AN ANALYSIS TO REDUCE THE MATERIAL SCRAP AND

COST IN RAILWAY WAGON WORKSHOP USING PROFILE

CUTTING DIAGRAM IN AUTOCAD

SUBMITTED BY PROJECT GUIDE

MOHAMED JAVID.H (312311114069) Mr.A.S.M.UDAYAKUMAR,(M.E.,)

MOHAN.M (312311114070) Assistant Professor

Department of Mechanical engineering

COMPANY PROFILE

• The Golden Rock Railway Workshop is situated in Ponmalai (Golden Rock),Tiruchirapalli in the Indian state of Tamilnadu,

• It is one of the three Mechanical railway workshops serving the southern zone of the Indian Railways

• Wagon manufacturing • Diesel loco periodic overhauling (POH)

• Carriage maintenance.

OBJECTIVE

• The objective is to reduce the material scrap and cost which is involved in the manual gas cutting process in wagon production.

• By suggesting improved method of profile cutting diagram using profile cutting machine the raw material is saved.

• Thereby,reducing cosumption of material scrap and cost in wagon production.

SHOPS IN GOLDEN ROCK WORKSHOP

• Diesel shop• Tool room shop• Coil manufacturing shop• Electrical and electronics shop• Carriage body shop• Boiler shop• Under truck shop• Traction motor shop• Wheel shop• Carriage repair shop• Wagon body shop• Wagon component shop• Wagon assembly shop

RAILWAY WAGON

• Railway wagon are the type of unpowered railway vehicle used for the transportation.• A variety of wagon types are in use to handle different types of goods,

but all goods wagons in a regional network typically have standardized couplers and other fittings, such as hoses for airbrakes, allowing different wagon types to be assembled into trains.• For tracking and identification purposes, goods wagons are generally

assigned a unique identifier, typically a UIC wagon number, , a company reporting mark plus a company specific serial number.

RAILWAY WAGON

TYPES OF WAGON PRODUCED IN GOLDEN ROCK WORKSHOP

• BLC Wagon (Bogie low platform container flat wagon)• BLC -A car, BLC- B car• BOX NHL Wagon• BLL Wagon ( Bogie low platform longer container flat wagon)• CONTAINER Wagon

WAGON SHOPS IN GOLDEN ROCK WORKSHOP

• Wagon body shop(WBS)• Wagon component shop(WCS)• Wagon assembly shop(WAS)

RAW MATERIAL USED

• The raw material used for the production of wagon is Mild Steel IS 2062 E450D .

Mechanical properties

Yield strength = 450 Mpa Tensile strength = 570-720 Mpa Elongation = 19 %

BLC - WAGONS

• BLC - Bogie low platform container flat wagon• There are two types of BLC wagons ,they are BLC-A wagon and BLC-B

wagon.• Bogie Low Platform container flat (BLC) wagons has been designed for

the transportation of long ISO containers at an operating speed of 100 kmph.• BLC (A-CAR) wagons are placed at extreme ends in the formation of

one unit of 5-cars (with 3 BLCB wagons in middle).

SPECIFICATION OF BLC-A CAR

SPECIFICATIONS OF BLC-B CAR

VARIOUS STAGES IN WAGON ASSEMBLY SHOP FOR BLC WAGONS

BLC UNDER FRAME ASSEMBLY

• Headstock CBC (center buffer coupler) end• Bottom center sill bottom plate• Cross member CBC end• Cross member for anchor bracket web• Headstock bottom flange CBC end• Solebar web plate corner CBC end In the BLC underframe assembly ,the above components mentioned

are assembled.

CURRENT METHOD OF CUTTING RAW MATERIAL

• In the golden rock workshop ,the cutting of raw material of 12 mm thick mild steel IS 2062 E450 D is done only by manual gas cutting process.• They are using oxy acetylene gas cutter for cutting the raw material

through manual method• The oxy-acetylene cutting process is achieved by blowing away the

molten material, which is melted by the combustion heat of acetylene gas and oxygen. Generally, only steel material is cut using this process and material of remarkable thickness can be cut. However, the thickness that can be cut is based on a user's skill and the size of a torch used.

