Government of India Ministry of Railways

QMS-09:2012 (Revision 1_d1of May.’12)

Infrastructure, manufacturing, testing & quality control requirements

for

Cast steel Casnub & CONCOR Bogies &

Components

Centre Pivot assembly Side Bearer Housing

End Piece & Strut casting of brake beam Wedge

Cast Steel Brake Beam [Casnub 22WM], Drg. No. WD-85084-S-1)

As per RDSO Specification nos.

WD-21-Casnub 22 NLB-Bogie-93 (Rev.2), WD-17-Casnub 22 HS-bogie-92 (Rev.3),

WD-34-Casnub 22 HS bogie-2004 (Mod – I) WD-39-Casnub 22 HS bogie-2004 (Mod – II)

CONTR.LCCF 20(C)-96 (Rev.2)

Inspection & Liaison Directorate

Research Designs & Standards Organisation Manak Nagar Lucknow – 226011

May’2012

_________________________________________

QMS-09:2012(Rev 1)_d1_Page 2 of 12

1.0 SCOPE

This schedule covers the technical requirements for manufacture, testing and quality control

requirements for light weight Casnub 22 NLB Cast steel bogies, side frame, Bolster &

CONCOR bogies for Broad gauge wagons.

2.0 REQUIREMENTS

2.1 Vendors seeking approval shall satisfy the requirements for category “A” foundry as per

IS:12117 (1996) or latest.

2.2 The firm should have acquired ISO 9000 series certification or QS certification.

3.0 GENERAL INFRASTRUCTURAL AND

MANUFACTURING FACILITIES

Name of components

Bogie

(SF

&B

olster)

CP

Assy

.

SB

ho

usin

g

Wed

ge

End

pc.

&

Stru

t Castin

g

Cast

Steel

Brak

e Beam

3.1 Covered shed with sufficient height and space

provided with at least one number EOT Crane in each

bay covering the below mentioned activities:

I) Melting, Moulding , Fettling

II) Heat Treatment

III) Gauging & assembly

IV) Load testing area.

√ √ √ √ √ √

3.2 Covered area with sufficient space for handling raw

material like Sand, Scrap etc provided with EOT

crane and conveyor, magnetic chuck.

√ √ √ √ √ √

3.3 Ensure that at least one number tilting type electric arc

furnace having laddle refining facility with minimum

5t capacity is available.

√ √ √ √ √ √

3.4 Minimum three numbers of Charging buckets of

suitable capacity for scrap and foundry returns should

be available.

√ √ √ √ √ √

3.5 Facilities for preheating of laddle should be available

(with High Alumina bricks). Laddle lining should be

of Kaltex or of High Alumina bricks. In case of use of

cold laddle board, it should be ensured that there is no

drop in temperature of molten metal and it is one time

used only.

√ √ √ √ √ √

3.6 Separate identified area for different grade of scrap

and foundry returns should be available for avoiding

wrong charging.

√ √ √ √ √ √

_________________________________________

QMS-09:2012(Rev 1)_d1_Page 3 of 12

GENERAL INFRASTRUCTURAL AND

MANUFACTURING FACILITIES

Name of components

Bo

gie

(SF

&B

olster)

CP

Assy

.

SB

ho

usin

g

Wed

ge

En

d p

c. &

Stru

t Castin

g

Cast S

teel

Brak

e Beam

3.7 Facilities should be available for oxygen lancing and

Argon purging for removal of entrapped gases in arc

furnace.

√ √ √ √ √ √

3.8 Material handling facilities like mobile crane, Pay

loader, Fork lifter, Tram beam, Piller crane, Magnetic

chuck should be available.

√ √ √ √ √ √

3.9 Weighing machine of 1T capacity for ferro alloys

charge and finished casting weighment √ √ √ √ √ √

3.1

0

Ensure that refractory pouring cups & down spruce are

used. √ √ √ √ √ √

4.0 SAND PREPARATION

4.1 Ensure that Sand drier of 1t/hr capacity with conveyor

and cooling arrangement are provided with

intermediate hopper.

√ √ √ √ √ √

4.2 Automatic sand continuous mixer machine for making

‘Mould’ and ‘Core’ should be available. The mixer

should be intensive type with calibrated dozing of

important ingredients.

