WAGON REPAIR WORKSHOP

NORTH CENTRAL RAILWAY, JHANSI (U.P)

REPORT OF VOCATIONAL TRAINING ON THE TOPIC:-

“RAILWAYS WHEEL”

SUBMITTED TO : SUBMITTED BY:

Mr. JAYANT TIWARI Mr. Shivam Chakravarti
Senior Instructor B.T.C Mr. Purav Raikwar
N.C.R., Jhansi (U.P.) Miss Manjari Upadhyay

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 ACKNOWLEDGEMENT
We express our solicit gratitude and heartiest thanks to Mr. Ajay Srivastava (Chief
Workshop Manager) for allowing us Complete our vocational training
successfully at Wagon Repair Workshop NCR Jhansi.

We are thank to

• Er. Shivendra – DY CME (I)

• Er. Ajay Kumar Wakankar (ACMT)
For allowing us at wagon repair workshop NCR Jhansi.
We are thank to
• Shri JAYANT TIWARI (S.I. INSTRUCTOR, BTC),
• Mr. Shailendra Kumar (Sr. INSTRUCTOR),
• Mr. Rajesh Kumar (Sr. INSTRUCTOR, BTC),
• Mr. Shambhu Kumar (SR. INSTRUCTOR, BTC)
For lectures on these topics and timely tips without which have difficult to
complete the project.
Also to those who helped in cooperating to bring out this report within a short
time.
I have no word to express my gratefulness to my project teachers for their
inspiring guidance, valuable help and angelic support for the completion of my
project.
Any other names, which desire a mention and have not been because of my
negligence. I would like to apologize

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 CONTENT

1. Introduction
2. Brief history of Jhansi workshop
3. Statics of Jhansi workshop
4. Wagon Repair Process
5. Overview of Different Shops
6. Detailed explanation of Railway Wheels
6.1 Introduction of Wheel
6.2 Types of Wheels
6.3 Wheel material
6.4 Mechanical properties of cast wheel
6.5 Component of wheel set
6.6 Wheel maintenance procedure
6.7 RARD
6.8 Wheel machining
6.9 Wheel profile
6.10Wheel defect
6.11Tyre defect gauge
6.12Assignment
7. References

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 1. INTRODUCTION

Jhansi Wagon Repair Workshop is the biggest wagon repair workshop of

Indian Railways. It under takes P.O.H. of 610 wagons per month which
constitutes approximately 18% of wagon P.O.H. done in India Railways
.Over 400 Box-N wagon per month under go P.O.H. in Jhansi workshop.

In addition, Jhansi Workshop under takes re-building of 50 Box-N wagon

per month, which is around 14% of this activity in Indian Railways.

Jhansi workshop has great historic value as it was established by Indian

Mid Land Railways in 1895 for maintenance of locomotives, coaches and
wagons. The work of locomotives repair was transferred in 1930 to Parel
Workshop Wheel Coach P.O.H. was discontinued in 1997.

The work of rehabilitation of Box-N wagon uses stainless steel has

commenced in Jhansi workshop in December, 2008. Estimates of new
coach midlife rehabilitation workshop and modernization of Jhansi
workshop have also been sanctioned by General Manager of North Central
Railway.

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 2. BRIEF HISTORY OF JHANSI WORKSHOP

YEAR ACTIVITY

1895 Completion of construction of Jhansi workshop and start of loco,

coach and wagon repair activities.
1895 Completion of construction of Jhansi workshop and start of loco,
coach and wagon repair activities.

1900 Indian Mid Land Railway Merged.

1919 Opening of government technical institute under the state

government management.

1930 Loco repair work was transferred from Jhansi workshop to Parel
Workshop. (Mumbai)

1958 Government technical institute was taken over by railway and

renamed as railway training school.

1961 Introduction of incentive scheme and institute was renamed as

system technical institute.

1961-1967 Manufacturing of wagons containers.

1962 Shop capacity increased from 30 wagons to 45 wagons diesel

power house set up.

1965 P.O.H. of bogie wagons transferred from Matunga workshop to

Jhansi workshop.

1990 Introduction of P.O.H. of BOX-N and BCN wagons.

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1992 Conversion of box wagon into into container flat wagons. System
technical institute was renamed as supervisor training center.

1995 Celebration the first centenary of Jhansi workshop in November,

1995. Modernization of Jhansi workshop start.

1996 Introduction of P.O.H. of Tank wagon.

2001 ISO 9001:2000 certificates awarded to Jhansi workshop in June,

2001.

2007 Second modernization work of Jhansi workshop sanctioned.

2008 P.O.H. of BVZI started, coach M.L.R.(Mid Life Rehabilitation)

workshop sanctioned, rehabilitation of BOX-N wagons, started
using stainless steel wagon.

2009 Manufacturing of BOXN`R`

2010 Modernization of Workshop & Coach M.L.R (Mid Life

Rehabilitation) work started.

