QM-C-7.1/BOGIE/0001 Inspection Plan(Check Sheet) · revision 0 qm-c-7.1/bogie/0001 page 1 of 24 ... metallurgical report of casnub, side frame 1.(a) ... metallurgical report of casnub,

Govt. of India

Ministry of Railways

Research Designs & Standards Organization

Manak Nagar, Lucknow-226 012

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Signature of firms Representative RDSO Representative

REVISION 0 QM-C-7.1/BOGIE/0001 Page 1 of 24

QM-C-7.1/BOGIE/0001

Inspection Plan(Check Sheet)

Item: CASNUB BOGIE

Specn. : WD-21-Casnub-22 NLB Bogie-93, Rev.2 of July’02

Amd.: 4 of Feb’2010

Drg. No. & Alt.:

Specn. : WD-17-Casnub-22 HS Bogie-92, Rev.3


Drg. No. & Alt.:

Specn. : WD-34-Casnub-22 HS(MOD-1)-2004


Drg. No. & Alt.:

Govt. of India




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1 Name of Manufacturer :

2 Date of offer :

3 RDSO File No :

4 Description of material :

5 Drawing and Alt. No :

6 Specification and grade :

7 P.O. No :

8 Total quantity Ordered :

9 Quantity Earlier passed :

10 Quantity now offered :

11 Consignee :

12 D.P :

1. Date of inspection

2. Quantity accepted

3. Quantity rejected

4. Balance order

Govt. of India




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METALLURGICAL REPORT OF CASNUB, SIDE FRAME

1.(A)CHEMICAL COMPOSITION (as per M&C Heat Clearance Register)

Heat No.

Casting

S.No.

Offer

Qty.Cast

Qty. Passed

Qty. Offered

Qty. Balanced

%Spec

C - 0.2-0.3

Mn - 0.6-1.1

Si - 0.3-0.5

S - 0.04max

P - 0.04max

S&P - 0.07max

(B) MECHANICAL PROPERTIES (AS PER THE REGISTER)

SPEC.N/mm2

UTS-500

YS-300

EL%-20min

RA%-30min

IMP-25 J

Date of

heat clearance

Govt. of India




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METALLURGICAL REPORT OF CASNUB, BOLSTER

1(A) CHEMICALCOMPOSITION (as per M & C Heat Clearance Register)

Heat no.

Casting

Sl. No.

Offer

Qty. Cast

Qty. passed

Qty. offered

Qty. Baln.

%age SPEC

C - 0.2-0.3

Mn - 0.6-1.1

Si - 0.3-0.5

S - 0.04max

P - 0.04max

S&P - 0.07max

(B) MECHANICAL PROPERTIES (as per the Register)

SPEC.N/mn2

UTS-500

YS-300

EL%-20min

RA%-30min

Imp 25 J

Govt. of India




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LUG ANALYSIS

Break one lug .one each from any S/frame and Bolster

M&C Test

RDSO Observation

Requirements SF Sl. No.

Heat No.

Bol. Sl. no.

Heat No.

SF Sl. No.

Heat No.

Bol Sl. No.

Heat No.

1. Chemical

C % 0.2 to 0.3%

Mn % 0.6 to1.1 %

Si % 0.3 to 0.5%

P% 0.04% max

S% 0.04 %max

S&P 0.07 %max

2 . Grain Size

4 Min.

3.Microstructure

Normalized

Final Observation:

1. Chemical Composition is as per STR.

2. Checked H.T. Register & confirmed that all the serial no. offered have been properly heat treated as per

H.T. register.

Govt. of India




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GAUGE FOR INDIVIDUAL CASTING – 5%

A) SIDE FRAME

S.NO DESCRIPTION DRAWING NO OBSERVATION

1 Central opening height gauge

(GO & NO GO )

WD – 98022 – S/2

2 Distance between friction liner &

dimension 470 mm

WD – 98022 –

S/3,3A

3 Bolster Anti Rotation control lug gauge

(GO & NO GO )

WD – 98022 – S/4

4 Column side width – cum off set check WD – 98022 – S/5

5 Central opening bottom distance gauge (

GO & NO GO )

WD – 98022 – S/6

6 Central opening bottom profile ( GO / NO

GO )

WD – 98022 – S/7

7 Spring plank seat profile gauge WD – 98022 – S/8

8 Pedestal roof profile & width check WD – 98022 – S/9

9 Pedestal jaw lug vertical profile check WD – 98022 – S/10

10 Pedestal jaw lug transverse profile check WD – 98022 – S/11

11 Pedestal jaw gap check ( GO/ NO GO ) WD – 98022 – S/12

12 Pedestal to key slot distance limit gauge WD – 98022 –

S/13,13A

13 Brake beam pocket size check WD – 98022 – S/20

14 Brake beam pocket Nib hole check WD – 98022 – S/21

15 Jaw opening centre marking device WD – 98022 – S/22

16 Rivet fit bolt hole position check gauge WD – 98022 – S/23

17 Column locater for side frame rivet WD – 98022 – S/24

18 Warp check gauge WX – 01093 D

19 Pedestal roof level distance check WX – 01093 E

20 Wheel base check cum pairing gauge WX – 01093 F

21 Central opening off set check WX – 01093 G

22 Brake beam location alignment check WX – 01093 H

Govt. of India




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GAUGE FOR INDIVIDUAL CASTING – 5 %

