govt. of india ministry of railways research designs ... · ministry of railways research designs...

Govt. of India

Ministry of Railways

Research Designs & Standards Organisation

Manak Nagar, Lucknow-226 012

------------------------------------------------------------------------------------------------------------

Signature of Firm‟s Representative Signature of RDSO Inspector

REVISION 0 QM-C-7.1/Misc./0001 of 13

QM-C-7.1/MISC/0001

Inspection Plan(Check Sheet)

Item: Cartridge Taper Roller Bearing for BG Freight stock Specn. : AB/RB-39-2002 Rev.3 Amd 2 of Nov'08

Amd.:

Drg. No. & Alt.: Proprietary item

---------------------------------------------------------------------------------------------------------------------------

1. Firm’s Name

2. Description of Firm

3. Date of Inspection

4. Contract Details

(a) Contract No & Date

(b) Order Placing Authority

(c) Specification No.

(As mentioned in contract)

(d) Drawing N0.

(As mentioned in contract)

5. Quantity on order

6. Quantity offered for inspection on Date

7. Quantity Now passed

8. Quantity Rejected

9. Quantity passed earlier

10. Delivery Period

11. D.M No. DT & Qty of Side Frame Key

12. DM No. DT & Qty of Locking Plate

13. DM No. DT. & Qty of Axle End Cap Screw

14. DM No. DT. & Qty of N.J Adapter

15. Consignee

Govt. of India




------------------------------------------------------------------------------------------------------------



WAGON INSPECTION AND LIASION CELL

INSPECTION CHART FOR

CARTRIDGE TAPERED ROLLER BEARING 6x11 CLASS „E‟

BEARING ASSEBLY DATE

DRAWING No. BP 200923-1-NBC (NARROW) LOT SIZE-

(LATEST APPROVAL ALTERATION) UNIT – MM

SR

No.

CRITERIA/PARAMETER SPECIFICATION OBSERVED MEASURING

INSTRUMENT

FREQUENCY

QTY.CHKD ACCEPTED REJECTED

1 LATERAL END PLAY 0.508(0..20”) to 0.66(0.026”)

Lateral Play Fixture

LC=0.001

REF. NOTE (1)

2 BRG RADIAL RUNOUT & SIDE RUNOUT (INNER

RING/CONE ROTATING)

0.051 Magnetic stand Gauge

LC=0.001

REF. NOTE (1)

3 GREASE QUANTITY 455 ± 30 Welding machine

lc=10gm

REF. NOTE (2)

&

REF. NOTE (3)

4 CAGE FLAOT 0.432 ± 0.152 Float Checking

Gauge LC= 0.01

REF. NOTE (2)

&

REF. NOTE (3)

5 VISUAL INSPECTION FOR 1. SEAL DENTED

2. CUP BROKEN

/CRACKED 3. ANY OTHER DEFECT

IN ANY OTHER

COMPONENT

VISUAL

REF. NOTE (1)

6 MARKING ON EACH

BEARING 1. MANUFACTURER

TRADE NAME

2. COMPLETE DESIGNATION OF

BRG 3. YEAR AND MONTH

OF MFGR.

VISUAL

REF. NOTE (1)

7 WARPING AND PACKING 1. WARPING IN WAX

PAPER

2. PACK IN POLYETHENE

SHEET AND CARTONS

VISUAL

REF. NOTE (1)

CONCLUSION

LOT

ACCEPTED

REJECTED

SIGN

NOTES :

(1) SAMPLE CHECK : 1 BRG PER 1000 BRGS OR A PART THEREOF (2) ONLY 1 BRG FROM A LOT OF 1000 BGRS OR A PART THEREOF WILL BE DISASSEMBLED FOR GREASE QUANTITY, CAGE FLOAT,

CONE DIMENSIONS ETC.