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 3. STATICS OF JHANSI WORKSHOP
➢ Established 1895
➢ Total area 3.4 Lakh square meter
➢ Covered area 65000 square meter
➢ Approximately no. of worker 6135
➢ Total machine and plants 576+
➢ Electric load 531253KW/month
➢ Budget sanctioned 171635100 Rs/-
➢ Average wagon holding 920
➢ Total outturn per day 24.5
➢ Outturn of tank wagon 105 per month
➢ Outturn of BOX-N/BCN 476 per month
➢ Average working days of a wagon 6 days
➢ P.O.H. unit cost of wagon 260000 Rs/-

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 4. Wagon Repair Process
• Firstly wagon come in pocket yard.
• Senior Section Engineer (S.S.E) of inspection department inspect
• deeply the wagon and that time coding is done according to work.
• Light Repair- 1
H/Repair- 6
Under Frame- 5
RE Floor- 6RF
RE Roofing- 6RR
Re Hab- RH
For Condemn- U/Inspection
• In the yard noted that which wagon required POH, ROH &
• NPOH.
• In the inspection department the repairable part of wagon marked.
• From the yard the BOXN is directly send in striping shop.
• All corrosive parts separated by cutting operation and clean well.
• After parts is clean well and then according to work demand
• wagon is sending in different shop.

• Usually vaccum brake wagon sending in BWR shop, Heavy repairable

wagon sending in BNR- I & BNR-II and Re Hab wagon sending in Re
habitation shop.

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❖ Firstly in shop the BP of wagon and centre pivot pin of wagon is cut
and after cut the lifting the wagon and lowered on trassels by
separating of body parts of wagon.
• After dismental of wagon is sending in wagon shop and the wheel is
sending in wheel shop for the new profile with Ultrasonic Testing
(U.S.T).
• After the lower the body parts on trassels air brake parts like as
Auxiliary Reservoir (A.R), Controlling Reservoir (C.R), Brake
Power (B.P), Distributor Valve (D.V), Dirt collector, Angle cock is
separated.
• All parts of air brake are sending in the air brake shop, all air brake
steam tested on 10 kg/cm2
.
• All parts after handling assemble in a wagon to make a perfect BOXN.
According to painting schedule paint is done on wagon.
After the doing Stenciting the writing work on wagon

• After complete these operation the testing air brake testing done by single
wagon test rig (S.W.T.R)
Now the BOXN check by NXTR it is final inspection, if BOXN wagon is
completely OK then the gate paas permitted to wagon and wagon go out from
the workshop.

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 5. Overview of Different Shops
5.1 Millwright shop
Milling simply refers to crushing or grinding or simply cutting a metal by using
machines like Lathes and milling. Milling is the machining process of using
rotary cutters to remove material from a work piece 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 operations. It is one of the most commonly used processes in industry and
machine shops today for machining parts to precise sizes and shapes.

WRS millwright shop is divided into four sections namely “crane, Compressor,
machine section and motor shop”. Here mainly repairing work related to some
parts of other machines used in the workshop is done. Works of maintenance,
goods delivery or supplying good, milling, cutting, and various operations are
performed in this shop.
5.1(a) Motor shop
Workshop needs machines and heavy parts that need to be carried from a place
to another, loading and unloading of such parts and when it comes to railway
workshop these parts get even bigger and heavier. So they require heavy cranes
and all for their transportation. This work is performed by the machines present
in the motor shop of WRS. Motor shop has:
1. Road Cranes: For lifting (loading and un-loading) heavy parts such as
wheels or for putting de-railed bogies back on track. There are four cranes,
which have capacities of 16 tonnes to 5 tonnes and are diesel operated with four
cylinder engine installed in them. They all are hydraulically operated.

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2. Eicher Trucks: Eicher Motors Limited (EML) incorporated in 1982, is an
Indian automaker company based in Gurgaon, India.In every shop there is
requirements of materials and other parts and transportation of parts from one
shop to other. These heavy parts require some heavy vehicles that can carry
them. This work is performed by these trucks. There are three trucks in WRS for
this purpose.

3. Forklift: A forklift truck (also called a lift truck, a fork truck, or a forklift) is
a powered industrial truck used to lift and transport materials. The modern
forklift was developed in the 1960s by various companies. There are ten such
trucks that can lift up to three tonnes of weight. Various parts of a forklift are
truck frame, counterweight, cab, tilt cylinders, hydraulics, lifting cylinders,
mast carriage, a load back rest and a power source. The power source used here
is a four cylinder diesel engine that provides the power to the front wheels. And
to the motor on the back axle used for various works such as for hydraulic
operations, for tilting the cylinders and others. The drive here is on the back
wheel. Forklift is mainly guided by five different oils- engine oil (40 no.),
differential oil (90 no.), transmission oil or crank case oil (10 no.), hydraulic oil
(68-78 no.), brake oil in master cylinder (Simpson p-4 oil).

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5.1(b) Machine shop
Every machine needs proper care and with the time there parts get worn out, so
these parts needs to be replaced or maintained. This function is performed in the
machine shop. Here different parts of the machines are repaired. This shop has
two heavy lathes where the parts like tyres of overhead cranes are repaired and a
radial drill. There are also two grinding machines, a slotter and a shaper and two
centre lathe.
Works like tyres of overhead cranes, heavy shafts and other heavy materials are
repaired here. This is a conventional machine that is timed for feed; that is
automatic feeding can be applied. The part is fixed in the lathe and with the tool

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6.1(c) compressor shop
An air compressor is a device that takes in air at atmospheric pressure and
supplies it at higher pressure. It converts power (usually from an electric motor,
a diesel engine or a gasoline engine) into kinetic energy by compressing and
pressurizing air, which, on command, can be released in quick bursts. Air
Compressors are classified mainly in two parts; positive displacement and roto-
dynamic.These compressors have furthure classifications accodingly. Main
components common to almost all the compressors are air filter, section valve,
delivery valve, low pressure Positive displacement Reciprocating Scroll
Compressors Rotary Rotodynamic Turbo/ Centrifugal cylinder, after cooler, high
pressure cylinder, lubrication system, primary and secondry filters, load and
unload valves, coolant section and a tank. Screw Roller Vane Type In WRS we
have two types of compressors reciprocating and screw type. They are
electrically operated and being supplied by one of the leading compay in the
mechanical pneumatic market(Kirloskar Pneumatics).

