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A SUMMER TRAINING REPORT AT DIESEL LOCOMOTIVE WORKS

VARANASI

Submitted by-Sanjeev Kumar


Course-IDD (Part-III)
Department-Mechanical engineering
Roll no-14134013
Institue-IIT BHU
ACKNOWLEDGEMENT

I would sincerely like to thank the employees and


the officers of DLW, VARANASI for their help and
support during this training. Despite their busy
schedules, they took time out for us and
explained to us the various aspects of the working
of the plant from the production shops.

This training provided me immense knowledge


not only in the field of mechanical engineering but
I also got to learn about the prestige that DLW has
in our country.

Their logo Our locos moves the nation explains


the whole story of their importance in this
country. People working in DLW work their best
to provide us the most comfortable locomotives.
PREFACE

The objectives of the practical training are to learn


something about industries practically and to be
familiar with the working style of a technical
person to adjust simply according to the industrial
environment.
It is rightly said practical life is far away from
theoretical one. We learn in class room can give
the practical exposer real life experience no doubt
they help in improving the personality of the
student, but the practical exposure in the field will
help the student in long run of life and will be able
to implement the theoretical knowledge.
As a part of academic syllabus of four year degree
course in Mechanical Engineering, every student
is required to undergo a practical training.
I am student of third year mechanical and this
report is written on the basis of practical
knowledge acquired by me
during the period of practical training taken at
Diesel Locomotive Works, Varanasi.
CONTENTS

[1].Introduction to DLW.

[2].Tool Room .

[3]. Heavy Welding Shop.

[4]. Light Machine Shop...

[5]. Machine Shop.


INTRODUCTION TO DLW

Diesel Locomotive Works (DLW) is a production unit under the


ministry of railways. This was setup in collaboration with American
Locomotive Company (ALCO), USA in 1961 and the first locomotive
was rolled out in 1964. This unit produces diesel electronic
locomotives and DG sets for Indian railways and other customers in
India and Abroad.

Subsequently a contract for transfer of technology of 4000 HP


Microprocessor Controlled AC/AC Freight (GT 46 MAC) / passenger
(GT 46 PAC) locomotives and family of 710 engines has been signed
with electro motive division of GENERAL MOTORS of USA for
manufacture in DLW. The production of these locomotives has now
started and thus DLW is the only manufacturers of Diesel Electric
Locomotives with both ALCO and General Motors technologies in the
world
History of diesel locomotives

In the early 1960s Indian Railways began conversion of its


mainline from steam to diesel locomotives. For this
conversion General Motors Electro-Motive Division (EMD) and
the American Locomotive Company (ALCo) were asked to
submit designs for new diesel locomotives. Each company
submitted prototypes. Indian Railways designated these
prototypes the WDM-4 class and the WDM-2 class respectively.

Technologically the General Motors WDM-4 was superior to


ALCO's WDM-2, but Indian Railways required a transfer of
technology agreement that would allow these locomotives to be
manufactured in India. General Motors did not agree to the
transfer of technology agreement so the ALCo prototype was
selected for production. The first few prototype WDM-2 were
imported. After Diesel Locomotive Works (DLW) completed
construction of its factory in Varanasi, production of the
locomotives began in India. The first 12 locos were built using
kits imported from ALCo in the United States. After that DLW
started manufacturing the WDM-2 locomotives from their own
components. Since then over 2,800 locomotives have been
manufactured and the WDM-2 has become the most popular
locomotive in India.

However, even before the arrival of WDM-2 another type of


diesel locomotive was imported from ALCo beginning in 1957.
This locomotive was classified as WDM-1
.
Later a number of modifications were made and a few
subclasses were created. This includes WDM-2A, WDM-2B
and WDM-3A (formerly WDM-2C).

The WDM-2 is the diesel workhorse of the Indian Railways,


being very reliable and rugged.
Introduction to Tool Room

Tool shop had 6 sections for carrying out different operations.

1.Machine section-
Universal CNC machine which worked on 6 axis x,y,z,a,b and w.
Had tool of various sizes rangign from T1 to T24
Tool used in the machine was high speed steel.
Fluid used was soluble oil which is 1:20 ratio of oil and water

Universal CNC milling machine

2.Grinding section- Universal cnc grinding machine to perform the


grinding operations.
3.New development-In this the new parts were manufactured.