(3) FOR CHECKING GREASE QUANTITY WEIGH THE BRG BEFORE DISASSEMBLY AND AFTER CLEANING AGAIN WEIGH

Govt. of India




------------------------------------------------------------------------------------------------------------






COMPONENT – CUP DATE-

DRAWING NO. BP 200257-NEI(PRODUCT ACCEPTANCE DRG) LOT SIZE – (LATEST APPROVAL ALTERATION) UNIT – MM

SR No

CRITERIA/PARAMETER SPECIFICATION OBSERVED MEASURING INSTRUMENT

FREQUENCY

NOS CHECKED ACCEPTED REJECTED

1 MATERIAL

REF NOTE(2)

STEEL TO AISI/SAE

4320H OR BMS – 931

(As per Specification no. SC – 3063 or SC – 3064)

Spectrometer 1 SAMPLE

PER MONTH

(CHEMICAL ONLY)

2 Hardness 58 to 63 HRC ON

FACES

Rockwell/vicker

hardness testing

machine

3 DIMENSIONS

WIDTH

A 163 + 0.050 / -0.254 HEIGHT GAUGEE

LC=0.01 5 PER VISIT

O. DIA

B 220.6625 + 0.127/-0 COMPARATOR

GAUGE LC=0.01 5 PER VISIT

COUNTER BORE

C 209 + 0.050/ -0.127 COMPARATOR


INCL.ANGLE

19 DEG – 56‟ – 30” REF. COMPARATOR

GAUGE L C=0.001 5 PER VISIT

TRK. DIA. 210.3374 = 0.127 / -0.254 5 PER VISIT

END CHAMFER 2.54 ± 0.3 5 PER VISIT

COUNTER BORE DEPTH 14.021 ± 0.28 5 PER VISIT

SEAL GROOVE DEPTH 0.53 ± 0.15 GO NOGO

GAUGE 5 PER VISIT

4 MARKING VISUAL 2 PER VISIT

5 PHOSPHATING 2 PER VISIT

6 RUST PREVENTIVE OIL

COATING

VISUAL 2 PER VISIT

7 SURFACE ROUGHNESS TRK OD(Ra)

1.13 Microns Max. TALLYSURF

MACHINE 2 PER VISIT

8 SURFACE ROUGHNESS TRK OD(Ra)

0.68 Microns max. TALLYSURF

MACHINE 2 PER VISIT

CONCLUSION LOT ACCEPTED REJECTED SIGN.

NOTE :

(1) INDEGNIOUS CUPS MADE FROM AISI/SAE 4320H STEEL MARKING 4(a) IS APPLICABLE.

(2) INDEGNIOUS CUPS MADE FROM BMS – 931 STEEL MARKING 4(b) IS APPLICABLE.

Bearing Assy/

Spare

Govt. of India




------------------------------------------------------------------------------------------------------------






COMPONENT – ROLLER DATE-

DRAWING NO. BP 200217-NEI (PRODUCT ACCEPTANCE DRG) LOT SIZE – (LATEST APPROVAL ALTERATION) UNIT – MM

SR

No

CRITERIA/PARAMETER SPECIFICATION OBSERVED MEASURING

INSTRUMENT

FREQUENCY


1 MATERIAL

REF NOTE(2)

STEEL TO AISI/SAE

4320H OR BMS – 931

(As per Specification no.

SC – 3063 or SC – 3065)


PER MONTH

(CHEMICAL

ONLY)


FACES

Rockwell/vicker

hardness testing

machine

10 PER VISIT

3 DIMENSIONS

SMALL O. DIA A 17.2405 (REF.) (REF NOTE 2)

COMPARATOR


LARGE O. DIA B 220.6625 + 0.127/-0 COMPARATOR


INCL. ANGLE C 209 + 0.050/ -0.127 COMPARATOR


ROLLER O. DIA VARIATION WITH IN

ONE CONE ASSEMBLY

D 19 DEG – 56‟ – 30” REF. COMPARATOR


LENGTH E 41.958 (REF.) COMPARATOR


LENGTH VARIATION

WITHIN ONE CONE ASSEMBLY

H 0.508(MAX)

(REF NOTE 1)