Reciprocating Compressors: Reciprocating compressor compresses the vapor

by moving piston in cylinder to change the volume of the compression chamber.
The main elements of a reciprocating compressor include piston, cylinder, valves,
connecting rod and crankshaft. Reciprocating compressor works on a simple
mechanism, The air at atmospheric pressure enters to it through a valve during
the sucttion stroke due to vaccum createdin it and then the piston compresses the
air to a particular volume. After reaching a particular pressure another valve opens
which is connected to a hose maintained at a particular pressure. This compressed
air reaches the tank through which it is supplied for the particular job.

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Screw Compressors:Screw compressors are also belong to the positive
displacement compressor family. In screw compressors, the compression is
accomplished by the enmeshing of two mating helically grooved rotors suitably
housed in a cylinder equipped with appropriated inlet and discharge ports. Here
the air is brought by a smaller lobe srew and is supplied to a large lobe screw.
The air get filled in the interlobe space where it gets compressed and then is
supplied to the tanks.

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 5.2 Welding shop
Introduction:-
Welding is a process for joining two similar or dissimilar metals by fusion. It joins different
metals/alloys, with or without the application of pressure and with or without the use of filler
metal. The fusion of metal takes place by means of heat. The heat may be generated either
from combustion of gases, electric arc, electric resistance or by chemical reaction. During
some type of welding processes, pressure may also be employed, but this is not an essential
requirement for all welding processes.
CLASSIFICATION OF WELDING PROCESSES
Welding Processes
1. Fusion Welding Processes
1.Oxy-Fuel Gas Welding
2. Arc Welding
3. Resistance Welding.
2. Solid-State Welding Processes
1. Forge Welding
2. Cold Pressure Welding
3. Friction Welding
4. Explosive Welding
5. Diffusion Welding
6. Cold Pressure Welding
7. Thermo-compression Welding
3. Thermite Welding Processes
1. Thermite Welding
2. Pressure Thermite Welding
4. Radiant Energy Welding Processes
1. Laser Welding
2. Electron Beam Welding.
5. Thermal Cutting Processes
1. Gas Cutting
2. Arc Cutting
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GAS WELDING PROCESSES
A fusion welding process which joins metals, using the heat of combustion of
an oxygen /air and fuel gas (i.e. acetylene, hydrogen propane or butane)
mixture is usually referred as ‘gas welding’. The intense heat (flame) thus
produced melts and fuses together the edges of the parts to be welded,
generally with the addition of a filler metal.

Oxy-Acetylene Welding
In this process, acetylene is mixed with oxygen in correct proportions in the
welding torch and ignited. The flame resulting at the tip of the torch is
sufficiently hot to melt and join the parent metal. The oxy-acetylene flame
reaches a temperature of about 3300°C and thus can melt most of the ferrous
and non-ferrous metals in common use. A filler metal rod or welding rod is
generally added to the molten metal pool to build up the seam slightly for
greater strength.

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Gas Welding Equipments
An arrangement of oxy acetylene welding set up is shown in Fig. The basic
tools and equipments used for oxy-acetylene welding are following:

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ARC WELDING PROCESSES
The process, in which an electric arc between an electrode and a workpiece or
between two electrodes is utilized to weld base metals, is called an arc welding
process. The basic principle of arc welding is shown in Fig 17.9(a). However
the basic elements involved in arc welding process are shown in Fig. 17.9(b).
Most of these processes use some shielding gas while others employ coatings or
fluxes to prevent the weld pool from the surrounding atmosphere.

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 5.3 AIR BRAKE SHOP
An air brake is a conveyance braking system actuated by compressed air. Modern trains
rely upon a fail-safe air brake system that is based upon a design patented by George
Westinghouse on March 5, 1868. The Westinghouse Air Brake Company (WABCO) was
subsequently organized to manufacture and sell Westinghouse's invention. In various
forms, it has been nearly universally adopted. In the air brake's simplest form, called the
straight air system, compressed air pushes on a piston in a cylinder. The piston is
connected through mechanical linkage to brake shoes that can rub on the train wheels,
using the resulting friction to slow the train. The mechanical linkage can become quite
elaborate, as it evenly distributes force from one pressurized air cylinder to 8 or 12
wheels.

DISTRIBUTOR VALVE (D.V.):-

Distributor valve is the most important functional component of the air brakesystem and is
also sometimes referred to as the heart of the air brake system. Thefunction of the
distributor valve is to distribute compressed air received from brake pipe to auxiliary
reservoir and control reservoir. In addition to this it also senses drop and rise in brake pipe
pressure for brake application and release respectively. It is connected to break pipe through
branch pipe. Various other components connected to the distributor valve are auxiliary
reservoir, brake cylinders and control reservoir.

