BG Wagon Underframe Design
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Questions and Answers

What is the primary function of the underframe in a wagon?

  • To provide aesthetic appeal to the wagon
  • To support the load and distribution of forces (correct)
  • To enhance the speed capabilities of the wagon
  • To facilitate the assembly of different wagon components

Which of the following components is NOT a main member of a conventional BG wagon underframe?

  • Sole bars
  • Cross bars
  • Axle (correct)
  • Head stock

What role do gusset plates and knees serve in the underframe's construction?

  • They impart additional strength to the joints (correct)
  • They provide aesthetic design features
  • They add weight to the underframe
  • They are used to create additional loading surfaces

How is the load transferred to the bogie frame in bogie wagons?

<p>By means of a pivot arrangement (A)</p> Signup and view all the answers

What determines the permissible wheel base of a bogie wagon?

<p>The type of loading pattern and quantum (C)</p> Signup and view all the answers

Which aspect is critical in designing the underframe to handle buffing loads?

<p>The arrangement and distribution of cross members (A)</p> Signup and view all the answers

In the context of the underframe design, what does the term 'loading per meter' refer to?

<p>The amount of load supported by each meter of the underframe (C)</p> Signup and view all the answers

What is primarily used for joining underframe members in modern wagons?

<p>Welding (B)</p> Signup and view all the answers

What feature is added to under-frames during manufacturing to prevent sagging under load?

<p>Initial camber (D)</p> Signup and view all the answers

Which term describes the strong cross members found in bogie wagons?

<p>Bolsters (D)</p> Signup and view all the answers

What is the permitted tolerance for the inside length of riveted wagons?

<p>+5 mm and -5 mm (D)</p> Signup and view all the answers

Which of the following is NOT a permitted tolerance in new wagon construction for inside dimensions?

<p>+4 mm for inside width (D)</p> Signup and view all the answers

What is essential for the under-frame and all its members to ensure quality and safety?

<p>True and square conformance (D)</p> Signup and view all the answers

What is the maximum permitted difference between the diagonals of the under-frame?

<p>5 mm (B)</p> Signup and view all the answers

What aspect of the under-frame is critical to comply with during manufacturing tolerances?

<p>Manufacturing precision (C)</p> Signup and view all the answers

What was the joining method used in earlier wagons before welding was adopted?

<p>Riveting (C)</p> Signup and view all the answers

What material is primarily used for sole bars in most bogie wagons?

<p>ISMC-250x9.0 web channel of copper bearing mild steel (D)</p> Signup and view all the answers

What is a necessary condition for patching a sole bar according to IRCA standards?

<p>Each patch must be riveted to the sole bar web and flange. (D)</p> Signup and view all the answers

What method is used to repair slightly bent sole bars?

<p>Local heating and straightening. (A)</p> Signup and view all the answers

Where does damage to sole bars typically occur?

<p>Adjacent to head stock stanchions at the door location. (C)</p> Signup and view all the answers

Which of the following statements about patch repairs is correct?

<p>When inner and outer patches cannot be fitted, only one may be used. (C)</p> Signup and view all the answers

What is the maximum allowable tolerance for the length of a barrel measured over the centre of the two dished ends?

<p>+10 mm/-3 mm (A)</p> Signup and view all the answers

Which of the following is NOT a tolerance for the distance between door center line to the center line of door hinge?

<p>+2 mm (D)</p> Signup and view all the answers

What is the tolerance for the door length?

<p>+5 mm (B)</p> Signup and view all the answers

What is the tolerance for the distance between bogie pivot centers when riveted?

<p>+3 mm (C)</p> Signup and view all the answers

How much is the tolerance for the distance between stanchions at the body side?

<p>+3 mm (A)</p> Signup and view all the answers

Which of the following indicates a negative tolerance for coupler height from the bogie top pivot when bogies are provided as free supply items?

<p>-3 mm (A)</p> Signup and view all the answers

What is the tolerance for the distance between bogie pivot centre and adjacent headstock?

<p>-2 mm (B), +2 mm (C)</p> Signup and view all the answers

What is the tolerance for the door opening, both vertical and horizontal?

<p>-3 mm (A)</p> Signup and view all the answers

What is the tolerance for door width?

<p>+3 mm (D)</p> Signup and view all the answers

What tolerance applies to the distance between the bogie pivot centers when welded?

<p>+5 mm (A)</p> Signup and view all the answers

What is the plate thickness of the Cross Bar?