COMPARATOR


OVALITY J 0.005 COMPARATOR


4 SURFACE ROUGHNESS O. DIA (Ra)

0.3 Micron max TALLYSURF

MACHINE 2 PER VISIT 2 PER VISIT

5 MARKING / IDENTIFICATION OF INDENIOUS

ROLLERS (AT LARGE END FACE) (a) DOUBLE DIMPLES FOR ROLLERS MADE FROM

AISI/SAE 4320H STEEL

SINGLE DIMPLE WITH “-“ MARK FOR ROLLRS MADE FROM BMS – 931 STEEL

VISUAL


NOTE :

(1) TO BE CHECKED FROM GRADE ROLLER LOTS OR CONE ASSEMBLIES PRIOR TO CLOSE-IN

(2) ROLLERS DIA AS CHECKED ON COMPOSITE GAUGE SHOULD BE WITH IN DEG TOL + 0.075/0.060 AND DIFFERENCE OF READINGS

AT BOTH ENDS SHOULD NOT EXCEED 0.00635 MM

Bearing Assy/

Spare

Govt. of India




------------------------------------------------------------------------------------------------------------






COMPONENT – CONE DATE-


SR No


FREQUENCY


1 MATERIAL

REF NOTE(2)

STEEL TO AISI/SAE

4320H OR BMS – 931

(As per Specification no. SC – 3063 or SC – 3063)


PER VISIT

ONLY)


FACES

Rockwell/vicker

hardness testing

machine

3 DIMENSIONS

BORE A 144.450+0.025/-0 COMPARATOR

GAUGEE LC=0.01 10 PER VISIT

LARGEFLANGE O. DIA B 177.622 DIA Mic. LC=0.01 10 PER VISIT

WIDTH C 58.725 +0.076/-254 HEIGHT GAUGE

LC=0.01 10 PER VISIT

TRK.INCLINATION ANGLE

D 16DEG. –24‟(REF) BLUEGAUGE L

C=0.001 10 PER VISIT

BORE RADIUS (LARGE

END)

E 1.6 RAD 10 PER VISIT

OUT OF ROUND (BORE) 0.0125 COMPAARTOR


4 TRACK DIAMETER (COMPARE WITH MASTER)

170.795 REF. COMPARATOR


5 SURFACE ROUGHNESS

BORE(Ra)

1.13 MICRON Tallysurf Machine 2 PER VISIT

6 SURFACE ROUGHNESS TRK(Ra)

0.55MICRON MAX Tallysurf Machine 2 PER VISIT



NOTE :

(3) INDEGNIOUS CONES MADE FROM AISI/SAE 4320H STEEL MARKING 7(a) IS APPLICABLE. (4) INDEGNIOUS CONES MADE FROM BMS – 931 STEEL MARKING 7(b) IS APPLICABLE.

Bearing Assy/

Spare

Govt. of India




------------------------------------------------------------------------------------------------------------






COMPONENT – CAGE DATE-


SR No


FREQUENCY NOS CHECKED ACCEPTED REJECTED

1 MATERIAL

REF NOTE(2)

AISI/SAE 1008 Spectrometer VENDOR‟S

RECORD

(REF. NOTE 1)

2 DIMENSIONS

WIDTH A Vernier Caliper‟s

LC= 0.02 5 PER VISIT

SMALL BORE B Vernier Caliper‟s


LARGE O. DIA C Vernier Caliper‟s


ROLLER POCKET LENGTH

Vernier Caliper‟s

LC= 0.02

CONCLUSION LOT ACCEPTED REJECTED SIGN

NOTE : (1) ONCE IN TWO MONTH CROSS CHECK THE TESTS.

Bearing Assy/

Spare

Govt. of India




------------------------------------------------------------------------------------------------------------



WAGON INSPECTION AND LIAISON CELL


COMPONENT-WEAR RING DATE

DRAWING NO.bp-201313- NEI (PRODUCT ACCEPTANCE DRG) LOT SIZE-

(LATEST APPROVED ALTERATION)

UNIT -MM

Sr

No

CRITERIA/PARAMETER SPECIFIATION OBSERVED MEASURING

INSTRUMENT

FREQUENCY

NOS.CHKD ACCEPTED REJECTED

1. MATERIAL AISI/SAE C1050 Spectrometer 1 PER VISIT (CHEMICAL)

2. HARDNESS AT SEAL LIP

CONTACT AREA

50 TO 62 HRC

AFTER INDUCTION

HARDENING

Rockwell/Vicker

hardness testing

Machine

2 PER VISIT

3.