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Description of various components and sub-assemblies:-
A. MAIN VALVE The main valve is housed in the main body. The various parts along
with part numbers (as per manufacturer’s catalogue) are shown in Fig.

The main valve consists of two diaphragms i.e. large and small. The top face of the large
diaphragm, which is situated at the lower position of the stem assembly, is subjected to brake
pipe pressure whereas the bottom face is subjected to control reservoir pressure. The small
diaphragm is situated at the upper position of the stem. The top face of small diaphragm is
subjected to brake cylinder pressure and bottom faceto atmosphere.

B. CUT OFF VALVE

The cut off valve has two diaphragms, upper and lower. The top face of lower diaphragm is subjected
to control reservoir pressure and the bottom face to the brake pipe pressure. The bottom face of upper
diaphragm is subjected to brake cylinder pressure, and the top face is subjected to atmosphere and
compressed spring pressure.

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 C. AUXILIARY RESERVOIR CHECK VALVE
The auxiliary reservoir check valve is housed in the main body. It consists of thefollowing
items

D. QUICK SERVICE VALVE

The quick service valve is housed in the main body and consists of the

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 5.4 WHEEL SHOP
Introduction:-
Wheel shop is a shop under which inspection; operations are performed on the wheel and
axle for achieving good strength and tolerance with required shape and size like diameter.
There are various operations are performed such that turning, threading, boring etc. on wheel
with using of machines for getting required shape and size.
(1) Turning lathe machine
(2) CNC lathe machine
(3) Wheel press machine

Turning lathe machine:-

In the turning lathe machine, single point cutting tool Is used and turning can done on flange
of the wheel to taking required diameter.

Figure: Turning lathe machine

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CNC lathe machine:-
The full name of this machine is computerized numeric control lathe machine means that
there are various operations are performed at one programming setting on CNC lathe
machine. We have installed more than twenty CNC machines which are currently in
operation.
• Machine with multi-gauge option can be supplied.
• Axle length will proportionally change with track gauge.
• Special Electrical Power conditions can be considered.
• Above leading parameters can be suitably modified to meet
specific requirements.

Figure: CNC Turning lathe machine

Wheel press machine:- Wheel Presses are used to mount / dismount wheels and
brake discs onto / from axles. The Wheel Press will comprise a substantial steel frame with
hydraulic cylinders to apply the necessary pressing loads. The function of the Wheel Press
depends on the required parameters of operation and the throughput required from the
equipment

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CTRB Section:-
The CTRB means Cartage Taper Roller Bearing. Tapered roller bearings are bearings that
can take large axial forces (i.e., they are good thrust bearings) as well as being able to sustain
large radial forces. Generally, two types of bearing are used:
1. Taper roller bearing
2. Ball bearing
For sufficient speed of wagons, taper roller bearing is mostly used. The
bearing assembly is made from different parts.
1. Backing rings
2. Cup
3. Cone
4. Lock joint
5. End bearing cover
6. Taper roller bearing
7. Grease seal

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 5.5 MACHINE SHOP
Introduction:-
A machine is a tool that consists of one or more parts, and uses energy to achieve
a particular goal. Machines are usually powered by mechanical, chemical,
thermal, or electrical means, and are frequently motorized. Historically, a
powered tool also required moving parts to classify as a machine; however, the
advent of electronics technology has led to the development of powered tools
without moving parts that are considered machines.

Overview of Machine Shop in Railway Workshop

S. Name Of Machine S. Name Of machine

No. No.

1. Centre Lathe Machine 793 14. Vertical Drill Machine 787

2. Centre Lathe Machine 795 15. Radial Drill Machine 746

3. Centre Lathe Machine 796 16. Radial Drill Machine 749

4. Turret Lathe Machine 417 17. Radial Drill Machine 754

5. Turret Lathe Machine 466 18. Radial Drill Machine 777

6. Turret Lathe Machine 481 19. Radial Drill Machine 784

7. Slotter Machine 401 20. Radial Drill Machine 786

8. Slotter Machine 403 21. Radial Drill Machine 788

9. Shaper Machine 726 22. Radial Drill Machine 892

10. Milling Machine 743 23. Radial Drill Machine 893

11. Milling Machine 744 24. Radial Drill Machine 910

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 Centre Lathe or Engine Lathe Machine:-
The term “engine” is associated with this lathe due to the fact that in the very early daysof its
development it was driven by steam engine. This lathe is the important member of thelathe
family and is the most widely used. Similar to the speed lathe, the engine lathe has allthe basic
parts, e.g., bed, headstock, and tailstock. But its headstock is much more robust inconstruction
and contains additional mechanism for driving the lathe spindle at multiplespeeds. Unlike the
speed lathe, the engine lathe can feed the cutting tool both in cross and longitudinal direction
with reference to the lathe axis with the help of a carriage, feed rod and lead screw.

Turret Lathe Machine:-

The development of these lathes results from the technological advancement of the engine lathe
and these are vastly used for mass production work. The distinguishing feature of this type of lathe is
that the tailstock of an engine lathe is replaced by a hexagonal turret, on the face of which multiple
tools may fitted and fed into the work in proper sequence. Due to thisarrangement, several different
types of operations can be done on a job without re-setting ofwork or tools, and a number of
identical parts can be produced in the minimum time.