<p>5/8 mm (B)</p> Signup and view all the answers

Which component of the wagon has a specified thickness of 10 mm?

<p>Head Stock (B)</p> Signup and view all the answers

Which type of wagon is associated with the underframe arrangement shown in Fig. 5.4?

<p>Type BOXNHL (B)</p> Signup and view all the answers

What is the main structural feature associated with the underframe of a bogie open wagon?

<p>Bogie centres (D)</p> Signup and view all the answers

Which figure represents the underframe of the Bogie Covered Wagon Type 'BCNHL'?

<p>Fig. 5.5 (B)</p> Signup and view all the answers

What is the specified length over the bogie centres in the underframe content?

<p>6524 mm (B)</p> Signup and view all the answers

What is not a part of the underframe components mentioned?

<p>Wheel Assembly (C)</p> Signup and view all the answers

Which figure depicts the arrangement for the Bogie Open Wagon Type 'BOXN'?

<p>Fig. 5.3 (C)</p> Signup and view all the answers

What is the primary focus of Chapter 5 in the document?

<p>Underframe structures (D)</p> Signup and view all the answers

Which of the following types is NOT mentioned in the underframe content?

<p>BOGIE (C)</p> Signup and view all the answers

What contributes to the overall strength and load distribution of the wagon underframe?

<p>Diagonal members and gusset plates (C)</p> Signup and view all the answers

Which statement accurately reflects the design considerations for an underframe?

<p>The pattern of loading directly influences the underframe dimensions. (C)</p> Signup and view all the answers

Which underframe member primarily provides strength against diagonal deflections?

<p>Gusset plates (B)</p> Signup and view all the answers

What is the role of the bolster in a conventional underframe design?

<p>It provides lateral stability to the bogie frame. (C)</p> Signup and view all the answers

How is excessive load on an individual member of the underframe controlled?

<p>Uniform distribution of loads across all members (C)</p> Signup and view all the answers

Which of the following components are integral for absorbing and distributing buffing loads?

<p>Gusset plates and knees (C)</p> Signup and view all the answers

What is the main purpose of using rolled/CRF sections in the construction of underframe members?

<p>To enhance the load-bearing capacity and structural integrity (A)</p> Signup and view all the answers

What is a required characteristic of patches used for repairing sole bars?

<p>They must be riveted to the sole bar web and flange. (A)</p> Signup and view all the answers

What is the preferred method for repairing cracks that extend to the webs of sole bars?

<p>Electric welding with proper support patches. (B)</p> Signup and view all the answers

In which scenario may only an outer patch be fitted on a sole bar?

<p>When inner and outer patches cannot be fitted due to other fittings. (C)</p> Signup and view all the answers

What type of steel is used for sole bars on BOXNCR wagons?

<p>IRSM-41 carton steel. (D)</p> Signup and view all the answers

What material thickness is specified for the outer patch covering a crack?

<p>At least 10 mm. (B)</p> Signup and view all the answers

What is the tolerance for the length of a barrel measured over the centre of the two dished ends?

<p>+10mm/-3mm (C)</p> Signup and view all the answers

When considering the door length in wagon design, which of the following tolerances is accurate?

<p>+5mm (D)</p> Signup and view all the answers

What is the permitted tolerance for the distance between the bogie pivot centres in a riveted design?

<p>+2mm (D)</p> Signup and view all the answers

Which tolerance applies to the coupler height from rail level in the case where the bogies are fabricated by the wagon builder?

<p>+0mm (C)</p> Signup and view all the answers

What is the tolerance for the body side distance between stanchions?

<p>+3mm (B)</p> Signup and view all the answers

Which of the following tolerances is correct for the vertical or horizontal door opening?

<p>-3mm (D)</p> Signup and view all the answers

What tolerance applies to the distance from the door centre line to the centre line of the door hinge?

<p>+1.5mm (C)</p> Signup and view all the answers

What is the tolerance for the distance between the stanchions at the body end?

<p>+1.5mm (B)</p> Signup and view all the answers

Which tolerance is stated for the coupler height from the bogie top pivot when bogies are provided as free supply items?

<p>-3mm (D)</p> Signup and view all the answers

What is the specified thickness of the bolster in the underframe components?

<p>10/12 mm (B)</p> Signup and view all the answers

Which wagon type is illustrated in Fig. 5.5?

<p>Bogie Covered Wagon Type 'BCNHL' (B)</p> Signup and view all the answers

Which component of the wagon has a specified thickness of 10 mm?