DIMENSIONS

SMALL BORE A 144.4625+0.038/-0 Comparator Gauge


O.DIA B 157.226±0.050 Comparator Gauge


WIDTH C 42.672+0.127/-0.254 Height Gauge


TAPER ON O.DIA D 0.050 MAX Comparator Gauge


I.D.TAPER 0.0127 MAX Comparator Gauge


CONCENTRICITY

SMALL BORE TO O.D

E 0.100 MAX (TIR) Gauge & Magnetic

Stand LC=0.001 2 PER VISIT

FACE PARALLELISM 0.025 MAX (tir) Height Gauge


OUT OF ROUND O.D

&I.D

0.025 MAX (tir) Comparator Gauge



5 SURFACE ROUGHNESS O.DIA

(RA0

0.68 Micron MAX Tallysurf Machine 2 PER VISIT

6 SURFACE ROUGHNESS

SMALL BORE (RA0

1.13 Microns MAX Tallysurf Machine 2 PER VISIT

7 GROUND STRAIGHT PORTION ON WEAT RING

O.DIA MUST BE FREE FROM TOOL DRAGS,

UNGROND AREAS, NICKS, SPIRAL PATTERN, GALLING & RAISED EDGES

2 PER VISIT


NOTE (1) ALL DIAMETER TOLERATNCES ARE AVERAGE INDICATOR READINGS UNLESS OTHERWISE NOTED

Bearing Assy/

Spare

Govt. of India




------------------------------------------------------------------------------------------------------------



WAGON INSPECTION AND LIAISON CELL INSPECTIN CHART FOR


COMPONENT- SPACER DATE

DRAWING NO.pe/hm-129848-XA LOT SIZE-


UNIT -MM

Sr

No

CRITERIA/

PARAMETER

SPECIFIATION OBSERVED MEASURING

INSTRUMENT

FREQUENCY


1. MATERIAL LOW CARBON STEEL

ROLLED RING TO IS:2062

Gr-1 OR LOW CARBON HOT FINISHED

SEAMLESS TUBING TO

IS:3601- 1984 Gr-HFS-240

Spectrometer 1 PER VISIT

(CHEMICAL ONLY)

2. DIMENSINS A 156.37 NOM ±0.25 Vernier Calipers

LC=0.02 5 PER VISIT

B 144.86+0.66/- Vernier Calipers

LC=0.02 5 PER VISIT

C 38.86 NOM Height Gauge


D 0.8 MIN Vernier Calipers

LC=0.02 5 PER VISIT

WIDTH VARIATION E 0.050 MAX Height Gauge


FACE FLATNESS F 0.025 MAX Height Gauge



4 SURFACE ROUGHNESS

AT FACES (Ra)

1.25 Micron MAX Visual 5 PER VISIT


Bearing Assy/

Spare

Govt. of India




------------------------------------------------------------------------------------------------------------