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 Slotter Machine
The slotter or slotting machine is also a reciprocating type of machine tool similar to a shaper
or a planer. It may be considered as a vertical shaper. The chief difference between a shaper
and a slotter is the direction of the cutting action. The machine operates in a manner similar to
the shaper, however, the tool moves vertically rather than in a horizontal direction. The job is
held stationary. The slotter has a vertical ram and a hand or power operated rotary table.

Shaper Machine:-
Shaper is a reciprocating type of machine tool in which the ram moves the cutting tool
backwards and forwards in a straight line.It is intended primarily to produce flat surfaces.
These surfaces may be horizontal, vertical, or inclined. In general, the shaper can produce any
surface composed of straight-line elements.A shaper is used to generate flat (plane) surfaces
by means of a single point cutting tool similar to a lathe tool.

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Milling Machine:-
In milling machine, the metal is cut by means of a rotating cutter having multiple cutting edges. For
cutting operation, the work piece is fed against the rotary cutter. As the work piece moves against the
cutting edges of milling cutter, metal is removed in form chips of trochoid shape. Machined surface is
formed in one or more passes of the work. The work to be machined is held in a vice, a rotary table, a
three jaw chuck, an index head, between centres, in a special fixture or bolted to machine table. The
rotatory speed of the cutting tool and the feed rate of the work piece depend upon the type of material
being machined

Grinding machine:-
Grinding is generally called as fine machining or finishing operations of removing
materialsfrom surface usually 0.25-0.50 mm in most operations through the use of grinding
wheel.Grinding wheel is highly useful in removing extra unwanted metal and sharpening
cuttingtools such as chisels, drill, taps, and other cutting tools.

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 TOOL ROOM SHOP
Introduction
These days small, medium and heavy industries are using automatic machines. But bench and
fitting work also plays a significant role for completing and finishing a job to the desired
accuracy. Most of semi-finished works can be accomplished with fairly good degree of
accuracy in a reasonable time through various kinds of quick machining operations. Some of
the commonly used tools are discussed as under.

TOOLS USED IN FITTING SHOP

Tools used in bench and fitting shop are classified as under.
1. Marking tools 2. Measuring devices 3. Measuring instruments
4. Supporting tools 5. Holding tools 6. Striking tools
7. Cutting tools 8. Tightening tools 9. Miscellaneous tools.

Marking Tools:-
These are sub classified as steel rule, circumference rule, straight edge, flat steel
square, scriber, semi-circular protractor, divider, trammel, prick punch, centre
punch, try square, bevel square, vernier protractor, combination set and surface
gauge.
Measuring Tools:-
Steel Rule:-Steel rule is generally employed for purpose of measuring rough
dimensions and laying out them. It is always advisable to start measuring from 1
cm mark because the end of the rule is generally worn out
Circumference Rule:-It is commonly used for measuring or laying out
or as a straight edge. The specialty in this rule is that the circumference can be
taken directly, below the diameter dimension
Straight Edges:-
There are two types of straight edges namely four edge type Fig.(a) and bridge type Fig. (b)
which are made of carbon tool steel and alloy steel. They are generally flat graduated bar of
steel with one longitudinal edge bevelled.

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Bevel Protractor:-
The bevel protector is an instrument used for testing and measuring angles within the limits
of five minutes accuracy. The common components of this instrument are base, disc which is
fitted with a pivot at the centre and carries a datum line. On this pivot of the protector, the
dial is allowed to rotate when the clamping nut is released.

Universal Surface Gauge:-

Fig. shows the universal surface gauge, which is an improved variety of the surface gauge
simple scribing block. It is designed in such a way that appreciably finer adjustments can be
made very quickly. It consists of a cast base perfectly machined and ground at the top, bottom
and all sides. The baseof the gaugeusually carries a V-shaped slot at the bottom so as torender
it suitable for use on round objects

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Measuring Devices:-
Vernier Calliper:-
Fig. shows the vernier calliper, which is commonly used to measure accurately
(1) Outside diameters of shafts, (2) Thicknesses of various parts,
(3) Diameters of holes or rings (4) Internal dimensions of hollow jobs.

Fillet and Radius Gauge:-

Fig. shows the fillet and radius gauge, which is similar in construction to a screw pitch gauge
and carries a similar metal case containing a number of steel blades in it. One set of blades,
mounted on one end of the case carries concave end faces and the other setat the other end of
the case, carries blades, which have convex end formations.

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 6. Detailed explanation of Railway Wheels
Introducttion
Railway wheels are fundamental components of rail transport systems, essential for the safe
and efficient operation of trains. Their design, material, and maintenance are critical to
ensuring the durability and reliability of rail vehicles. Here is a detailed introduction to
railway wheels:
1. Design and Structure
Components of a Railway Wheel:
• Tread: The part of the wheel that contacts the rail. The tread's shape is usually slightly
conical, which helps in keeping the train centered on the tracks. The conical shape
allows for a self-centering action, reducing the wear on both wheels and rails.
• Flange: A raised edge on the inner part of the wheel, which prevents the train from
derailing, especially on curves and switches.
• Web: The portion of the wheel connecting the tread to the hub. The web provides
structural integrity and strength to the wheel.
• Hub: The central part of the wheel, which is mounted onto the axle. The hub is
crucial for transmitting the load from the wheel to the axle and vice versa.
2. Materials
• Steel: The most common material for railway wheels due to its strength, durability,
and ability to withstand high stress and wear. The steel used is often heat-treated to
enhance its properties.
• Composite Materials: Some modern wheels incorporate composite materials to
reduce weight and improve performance, though these are less common than steel
wheels.