4.Breakdown section-Here the older components were machined to


put to use again.

5.Pneumatic section-Compressed air pressure was used to clean the


surfaces of componenets.

INTRODUCTION OF HEAVY WELDING SHOP:

In the DLW there are basically three type of welding used in HWS.
The welding quality of DLW is very high quality. After the machining
process we cant say that this piece is not single piece.
1. Submerged arc welding
2. Manual metal arc welding
3. MIG welding

SUBMERGED ARC WELDING:


In submerged arc welding the welding process will be covered with
the flux so that it will not react with oxygen and nitrogen. Because of
the versatility of the process and the simplicity of its equipment and
operation, shielded metal arc welding is one of the world's most
popular welding processes.
It dominates other welding processes in the maintenance and repair
industry, and though flux-cored arc welding is growing in popularity,
SMAW continues to be used extensively in the construction of steel
structures and in industrial fabrication. The process is used primarily
to weld ironand steels (including stainless steel) but aluminium,
nickel and copperalloys can also be welded with this method.

GMAW COMPONENTS:

1. DC or Direct Current power supply


2. Electrode or wire feed controller
3. Wire drive roller assembly
4. Shielding gas source (cylinder) & regulator
5. Manually held Gun & ground clamps
6. Wire reel
MIG WELDING:

MIG welding can be used for most types of metals; steel, stainless
steel, as well as aluminium. But welding aluminium is very different
from welding mild steel because aluminium is a metal that is
different from steel. So when we weld aluminium, we have to use
other parameters, other settings. Aluminium has a lower melting
temperature than mild steel, for example, so you should expect that
we should use a lower heat input but in spite of this. So we have to
use a higher local heat-input but a faster welding speed than with
steel to get good fusion and penetration. This sounds as if aluminium
welding is difficult, but it's not. The welding sets that we use adjust
the welding parameters automatically, so the welder can
concentrate on the welding operation, the movement of the welding
gun and the weld pool.

INTRODUCTION TO LIGHT MACHINE SHOP

This shop deals with the matching of various small components


required for the power pack unit such as, cam shaft, connecting rod,
liners, gears,levers, F.P. Support, Piston pin, nuts and bolts bushes,
various shafts etc.
INTRODUCTION TO MACHINE SHOP

Machine shop work is generally understood to include all cold-metal


work by which an operator, using either power driven equipment or
hand tools, removes a portion of the metal and shapes it to some
specified form or size. It does not include sheet metal work and
copper smithing. The function of all machine tools is to produce
metal parts by changing the shape, size, or finish of a piece of
material. The shape of a part made with a machine tool is limited by
the types of motion the tool can apply.
Standard machine tools are grouped in six basic classes:
1. LATHES
2. DRILLING MACHINES
3. SHAPERS
4. PLANERS
5. MILLING MACHINES
6. GRINDING MACHINES

SAFETY RULES FOR MACHINE TOOLS:

The following are general safety rules for any machine tool:
1. Gears, pulleys, belts, couplings, ends of shafts having keyways, and
other revolving or reciprocating parts should be guarded to a height
of 6 feet above the floor. The guards should be removed only for
repairing or adjusting the machine and must be replaced before
operating it.
2. Safety setscrews should be used in collars and on all revolving or
reciprocating members of the machine tool or its equipment.
3. Do not operate any machine tool without proper lighting.
4. Never attempt to operate any machine tool until you fully
understand how it works and know how to stop it quickly.
5. Never wear loose or torn clothing and secure long hair, since these
items can become caught in revolving machine parts. Ties should be
removed and shirt sleeves should be rolled up above the elbow.
6. Gloves should never be worn when operating machinery except
when absolutely necessary.
7. Always stop the machine before cleaning it or taking
measurements of the work piece.
8. Do not lubricate a machine while it is in motion. Injury to the
operator and damage to the machine may result from this practice.
9. Always wear safety glasses or goggles while operating machine
tools. Also, wear respiratory protection if operation creates
hazardous dust. All persons in the area where power tools are being
operated should also wear safety eye protection and respirators as
needed.
10. Know where tire extinguishers are located in the shop area and
how to use them.

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