MAUAL GAS CUTTER

LIMITATIONS- MANUAL GAS CUTTING PROCESS

• Skilled labour is required for cutting the raw material• Time consuming process• More wastage of raw material incurred• Complex shape cannot be cutted• Safety for the worker is not assured.

PROPOSED METHOD OF CUTTING THE RAW MATERIAL

• Our objective of the project is to reduce the consumption of raw materials and scrap,and to reduce the cost incurred for raw material.• In order to reduce the scrap, profile cutting diagram is used in CAD

modelling software(AUTOCAD).• The cutting diagram thus made in the software is fed into the

automatic profile cutting machine where cutting of different and complex componenets are made.

PROFILE CUTTING MACHINE

THE MAJOR COMPONENTS CUTTED FOR UNDERFRAME ASSEMBLY

• Headstock CBC (center buffer coupler) end• Bottom center sill bottom plate• Cross member CBC end• Cross member for anchor bracket web• Headstock bottom flange CBC end• Solebar web plate corner CBC end

THE COMPONENTS MADE BY MANUAL GAS CUTTING PROCESS

CONSUMPTION OF RAW MATERIAL FOR EXISTING METHOD - FOR 45 BLC WAGONS

PROFILE CTTING DIAGRAM OF RAW MATERIAL FOR SUGGESTED METHOD - FOR 45 BLC WAGONS

LAYOUT -2

LAYOUT - 3

LAYOUT - 4

LAYOUT - 5

RAW MATERIAL USED DETAILS:-

CONSUMPTION OF RAW MATERIAL FOR SUGGESTED METHOD - FOR 45 BLC WAGONS

KEY BENEFITS OF PROFILE CUTTING MACHINE

• Fully automatic and interactive control over all aspects of the CNC profile cutting process.• Machine Drivers available for virtually all CNC profile cutting machines

including laser, plasma, oxy-fuel, and waterjet machines. • Easily incorporate part or process revisions.• Direct interface to Autodesk Inventor, SolidWorks, and Solid Edge.• Uses the industry standard AutoCAD DWG file as the native file format. This

eliminates proprietary files that can’t be opened by any other software.• Available as a stand-alone application or, for AutoCAD users, as a plug-in to

the latest AutoCAD or AutoCAD Mechanical software.

COMPARISON OF RAW MATERIAL CONSUMPTION

• TOTAL RAW MATERIAL REQIRED FOR EXISTING METHOD( in tonne) = 9.041 tonne • TOTAL RAW MATERIAL REQIRED FOR SUGGESTED METHOD

(in tonne) = 7.88 tonne

• TOTAL AMOUNT OF RAW MATERIAL SAVED = 9.041-7.88 = 1.161 tonne

COST COMPARISON

• COST FOR 1 Kg OF RAW MATERIAL(IS 2062 E450D) = Rs. 60.57• COST FOR 1 tonne = Rs. 60570.• COST FOR EXISTING METHOD = Rs. 5,47,613• COST FOR SUGGESTED METHOD = Rs. 4,77,291• TOTAL AMOUNT OF COST SAVED = Rs. 70322 (FOR 45 BLC WAGONS) • FOR 1 YEAR 720 WAGONS ARE PRODUCED,IF THE SUGGESTED METHOD IS

IMPLEMENTED IN THE ORGANISATION.• TOTAL AMOUN OF COST SAVED PER YEAR = Rs. 11,25,152

CONCLUSION

• Instead of using the manual cutting process, if the suggested method is followed the cost as well as the scrap can be reduced to a considerable amount and the dependence of labour can be minimized. Using the profile cutting machine the time also be saved and the complex can be cutted with ease.