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 Types of Wheels
Railway wheels are designed and specified based on the type of wagon they will be used in,
considering factors such as load capacity, speed, and operational conditions. Here are some
common types of wheels used in different types of wagons and their typical sizes:
1. Freight Wagons
Types of Wheels:
• Solid Wheels: These are simple, robust wheels made from a single piece of steel. They are
durable and can handle heavy loads.
• Resilient Wheels: These include a layer of resilient material (such as rubber) between the
wheel and the axle to reduce noise and vibration.
Sizes:
• Diameter: Typically ranges from 800 mm to 1,000 mm.
• Width: Around 130 mm to 160 mm.
Examples:
• General Freight Wagons: Often use solid wheels with diameters around 920 mm.
• Heavy Haul Wagons: Might use larger wheels, up to 1,000 mm in diameter, to support
heavier loads.
2. Passenger Coaches
Types of Wheels:
• Monoblock Wheels: Made from a single piece of steel, offering high reliability and safety for
passenger trains.
• Composite Wheels: Feature a steel hub with a rubber or composite outer layer to reduce
noise and improve ride comfort.
Sizes:
• Diameter: Typically ranges from 760 mm to 950 mm.
• Width: Around 135 mm to 150 mm.
Examples:
• Intercity Coaches: Commonly use wheels with a diameter of about 920 mm.
• High-Speed Trains: Might use slightly larger wheels, around 950 mm, for better stability at
high speeds.
3. High-Speed Trains
Types of Wheels:
• Forged Wheels: High precision and strength, designed to handle high speeds and dynamic
loads.
• Hollow Wheels: Reduce weight and improve dynamic performance at high speeds.
Sizes:

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 • Diameter: Typically ranges from 850 mm to 920 mm.
• Width: Around 140 mm to 150 mm.
Examples:
• High-Speed Trains: Often use wheels with diameters around 920 mm to provide a balance of
speed and stability.
4. Metro and Light Rail
Types of Wheels:
• Resilient Wheels: Commonly used to reduce noise and vibration in urban environments.
• Solid Wheels: Used in some systems for their simplicity and durability.
Sizes:
• Diameter: Typically ranges from 660 mm to 760 mm.
• Width: Around 120 mm to 135 mm.
Examples:
• Metro Trains: Frequently use wheels with diameters around 710 mm.
• Light Rail Vehicles: Might use slightly smaller wheels, around 660 mm, to navigate tighter
curves and urban tracks.
5. Trams
Types of Wheels:
• Resilient Wheels: These are often used to minimize noise and vibrations in city
environments.
• Single-Plate Wheels: Sometimes used for their simplicity and effectiveness in light rail
applications.
Sizes:
• Diameter: Typically ranges from 500 mm to 660 mm.
• Width: Around 100 mm to 120 mm.
Examples:
• Urban Trams: Commonly use wheels with diameters around 600 mm.
6. Special Purpose Wagons
Types of Wheels:
• Heavy-Duty Wheels: Designed for carrying exceptionally heavy or oversized loads.
• Low-Profile Wheels: Used for wagons that require a lower center of gravity.
Sizes:
• Diameter: Varies widely based on the specific purpose, ranging from 800 mm to 1,200 mm.
• Width: Around 140 mm to 160 mm.

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 Material of Wheel

The chemical composition of the steel for Cast Wheel

C 0.47% to 0.57% for type A used for carriage stock
0.57% to 0.67% for type B used for wagon stock
Mn 0.60 to 0.80%
P 0.03% max
S 0.03% max
Cr 0.15% max
Ni 0.25% max
Mo 0.06% max
Combined % for Cr, Ni & Mo must be 0.40% max
The procedure to calculate chemical composition will be in accordance to IS:228

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 Mechanical Properties of Cast Wheel
Sl. Particulars Type A Type B
No.

1 Tensile Strength at 15 mm below tread face 900 N/m2 min. 930 N/m2 min.

2 Tensile strength at middle of the web 800 N/m2 min. 800 N/m2 min.

3 Minum yield strength at 15 mm below tread 50% of UTS 50% of UTS

face

4 Minimum yield strength at middle of the web 50% of UTS 50% of UTS

5 Minimum elongation at 15 mm below tread 5.0% 4.5%

face

6 Minimum elongation at middle of the web 7.0% 7.0%

7 Hardness range at 15 mm below tread face 255-320 BHN 271-341 BHN

8 Minimum impact strength at 15 mm below 10 J/cm2 at 20 --

tread face deg C

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 Components of Wheel set

•(solid)
Wheel disk
on both sides
of the axle.

•theseAnwheel
axle to hold
disks in
position.

