04-04-2011, 10:32 AM
Submitted by
R.KUMARESAN
S.SIRUMURUGAN
S.SIVASANKAR
Failuer analysis crankshaft in diesel locomotive.docx (Size: 385.17 KB / Downloads: 1,046)
ABSTRACT
In basic PONMALAI RAILWAY YARD is the maintenance oriented company. So spare utilization can be decides organization efficiency. So reducing of spare failures can be increasing the organization efficiency. In our project analyzed failures of crankshaft in diesel locomotive.
This project deals with the analysis about the various causes of failures of the Crankshaft of the diesel locomotive engine. It is found that the cost for the crankshaft is very high whereas the lifecycle is not satisfactory. The causes for the failure of the crankshaft and the possible ways of minimizing the failure effects were briefly studied from the past failure specimen. The load bearing capacity of the crankshaft is theoretically calculated and compared with the actual load acting on the crankshaft. The remedy for maximizing the lifecycle for the crankshaft was found and suggestions were made to reduce the frictional forces acting on the shaft. This prevents excessive wear and deformation of the crankshaft. Thus the lifecycle of the crankshaft is increased and the cost for the maintenance is reduced.
SOUTHERN RAILWAY
The Southern Railway Company, which operated in England from 1923 to 1947. For the modern UK train operating company, see Southern (train operating company). For the US railroad merged into Norfolk Southern, see Southern Railway (U.S.).For other uses, see Southern Railway (disambiguation).
The Southern Railway (SR) was a British railway company established in the 1923 Grouping. It linked London with the Channel ports, South West England, South coast resorts and Kent. The railway was formed by the amalgamation of several smaller railway companies, the largest of which were the London & South Western Railway (LSWR), the London, Brighton and South Coast Railway (LBSC) and the South Eastern and Chatham Railway (SECR). The construction of what was to become the Southern Railway began in 1838 with the opening of the London and Southampton Railway, which was renamed the London & South Western Railway.
The railway was noted for its astute use of public relations and a coherent management structure headed by Sir Herbert Walker. At 2,186 miles (3,518 km), the Southern Railway was the smallest of the "Big Four" railway companies and, unlike the others, the majority of its revenue came from passengers rather than freight. It created what was at that time the world's largest electrified railway system and the first electrified InterCity route (London--Brighton). There were two Chief Mechanical Engineers; Richard Maunsell between 1923 and 1937 and Oliver Bulleid from 1937 to 1948, both of whom designed new locomotives and rolling stock to replace much of that which was inherited in 1923. The Southern Railway played a vital role in the Second World War, embarking the British Expeditionary Force, during the Dunkirk operations, and supplying Operation Overlord in 1944; because the railway was primarily a passenger network, its success was an even more remarkable achievement.
The Southern Railway operated a number of famous named trains, including the Brighton Belle, the Bournemouth Belle, the Golden Arrow and the Night Ferry (London - Paris and Brussels). The West Country services were dominated by lucrative summer holiday traffic and included named trains such as the Atlantic Coast Express and the Devon Belle. The company's best-known livery was highly distinctive: locomotives and carriages were painted in a bright Malachite green above plain black frames, with bold, bright yellow lettering. The Southern Railway was nationalised in 1948, becoming the Southern Region of British Railway.
GOLDEN ROCK---A PROFILE
Named after the “PONMALAI” situated in the rock city Tiruchirapalli, Tamilnadu, this workshop caters to the maintenance need of Indian Railways Rolling Stock.
This workshop is well designed and constructed shop with mixed gauge track to carry out repairs to both MG and BG rolling stock. This workshop was accepted new challenges undertaking varied responsibilities and is known for its excellent quality of work. The workshop has a proud history and has even assisted Royal Air force in repairing Fighter Bombers during second world war.