B) BOLSTER - 22 HS


1 Limit gauge for lateral lug gap ( GO/ NO

GO )

2 Snubber pocket width check ( GO/NO

GO)

3 Pocket & Lug alignment check (GO/NO

GO)

4 Lug Edge distance check (GO/NO GO)

5 Bolster top spring height gauge

6 Bolster top side bearer height check

7 Spring spigot location check

8 Snubber pocket angle check

9 Wedge wing profile check

10 Bolster spigot height check

11 Span squareness & co – axality check

12 Co – planarity check

C) COMPONENT WEDGE

1

Squareness & slope checking gauge WD – 097031 – S/16

2

Wedge height & centre point

location gauge

WD – 097031 – S/17

3

Wing profile & R – 1500 ( GO )

width check gauge

WD – 097031 – S/18

Govt. of India




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B) BOLSTER 22 HS (MOD – I)



GO )


GO)


GO)

4 Lug Edge distance check (GO/NO GO)

5 Bolster top spring height gauge

6 Bolster top side bearer height check

7 Spring spigot location check

8 Snubber pocket angle check

9 Wedge wing profile check

10 Bolster spigot height check

11 Span squareness & co – axality check

12 Co – planarity check

C) COMPONENT WEDGE

1

Squareness & slope checking gauge

2


location gauge

3


width check gauge

Govt. of India




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B) BOLSTER - 22NLB



GO )

WD – 97031 – S/2


GO)

WD – 97031 – S/3


GO)

WD – 97031 – S/4

4 Lug Edge distance check (GO/NO GO) WD – 97031 – S/5

5 Bolster top spring height gauge WD – 97031 – S/8

6 Bolster top side bearer height check WD – 97031 – S/9

7 Spring spigot location check WD – 97031 – S/10

8 Snubber pocket angle check WD – 97031 – S/11

9 Wedge wing profile check WD – 97031 – S/12

10 Bolster spigot height check WD – 97031 – S/13

11 Span squareness & co – axality check WX – 01093 AB

12 Co – planarity check WX – 01093 CC

C) COMPONENT WEDGE

1

Squareness & slope checking gauge WD – 097031 – S/16

2


location gauge

WD – 097031 – S/17

3


width check gauge

WD – 097031 – S/18

Govt. of India




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GAUGE FOR INDIVIDUAL CASTING – 5%

S.NO DESCRIPTION OBSERVATION

D TOP AND BOTTOM PIVOT CASTING

1 Inner dia check gauge

2 Rivet hole check gauge

3 Center pin hole check gauge

4 Depth check gauge

5 Bottom flange check gauge

6 Outer dia check gauge for c.p.top

7 Rivet hole check gauge for c.p.top

8 Center pin hole check gauge for c.p.top

9 Flange check gauge for c.p.top

E SIDE BEARER SEAT ( WD – 92093 – S/1 ) ALT - 7

ITEM - 2

1 Gauge for checking slot for side bearer seat

2 Gauge for checking 85.0 & 95.0 dim for side bearer seat

F SLIDE BLOCK ( WD – 92093 – S/1) ALT – 7 ITEM - 1

1 Slot for slide block

2 Hole centre gauge for side block with liner

3 Gauge for checking radius for slide block

F SIDE BEARER HOUSING (SK – 69594 ITEM - 4

1 Side bearer length gauge

2 Side bearer width gauge

3 Side bearer thickness gauge

4 Side bearer height gauge

G SIDE BEARER HOUSING (AAL – 021101)

1 Free height (142 +/-1)

2 Deflection 17 – 19 mm at load 2.7 Tone

Govt. of India




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A. OTHER CHECKS :

(a) Check any notch mark/cut mark/cross joint is visible in the vulnerable areas of the bogies.

(b) Whether any porosity , pinholes ,sand fusion ,excess sand sticking beyond acceptable limits are

notices.?

(c) Whether surface finish is with in acceptable limit.?

(d) Whether springs of same colour code are used in same bogie.?

(e) Whether prior permission for welding at critical zone is obtained ( if any welding is done)?

(f) (a) whether centre pivot top and side bearer – housing areas are machined?

(b) measure 15+/-2 mm dimension for two assembled bolsters and record dimensions.

(1) Casting serial no. (ii) Casting serial no.