WAGON INSPECTION AND LIAISON CELL INSPECTION CHART FOR

CARTRIDGE TAPERED ROLLER BEARING 6X11 CLASS „E‟

COMPONENT-BACKING RING DATE

DRAWING NO.PE/E-115-NBC (PRODUCT ACCEPTANCE DRG) LOT SIZE-


UNIT –MM

Sr

No


INSTRUMENT

FREQUENCY


1. MATERIAL AISI 1040STEEL OR

IS:1875 CLASS 4 OR

En 8D to BS:470

Spectrometer PER VISIT

1 PHYSICAL

2 CHEMICAL

2. HARDNESS 170 BHN (MIN) Rockwell/Vicker

hardness testing

Machine

2 PER VISIT

3. DIMENSIONS A 198.76± 0.127 Vernier Calipers

LC=0.01 5 PER VISIT

B 178.511/178.384 Go No Go Gauge 5 PER VISIT

D 46.0+0/0.8 Vernier Calipers

LC=0.01 5 PER VISIT

E 39.37/39.12 Go No Go Gauge 5 PER VISIT

F 30.40/30.15 Go No Go Gauge 5 PER VISIT

K 157.124 /156.972 Go No Go Gauge 5 PER VISIT

FILLET RADIUS R

1

38.1+1.5/-0 Go No Go Gauge 5 PER VISIT

OUT OF ROUNDNESS “B‟

DIA

NOT TO EXCEED

0.038

Comparator Gauge


4 ECCENTRICITY „B‟ DIA TO “K” DIA

0.080 max Eccentricity Gauge

LC=0.01 5 PER VISIT

5 MARKING

VISUAL 5 PER VISIT

6 SURFACE ROUGHNESS WEAR RING ABUTMENT FACE &

FILLET RADIUS R1 (Ra)

2.5 Micron Visual 2 PER VISIT

6 SURFACE ROUGHNESS SMALL BORE (RA0

1.13 Microns MAX Tallysurf Machine 2 PER VISIT

7 GROUND STRAIGHT PORTION ON WEAT RING O.DIA

MUST BE FREE FROM TOOL DRAGS, UNGROND

AREAS, NICKS, SPIRAL PATTERN, GALLING & RAISED EDGES

2 PER VISIT


Bearing Assy/

Spare

Govt. of India




------------------------------------------------------------------------------------------------------------






COMPONENT-AXLE AND CAP (SHROUDED) DATE

DRAWING NO.PE/CP-201747-F-NBC (PRODUCT ACCEPTANCE DRG) LOT SIZE- (LATEST APPROVED ALTERATION)

UNIT –MM

Sr

No


INSTRUMENT

FREQUENCY


1. MATERIAL DUCTILE IRON

CASTING TO ASTM

A536 Gr 80-55-06 OR IS:1865 Gr SG500/7


1 PHYSICAL

(PROPETIES AS PER NOTE 4 OF

DRG

2. HARDNESS (CASTING) 187 TO 255 BHN Rockwell/Vicker

hardness testing

Machine

2 PER VISIT

3. DIMENSIONS

157.58±0.08

Go No Go Gauge

5 PER VISIT

147 (NOM) Vernier Calipers

LC=0.01 5 PER VISIT


LC=0.01 5 PER VISIT


LC=0.01 5 PER VISIT


LC=0.01 5 PER VISIT

28.68± 0.38 Vernier Calipers

LC=0.01 5 PER VISIT

14.58 (NOM) Vernier Calipers

LC=0.01 5 PER VISIT


LC=0.01 5 PER VISIT


LC=0.01

98.425±0.3 PCD Gauge

4 HOLE DIA 27±0.8 (CAST)

27±0.4 (DRILLED)

Vernier Calipers

LC=0.01 5 PER VISIT

5 MARKING

VISUAL 5 PER VISIT

6 SURFACE ROUGHNESS

WEAR RING LOCATING DIA & ABUTMENT FACE

6.3 Micron max Visual 2 PER VISIT

CONCLUSION

LOT

ACCEPTED REJECTED SIGN

Bearing Assy/

Spare

Govt. of India




------------------------------------------------------------------------------------------------------------






COMPONENT- SIDE FRAME KEY DATE

DRAWING NO.SK-69594 LOT SIZE- (LATEST APPROVED ALTERATION)

UNIT –MM

Sr

No


INSTRUMENT

FREQUENCY


1. MATERIAL STEEL FORGING

TO IS:1875 CLASS 4


1 PHYSICAL 2.CHEMICAL

2. DIMENSIONS A 32+1.5/-0

Go No Go Gauge

5 PER VISIT

C 85 (NOM) Vernier Calipers LC=0.02

5 PER VISIT

D 54+1.5/-0 Go No Go Gauge 5 PER VISIT

E 19 (NOM) Vernier Calipers

LC=0.02

5 PER VISIT

J 21+1.0/-0 Vernier Calipers LC=0.02

5 PER VISIT

K 24 (NOM) Vernier Calipers

LC=0.02

5 PER VISIT

L 25.5+1.5/-0 Vernier Calipers

LC=0.02

5 PER VISIT

M 19 (NOM) Vernier Calipers

LC=0.02

5 PER VISIT

3 MARKING

VISUAL 5 PER VISIT

CONCLUSION

LOT

ACCEPTED REJECTED SIGN

Bearing Assy/

Spare

Govt. of India




------------------------------------------------------------------------------------------------------------






