MANUFACTURING PROCESS PLAN FOR IMPROVED SEJ WITH 65 mm GAP MAXIMUM

MANUFACTURING
PROCESS PLAN FOR IMPROVED SEJ WITH 65 mm GAP MAXIMUM

(As per Drawing Nos. RDSO/ T-6922 & RDSO/T-6930)

 

SL.

NO.

OPERATIONS

PROCESS DESCRIPTION

1)

STACKING OF RAILS

Rails received from
the Purchaser / Railway Depot / SAIL are stacked properly in layers with
steel spacers between the layers adopting the procedure specified by RDSO.

1.1

VISUAL
CHECK AND ULTRASONIC TEST

Ø  Rails
are taken out from the stack with EOT cranes using two point slinging       and are spread on steel supports.
Spread rails are cleaned thoroughly to      
remove rust, scales and checked visually for surface / rolling
defects.

Ø  After
visual checking, the rails are subjected to Ultrasonic Test using approved
model of Ultrasonic Rail Tester

Ø  Before
testing the rails, the USFD instrument is calibrated with the help of RDSO
specified Standard Test Piece.

Ø  Hundred
per cent rails are subjected to Ultrasonic testing.

 

1.2

MARKING

Ø  Ultrasonically
passed rails are marked with white paint on top of rails.  Then the rails are marked for cutting to
required lengths as per Drg. On marking for cutting, a job No. is marked on
the top of rail.

Ø  The cast
numbers of the ultrasonically passed rails are recorded in a Register and the
job number recorded against each.

1.3

CUTTING
OF RAILS

Rails marked for
cutting are paced on cutting machine on level platform fixed with rollers and
cut to the marked length with Hack-Saw / Band Saw machines.  The squareness of the cut end of the rails
checked with try-square.

1.4

HEAT
TREATMENT

Straightened rails
are taken for Heat Treatment / Pearlitised by Induction Heating Process.

1.5

TESTING
OF HEAD TREATED RAILS

Heat treated rails
are further subjected to Ultrasonic and MPT Testing before machining. Heat
treated rail also tested for hardness, micro/macro testing &
straightening, and mechanical properties.

 

2)

 

FABRICATED
STOCK RAILS

 

2.1

DRILLING

After straightening
the rail are marked for drilling and drilled with radial drill machines.

2.2

MACHINING

a)  NOTCHING – Straightened rails are marked
for notching and machining of 

     Head and Foot.

     Notching of head and foot are done by
shaper machines as per marking and   

     Checked with checking gauges.

 

 

b)  HEAD & FOOT MACHINING – After notching
the rails are taken for head and foot machining on planer machines and
machined straight as per marking    
and are checked with checking gauge.

 

 

c)  RADIUSING AT END – After head and foot machining
the rails are taken for      and
radiusing by shaper machines and checked with checking gauge.

2.3

ASSEMBLY
OF FABRICATED STOCK RAIL

After complete head
and foot machining of the two rails of length 7140mm cutting 20mm length from
both side of  stock rails and filing /
grinding of sharp edges formed to radius not greater than 2R and 5920mm are
assembled together to form the fabricated stock rails using HTS bolts.

 

2.4

FOOT
MACHINING OF FABRICATED STOCK RAIL

After assembly the
combined foot of fabricated stock rails if machined to single foot width to
accommodate on normal track sleepers.

2.5

STRAIGHTENING
OF STOCK RAILS

Fabricated
stock rails after assemblies are taken for straightening once again before
final assembly with tongue rails.

 

 

3)

 

TONGUE RAILS

 

3.1

MARKING
FOR MACHINING

Tongue rails after
heat treatment and straightening are marked for head and foot machining.

 

3.2

MACHINING

a)  NOTCHING – Straightened rails are marked
for notching and machining of     

     Head and Foot.  Notching of head and foot are done by
shaper machines as 

     Per marking and checked   with checking gauges.

 

 

 

b)  HEAD & FOOT MACHINING – After notching
the rails are taken for head and foot machining on planer machines and
machined straight as per marking and are checked with checking gauge.

 

 

 

c)  RADIUSING AT END – After head and foot
machining the rails are taken for

     end radiusing by shaper machines and
checked with checking gauge.

 

4)

Removal of sharp edges

Finishing as
per  Gauge and removal of sharp edges
by filing / grinding to radius not greater than 2R

 

5)

ASSEMBLY OF SEJ

 

Final assembly is
done in the assembly bay inside the shop floor.  The assembly of finished tongue and stock
rails is done by skilled workmen using C.I. 
Chairs and M.S. Brackets with T-Head bolts and nuts.  While assembly hydraulic Jim crows are used
by ailing the gauge face and matching of tongue and stock rails.

 

6)

INTERNAL INSPECTION

The final assembly
of SEJ and their components are checked by in-house inspection team. The
inspection is carried out using steel tape, scale, Vernier Caliper, approved
gauges and templates. The observations are recorded in Inspection Register.
Mechanical & chemical testing of components are also done.

 

7)

EXTERNAL INSPECTION

The products
internally inspected and accepted are offered for inspection by the external
agencies (RDSO / RITES / Purchaser or their authorized agents).

8)

PAINTING

After inspection
and acceptance by the external agency, the products are painted following the
procedure as laid in IRS/T-10/2000. 
The thickness of paint is checked.

 

9)

MARKING

Painted materials
are left for drying and then they are marked as per IRS/T-10.

 

10)

PACKING AND
DESPATCH

Inspected,
accepted, painted and marked materials are packed in double gunny bags,
bundled or lashed with stout wire and dispatched to the Consignee.

 

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