(a) (a)

(b) (b)

Govt. of India




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INSPECTION SHEET FOR ASSEMBLED BOGIES

1. Serial Nos. of bogies offered

S.No

Bogie Sl. No

S.No Bogie Sl. No

1

S.F. NO . 1

B.S.NO. 1

2

S.F. NO . 1 B.S.NO. 1

S.F.NO . 2

S.F.NO . 2

3

S.F. NO . 1

B.S.NO. 1

4

S.F. NO . 1 B.S.NO. 1

S.F.NO . 2

S.F.NO . 2

5

S.F. NO . 1

B.S.NO. 1

6

S.F. NO . 1 B.S.NO. 1

S.F.NO . 2

S.F.NO . 2

7

S.F. NO . 1

B.S.NO. 1

8

S.F. NO . 1 B.S.NO. 1

S.F.NO . 2

S.F.NO . 2

9

S.F. NO . 1

B.S.NO. 1

10

S.F. NO . 1 B.S.NO. 1

S.F.NO . 2

S.F.NO . 2

Govt. of India




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LOAD CHART REPORT FOR 22 - NLB BOGIE – 22.9 T AXLE LOAD

S.F. NO.

BOL NO.

S.F. NO.

SL.

NO

DETAILS OF ITEM CHECKED SPECIFIED ( MM ) OBSERVED

1 a) Diagonal

b) Max diff. Between two diagonals

c) Max diff. Of half diagonals

a) 3018 +/-4.5

b) 3.5

c) 4.0

2 a) Wheel base

b) Max diff. Between two wheels base

c) Button no.

a) 2000+/-5

b) 2 but should be of same button.

c) 1,2,3,4,&5

3 a) Journal center

b) Max diff. Between two Journal

Centers

a) 2260 +/-1.5

b) 1

4 a) Dis. Between RL to bottom of

Side Frame

a) 165 +0/-5

5 Distance between side Bearer

Centers

1474±5 max

6 a) Gap bet. Side Frame & Spring

plank

b) Gap diff. bet. Side Frame Spring

plank seat & Spring plank

a) 0.5 max

b) 0.5 max

LOAD

TEST

LIGHT

BOGIE

HEIGHT

UNDER

6 TONE

HEIGHT

UNDER

40. 5 TONE

HEIGHT

UNDER

60. 8

TONE

HEIGHT

AFTER

REALEASE

LIGHT

BOGIE

HEIGHT

UNDER

6 TONE

HEIGHT

UNDER

40.5

TONE

HEIGHT

UNDER

60. 8

TONE

HEIGHT

AFTER

REALEA

SE

7 Center

pivot Ht

From RL

957

+3

-8

933

+3

-8

895

+3

-8

872

+ 3

-8

8 A) Side

Bearer

Ht From

RL

960

+6

-8

922

+6

-8

884

+ 6

-8

861

+ 6

-8

9 Spring

group

height

279±3

255 ± 3 217 ± 3 194 ± 3

Govt. of India




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LOAD CHART REPORT FOR 22 - HS BOGIE – 22.9 T AXLE LOAD

S.F. NO.

BOL NO.

S.F. NO.

SL.

NO


1 a) Diagonal



a) 3018 +/-4.5

b) 3.5

c) 4.0

2 a) Wheel base


c) Button no.

a) 2000+/-5


c) 1,2,3,4,&5

3 a) Journal center

b) Max diff. Between two J.C a) 2260 +/-1.5

b) 1


Side Frame

a) 165 +0/-5

5 Distance between Side Bearer

Centers

1474±5 max


plank



a) 0.5 max

b) 0.5 max

LOAD

TEST

LIGHT

BOGIE

HEIGHT

UNDER

6 TONE

HEIGHT

UNDER

40. 5 TONE

HEIGHT

UNDER

60. 8

TONE

HEIGHT

AFTER

REALEASE

LIGHT

BOGIE

HEIGHT

UNDER

6 TONE

HEIGHT

UNDER

40. 5

TONE

HEIGHT

UNDER

60. 8

TONE

HEIGHT

AFTER

REALEA

SE

7 Center

pivot Ht

From RL

965

+3

-8

932

+3

-8

892

+3

-8

870.5

+ 3

-8

8 A) Side

Bearer

Ht From

RL

921

+4.6

-9.6

881

+ 4.6

-9.6

859.5

+ 4.6

-9.6

9 Spring

group

height

284 ±3 251 ± 3 211 ± 3 189.5 ± 3

Govt. of India




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LOAD CHART REPORT FOR 22 - HS (MOD-I) BOGIE – 22.9 T AXLE LOAD

S.F. NO.

BOL NO.

S.F. NO.

SL.

