motor to drive two axles. G. Secondary suspension air bag: Rubber is a suspension bags are provided as a secondary suspension system for the bogie. Whenever required pressurized are is let into the rubber begs to balance and attain its position. 7. Wheel Slide Protection System Lead to Axle box Where a Wheel Slide Protection (WSP) system is fitted, axle boxes are fitted with speed sensors. These are connected by means of a cable attached to the WSP box cover on the axle end. 8. Loose Leads for Connection to Carboy The motor circuits are connected to the traction equipment in the car or locomotive by flexible leads shown here. 9. Shock Absorber To reduce the effects of vibration occurring as a result of the wheel/rail interface. 10.Axle bars: It gives the ennnectinn hetween the wheels and the frame. Casting of the axle bars are done in tarikhere and it is modified to design requirements like drilling, milling, honing, horing to get required accuracy ~24~€ o a & 8 3S a a s or br br C e q e eS 11.Axle box cover: It gives support to primary suspension coil. 12. Bogie bolster: The body bolster is box type fabricated member made up of channels and welded to the body of the coach. It is a free floating member. The body bolster transfers the dead weight of the coach body to the frame. There are two types of bolsters in a bogie i.e, the body bolster and bogie bolster. The body bolster is welded to the coach body and bogie bolster is a free floating member which takes the entire load of the coach through the body bolster. The body bolster has two side bearers and center pivot pin. These three acts as a male part which matches with mating parts welded to the bogie. Process of manufacturing All the parts required for the bogie are supplied to BEML from South Korean HYUANDAI ROTEM Company. In bogie hanger of the BEML all these parts are assembled according to the drawings. The bogie of different cars are different from each other like DM car, M car, T car etc. After all these processes the bogie is subjected to testing, where they use universal testing machines for load testing. If any wrong is detected that is corrected by them and they send them to the outfitting hangar to fit it to the car body.UNDER FRAME ‘As undertrame is a trame work ot metal carrying the main body structure of a vehicle. Ihe parts of the car body shell will be made in a machine shop(s) either at the manufacturer's plant or contracted out sub-suppliers. These parts may be structural members, ribs, bolsters or panels. !he parts are assembled together in a jig. Ine underframe 1s usually the first part os the body shell to be built and its principle parts include sole bars runners, bolsters and transoms. The underframe is provided a camber where it is bent along the longitudinal length upward from the ends to the center to prevent it from sagging in the middle due to the weight. There are two sub departments at BEML: * Indian railway department * Metro underframe department The manufacturing of underframe is as follows: 1. Underframe assembly jig where all parts are laid out and welded into place. . Underframe is inverted in assembly jig where the bolsters are added and camber will be introduced. . More sections are welded. . The completed underframe is then sent to the assembly section where the sidewalls are welded to the underframe.METRO COACH DEPARTMENT This is the department where complete car body is done by integration of side walls, end walls and roof ete. The stages involved in DMRC car body are:- . Car body integration . Indirect spot welding. . 1stage of straightening. . Metal finishing. . Second straightening. . Electro grinding. gel cleaning and sealant application. '. QC and GC offer (internal and customer clearance). - Acid wash. CeaeeaazvregaogIaIgervce s . Roof leak test. @ 10.Underframe bottom painting. w 1LOrientation of carbody. r 12.Move to outfitting. v 1, CARBODY INTEGRATION: In this stage the integration of end walls, sidewall, underframe and roof is done. Side walls, end walls, roof are made according to the drawings provided. Each car requires 10 side blocks i.e. 5 on each side and 2 end blocks. Roof body is made so that it helps in attaching the curved roof sheet on it. Roof frame is done with the help of ROBOT SPOT WELDING which is, completely automated by CNC which is used to join sheet on the roof frame. Car body assembly is done on CARBODY ASSY-JIG. First the underframe is placed on the assembly jig end side walls and end walls are placed In the position so that they could be welded, Two different types of Camps are used tu huld the side walls and the end walls. Clamps are tightened and are welded from inside by MIG welding. ~276© Then the roof is placed over the body assembled and is welded (TIG welding) continuously. 2. INDIRECT SPOT WELDING: The side walls are welded to the underframe body by indirect spot welding due to space limitation and to ensure effective Weld. MIG welding is done inside the coach and TIG welding outside the coach is performed for better aesthetic value. 