([RWFIMISPECN-1701671987 AR "o] GOVERNMENT OF INDIA (Ministry of Railways) SPECIFICATION FOR GRAPHITE MOULD BLANKS TYPE A: 1097 Dia x 575 Height TYPE B: 1224 Dia x 575 Height TYPE C: 1325 Dia x 575 Height TYPE D: 1021 Dia x 575 Height Issued by MECHANICAL DRAWING OFFICE RAIL WHEEL FACTORY YELAHANKA, BANGALORE-560 064 INDIA _ | Lee Popup (_ —— Chaudies v¥| [ fC go SSED PREPARED BY Page of 11 [—“aeeroven ay REVIEWED BY VERIFIED ay —1.0 2.0 3.0 34 3.2 3.3 RWE/M/SPECN-1/018/1987 Alt ‘| SPECIFICATION FOR GRAPHITE MOULD BLANKS SCOPE ‘The Specification covers the design, manufacture and supply of Graphite Mould Blanks at Rail Wheel Factory, Bangalore - 560 064, Kamataka State, India as per instructions and conditions of contract. GENERAL DESCRIPTION Graphite Mould Bianks of dimensions and sizes specified in technical data of the specification JOB REQUIREMENTS ‘The Graphite Blanks shall be used as permanent graphite moulds (Cope and Drag), after machining, for manufacture of Cast steel wheels by the pressure pouring method, i.e., forcing up molten metal into mould cavity through the in- gate made up of clay graphite The temperature of molten metal is in the range of 1600-1620°C. Moulds are pre heated to 350°C before using and the surface is protected using fused silica spray coating. Cast moulds are recycled after cleaning the surface by sand blasting using fine sand. The graphite Mould shall with stand the operating condition and shall have good wear! erosion and oxidation resistance under the operating condition MANUFACTURE AND QUALITY ASSURANCE PLAN (QAP) The manufacturer shall take extreme care to meet the product requirement and job requirement and have optimum erosion and oxidation resistance so that the consumption rate shall be the minimum. The blanks shall be adequately pitch impregnated to achieve the bulk density specified. The particle size and their size distribution in the raw material shall be selected in such 2 manner to obtain the optimum performance. The manufacturer shail submit their QAP along with their bid for approval by RWF, which will be followed in the manufacturing of Graphite Mould Blanks to satisfy the technical requirement as required under this specification. Manufacturer shall get their QAP approved from RWF in advance, ie., before starting manufacturing of graphite mould blanks, unless a waiver is given to this effect. MANUFACTURERS TEST CERTIFICATE (MTC) The manufacturer shall submit the MTC containing the test results of the Graphite Mould Blanks for all parameters specified under Clauses 4.1, 4.3, 4.4 & 4.5 and ensure the compliance of the specified parameters under Clause 5.0 Page 2 of 1134 4.0 44 4441 42 RWFIMISPECN-1/016/1987 Alt “o} TESTING FACILITY The manufacturer shail have testing facility for characteristics specified in clause 4.3.1 to 4.3.7. In case any facility is not available in-house, the manufacturer shall carry out the test through a reputed laboratory on his own ‘expense. Testing from any out-side agency shall be clearly brought out in the offer, TECHNICAL DATA Sizes of Graphite Mould Blanks shall be as follows: Blank dia for a) Type A {1097 dia} 1097°%.mm dia x 675 “9mm height b) Type B (1224 dia} 1224°%.9mm dia x §75°*/.) mm height. ©) Type C {1325 dia} 1325°%/.gmm dia x §75°/.9mm height. d) Type D {1021 dia} 1021°9.9mm dia x 575°4/.9mm height. Surface finish of the Graphite Mould Blank: —_N8 all over. A cylindrical coupon for sample preparation for testing shal! be drawn from Graphite Mould Blank (GMB) as shown in the sketch below. The sample shall be drawn in such a manner that it shall not damage or make the blank Unsuitable for the intended purpose. Page 3 of ¢aaBT ARI RWE/M/SPECN.1/016/1987 Alt ‘o} 4.3 Other technical parameters shall be as follows: S28? | characteristic | Unit | SPetied | Tea Metros | Fee fy 431 _ | Bulk Densty gmion | 1,604.70 | ASTM A Blanks | As per the 559 sketch at _| clause 4.2 432 | Slectioresistiviy | Ohm- [76X10 | ASTM ATBlanks | As per the (measured paralel_ | om cétt sketch at to avs) (max) | clause 42 [433. | Permesbiity AS [076080 | ArFow ‘AIBlanks | As per the (baralelto axis) | ant Method AFS: sketch at : | clause 4.2 434 | Flouralstengih [Kal | Notless | ASTMG 651- | AllBlanks [As por the (Garalelto axs) cm? | than 100- | Latest, sketch at (rin) 4 point | 4-point loading clause 4,2 foating Or ASTM D-7972- Or | Latestfor3 Equivalent | point oading in3 point loading 435 | Stidure and | Shalnot show any | Visual ‘ABianks | Full moult surface extraneous material _| inspection surface 436 | Ash content by [0.20 | Losson Balch | As per the (max) weight ignition wise | sketch at ASTMC-561 cause 4.2 437 |Maimumgrain [mm | 08 Vetfication of | Batch | Sample from size used | manufacture | wise | processed records raw material mix 4.4 Apparent porosity preferred is less than 24% but shall not be more than 29% when tested as per ASTM C-1039 or by calculation as: {(True density - App. density) / True density} X10 45 The permeability range in a lot shall be uniformly distributed. The manufacturer shall aim to achieve the permeability range distribution of the lot in such a way that the following shall be met [Permeability Range Percentage of mould in a lot 0.16 - 0.40 AFS 0.41 - 0.80 AFS 80% 0% SSE (Tprepareoay —] Page 4 of 17RWF/MISPECN-1/016/1987 Ait ‘o} 5.0 OTHER FEATURES i) The graphite mould blanks shall have sufficient thermal shock resistance to withstand high temperature of molten steel without cracking ji) The graphite mould blanks shall have low co-efficient of thermal expansion. iil) The Graphite mould blanks shall be easily machinable; contour of the wheel shai be machined by form tools on cope and drag, iv) The supplier shall legibly print the permeability values and ash content on the mould blank. 6,0 WARRANTY For the under mentioned conditions, the shop operating parameters & practices are considered common for ail manufacturer/suppliers: i) If after removing the mould coating and oxidised surface, an area with unsatisfactory structure becomes visible and requires machining, the contractor shall offer incremental credit whenever void/flaws greater than 6 mm in depth are noticed ii) RWF will proceed with machining of all such moulds until the void/flaw disappears. The extra machining (in excess of 6 mm) necessitated by the said void/law in the structure will have to be compensated by the contractor (without insisting on joint inspection). The rate of such compensation should also be stated at the time of making the offer. il) However, if the voidiflaw does not get eliminated even after machining to a depth of 36 mm, the mould will be kept aside and offered for joint inspection with the supplier and further disposal will be decided during such joint inspection. iv) The contractor shall, if required, replace the Stores or such portion thereof as is rejected by the purchaser free of cost at the ultimate destination, or at the option of the purchaser and the contractor shall pay the purchaser value thereof at the contract price, and to such other expenditure and damages as may arise by reason of the breach of conditions herein specific. v) If any defective Stores is not replaced within the above mentioned 3 months, the purchaser may proceed todo the replacement at contractor's risk and cost and also without prejudice to any other rights of the purchaser under this contract. ‘SSE/D PREPARED BY] Page 6 of 17vi) vil) 7.0 8.0 84 82 (RWFAWSPEON-701671967 Ak 6} If the contractor so desires, the replaced parts can be taken by him or his representatives