ARMOURY GATE PONMALAI (GOLDEN ROCK) WORKSHOPS:
Statistics
Year Built: 1926-1928
Total Area: 200 Acres
Area Covered: 26 Acres
Track Length: 67KMS
No of Quarters: 3807
Presently GOC shops is undertaking periodic over hauling of BG/MG Diesel locomotives, steam locomotives, “x” class locomotives, BG/MG coaches manufacturing of BOXNHS, BOXNHL, & BLC wagons.
The Diesel Locomotive
The modern diesel locomotive is a self contained version of the electric locomotive. Like the electric locomotive, it has electric drive, in the form of traction motors driving the axles and controlled with electronic controls. It also has many of the same auxiliary systems for cooling, lighting, heating, braking and hotel power (if required) for the train. It can operate over the same routes (usually) and can be operated by the same drivers. It differs principally in that it carries its own generating station around with it, instead of being connected to a remote generating station through overhead wires or a third rail. The generating station consists of a large diesel engine coupled to an alternator producing the necessary electricity. A fuel tank is also essential. It is interesting to note that the modern diesel locomotive produces about 35% of the power of a electric locomotive of similar weight.
The Diesel Engine
The diesel engine was first patented by Dr Rudolf Diesel (1858-1913) in Germany in 1892 and he actually got a successful engine working by 1897. By 1913, when he died, his engine was in use on locomotives and he had set up a facility with Sulzer in Switzerland to manufacture them. His death was mysterious in that he simply disappeared from a ship taking him to London.
The diesel engine is a compression-ignition engine, as opposed to the petrol (or gasoline) engine, which is a spark-ignition engine. The spark ignition engine uses an electrical spark from a "spark plug" to ignite the fuel in the engine's cylinders, whereas the fuel in the diesel engine's cylinders is ignited by the heat caused by air being suddenly compressed in the cylinder. At this stage, the air gets compressed into an area 1/25th of its original volume. This would be expressed as a compression ratio of 25 to 1. A compression ratio of 16 to 1 will give an air pressure of 500 lbs/in² (35.5 bar) and will increase the air temperature to over 800° F (427° C).
The advantage of the diesel engine over the petrol engine is that it has a higher thermal capacity (it gets more work out of the fuel), the fuel is cheaper because it is less refined than petrol and it can do heavy work under extended periods of overload. It can however, in a high speed form, be sensitive to maintenance and noisy, which is why it is still not popular for passenger automobiles.
Diesel Engine Types
There are two types of diesel engine, the two-stroke engine and the four-stroke engine. As the names suggest, they differ in the number of movements of the piston required to complete each cycle of operation. The simplest is the two-stroke engine. It has no valves. The exhaust from the combustion and the air for the new stroke is drawn in through openings in the cylinder wall as the piston reaches the bottom of the down stroke. Compression and combustion occurs on the upstroke. As one might guess, there are twice as many revolutions for the two-stroke engine as for equivalent power in a four-stroke engine.
The four-stroke engine works as follows: Down stroke 1 - air intake, upstroke 1 - compression, down stroke 2 - power, upstroke 2 - exhaust. Valves are required for air intake and exhaust, usually two for each. In this respect it is more similar to the modern petrol engine than the 2-stroke design.
In the UK, both types of diesel engine were used but the 4-stroke became the standard. The UK Class 55 "Deltic" (not now in regular main line service) has a two-stroke engine. In the US, the General Electric (GE) built locomotives have 4-stroke engines whereas General Motors (GM) always used 2-stroke engines until the introduction of their SD90MAC 6000 hp "H series" engine, which is a 4-stroke design.
The reason for using one type or the other is really a question of preference. However, it can be said that the 2-stroke design is simpler than the 4-stroke but the 4-stroke engine is more fuel efficient.
Size Does Count
Basically, the more power you need, the bigger the engine has to be. Early diesel engines were less than 100 horse power (hp) but today the US is building 6000 hp locomotives. For a UK locomotive of 3,300 hp (Class 58), each cylinder will produce about 200 hp, and a modern engine can double this if the engine is turbocharged.