3. FIRST STRAIGHTENING: ‘The car body Is subjected to straightening by heating with blow torch followed: by heavy hammering to ensure that it is well within the required dimension and lulerance. IL is followed by flooding with cold water to reduce the heat In the metal (supplied with the help of pipes/tubes). 4, METAL FINISHING: * In this stage all the brackets for inside and outside the carbody are welded for holding different components. * Some of the holding brackets and its purposes arc listed below: ® Dome and light fixing brackets Seat fixing brackets Attachments for AC ducts Attachments for fixing windows and handles Rain water drain pipes rn s a a A 8 6 8 6 @ @ @ we Y S) U } a Attachments for door mounting and for motor to drive door For wire mounting For display hoards and cameras * Totally around 590 items are fixed inside each car body © Around S00 rads for holding purposes in each coach. 5. SECOND STRAIGHTENING: Itis again subjected Lo straightening because of metal finishing process.Cee Goo sve 9O' S Ca w we 6. ELECTRO GRINDING, GEL CLEANING AND SEALANT APPLICATION: * Electro Grinding, Gel Cleaning and Sealant Application is done to ensure good surface finish and to make the car leak proof. Electro cleaning is done with the help of MAGIC CLEANER which is used to remove the spot weld marks on the surface of car body. Voltage of 230 Vis used in this process. SR 600 form Korea is used to remove weld marks. It is first applied with the help of brush and after some time it is rubbed with the help of Scratch belt, ‘+ Sealant (Sabotech) is applied and allowed to dry for around 4 hours. 7. QC AND GC OFFER (INTERNAL AND CUSTOMER CLEARANCE): Inspection is done by the company personnel and then by the customer for clearance. 8. ACID WASH: HYSC 2200(HNO3 + HCl) is the acid used to remove all the weld marks and the heat marks from the previous processes. 9. ROOF LEAK TEST: Car body is first covered with plastic sheet with the help of tape wherever is necessary and the water in the form of rain is forced on to the roof of is then checked for leakage. 10. UNDERFRAME PAINTING: Underframe is painted with anti-drum paint around 60} thick to absorb vibrations and to produce daniping effect. 11. Orientation of carbody: In this stage the car body is checked for its proper orientation. After all these processes the carbody is sent to the outtitting hangar.BOIOOQY Cece ae Oo OD FURNISHING DEPARTMENT 1. Under gear finishing: Painting clearance Cable duct installation Air brake system installation Y Reservoir Y Brake Y Control valve ¢ Under gear equipment and Bogie installation Roof equipment installation 2. Interior furnishing: * Glass wool installation © Air duct installation © Roof cable duct installation Y Control system wiring Y Allinternal wiring © Panel installation © Seat and grab pole installation * Door installation Some of the components installed inside the car body are: * EDB: Electrical Distribution Board * ECM: End Cubical Module * PAD: Passenger Alarm Device * PAMP: Passenger Addressing Amplifier © DIL: Door Inside Light ® DCU: Door Control Unit 3. Wiring: A cable harness also known as wire harness is an assembly of wires which transmit signals or electric power. These cables are secured with the help of straps, cable ties, sleeves etc., to minimize size and prevent shorting. ~30~4. Piping: This is a network of pines used to perform the required made of transferring the fluids. 5. Outfitting: Cable looms attached lu Whe underside of the car Piping attached to the underside of the car Fitting of air reservoirs Installation of Interior ducts.CB BPAI OOO MS Ss “ere e€ € ee & GB TEST AND INSPECTIONS PERFORMED INSPECTION: Inspection will be performed at each stage of manufacturing for proper dimensions. or for any other damages that may occur during the processes of manufacturing. Few important tests performed are: 1. Weighment test: This test is done to check the profile clearance and floor leveling. The weighing system works by weighing trains while they are in motion. It can also be used to calculate the number of passengers in carriages and for loading system with automatic teedback to ensure that loading will be optimized. 2. Dielectric test: It is a non-destructive test thal determines the adequacy of electrical insulation for nurimally occurring over vullege transients. This Is a high voltage test that Is applied to all devices for specific time in order to ensure that the insulation is not marginal. This circuit is subjected to GOHV for 90 secunus. 3. HVAC (heating, ventilation and air conditioning): HVAC is the technology of indoor and vehicular environmental comfort. HVAC System design is a sub discipline of mechanical engineering, based on the principles ot thermodynamics and tluid mechanics. TSH OO Oreo IoniECo aEOUTLOOK OF METRO CARBODY: METRO INTERIOR: PIICVUOOLE8B1ESSBHPDHIRBRIDID