in India for disposal as he deems fit within a period of 3 months, from the date _of replacement of the Stores. At the expiry of this period, no claim whatsoever shail lie on the purchaser. If a cope produces more than 5 wheel rejections attributable to mould quality, duly discounting for process variation, the mould will be rejected and warranty claim will be raised Note: i. The Wheel defects (XC set) lkely to be caused due to poor graphite mould quality is based on RWF's 35 years of experience with different make/type of moulds and process variation. List of defects in XC set: XC46-Pocker, XC56-Hollowface Hub, XC626-Graphite Inclusion, XC15-Pinhole, XC33-hole in bore. ji, Process related defects to be discounted are defined as a. Defects arising just after machining ie., at Cope Life 1, will be taken on process account. b. In case more than 2 of above defects are arising in a particular heat these defects also will be taken as on process account, PERFORMANCE The performance of the firm will be adjudged based on % Warranty replacements with respect to the supplied quantity against the particular purchase order. INSPECTIONS, TEST CERTIFICATE AND ACCEPTANCE The manufacturer will submit their Internal Test Certificate along with the supply as specified in clause 3.3. Acceptance will be based on manufacturers internal test certificate indicating compliance to technical parameters and other features detailed under main clauses 4.0 and 5.0 respectively. If laid down in the purchase order, RWF or its authorised representative may carry out inspection at the manufacturer's premises. The manufacturer shall offer the Graphite Mould Biank after the internal inspection and compliance of specified requirements along with Manufacturer's Test Certificate. The RWF’s authorised representative shall have access to verify the manufacturing process, records, and witness the testing of the offered Graphite Mould Blanks either at their own laboratory or at the authorised outside laboratory. It is the responsibility of the manufacturer to offer him free access to carry out the inspection: SSE Fe Page 6 of( RWFRMISPECH: (107687 AK} 9.0 PACKING & HANDLING The graphite mould blanks shall be suitably packed in wooden cases to avoid transportation damage. Cases must amenable to handle by forklift trucks. 10.0 TRIAL OF THE SUPPLY The material for trial shall necessarily meet all the requirements mentioned elsewhere in this specification prior to shop floor trial. Only after this, the material will be taken up for shop floor trial by RWF as per Trial Scheme at Annexure-1 and the corresponding Trial Report shall be prepared as per Annexure-2. Page 7 of 17RWF/M/SPECN-1/016/1967 Alt ‘o} Annexure -1 TRIAL SCHEME OF GRAPHITE MOULD BLANK Trial Scheme No. RWFIM/SPECN-1/016/1987 alt .../ Trial Scheme PL.NO. 2 | Objective of Trial To establish the suitability of graphite mould blank as per Specn No. RWF/M/SPECN- [ 1016/1987 alt... - 3 _| Description of Material GRAPHITE MOULD BLANK PO Number & PO date PO Qty ‘Supplier | 4 |IDNNumber&Date | |__[IDN Qty. - 5 | Authority for conducting | Dy. CME/ Mig Trial 6 | Earlier trial details First Time Supply/ Second time/ Third time - i 1 7_| Trial Parameters ‘As mentioned in Trial Scheme |_ 8 | Specification RWE/M/SPECN-1/016/1987 alt [9 [Pre-trial Testing details | Met. Lab Report & MTC 10 | Trial qty Full IDN Qty/ 5% of the tendered quantity 77 | Equipment / Station Mould Room process _ ( to be filled by Team Members) Trial Parameters: 1. Total quantity graphite mould blank to. be drawn and trial conducted on the entire quantity under the whichever is less. purchase order/5% of the tendered quantity, Inspection & testing by shop and whenever required by laboratory completely in line (not in part) with the