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
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