<p>Head Stock (A)</p> Signup and view all the answers

What does Fig. 5.2 show in relation to bogies?

<p>Underframe of the Bogie Open Wagon (C)</p> Signup and view all the answers

In which figure is the arrangement for the Bogie Open Wagon Type 'BOXNHL' presented?

<p>Fig. 5.3 (C)</p> Signup and view all the answers

What is a unique feature of the underframe shown in Fig. 5.4?

<p>It is for a Bogie Covered Wagon (D)</p> Signup and view all the answers

What is identified as the 'length over heads' in the content?

<p>10713 mm (C)</p> Signup and view all the answers

Which term refers to the specific distance measured between bogie pivot centers?

<p>Bogie Base (D)</p> Signup and view all the answers

Which of the following is NOT mentioned as a feature of the underframe arrangement in the manual?

<p>Adjustable heights (D)</p> Signup and view all the answers

What is the purpose of providing a positive camber in the underframe of a bogie wagon?

<p>To prevent sagging after loading in service. (A)</p> Signup and view all the answers

What modification was requested by RDSO to address issues observed in BRN wagons?

<p>Modifications to prevent breakage of fixed ends and sagging. (A)</p> Signup and view all the answers

During periodic overhauls, what is a common requirement for damaged head stock pressings?

<p>They should be stripped, straightened, and refitted. (C)</p> Signup and view all the answers

What action is recommended when cracks develop at the side bearer location on the underframe bolster bottom flange?

<p>Follow the repair procedures provided in RDSO technical pamphlets. (C)</p> Signup and view all the answers

What is the specification for repairing damaged centre sills on bogie wagons?

<p>Repairs should be done according to RDSO Drg.No.WD-99031-S-1. (D)</p> Signup and view all the answers

What is the consequence of not addressing damages to the underframe during periodic overhauls?

<p>Increased risk of serious failures while in service. (A)</p> Signup and view all the answers

What should be kept in stock to efficiently handle head stock pressing repairs?

<p>Spare head stock pressings. (B)</p> Signup and view all the answers

What design aspect of bogie wagons makes them susceptible to cracks at certain locations?

<p>The length of the underframe compared to four wheelers. (B)</p> Signup and view all the answers

In case of significant damage, what is the recommended action for the head stock pressings?

<p>Replace the damaged ones with new pressings. (D)</p> Signup and view all the answers

What is a critical procedure for re-cambering of bogie wagons as per the guidelines?

<p>Following the procedure in RDSO pamphlet No.G-107. (C)</p> Signup and view all the answers

Flashcards

Underframe of a wagon

The main load-bearing structure of a wagon, influencing its size, design, and loading capacity.

Wagon underframe design

Heavily reliant on the wagon type, load pattern, track conditions, and permissible wheelbase.

BG wagon underframe

The specific underframe design for broad gauge (BG) wagons, with key members like sole bars, head stocks, and longitudinals.

Sole bars and Head Stocks

Main longitudinal members that form the outer framework of a wagon underframe

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Cross members

Supporting structural components that span across a wagon underframe.

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Gusset plates and knees

Reinforcing components at crucial joints in the underframe, boosting strength & load distribution.

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Load transfer in bogie wagons

The method by which weight is transferred from the underframe of the wagon to the bogie frame using pivot arrangements.

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Underframe Members

Components forming the base structure of a wagon.

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Joining Methods

Welding and riveting are ways to connect rail wagon underframe members.

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Bolsters

Stronger cross-members in bogie wagons for fitting upper pivot castings.

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Camber

Initial curve given to underframes during manufacturing to prevent sagging.

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Tolerance (Inside Length)

+5mm/-5mm (riveted), +7mm/-3mm (welded) for the inside length of the underframe.

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Tolerance (Inside Width)

+3mm and -3mm.

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Tolerance (Inside Height)

+3mm and -3mm.

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Diagonal Tolerances (Underframe)

5mm difference between wagon diagonal measurements allowed.

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Diagonal Tolerances (Body)

5mm (sides), 5mm (ends), 4mm (doors) difference in body diagonal measurements allowed.

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Manufacturing Tolerances

Acceptable deviations in measurements during construction for wagon parts;underframe, body, doors.

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Cross Bar

A 5/8 mm plate component of the wagon's undercarriage.

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Bolster

A 10/12 mm plate part of the wagon's underframe, providing support.

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Head Stock

A 10 mm pressing component on the underframe.

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Centre Sill

A central support structure of the wagon.