√ √ √ √ √ √

4.3 Ensure that the system exist for testing of prepared

sand as per the following frequency: √ √ √ √ √ √

i) Moulding sand 1 in every 5 batch.

ii) Core sand 1 in every 20 batch.

4.4 Whenever the sand is tested the following properties

of prepared sands shall be checked.

√ √ √ √ √ √

Green Compressive Strength, Green Shear Strength,

Moisture, Permeability, Shatter Index flowability,

hardness etc.

The acceptance value for each test must be clearly

specified and any sand not meeting the above

parameters must not be used for mould/core making.

4.5 Jolt and Squeeze machine or machanised moulding

line should be available for moulding. In case of no

bake system, facility for jolting is available.

√ √ √ √ √ √

4.6 Mould cavity & core must be painted with mould

wash Alkalic base in nature to reduce mould metal

reaction.

√ √ √ √ √ √

4.7 Ensure that the facilities are existing for preparation of

cores by ‘No bake’ method. √ √ √ √ √ √

_________________________________________

QMS-09:2012(Rev 1)_d1_Page 4 of 12

5.0 HEAT TREATMENT

Name of components

Bo

gie

(SF

&B

olster)

CP

Assy

.

SB

ho

usin

g

Wed

ge

En

d p

c. &

Stru

t Castin

g

Cast S

teel

Brak

e Beam

5.1 Heat treatment facilities capable of handling the entire

production must be available in house. Heat treatment

furnace should be of either oil fired or electric type.

√ √ √ √ √ √

5.2 Heat treatment furnace should be provided with multi

point automatic continuous temperature recording

arrangement with digital indicators for each point (one

point at every five feet length).

√ √ √ √ √ √

5.3 The heat treatment furnace must be calibrated using

sufficient no of thermocouple for assessing

temperature at different zones at various temperature

ranges. The calibration of furnace is to be done at least

once in a year.

√ √ √ √ √ √

5.4 Thermocouples, temperature indications should be

calibrated at least once in 6 month. √ √ √ √ √ √

5.5 Serial nos. of castings under heat treatment should be

recorded in a register for traceability with temperature

time curve and date. Display of temperature curve

near the furnace for the guidance of the operator

should be ensured.

√ √ √ √ √ √

5.6 Arrangement of proper sealing of doors of HT furnace

should be available to avoid oxidation / scale

formation on the surface of the casting. There should

be positive pressure inside to avoid entry of air from

outside.

√ √ √ √ √ √

5.7 The Heat Treatment recorder/Graph should have

sealing arrangement to avoid tampering . √ √ √ √ √ √

5.8 Positioning of the nozzles of oil fired furnace should

be such that the flame does not come in direct contact

with the castings.

√ √ √ √ √ √

5.9 The burners of HT furnace should be calibrated at

every three months. √ √ √ √ √ √

5.1

0

Heat treatment facility (Induction Hardening/flame

hardening) for achieving hardness for flat type C P

assy.

X √ X X X X

6.0 SHOT BLASTING MACHINE

6.1 Suitable shot blasting machine conveyor monorail type

or rotatory table type or continuous conveyor type

should be available.

√ √ √ √ √ √

6.2 Casting to be given shot blasted before and after heat

treatment using steel shot of size SS 1000, IS 4606. √ √ √ √ √ √

_________________________________________

QMS-09:2012(Rev 1)_d1_Page 5 of 12

7.0 SAND TESTING

Name of components

Bo

gie

(SF

&B

olster)

CP

Assy

.

SB

ho

usin

g

Wed

ge

En

d p

c. &

Stru

t Castin

g

Cast S

teel

Brak

e Beam

7.1 All incoming sand must be tested before acceptance as

per frequency set by QC Department. The following

must be checked √ √ √ √ √ √ i) AFS grain size.

ii) Clay content.

iii) Moisture content.

iv) Loss of Ignition

7.2 For testing incoming virgin sand, moulding sand, core

sand the following equipment at least one number

each should be available.