sp specification. .ecification. Sampling for inspection as per RWF Examination of MTC (Manufacturer's Test Certificate) and comments on its suitability, ic Requirements: Study the trend of XC set (x (C46-Pocker, XC56-Hollowface Hub, XC626-Graphite Inclusion, XC15-Pinhole, XC33-hole in bore) whee! rejections in the trial moulds and find out number of GMBs producing more than 5 rejections duly discounting process variations and compare with that of other makes by ensuring same process parameter during use and in the same period (or just preceding/succeeding period) — Chodig 32/0 [respira Page 8 of 17RWWEIMISPEEN-T1016/1887 A “o} Annexure -2 TRIAL REPORT OF GRAPHITE MOULD BLANK [ RWFIM/SPECN-1/016/1987 alt .../ Trial Scheme _ - PLNO.... 2 | Objective of Trial To establish the suitability of graphite mould blank as per Specsi No. RWF/M/SPECN- _ | 11016/1987 alt 3 | Description of Material GRAPHITE MOULD BLANK PO Number & PO date PO ty Supplier 4 [TDN Number & Date 7 7 IDN Qty. — 3 | Authority or conducting | by. CME/ Mig Trial 6 |Earlertrialdetais —‘| Fist Time Supply? ‘Second time/ Third time I 7_| Trial Parameters I ‘As mentioned in ii ‘Scheme 8 — RWE/M/SPECN-1/016/1987 alt 9_| Pre-trial Testing details __| Met. Lab Report & MTC. 40_| Trial gty Full IDN Qty/ 5% of the tendered quantity 11_| Equipment/ Station Mould Room process Nominated Officers ACMTW & AWMIMR to be filled by Team Members) Application Test: Shop Floor test conducted from date to date &H.No, Trial Parameters: 1 Total quantity of graphite mould blank to be drawn and trial conducted on the entire quantity under the purchase order/5% of the tendered quantity, whichever is less. ‘Comments: 2 Inspection & testing by shop and whenever required by laboratory compietely in line (not in part) with the specification. Sampling for inspection as per RWF specification _ 7 Enclosure Details: Page 9 of 17RWF/M/SPECN-1/016/1987 At] 3 Examination of M Lab report & MTC (Manufacturer's Test Certificate) and comments on its suitability = ‘Comments with documents: oceeunens - — ] Specific Requirements: 4. Study the trend of XC set (KC46-Pocker, XC56-Hollowface Hub, XC626-Graphite Inclusion, XC15-Pinhole, XC33-hole in bore) wheel rejections in the trial moulds and find out number of GMBs producing more than 5 rejections duly discounting process variations and compare with that of other makes by ensuring same process parameter during use and in the same period (or just preceding/succeeding period). Observations: AWM/WM ACMTW SSE/MR ww Remarks of Dy CME/Mfg. Remarks of AEDIM&C CWE Page 10 of 17RWE/M/SPECN. 1016/1987 Alt AMENDMENT SHEET a rm — vn Tae ae son : Dest a Denibn — = |e 2 i | slalalaq}al ile iff: {|i | 5 i Hi Aaa aa 434 i TI | 404 tl |e : : j ned Vip f lta] | PTL aERAH } ale Pl Ee i | i rH le i area Twa Mt epee cp wee MO coe pan no fin § el cin epee cen ‘as row sin art tn tna pr ate poo fan, te tot ese tentaunelsbeye cat wero ae ces ri ra vee coos Serenata ceeeeare | sal eo ao | | permeate’ gaty esos Span comraSoun beltcege pecan gay tad PY Se wi | istitis exceeded, atte copes, which | Wi process vataon Ut of dleds In XC set XCAB- Case pent ot eee Pose ‘lobes a, C85 ape se hop est fete anon tin nb 1 pnt coats ene ors 2 pabuene tar tochig a 08 sitter oraeees eeu oy heme ne tte ees eg 8 prin vcs ot feast ren) Pesrorance ee cron fous 8 pecker ee | | un mene oma ae! at cree on ra | | anttnpernn oan ees v0 a nro a aes " Specie Ragone Sc Raven 1 Comme te conto par| | 1 buyhntet ot CA Po nn omer ete ad nat sha ieen opie ar oP No tamer oer ates by owe | | tom vd in nt oa at ae ‘same process parameter during use | “12 | numbor of GMB posing more than § recone diy th be san ptod or a a preceding Pte certs sy sane geo or Cm dine se Pt rt stags oe SSE/D PREPARED EY Page 11 of 7