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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