√ √ √ √ √ √

a) Permeability tester.

b) Sand Rammer

c) Quick moisture teller

d) Chemical balance

e) Sand sieve shaker

f) Sand Muller 25 kg.

g) Shatter Index tester.

h) Dry compression strength tester.

i) Sand mouldability / Compatibility tester

j) Sand flowability tester

k) Mould/Core hardness tester

l) Methylene blue test equipment for clay.

m) Portable hardness tester other than

poldy

7.3 Ensure that the calibration of the above equipments is

done once in a year. √ √ √ √ √ √

8.0 CHEMICAL LABORATORY

8.1 Computerised emission spectrometer with automatic

printer should be available for analysis and recording

of steel composition at different stages of

manufacturing.

√ √ √ √ √ √

8.2 Wet analysis facilities including Strohelien apparatus

for carbon analysis, conducting chemical test of

incoming rawmaterials, refectories, ferro alloys should

be available in addition to spectro.

√ √ √ √ √ √

8.3 Metalographic polishing equipment, Belt polisher etc.

should be available √ √ √ √ √ √

_________________________________________

QMS-09:2012(Rev 1)_d1_Page 6 of 12

9.0 PHYSICAL LABORATORY Name of components

Bo

gie

(SF

&B

olster)

CP

Assy

.

SB

ho

usin

g

Wed

ge

En

d p

c. &

Stru

t Castin

g

Cast S

teel

Brak

e Beam

9.1 Universal testing machine of 40T capacity with

graphical recording facilities for conducting tensile

test of sample from each heat should be available.

The machine is to be calibrated once in a year.

√ √ √ √ √ √

9.2 At least two types of Fixed bench type heavy duty

hardness checking equipment viz. BHN, HRC,

VPN should be available. The instrument should

have optical instrument/digital display attachment

for giving direct reading.

√ √ √ √ √ √

9.3 Impact testing machine 0-300J capacity for

conducting impact test at room temperature and sub

zero temperature should be available. Liquid

Nitrogen container and stainless steel bath with

digital temperature indicator for sub zero test

arrangement must be available.

√ √ √ √ √ √

9.4 Shadowgraph facilities for assuring correct notch

profile and dimension for impact test specimen.

√ √ √ √ √ √

9.5 Liquid penetrant test facilities for checking surface

welding cracks.

√ √ √ √ √ √

9.6 Magnetic particle Inspection facilities for crack

detection should be available. √ √ √ √ √ √

9.7 Radiographic examination facilities with well

equipped standard room should be available. In case

radiography facility is outsourced then facility for

dark room , viewer and storage should be available.

Radiography should be carried out by engaging

BARC certified level – II operator.

√ √ √ √ √ √

9.8 Relevant ASTM E-446 reference radiograph for

comparing level of radiographic quality should be

available.

√ √ √ √ √ √

9.9 Metallurgical micro scope with 1000 x

magnification. Facility for image analyzer with

software and printing facility should be available.

√ √ √ √ √ √

9.10 SCRATA comperator for assessing surface quality. √ √ √ √ √ √

9.11 Person in charge of the metallurgical area is at least

Graduate in metallurgical with not less than 5 years

experience.

√ √ √ √ √ √

_________________________________________

QMS-09:2012(Rev 1)_d1_Page 7 of 12

Name of components

Bo

gie

(SF

&B

olster)

CP

Assy

.

SB

ho

usin

g

Wed

ge

En

d p

c. &

Stru

t Castin

g

Cast S

teel

Brak

e Beam

9.12 Staff conducting test like chemical analysis, Sand

testing of mechanical properties have adequate skill

and competence and have under gone training to

give the reasonable reliability.

√ √ √ √ √ √

9.13 Skill of such staff is periodically qualified by making

them carry out test on blind samples. √ √ √ √ √ √

9.14 Muffle furnace 0-1200 degree C with temperature

recorder should be available for chemical analysis

and Jominy test with calibration on yearly basis.

√ √ √ √ √ √

9.15 Hot air oven, Hot plate, Electrical oven and other

accessories and chemical agents necessary for wet

analysis should be available including platinum

crucibles (atleast 2 nos.)

√ √ √ √ √ √

10. STATIC LOAD TESTING

10.1 Load testing arrangement for Bogie with 100t

hydraulic power pack should be available. √ X X X X X

10.2 Load testing arrangement for Cast Steel brake beam

with 15 t hydraulic power pack should be available X X X X X √

10.3 Proof load and destructive load testing arrangement

for side frame and bolster with hydraulic power pack

of 300tonnes capacity should be available.