•rollerAxlebearing.
boxes with

Sr No. Details ICF (size in LHB (size in mm)

mm)
1. Diameter for New wheel 915+3/-0 915+4/-0

2. Axle length 2316+0.5/- 2440+0.5/-0.0

0.0
3. Journal Daimeter 130.043 130.043

4. Diameter of old wheel 837 857

5. Distance b/w two flange 1600+1/-0 1600+1/-0

6. Thickness of flange 29.4 29.4

7. Thickness of disk 130+2/-2 130+2/-2

8. Axle wheel set (16 ton) 175-178 192-195

9. Axle wheel set (13 ton) 169-172 NA

10. Axle sholder Daimeter 145 160

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WHEEL MAINTENANCE PROCEDURE IN WORKSHOP
During pre-inspection of incoming wheels, the wheel set is inspected for assessing the
condition of the components. Measurement are carried out on the wheels received in shop for
repairs. Following measurements are carried.
• Measurements of a Wheel Gauge (Distance between Two wheels flanges on the same
Axle):
Distance between two wheel flanges on the same axle should be 160+2/-1 mm. This
measurement should be taken at three location apart with the help of an adjustable pi-gauge.
If wheel gauge is not in permissible limits then the wheel discs have to be pressed off and
then pressed on.
• Measurements of a Wheel diameter (tread diameter)/Wheel Flanges:The wheel
diameter is measure with the help of a trammel gauge. The difference in tread diameter of the
two wheel on the same axle should not exceed 0.5mm. The variation on diameter under the
same coach should not exceed 13mm. The profile is to be turned 1mm above the condemning
unit.
•Inspection of Wheel disc:-
The wheel should be inspected for reject able defects in accordance with RDSOs Instruction.
•Inspection of Wheel Flange:-
The flange on both sides of a wheel set are checked with the help of a profile. Gauge to
measure the height and thickness of flanges. Accurate measurements of flange height and
thickness are not possible with the profile gauge. It is not possible with the profile gauge. It is
recommended to use a wheel sets is nominated for necessary repairs. After recording the

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 Wheel Profile
80 % of the track in Indian Railways is having rails which are already worn in service.
Standard wheel profile running on these tracks tend to wear to a specific profile within short
time itself, and further wear from this profile is very slow. Hence if the wheels are turned
initially to this worn wheel profile, it will increase the wheel life by avoiding frequent re-
profiling.
The worn wheel profile is made standard for all the wheels in Indian railways as the standard
wheel profile is found uneconomical with lesser kilometres being run by the wheels within
condemnation.

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 Sizes of Wheel Profile
Further to reduce the metal removal during tyre turning, intermediate worn wheel profile based on
the flange thickness is introduced.

Flange Thickness (X) Y Z

28 mm 42.23 mm 13.5 mm

27 mm 41.29 mm 13.0 mm

26 mm 40.34 mm 12.5 mm

25 mm 38.41 mm 11.5 mm

24 mm 37.44 mm 11.0 mm

23 mm 36.47 mm 10.5 mm

22 mm 35.49 mm 10.0 mm

21 mm 34.5 mm 9.5 mm

20 mm 33.5 mm 9.0 mm

Wheel Defects
• Manufacturing Defects
• Improper Assembly Practices
• Normal Wear and Tear during service

Manufacturing Defects
• Casting Defects
• Improper Heat treatment
• Machining Imperfections

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 Improper Assembly Practices
• Stipulated dimensional tolerances for Wheel seat and bore not adhered to resulting in use of
higher or lower than the prescribed force during pressing leading to improper wheel set
assembly.
• Ovality on Journals - 0.02 mm (max)
• Taper on Journal - 0.01mm (max)
• Difference in dia of wheels on the same axle should not exceed 0.5 mm

Wheel defects
Measurable wheel defects arising due to normal wear & tear during service
• Thin flange
• Deep flange
• Sharp flange
• Less radius at root of flange
• Hollow tyre
• Thin tyre
• Flat tyre

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 Std & cond limits
Defect Std Cond

Thin flange 28.5 22 (Coaches) 16 (Wagons)

Deep flange 28.5 35

Sharp flange (radius) 14.5 5

Less radius at root of flange (radius) 14 (wwp) 13

Hollow tyre 5

Thin tyre Based on wheel dia

Flat tyre 50 (Coaches) 60 (wagons)

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 Tyre Defect Gauge

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 Checking for sharp flange

WhenX is parallelto Y,
If there is Gap in the
middleat A, the Wheelis
serviceable

WhenX is parallelto Y,
If there is gap on either side
of A, the Wheel is rejectable

Checking the root of flange

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 Checking Thin flange

WhenX is parallelto Y,
If thereis gapbet een
A and the root of
flange, the heel is
erviceable

When X is arallel to Y, If
there is no gap bet een A
and the root of flange, the
heel is rejectable

Checking Deep Flange

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 Assignment
➢ Why wheel profile?
Ans. To maintain Standard profile of Wheel & Rail profile are
Complementary to each other 100%.
➢ Percentage rejection .
Ans. Axle 5% and Wheel 8% .
➢ Process for supplying wheel for workshop?

1. Initial Inspection
Receiving and Documentation:

• Receiving: The wheels are received at the workshop, and initial documentation is
recorded, including the wheel's service history and any reported issues.
• Visual Inspection: A preliminary visual inspection is conducted to identify obvious
defects such as cracks, excessive wear, and other surface damages.

