SUMMER INDUSTRIAL TRAINING

ELECTRIC LOCOSHED
KANPUR NORTH CENTRAL RAILWAY
 PROJECT ON
GEAR FAILURE

Guided by:-N.P. SINGH(SSE) Submitted To:- MR. MO.ISRAR(SSE)

Submitted by:- VISHAL SINGH
ELECTRIC LOCO SHED
Branch:-MECHANICAL ENGINEERING
KANPUR
College:-P.S.I.T, KANPUR
 INTRODUCTION
Electric Loco Shed was set in 1965 by Railway Electrification
Organisation(8910 SQ. MTRS).

Locomotives in India consist of electric and diesel locomotives. Locomotives

are also called locos or engines.

An electric locomotive is a locomotive powered by electricity from overhead

lines, an on-board energy storage device such as a chemical battery or fuel cell.

Electricity is used to eliminate smoke and take advantage of the high efficiency
of electric motors.

3
 Initial cost Rs. 1.5 CRORES invested in setup of loco
Shed.
Its
main purpose is maintenance of :-
WAP4
WAP5
WAP7
WAG4 engines.
The present holding of the shed is 204 locomotives.
CLASSIFICATION
DIFFERENT DEPARTMENTS IN LOCO SHED
Energy auditing

Rotating parts failure

Air compressor failures

Degradation Processes(Mechanical-Gear Failure)

Degradation processes(Electrical)
 GEAR
A gear may be defined as any toothed member designed to transmit or
receive motion from another member by successfully engaging teeth.
 TYPES OF GEAR
Spurs Gear

Helical Gear

Bevel Gear

Worm Gear
 FAILURE IN GEAR SYSTEM

MODES OF
GEAR FAILURE

PITTING WEAR SCORING FRACTURE

 PITTING
A surface fatigue failure is mainly define as Pitting. Failure of this nature
depends on surface contact stress and number of stress cycles.

Pitting phenomenon is of two types:

Initial pitting
Destructive pitting
 WEAR
Wear is characterized by lapped surfaces that has problems on the
surfaces where the tooth contacts.

The main reason for corrosive wear is the chemical reaction of active
ingredients found in the lubricants.
 WEAR

CORROSIVE ABRASIVE
 CORROSIVE WEAR
This is a deterioration of the surface due to chemical reaction. It is
often caused by active ingredients in the lubricating oil, such as acid,
moisture, and extreme-pressure additives.
 ABRASIVE WEAR
When abrasive wear has taken place, contacting surfaces
show signs of a lapped finish, radial scratch marks or
grooves, or some other unmistakable indication that contact
has taken place.
 SCORING
Rapid wear resulting from a failure of the oil film due to overheating of the
mesh, permitting metal to metal contact. This contact produces removes
metal rapidly from the tooth surfaces.
 FRACTURE
Failure caused by breakage of a whole tooth or a substantial portion of a
tooth. This can result from overload or by cyclic stressing of the gear tooth
beyond the endurance limit of the material.

FATIGUE BREAKAGE
Gear tooth failure generally results from a crack originating in the root
section of the gear tooth. The whole tooth or a part of the tooth, breaks away.
 GEAR FAILURE ANALYSIS

NON
MECHANICAL MICROSTRUCTURE
DESTRUCTIVE CHEMICAL TEST
TEST TEST
TESTING
 NON DESTRUCTIVE TESTING

MAGNETIC
ULTRSONIC FLAW
PARTICLE ZYGLO TEST
DECTECTION
TESTING
 MAGNETIC PARTICLE TEST:-The magnetic particle (magna flux)
inspection method is used to detect cracks, laps, seams, inclusions and other types
surface of near surface discontinues in ferromagnetic materials. For carrying out the
test the fluorescent powder mixed in liquid is spread on the pinion surface

ULTRASONIC FLAW DECTECTION:- It uses high frequency sound

energy to conduct examinations and make measurements. Ultrasonic inspection can
be used for flaw detection/evaluation, dimensional measurements, material
characterization, and more.
 CHEMICAL TEST:-Quantitative chemical analysis of the helical pinion shaft is
carried out as per the standard procedure to validate the input data.

MECHANICAL TESTING:- Used to measure the hardness value at the

failure section. The required hardness value is 52 BHN. Absence of alloyed carbide
(chromium carbide) might be responsible for lowering of the hardness.

MICROSTRUCTURAL TEST :-Variation in the chemistry of the helical

pinion shaft and measured hardness value of the helical pinion shaft is correlated with
the metallographic examination of the failed component. Standard procedure of
polishing the samples using Emery papers Grade 0/1, 0/2, 0/3, 0/4 was followed
before micro examination
 CONCLUSION
My experience in Electric Loco Shed Kanpur was good. The work-
culture was remarkable and easy to adopt. The machines were
properly maintained and installed. Proper working of the machines
was done by the machine operators.
All the safety features were installed in the machines so that any

mishandling would not lead to accident. All the necessary equipment

and tools were present in the shop so that no interruptions in various
operations could take place and thus there is no loss of time.
 Any
Queries ?
Thank You!