√ X X X X X

11.0 MACHINING FACILITIES

11.1 The firm should have a machine shop equipped with the following machine

Plane miller machine of suitable capacity for

machining bolster surface.

Lathe machine.

Air Compressor.

Drilling machine.

Sawing grinder.

Welding transformer DC

Welding rectifier DC

Power saw od suitable sizes for sectioning sides

frame/Bolster & other components

√ X X X X X

√ √ √ √ √ √

√ √ √ √ √ √

√ √ √ √ √ √

√ √ √ √ √ √

√ √ √ √ √ √

√ √ √ √ √ √

√ √ √ √ √ √

11.2 Firm should have gauges as detailed in RDSO’s

specification number WD-31-Misc-99 & use these

during & after machining operations.

√ √ √ √ √ √

_________________________________________

QMS-09:2012(Rev 1)_d1_Page 8 of 12

Name of components

Bo

gie

(SF

&B

olster)

CP

Assy

.

SB

ho

usin

g

Wed

ge

En

d p

c. &

Stru

t Castin

g

Cast S

teel

Brak

e beam

12 QUALITY CONTROL REQUIREMENTS

12.1 There exists system of easy tracibility of the product

from casting stage to finished product stage. √ √ √ √ √ √

12.2 Quality assurance plan as per standard format QM-

RF-7.1-3 √ √ √ √ √ √

12.3 A graduate Engineer with at least 5 years experience

or a Diploma holder must head the inspection/final

quality control section with 10 years experience

exclusively for inspection of castings.

√ √ √ √ √ √

12.4 Inspection staff conducting non destructive testing is

adequately trained and qualified by recognised

agency and has adequate experience.

√ √ √ √ √ √

12.5 There exists quality manual of the firm indicating the

extent of control over production and testing. √ √ √ √ √ √

12.6 To ensure regular submission of foundry returns

detailing rejection rate, cause of rejection corrective

action taken on quarterly basis.

√ √ √ √ √ √

12.7 There exists a system of documentation in respect of

rejection at customer end, warranty replacement, on

line service failure of castings.

√ √ √ √ √ √

12.8 There exists system of recording plant, machinery

control equipments remaining out of service, nature

of repair done etc.

√ √ √ √ √ √

12.9 Welders engaged in welding works/reclamation

works of castings must be qualified as per IS:7318

must be revalidated at least once in 2 years.

√ √ √ √ √ √

13 GAUGING

13.1 Ensure that minimum three sets of gauges as per the

stipulated specifications are available for each

component (Annexure ‘A’).

√ √ √ √ √ √

14 TRAINING

14.1 Training need for all personnel to be identified.

Regular training should be organised covering

personnel identified for a particular period.

√ √ √ √ √ √

_________________________________________

QMS-09:2012(Rev 1)_d1_Page 9 of 12

Name of components

Bo

gie

(SF

&B

olster)

CP

Assy

.

SB

ho

usin

g

Wed

ge

En

d p

c. &

Stru

t Castin

g

Cast S

teel

Brak

e beam

15 DOCUMENTATION

15.1 System should exists for documentation of the

following:

a) Incoming raw-material register with TC

reference of supplier as well as internal

test result.

b) Stage inspection and test result

c) Calibration records

d) Casting records sl.no. wise, components

wise, month wise.

e) Register for heat treatment indicating

charge wise, loading serial no.wise

Temperature graph must be pasted on the

H.T register.

f) Weighment records of side frame and

bolster.

√ √ √ √ √ √

_________________________________________

QMS-09:2012(Rev 1)_d1_Page 10 of 12

ANNEXURE “A”

LIST OF GAUGES FOR CASNUB 22 NLB BOGIE

S.No. SIDE FRAME

Description Drawing No.