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Bogie Centres

The distance between bogies, measured as 6524

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Overhead Stock

A component above the underframe, 9784 in length

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Open Bogie (Non-Coupler)

A type of wagon bogie arrangement without coupler.

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Boxn Type Wagon

A type of open wagon.

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Length Over Transition

The length measurement of the wagon exceeding the transition.

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Underframe Arrangement

The layout of the wagon's underlying support components.

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Door Tolerance

Acceptable variations in door dimensions from the specified values.

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Bogie Pivot Centres Distance

The allowed range for the distance between the pivot points of bogies.

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Stanchion Distance (body side)

The permissible variation in distance between stanchions on the body side of a wagon.

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Door Opening Tolerance

The acceptable range for the vertical or horizontal opening of a door.

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Door Length Tolerance

The acceptable deviation in the length of the door.

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Door Width Tolerance

The allowable range for the width of a door.

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Door Hinge to Centre Line

The permissible deviation in the distance between the door's center line and the hinge center line.

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Coupler Height (Wagon Builder)

The allowable range for the coupler height from the rail level when the bogies are made by the same wagon builder.

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Coupler Height (Free Supply)

The allowable range for the coupler height from the bogie top pivot when the bogies are provided separately.

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Barrel Length Tolerance

The acceptable variation from the specified length of a pressure tank wagon barrel, measured across the center of the dished ends.

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Sole Bar Repair Methods

Methods for repairing damaged sole bars in wagon underframes, including cutting and grafting, welding cracks, and straightening bent bars.

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Sole Bar Patching Rules

Repair patches for sole bars must adhere to IRCA Part III rules and specifications, ensuring minimum thickness for the patch and proper covering of web and flanges.

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Sole Bar Material

Sole bars are primarily made of ISMC-250x9.0 web channel of copper bearing mild steel, but BOXNCR wagons use IRSM-41 carton steel, and new wagons often use CRF sections or micro-alloyed steel.

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Sole Bar Damage Locations

Sole bar damage often occurs near the head stock stanchions, particularly at door locations.

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Diagonal/Crossbar Repair

Repair procedures for diagonal and cross bars are consistent with those outlined for the sole bar repairs, following the procedure in para 506.

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Underframe purpose

The underframe is the main load-bearing part of a wagon, affecting its design and loading capacity.

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BG wagon underframe

The specific underframe design for broad gauge wagons, with important components like sole bars, head stocks.

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Underframe members

The main parts of a wagon underframe: sole bars, head stock, longitudinals, cross bars, bolster, floor, crib angle, end angle, gusset plates & knees, centre sill.

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Load transfer (bogies)

In bogie wagons, load is transferred to the bogie frame using a pivot arrangement.

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Gusset plates & knees

Reinforcing parts at critical points, improving strength and load distribution in the underframe.

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Sole bars

The main longitudinal (lengthwise) underframe members.

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Cross members

These support members run across the underframe.

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Door Tolerance

Acceptable deviation in door dimensions from specified values.

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Bogie Pivot Centres Distance Tolerance

Allowed range for distance between bogie pivot points.

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Stanchion Distance (Body Side)

Permissible variation in distance between stanchions on the body side.

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Door Opening Tolerance

Acceptable range for vertical or horizontal door opening.

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Door Length Tolerance

Deviation allowed in door length from the specified value.

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Door Width Tolerance

Allowed range for door width.

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Barrel Length Tolerance

Permissible variation in pressure tank wagon barrel length.

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Cross Bar

A 5/8 mm plate component of the wagon's undercarriage.

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Bolster

A 10/12 mm plate part of the wagon's underframe, providing support.

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Head Stock

A 10 mm pressing component on the underframe.

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Centre Sill

A central support structure of the wagon.

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Bogie Centres

The distance between bogies, measured as 6524.

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Overhead Stock

A component above the underframe, 9784 in length.

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Open Bogie (Non-Coupler)

A type of wagon bogie arrangement without coupler.

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Boxn Type Wagon

A type of open wagon.

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Length Over Transition

The length measurement of the wagon exceeding the transition.

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Underframe Arrangement

The layout of the wagon's underlying support components.

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Mild Steel Wagon Underframe

Wagon underframes constructed from rolled and pressed steel sections joined by welding.

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Underframe Camber

A deliberate curve in the underframe to prevent sagging under load.

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Bogie Wagon Headstock Damage

Common damage to the front part of bogie wagon underframes.

