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USE OF TRADITIONAL MACHINING OPERATIONS

TO DESIGN A WORKING MODEL OF

AUTOMATED RAILWAY CROSSING

(A TA 202 Course Project)

Submitted by

Deependra Rajpoot (13236)

Rajnish Singh (13547)

Vishwajit Kumar (13800)

Indian Institute of Technology, KANPUR

Jan’15 – Apr’15

Acknowledgement

We wish to express our sincere gratitude to Dr. V.K Jain, Professor, Mechanical Engineering Dept., for providing us an opportunity to do our project work in TA202A lab.

We sincerely thank Mr. PC Gond, Mr. Kuldeep Vishwakarma and Mr. HP Sharma for their guidance and encouragement in carrying out this project. We also wish to pay our sincere gratitude to all other staff members for their unparalleled support which played a vital role in the completion of our project.

All the facilities provided during the lab hours are greatly appreciable by us.

TABLE OF CONTENTS

A Acknowledgement

1 Introduction

2 Processes used

2.1 Drilling

2.2 Turning

2.3 Milling

3 Main parts

4 Relevant figures

5 Explanation

6 Conclusion

7 References

1. INTRODUCTION

This project was designed as a part of the course projects under TA202A:

Manufacturing Processes offered by IIT Kanpur. It is designed to work on the

problem of numerous railways accident at the unmanned railway crossings.

This mechanism tries to give a fully mechanical solution to this problem.

The Indian Railway is the fourth largest network in the world carrying 18

million people to their destinations each day. More than 16,000 trains run on

Railway tracks each day. But sadly 15% of all the railway accidents across the

world (177) occurred last year happened in India. The Report of High Level

Safety Review Committee of 2012 states that from 2007–08 to October 2011

railway accidents took 1019 lives and injured 2118 in India. It also killed 1600

railway staff and injured 8700 people. Unlawful trespassing kills about 15,000

persons each year as per the report. Fire, collision, derailments and

unmanned railway crossings are major reasons for the rail accidents.

Fig. 1.1 . Rail Accidents occurred in India in 2014.

2. Processes Used

In this project we applied the concept of secondary manufacturing

processes which is machining. The processes used are as follows:

2.1 Drilling

It is a cutting process that uses a drill bit to cut or enlarge a hole of circular cross-section in solid materials. The drill bit is a rotary cutting tool, often multipoint. The bit is pressed against the work piece and rotated at rates from hundreds to thousands of revolutions per minute. This forces the cutting edge against the work piece, cutting off chips (swarf) from the hole as it is drilled.

Exceptionally, specially-shaped bits can cut holes of non-circular cross-section; a square cross-section is possible.

Fig. 2.1 Vibrational Drilling of Aluminum

2.2 Turning

Turning is an engineering machining process in which a cutting tool, typically a non-

rotary tool bit, describes a helical tool-path by moving more or less linearly while the

work piece rotates. The tool's axes of movement may be literally a straight line, or they

may be along some set of curves or angles, but they are essentially linear (in the

nonmathematical sense). Usually the term "turning" is reserved for the generation

of external surfaces by this cutting action, whereas this same essential cutting action

when applied to internal surfaces (that is, holes, of one kind or another) is called

"boring". Thus the phrase "turning and boring" categorizes the larger family of

(essentially similar) processes. The cutting of faces on the workpiece (that is, surfaces

perpendicular to its rotating axis), whether with a turning or boring tool, is called

"facing", and may be lumped into either category as a subset.

Fig.2.2 Rough Turning of Aluminium

2.3 Milling

Milling is the machining process of using rotary cutters to remove material from a work piece

advancing (or feeding) in a direction at an angle with the axis of the tool. It covers a wide

variety of different operations and machines, on scales from small individual parts to large,

heavy-duty gang milling operations. It is one of the most commonly used processes in

industry and machine shops today for machining parts to precise sizes and shapes. Milling

can be done with a wide range of machine tools. The original class of machine tools for

milling was the milling machine (often called a mill). After the advent of computer numerical

control (CNC), milling machines evolved into machining centers (milling machines with

automatic tool changers, tool magazines or carousels, CNC control, coolant systems, and

enclosures), generally classified as vertical machining centers (VMCs) and horizontal

machining centers (HMCs).

