INSPECTION 2 TEST PLAN [DOG. NO: OATCRW-107 1 a 1. (10) ene [Sa MA bobe! ae cic cew PAGE NO: 4 of 7 : RITES LTD EFFECTIVE DATE: 4 (QA DIVISION) APPROVED BY:GGMMIER [oases Book No: Sate: 1, Specification ‘Drawing: ICF's Drg. No. T-0-2-619 All. 1/42, RDSO Speon, No © 9307.pd. Rev. 2 & Corrigendum sli No. 1 of Oct. 2006, IS 1364 Pt 2.0df 2. Date of inspection 3. Place of Inspection 4. Size of lot 5. Size of Sample (i)_As per Tablo-t of IS 2614/1969 for Dimension & visual examination. Totsize | ‘Visual Characteristics Dimensional Characteristics [Sample | Sample | Cum, Sample | Sample | Cum. | Black Fasteners size | Sampio siz | Sample [Major] Minor size size | Defects | Defects ac | Ro ae | Re [Ac | Re Bar é 40 [35 z 2 z a) wae ee Upto 09} First —|—20 2 [5 | Fist [8 3 ;o;2]o;a]| ° second | _ 20, 617 | secon |e | i |ilz{s}a FIO] Fret | 32 3] T] Fist |—is] 3 ToT 371} 4 a || secon | 13 | 2 |3|alals 500 3] a} Fst ~—2 | 20 1] 4] 2] 5 s0_| 100 | 12|13| second | 20 | « || 5 [6|7 rao | Fest | 80} 0 | 7 [11] Fret | 32] 32] 2] 5] 3] 7 second | 0_| too | t0|10| cooone | 3a | er lel 7 [slo Tora | Fest | 25} tas a | to] Fret | 0 80] se] 7] 5] o second | 125 | 250_| 26 | 27| second | 80 | 100 | a | 9 | 12 | 19 soor-io000 | Fret | 200) 200-41] 16) Fret | 00 | 80 [sy ojr [i second | 200 | 400_| 26 | 27| second | oo | 160 | 42 | 13 | +a | 19 TOTIGOGT Fist [315] 315) i1] 16] Fest) 2s] 125] 7 Pat at] 16 second | 315 | 630 | 26| 27 | secona | 126 | 250_| 10 | 40 | 26 | 27 ‘ver a5000-| Fret [500] 500] 17] 16] Fist | 200 200-[ ti 16 | 11] 16 second | 500 | 1000 | 26] 27-1 second | 200 | soo} 26 | 27 | 26 | 27 (ii)_Sample size for physical properties test (As per IS 2614/1969) No] Lotsize | Sample size | Acceptance No. 7 [Upto 7000 5 Gaamne| [2 {1001 = 3000 8 0 3__|3001= 10000] 13 0 4 | 10007- 20 0 35000 5 __| Over 35000 Sona 1 (ii) Heat-wise & heat treatment wise samples to be drawn for chemical testing 6. Document Checked a) ICF approval for Supply of Axle end screw. b) Internal’ External test certificate for raw material. The LE. should ensure that the records presented are correlated to the * material under inspection. ©) Intemal test and dimensional check report d) Calibration record of gauges, measuring instruments & test equipment, Prepared By- Checked by- Forwarded by- Technical Cell: RKD. CM: SKS.= /Mith TE, RITES LTD AXLE END SCREW (QA DIVISION) | =| INSPECTION & TEST PLAN [ROS_NO: OAICEW 07 1 ISSUE NO: 02 PAGE NO: 2 of 7 EFFECTIVE DATE: APPROVED BY:GGM-/ER 7. Tests/Checks ( to be witnessed by inspector ) ‘SNo] Parameter | Value Specified Observation Remarks @ | Visual + The product shail have intact surfaces & 1S 1967 Pind edges & shall be free of burrs consistent with the manufacturing methods used. J+ {tis not generally required that small burrs due to operations such as slotting, or resulting from forging, pressing or ‘rimming be removed, + Any burrs which influences the performance of product or would be a safety hazard when handled however shall be removed. + Trimming burrs beyond the bearing face of screws is not permissible. J+ _ No cracks should be on head. ()_| Dimensional Sheet Enclosed ICF's Drg. No (As per Drg. & To be taken from [$1364 Pt2) T-0-2-619 Alt iS 4218 Pi 4.pdt © _| Maternal Table 2 of IS 1367 (PT-Sy2002 ‘As per CL.4 of composition | (Corresponding to property class P 8.8) 9307 a) Carbon steel quenched & tempered: | C:0.25-0.55% P: 0.036% max 9, 0.0967 max Alternatively : b) Carbon steel with additives (eg. B, Mn & Cr) quenched & tempered: C: 0.15-0.40% Mn: 0.60% min. (Where C is < 0.25% in ladle analysis) ~") P: 0.035% max S: 0.035% max B: 0.003%max (@ _| Physical @ [As per Table-3 of IS 1367 PtS.pdt Test method: Mechanical |1. Tensile Strength: 800N/mm? min, 4.Tensile test Properties |2. Hardness: 320HV max/304HB max/32, 181608 & C1.8.2 HRC max 2. Hardness: 3. Surface hardness: 30 HV max increase 181500/ from core hardness while testing at IS1501PTt / HV0.3. 