1. Gauging Scheme for side frame WD-98022-S/1

2. Central opening height check WD-98022-S/2

3. Distance between friction liner and dimension 470 WD-98022-S/3

4. Bolster anti rotation control lug gauge WD-98022-S/4

5. Column side width cum offset check WD-98022-S/5

6. Central opening bottom distance gauge WD-98022-S/6

7. Central opening bottom profile WD-98022-S/7

8. Spring plank seat profile gauge WD-98022-S/8

9. Pedestal roof profile and width check WD-98022-S/9

10. Pedestal jaw lug vertical profile check WD-98022-S/10

11. Pedestal jaw lug transverse profile check WD-98022-S/11

12. Pedestal jaw gap check WD-98022-S/12

13. Pedestal roof to key slot depth check WD-98022-S/13

14. Warp check gauge WD-98022-S/14

15. Pedestal roof to spring plank seat distance check WD-98022-S/15

16. Pedestal roof level difference check WD-98022-S/16

17. Wheel base check cum pairing gauge WD-98022-S/17

18. Central opening offset check WD-98022-S/18

19. Brake beam pocket location & alignment check WD-98022-S/19

20. Brake beam pocket size check WD-98022-S/20

21. Brake beam pocket nib hole check WD-98022-S/21

22. Jaw opening center marking device WD-98022-S/22

23. Rivet & fit bolt hole position check gauge WD-98022-S/23

24. Column locator for side frame rivet hole location check WD-98022-S/24

_________________________________________

QMS-09:2012(Rev 1)_d1_Page 11 of 12

BOLSTER

1. Gauging procedure for bogie bolster WD-97031-S/1

2. Limit gauge for lateral lug gap WD-97031-S/2

3. Snubber pocket width check WD-97031-S/3

4. Pocket & lug alignment check WD-97031-S/4

5. Lugs edge distance check WD-97031-S/5

6. Span and Squareness checking gauge WD-97031-S/6

7. Co-axiality checking gauge WD-97031-S/7

8. Bolster top spring seat height check WD-97031-S/8

9. Bolster top side bearer height check WD-97031-S/9

10. Springs spigots location check WD-97031-S/10

11. Snubber pocket angle check WD-97031-S/11

12. Wedge wing profile check WD-97031-S/12

13. Bolster spigots height check WD-97031-S/13

14. Co-planarity check gauge WD-97031-S/14

WEDGE

1. Gauge Scheme for wedge WD-97031-S/15

2. Squareness and slope checking gauge WD-97031-S/16

3. Wedge height and contact point location gauge WD-97031-S/17

4. Wing profile & R1500(GO), width, checking gauge WD-97031-S/18

COMPONENTS

1. Brake beam checking gauge WD-99043-S/1

2. Centre pivot top checking gauge WD-99033-S/3 Sheet I & II

3. Centre pivot bottom checking gauge WD-99033-S/2

4. Spring plank:

4.1 Length cum convexity & ‘Fit Bolt’ hole location gauge WD-99032-S/2

4.2 Outer profile cum height check gauge WD-99032-S/3

4.3 Thickness cum flange end profile check gauge WD-99032-S/4

4.4 Rivet and ‘Fit Bolt’ hole size and location check gauge WD-99032-S/5

4.5 Spring spigot size, arrangement & group location check

gauge.

WD-99032-S/6

_________________________________________

QMS-09:2012(Rev 1)_d1_Page 12 of 12

4.6 Side Bearer housing gauges for checking dimensions &

profile

As per drawing

4.7 End Piece & Strut gauges for checking dimensions &

profile

As per drawing

ANNEXURE “B”

MAJOR STEPS FOR APPROVAL OF CASNUB BOGIES

1. Application by the firm along with self assessment of their foundry in accordance with

IS:12117(1996).

2. Visit by Director/Jt. Director to verify the compliance of IS:12117 by the firm.

3. Approval of the foundry as Class ‘A’.

4. Application by firm seeking approval to supply casting components – couplers, casnub bogies

etc.

5. Scrutinising the capability of the firm on the basis of information given in the application

form.

6. Visit by a team of RDSO officials to verify the manufacturing, testing and quality control

requirements in accordance with relevant specification and STRs.

7. Submission of following documents by vendor - Documented procedure of manufacture,

Methoding system for casting, as cast drawing details of castings, quality checks to be

followed, gauging scheme, quality conformance testing arrangements, assembly procedure,

quality assurance programme etc.

8. Perusal of the documents jointly by I&L and Wagon Design Dte.

9. Clearance to manufacture proto type if above details are considered satisfactory.

10. Development of three sets of gauges for side frame, bolster, centre pivot assembly, side bearer

housings, wedges, liners, brake block key, spring plank, other forged components, brake

beam, pull rod, push rod and various pins etc. The approval for the gauges wherever

necessary.

11. Testing of the proto type

12. Accordance of approval