NO


1 a) Diagonal



a) 3018 +/-4.5

b) 3.5

c) 4.0

2 a) Wheel base


c) Button no.

a) 2000+/-5


c) 1,2,3,4,&5

3 a) Journal center

b) Max diff. Between two J.C a) 2260 +/-1.5

b) 1


Side Frame

a) 165 +0/-5

5 Distance between Side Bearer

Centers

1474±5 max


plank



a) 0.5 max

b) 0.5 max

LOAD

TEST

LIGHT

BOGIE

HEIGHT

UNDER

7.332

TONE

HEIGHT

UNDER

40. 382

TONE

HEIGHT

UNDER

60. 954

TONE

HEIGHT

AFTER

REALEASE

LIGHT

BOGIE

HEIGHT

UNDER

7.332

TONE

HEIGHT

UNDER

40. 5382

TONE

HEIGHT

UNDER

60. 954

TONE

HEIGHT

AFTER

REALEA

SE

7 Center

pivot Ht

From RL

982. 5

+3/-8

932

+3\ -8

882.75

+3 / - 8

856. 75

+ 3 / - 8

8 A) Side

Bearer

Ht From

RL

989. 5

+4. 6/-

9. 6

918

+4. 6 /- 9.6

868.75

+ 4.6 / - 9.6

842. 75

+ 4.6 / - 9.6

9 Spring

group

height

290

+/-3

239. 5 ± 3 190. 25 ± 3 164.25 ± 3

11 Gap

between

top &

bottom

housing

(PU

SIDE

BEARE

R)

36±3 15. 5 ±3 15. 5 ±3 15. 5 ±3

Govt. of India




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LOAD TESTING REPORT

WD – 21 CASNUB – 22 – NLB / 22 HS / MOD - I

ITEM S.NO FREQUENCY

OF TESTING

LOAD

APPLIED

MAXIMUM

DEFLECTION

PERMANENT SET

MAX. AT CENTRE

SIDE FRAME

(Proof Test)

1 IN 50 117 T --------- 0.4 mm

Destruction Test 1 IN 100 or part

thereof for first

200 bogies there

after 1 in 1000

234 T

ITEM S.NO FREQUENCY

OF TESTING

LOAD

APPLIED

MAXIMUM

DEFLECTION

PERMANENT SET

MAX. AT CENTRE

BOLSTER

(Proof Test)

1 IN 50 117 T --------- 0.7 mm

Destruction

Test

1 IN 100 up to

200 bogies there

after 1 in 1000

254 T

Govt. of India




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DYE PENETRATION TEST

AGENT MAKE

EXPIRY DATE

CLEANER

PENETRANT

DEVLOPER

SL.NO ITEM DESCRIPTION

OF OPERATION

OBSERVATION REMARKS

Govt. of India




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WEIGHT OF SIDE FRAME AND BOLSTER

CASTING SR.NO.

ITEM NAME SPECIFIED

WEIGHT

(Kg)

OBSERVED

WEIGHTWEIGHT

( Kg )

Side frame (HS) 430 +/- 5.5%

Side frame (NLB) 430+/- 5.5%

Side frame (HS MOD-1) 430 +/- 5.5%

Bolster (HS) 565 +/-4.5%

Bolster (NLB) 565+/-4.5%

Bolster (HS-MOD-1) 565+/-4.5%

Govt. of India




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CHECK SHEET FOR CASNUB 22 HS(MOD-I) ASSEMBLED BOGIE FOR 22.9T AXLE LOAD

BOGIE NO:

SF

No.

SF

No.

BOL No.

Govt. of India




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BOGIE CLEARANCES

AS PER DRAWING

12.5 +1.5

2 +1.5

-0.0

4.5 +1.0

-1.5

4.5+1.0

-1.5

8 +3

-0.75

8 +3

-0.75

Govt. of India




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CHECK SHEET FOR CASNUB 22 NLB ASSEMBLED BOGIE FOR 22.9T AXLE LOAD

BOGIE NO:

SF

No.

SF

No.

BOL No.

Govt. of India




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BOGIE CLEARANCES

AS PER DRAWING

9 +1.5

2 +1.5

-0.0

4.5 +1.0

-1.5

4.5+1.0

-1.5

8 +3

-0.75

8 +3

-0.75

Govt. of India




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CHECK SHEET FOR CASNUB 22 HS ASSEMBLED BOGIE FOR 22.9T AXLE LOAD

BOGIE NO:

SF

No.

SF

No.

BOL No.

Govt. of India




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BOGIE CLEARANCES

AS PER DRAWING

12.5 +1.5

2 +1.5

-0.0

4.5 +1.0

-1.5

4.5+1.0

-1.5

8 +3

-0.75

8 +3

-0.75

Documents

QM-C-7.1/BOGIE/0001 Inspection Plan(Check Sheet) · revision 0 qm-c-7.1/bogie/0001 page 1 of 24 ... metallurgical report of casnub, side frame 1.(a) ... metallurgical report of casnub,