RAIL COACH FACTORY

KAPURTHALA,PUNJAB

SIX WEEKS SUMMER

VOCATIONAL TRAINING

(05-06-2014 to 16-07-2014)

Presented by
Amit Shukla
Regd no. 11106051
B-Tech (ME)
3571/14

CONTENTS

RCF PROFILE
SALIENT FEATURES
PRODUCTS OF RCF
TOOL ROOM (TR)
HEAVY WELDING SHOP (HWS)
SHELL ASSEMBLY SHOP
FURNISHING SHOP

RCF PROFILE

TheRail Coach Factory(RCF) inKapurthala, it is a production unit

owned byIndian Railways, that manufactures rail coaches and its
spare parts. It is the largest coach manufacturer in India.

This was setup by the Prime Minister of India Mr. Rajiv Gandhi in 1986 and the
first coach was rolled out in March , 1988.

Got its First Certification ISO-9001 in 1995, ISO 14001:2004 in 2003 and
OHSAS 18001:2007 in 2009 .

With Transfer of Technology Contract with M/s. Alstom-LHB, Germany, RCF

successfully design as Alstom-LHB Coach.

SAILENT FEAUTRES
Annual production capacity : 1710 coaches
Annual turn-over (Rs) : 2064 crore
Total number of staff :7969
Workshop land: 340 acre
Township area: 838 acre
Covered area in shops: 1,92,827 Sq.m

PRODUCTS OF RCF
1st AC Sleeper Coach (BG)
2 Tier AC Sleeper Coach (BG, MG)
3 Tier AC Sleeper Coach (BG)
AC (Air-Conditioned) Inspection Coach (BG)
AC Chair Car, Executive Class & Economy Class (BG, MG)
AC Buffet Car (BG)
AC Power Car (BG)
MG Diesel Electrical Multiple Units
Main Line Electrical Multiple Units (BG)
Non-AC Sleeper Class Day Coach (BG)
Non-AC General Coach (BG/MG)
Non-AC Luggage-cum-Brake Van (BG/MG)
Refrigerated Parcel Van (BG)
Non AC Inspection Coach (BG)
High Capacity Parcel Van (BG)
Accident Relief Train (BG)
Post Office Coach (BG)

1.TOOL ROOM
In this shop there are various mechanical operations are
done such as:
a. Lathe Machine(ex. Turret lathe, Bench lathe)
b. Slotter Machine.
c. Milling Machine(ex. Horizontal & Vertical )
d. Grinding Process.
Automatic lathes machines are high speed heavy duty
lathes in which the various controls like feeding the raw
material, tool change, feed, speed change and unloading
the work piece are automatically controlled.

LATHE MACHINE

CONTINUE

A Slotter is a type of machine tool that uses linear relative motion between
the work piece and a singe-point cutting tool to machine a linear tool path.
Milling machines may be manually operated, mechanically
automated, or digitally automated viacomputer numerical
control.
Milling machines can perform a vast number of operations, from
simple (e.g., slot and keyway cutting, planning, drilling) to
complex (e.g. die sinking).
Grindingis anabrasive machiningprocess that uses agrinding
wheelas thecutting tool.
Similar abrasive cutting
are lapping and sanding.

2.HEAVY WELDING SHOP

This shop mainly deals with the fabrication of the coach.

Main welding technologies used in HWS.

SMAW (Shielded metal arc welding)

GMAW (Gas metal arc welding)

SAW (Submerged arc welding)

FCAW(Flux-cored arc welding)

Worker Performing
SMAW :-

SAW(SUBMERGED ARC WELDING)

ADVANTAGES
High deposition rates (over 100lb/h (45kg/h) have been
reported).
High speed welding of thin sheet steels up to 5 m/min
(16ft/min) is possible.

DEPOSITION EFFICIENCY

Deposition efficiency = weight of weld metal X 100 / weight

of consumable
SMAW = 55%
GMAW = 95%
FCAW = 90%
SAW = 100%

OPERATING FACTOR

Operating factor = Pure arc time X 100 / Total welding

time
SMAW = 25%
GMAW = 45%
FCAW = 40%
SAW = 55%

3.SHELL ASSEMBLY SHOP

Stage 1 : Underframe is place on jig, then side and
end wall is place on jig along with underframe
then welded, roof is placed then fully welded, then
side and roof is to be tight by tie rods. After
welding all clamps and tie rods are removed.
Stage2 : End wall and side wall are welded to each
other. Door corner fitting, conditioning of
underframe, junction box, and cable box is fitted.
Window bar ,alarm tube bends, doorsill is fitted.
Skin testing is also done by heating on spot at
some distance and then hammering is to be done
to remove deformations.

CONTINUE
Stage 4 : Partition framing of lavoratory, seating
and door fitment is done.
Stage 5: Buffer and draw gear assembly like
casing, steel rod, plunger, rubber pad, spring and
plate is done in this stage.

4.FURNISHING SHOP
Furnishing means DECORATION.
So all the decoration is done in this shop

Flooring Section

flooring section

Panel Section
Plumbing and Lavoratory Section

CONTINUE
Seat and Birth Section
Bogie Installation Section

Electrical Stage
Window and Ceiling Section
Air Brake Section