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Centre Sill Repair

Repair procedure for damaged centre sills of bogie wagons, following specific drawings.

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BRN Wagon Fixed End Issues

Problems like breakage of fixed ends and sagging of sole bars seen in BRN wagons during first Post Overhaul (POH).

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Headstock Pressing Replacement

Replacing damaged headstock pressings for better alignment and preventing further damage.

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Underframe Repair Procedures

Specific procedures for repairing damages to the underframe components of wagons as outlined in RDSO technical pamphlets and drawings.

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Positive Camber

A slight upward curve in the underframe to prevent sagging after loading.

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Side Bearer Crack

Cracks that can appear in the side bearer location of the underframe bolster bottom flange.

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POH Repair of Headstock

During POH headstock pressings are stripped, straightened and refitted for proper alignment, or replaced if severely damaged.

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Sole Bar Repair Methods

Procedures for fixing damaged sole bars, including cutting, welding, and straightening.

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Sole Bar Patching Rules

Repair patches must follow IRCA Part III rules, ensuring sufficient thickness and covering the entire damaged area.

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Sole Bar Material

Common materials used for sole bars include mild steel and different types of steel alloys for various wagon types.

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Diagonal/Crossbar Repair

Procedure for repairing damaged cross and diagonal members in wagon underframes using the same repair techniques as sole bars.

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Sole Bar Damage Locations

Sole bar damage commonly occurs near head stock stanchions, particularly around door areas.

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Study Notes

General Underframe

  • Underframes are the main load-bearing part of wagons, directly impacting overall design and dimensions.
  • Loading per meter and track limitations are key design factors.
  • Buffing and impact loads also influence underframe strength calculations.
  • Pivot arrangements are critical for load transfer to bogie frames in bogie wagons.

BG Wagon Underframe Construction

  • Main Members: Includes sole bars, head stocks, longitudinal members, cross bars, bolster, floor, crib angle, end angle, gusset plates, and knees.
  • Structure: Typically consists of two outer longitudinal members (sole bars), two head stocks, strengthened by middle longitudinals and cross members.
  • Gusset plates and knees: Protect against diagonal deflection, distributing buffing loads.
  • Material: Various rolled/CRF sections (channels, Z-sections, hat sections) are used, with welding commonly employed for joining.
  • Bogie Wagons: Bolster cross members are stronger in bogie wagons.
  • Underframe camber: Underframes are initially cambered to prevent sagging under load.
  • Tolerances: Specific tolerances are permitted during construction for inside length, width, height, distances between bogie pivots, and stanchions, door openings, lengths, widths, and coupler heights.

Wagon Construction Tolerances

  • Inside length: +5mm (riveted), +7mm (welded)
  • Inside width: +3mm
  • Inside height: +3mm
  • Difference between diagonals (+/- measurements for under frame, body side, body end, door opening, and doors)
  • Distance between bogie pivot centres (+/- measurements for riveted and welded)
  • Distance between bogie pivot centre and adjacent headstock (+/- measurements)
  • Door opening (vertical or horizontal): (+/- measurements)
  • Door length: (+/- measurements)
  • Door width: (+/- measurements)
  • Distance between door center line and door hinge center line (+/- measurements)
  • Coupler height from rail level (+/- measurements)
  • Coupler height from bogie top pivot (+/- measurements)
  • Non-pressure tank wagon barrel tolerances (+/- measurements)

Other Major Sub-Assemblies

  • Draw gear/CBC sub-assembly
  • Containers locking/anchoring arrangements (container flats)
  • Side stanchions & lashing chains
  • Door operating mechanisms (hopper wagons)
  • Top centre pivot

Underframe Maintenance

  • Underframes are subjected to static and dynamic loads, including track unevenness and buffing impacts from marshalling
  • Regular maintenance is crucial for smooth operation.
  • Inspection is required for rivet/bolts, cracks, and alignment.
  • Repairs are critical for damaged components, head stocks, centre sills, and sole bars, with repairs following specific procedures as outlined.
  • Specific types of wagons (open, covered, brake vans) might have unique repair requirements.

Additional Information

  • Diagrams (figures) accompany the text, illustrating specific underframe components and dimensions.

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CnW Maintenance Manual Chapter 5 - Underframe PDF

Description

This quiz explores the intricate details of the BG wagon underframe construction and design. It covers the essential components, load-bearing structures, and material specifications that play a crucial role in wagon safety and efficiency. Test your knowledge on load calculations, structural integrity, and the essential parts of underframe design.

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