Fig.2.3 Internal (Inner diameter) Milling

3 Main parts of model

PART

NO.

PART NAME DIMENSIONS

(in mm)

PAGE

NO.

QTY.

1. Base Plate 550X550X10 6 1

2. Vertical middle plate 900X25X3 7 1

3. Gear 1 Φ48, OD = 51 8 1

4. Gear 2 Φ36, OD = 39 9 1

5. Gear 3 Φ24, OD = 27 10 2

6. Gear 4 Φ45, OD = 48 11 2

7. Gear 5 Φ30, OD = 33 12 2

8. Gear 6 Φ75, OD = 78 13 2

9. Gear1 support 50X70X10 14 2

10. Mid gear Support 50X160X10 15 4

11. Gear 3 support 50X88X10 16 2

12. Long rack 600X12.7X12.7 17 1

13. Train rack 60X12.7X12.7 18 1

14. Train base 68X100X15 19 1

15. Train shaft Φ8x110 20 2

16. Train Wheel Φ20X19 21 4

17. Crossing’s barrier 120X30X5 22 2

18. Angle 50X50X6 23 20

19. Railway track channel 33X15X900 24 2

4 Relevant Figures

Figures below shows isometric views of model developed by us for our TA202A

course project.

Fig.4.1 Isometric View of Automatic Rail crossing (from front)

Fig.4.2 Isometric View of Automatic Rail crossing (from back)

Fig 4.3.Automatic Rail Crossing System

Fig.4.4 Manual Rail Crossing System

5. EXPLANATION OF MODEL

This is a fully mechanical automatic train barrier that drops down as the train

approaches and opens again as the train recedes.

Working of the mechanism is as follows:

Initial position: The train is at the right of the barrier. The train has a small rack

mounted on its bottom. The barrier has a gear that is controlled by an assembly

of gears. These assemblies on both side is connected to a gear at the center of the

track. This middle gear is connected to a long underground rack moving along a

long rod, which is connected to another gear on the opposite end.

Middle position: When the train passes through the grounded pinion which in

turn moves another long rack in the same direction in which the train moves. This

rack has another pinion meshed with it which it rotates. Finally this gear rotates

the gear train that rotates the barrier. And the barrier opens up.

Final position: The train now passes by a set of spur gears connected together.

This helps to reverse the direction of the motion of the long rack, which rotates

the barrier in opposite direction. And that’s how the barrier drops down.

We are mainly focused on only mechanical aspect of automated railway crossing

in this project. Electrical aspects include uses of sensors, advanced warning

systems, etc.

6. Conclusions

Accidents at the railway crossings are happening on a high level these days.

Mishaps at level crossings account for 40% of train accidents and 66% of

fatalities.This shows the lacking awareness of railways' towards the scenario of

railway crossings. The only reason we get to is that our government is not able to

pay a decent amount of salary to the gatekeepers.There can be many solutions to

this,one of those is our project reflecting a new concept of Automatic Railway

Crossing. Some profits we gain from these solution is that it is inexpensive,serves

it’s purpose with a high level of commitment and also requires almost no man

power. It is purely a mechanical design. In fact, installment of such system has

reduced accidents and damage to infrastructures significantly in many countries.

Fig.5.1 A serious accident took place in Austria, Europe in 2014

.

7. References

1. Fundamentals of Modern Manufacturing, M. Groover

2. Wikipedia

3. Times of India

4. European Railway Agency - http://www.era.europa.eu/Document-

Register/Documents/SPR2014.pdf

5. Maps of India