INDUSTRIAL TRAINING IN

RAIL COACH FACTORY (RCF)

KAPURTHALA,PUNJAB

- Vinay Yadav
B.Tech (M.E)
11715037
 INTRODUCTION
RCF’S Origin:
• Built: 1986
• Location: Kapurthala, Punjab
• Industry: Railways
• Products: Rolling Stock

Growth of RCF:
• During year 2001-02, RCF manufactured 1250 coaches (974 non-AC & 276
AC) .
• Recent development in RCF is : Manufacturing new series of L.H.B coaches
with the help of agreement of German Technology in Design and
Manufacturing.
 OBJECTIVES OF RCF
• DESIGN IMPROVEMENT- Light weight Coaches, maximum Capacity.
• TECHNOLOGY
• PRODUCTIVITY
• QUALITY
• MANPOWER DEVELOPMENTS
• NATIONAL OBJECTIVES:
Self sufficiency
Energy conservation
Increased employment
Pollution free environment
 VARIOUS SHOPS IN RCF

• Sheet Metal Shop

• Fabrication Shop
• Shell Assembly Shop
• Paint Shop
• Bogie Shop
• Furnishing Shop
• Finishing Shop
 SHEET METAL SHOP
• Material brought from SAIL or import from Japan.
• Commonly used sheet for the part is carbon steel and mild steel.
• The carbon steel can be divided in to four groups or categories: -
1. Low Carbon Steel: - Carbon comp. 0.05 to 0.25%.
-Sheet, strips, tubing
2. Structure Steel :- Carbon comp. 0.2 to 0.35%.
-Used in welding, riveting
3. Forging Steel: - Carbon comp. 0.3 to 0.4%.
-Axle, bolt, pin
4. Tool Steel: - Carbon comp. 0.6 to 1.30%.
-Used to manufacture tool
 FABRICATION SHOP

1. Under Frame:
- Under-frame constitutes the chassis of the coach.
- 4 jigs are used to make the assembly.
2. Side Wall:
- Major parts of the sidewall are: body side pillar, sidewall sheet,
light rail, waist rail and stiffeners.
3. Roof: Main roof is assembled on a rotary jig.
4. End Wall: This is the end portion of the coach.
 SHELL ASSEMBLY SHOP

• In the shell assembly shop, sidewall, end wall, roof, under-frame is assembled and
other necessary operation for making shell is done.
• Shell assembly operations are done in five stages:
• Stage 1: Underframe sidewall, jigs, roofs welding, cable pipes.
• Stage 2: End walls, side walls welded, door corners fit
• Stage 3: Vestibule doorsill, alarm tube bends, ceiling support angle , Skin
tensioning and window bar fitting is done.
• Stage 4: Lavatory and seating is done.
• Stage 5: Buffer and draw gear assembly .
 PAINT SHOP

• In this shop, the shell is painted manually or with automatic painting plants
with different coats of chemical and paint etc.
• Various operations done in paint shop are:-
1. Shot Blasting
2. Primer Application: After shot blasting
- Internal
- External
3. Putty Application: to obtain uniform thickness.
4. Surface Application

5. Top Coat Application:

 BOGIE SHOP

The main parts of the bogie are: -

• Frame
• Wheels
• Bearings
• Brake System : Air Brake system is used for braking action.
• Alternator
• Suspension System: Suspension system has two parts
• a)Primary parts: It takes the load of shell only and restricted its vibrations.
• b)Secondary parts: It takes the load of shell as well as the thrust from wheels.
 TESTING OF FINAL BOGIE:

STATIC TESTING MACHINE:

• Static testing machine is used to test the bogie frame by applying same
amount of load as in actual service condition.
• Purpose : to check the strength and correctness of different Bogie parts
under the application of load on it.
• Load is applied by hydraulic system at the center of bogie.
• Under this load the deflection in spring is noted down .
• If the deflection is with in the safe limit
• Bogie gets the OK signal.
 FURNISHING SHOP
The furnishing shop is working for decoration of coaches.
The shop consists of no. of sections:

• Flooring & PVC Section

• Electrical Stage:
• Window and Ceiling Section:
• Panel Section:
• Moulding Section
• Lavatories Section:
..continue

• Plumbing Section
• Seat and Berth Section
• Lowering Section
• Electrical Stage
• Air Brake Section
• Finishing Stage
 FINISHING SHOP

Installation of Air Brake System and

Testing:
• Air brake system is installed in the coach and
is being tested by passing the compress air in
pipelines.
• Generally two-pipe line exists in which one is
white and another is green.
Rail coach is Ready.
THANK YOU