2. Cleaning
Cleaning Process:

• Debris Removal: Removing dirt, grease, and other contaminants from the wheels
using cleaning solutions and high-pressure washing.
• Detailed Inspection: Cleaning allows for a more detailed inspection to identify any
hidden defects.

3. Non-Destructive Testing (NDT)

Testing Methods:

• Ultrasonic Testing: Used to detect internal cracks and flaws within the wheel.
• Magnetic Particle Inspection: Identifies surface and near-surface cracks.
• Dye Penetrant Inspection: Helps to reveal surface defects by using a dye that
penetrates into cracks.

4. Measurement and Assessment

Dimensional Checks:

• Profile Measurement: Checking the wheel tread and flange profile against the
specified dimensions to determine the extent of wear.

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 • Diameter Measurement: Ensuring the wheel diameter is within acceptable limits.

Assessment:

• Wear Analysis: Assessing the level of wear and damage to determine if the wheel
can be repaired or needs replacement.
• Decision Making: Based on the assessment, deciding whether to proceed with repair
or discard the wheel.

5. Reprofiling
Machining Process:

• Wheel Lathe: Using a wheel lathe to reprofile the wheel tread and flange to restore
the correct profile.
• Balancing: Ensuring the wheel is balanced after reprofiling to prevent uneven wear
and vibration during operation.

6. Heat Treatment (if applicable)

Stress Relief:

• Heat Treatment: Some wheels may undergo heat treatment to relieve internal
stresses and improve durability.

7. Repair and Replacement

Minor Repairs:

• Crack Repair: Small cracks can sometimes be repaired through welding or other
methods, followed by re-machining.
• Surface Defects: Minor surface defects are smoothed out to restore the wheel surface.

Component Replacement:

• ReAxle and ReDisking: If needed, the axle or brake disks are replaced as part of
comprehensive maintenance.

8. Final Inspection and Testing

Quality Checks:

• Dimensional Inspection: Verifying that the wheel dimensions and profile are within
specified limits after repair.
• Non-Destructive Testing: Conducting final NDT to ensure no defects remain.

Functional Testing:

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 • Rolling Test: Some workshops perform rolling tests to ensure the wheel runs
smoothly without issues.

9. Reassembly
Wheelset Assembly:

• Mounting on Axle: Reassembling the repaired wheel onto its axle.

• Final Alignment: Ensuring proper alignment of the wheelset components.

10. Documentation and Certification

Record Keeping:

• Repair Records: Documenting all repair processes, inspections, and tests conducted
on the wheel.
• Certification: Providing necessary certifications indicating that the wheel meets all
safety and quality standards.

11. Reinstallation
Installation on Rail Vehicles:

• Mounting Wheelsets: Installing the repaired wheelsets onto rail vehicles (wagons,
coaches, etc.) in the workshop.
• Operational Readiness: Ensuring the vehicle is ready for service after wheelset
installation.

12. Monitoring and Follow-Up

Post-Repair Monitoring:

• Regular Inspections: Scheduling regular inspections to monitor the performance of

the repaired wheels.
• Feedback Loop: Using operational feedback to improve future repair processes and
ensure continuous improvement

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 ➢ Types of Wheel Diameter

Description Std Cond

Coach MG 915 825

ICF coach BG

LHB coach 915 845

BOXN 1000 906

UIC 1000 860

BLC 840 780

➢ Working of Ultrasonic Testing.

Ultrasonic rail testing is a full-track inspection solution that uses high-pitched waves to scan
rails and identify internal flaws in need of repair. Pandrol teams are experts in the application
of ultrasonic rail inspection, and our certified inspectors can provide comprehensive training
tailored to your infrastructure, setting, and use case.
Our range of ultrasonic equipment includes both manual and motorised inspection tools,
which can be operated at up to 20 km per hour. Learn more about our equipment, processes,
and training on this page.
Ultrasonic rail testing companies have a responsibility to provide reliable equipment, fully-
trained operators, and optimal results. Trust Pandrol’s track record for safety, accuracy, and
upholding industry-leading standards.

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 ➢ RARD(Reaxle and Redisking)
RARD, which stands for "ReAxle and ReDisking," is a specific procedure and
terminology used in the railway industry related to the maintenance and refurbishment
of railway wheelsets. Here is an explanation of each term:
• ReAxle:
This refers to the process of replacing or refurbishing the axle of a railway wheelset.
The axle is a critical component that connects two wheels and supports the weight of
the rail vehicle. Over time, axles can experience wear, fatigue, and damage,
necessitating their replacement or refurbishment to ensure safety and reliability.
The reaxle process involves removing the existing axle, inspecting it for defects, and
either repairing or replacing it with a new or refurbished axle. This process requires
precision to maintain the correct alignment and balance of the wheelset.
• ReDisking:
This refers to the process of replacing or refurbishing the disk brakes on a railway
wheelset. Disk brakes are an essential part of the braking system, providing the
necessary stopping power for the train.
The redisking process involves removing the worn or damaged brake disks, inspecting
the mounting surfaces, and installing new or refurbished brake disks. Proper
installation and alignment are crucial to ensure effective braking performance and
safety.

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 7. References
➢ Wheel Manual

➢ www.wikipedia.com

➢ Production Technology by R.K.Jain

➢ CNC Machines by Hfiz Muhammad Rizwan

➢ Workshop technology Machine Tool by HazarachandChaudhary

➢ www.irfca.in

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