COMPONENT- LOCKING PLATE DATE

DRAWING NO.SK-69594 LOT SIZE- (LATEST APPROVED ALTERATION)

UNIT –MM

Sr

No


INSTRUMENT

FREQUENCY


1. MATERIAL IS:513 Gr-D (1994) Spectrometer PER VISIT

1 PHYSICAL 2.CHEMICAL

2 DIMENSIONS

PLATE THICKNESS 1.6±0.11 Vernier Calipers

LC=0.02 5 PER VISIT

PCD OF BOLT HOLES 96.84±0.250 PGD Gauge 5 PER VISIT

118.3±0.8 Vernier Calipers

LC=0.02 5 PER VISIT

130.±0.8 Vernier Calipers

LC=0.02 5 PER VISIT

3 SURFACE PROTECTION VISUAL 5 PER VISIT

4 MARKING 6X11 E NBC

VISUAL 5 PER VISIT


Bearing Assy/

Spare

Govt. of India




------------------------------------------------------------------------------------------------------------




INSPECTION CHART FOR NARROW JAW ADAPTER

S.N

O.

CHARACTERISTICS ACCEPTANCE STANDARD INSPECTION METHOD (AS PER AAR M-924) AQL

%

NOS.

CHK

D.

NOS

ACC

NOS

REJ.

REMARK

S

1

2.

3.

4.

5.

6.

7.

8.

9.

10

11.

12.

13.

14.

15.

16.

17.

18.

19.

CENTRALITY

EQUAL THICKNESS

BEARING THRUST SHOULDER

BORE DIA CHORDAL

CONCENTRICITY AND TAPER

GAUGE

BEARING THRUST

SHOULDER DEPTH



CHAMFER ANGLE


CHAMFER LOCATION

M/C SURFACE FINISH

PEDESTAL FIT

OVER ALL WIDTH

BODY WIDTH

OUTER THRUST LUG SPACING

TOP THRUST LUG SPACING

CROWN RADIUS

OUTER THRUST LUG HEIGHT

GAUGE

MATERIAL

HARDNESS

TO BE WITHIN 1.6

0.5 MAX.

13.5 +0.40/-2.00

110.5+0.015/-0.112

MAX ALLOWABLE VARIATION

FOUR INDICATION 0.038

10.11+0/-0.914

166.7+01.6/-0

35+2.0+-2.0

4.76+0.77960

6.3 MICRONS

225.56+0.50/-2.00

181+2.00/-0

97+4.00/-0.80

155.5+2.00/-0

R1524+0/-508

21.0*1.6/-0.7

CENTRALITY GAUGE

EQUAL THICKNESS GAUGE

BEARING THRUST SHOULDER THICKNESS

GAUGE

CHORDAL GAUGE

CONCENTRICITY TAPER

GAUGE

BEARING THRUST

SHOULDER DEPTH

BEARING THRUST SHOULDER SPACING

AND RELIEF GAUGE

BEARING THRUST SHOULDER CHAMFER

ANGLE GAUGE

BEARING THRUST SHOULDER CHAMFER

ANGLE GAUGE COMPARATOR

PEDESTAL FIT GAUGE

OVER ALL WIDTH GAUGE

BODY WITH GAUGE

OUTER THRUST LUG SPACING GAUGE

TOP THRUST LUG SPACING GAUGE

CROWN RADIUS GAUGE

OUTER THRUST HEIGHT

2.5

4

10

1.5

1.5

2.5

2.5

2.5

10

10

0.1

10

1.5

10

10

10

2.5

With Bearing

Assy/ Spare

Govt. of India




------------------------------------------------------------------------------------------------------------



govt. of india ministry of railways research designs ... · ministry of railways research designs...

Documents