1S1586 & CL.8.4 Proof Load test: 580 Nimm# min 3. Strength under 5. Stress at 0.2% Non proportional wedge loading: Elongation: 640 N/mm min. 181608 & CL.8.6 6. Elongation after fracture: 12% min 4. Impact Strength |7. Reduction in area after fracture: 52%min | 181499 8 cle? 8. Strength under wedge loading: 5. Decarburization (Minimum ultimate tensile load)134000N test: CL8S 9. Impact Strength: 30 J min 6. Reiempering 10. Minimum height of non-decarburized test: CL8.10 fe ____| ‘thread zone: 0.460mm repared by- ‘Checked by- Forwarded by- IE: PP Technical Cell: RKD CM: SKSSS T INSPECTION & TEST PLAN | DOC. NO: OAIGEW-107 M FILES \ | ISSUE NO: 02 Oercniaatterone HERE PAGENO:30f7 ,, RITES LTD Cellet EFFECTIVE DATE: 47%] (QA DIVISION) APPROVED BY:GGM-IER ‘S. | Parameters | Value Specified ‘Observed | Remarks No. | 17. Maximum depth of complete 7. Surface decarburization: 0.015mm integrity: IS1367 12, Hardness after retempering: reduction in pid/sec2 hardness 20HV maximum (equivalent to ISO 13, Surface Integrity: 6157-3) a) Quench Crack: not permitted. b) Forging Crack: length= 16mm max, Note: Clause depth & width = 0.64mm max ‘number is from IS ©) Forging Bursts: should not extend 1967 PLS into the crown circle on the top of head surface or into the underhead bearing surface. Occurring at the intersection of 2 wrenching flats shall not reduce width across comers below the specified minimum. d) Shear bursts:width<0.25+0.02s (width across flat), Depth <0.64mm ©) Laps :0.34mm max f) Voids :0.25mm max g) Laps in thread : 0.27mm max h)_Damages 4.1 Num (Torque value) (| Surface [Phosphate coating having coating weight 4.3-| Test Method treatment [5.5 gmim* (Cl. 'B’ of phosphating process) to 1S. 3618.0 Is 3618 RDSO Spee. £.0307.pdt Rov. 2| 4) Ensure traceability of test panel to the material under test 2) Obtain Undertaking from the firm regarding test panel being given surface treatment along with the material under test. | Thread To be formed by cold Rolling process & C13 of RDSO Spe formation _| thread profile to be as per IS 4218, Pt. 1V, C9307 tolerance Class 69. To be checked? measured by travelling microscope profile projector in addition to conventional thread gauge. __ (p) | Marking Firm's Name/ Trade name, Material grade As per IS 1967 Pt (8.8) on each boll 3 & IS 1967 PLB ‘Marking on Packages: Product Designation Pictorial representation of the product, where possible. Total no.of pieces in @ package. Prepared by- Chesked by- Fonvarded by- IE: PP Technical Cell: RKD CM: SKSINSPECTION & TEST PLAN DOG NO: QAICEW-107 MBRITES ISSUE NO: 02 eriact eon AXLE END SCREW PAGE NO: 4 of 7 RITES LTD EFFECTIVE DATEy. 7), (QA DIVISION) APPROVED BY:GGM-VER S. | Parameters | Value Specified Observed Remarks No. Net mass of a package Name or identification of Manufacturer. @_| Packaging | Product shall be packed in cartons/ boxes in 1S 1367 Pt 18.p0f multiple of 10,20,50,100,200, 500 & in multiple of 500 to that mass of single pack shall not exceed the following ‘Type of Packaging Net mass in Ko Paper or plastic bag 3 Plastic box on carton 5 Plastic or metal crate/carton 40 Wooden crate or box 50 Name & signature of IE Note: i) Sampling shall be done according to IS:2500 - 2000 Pt I single sampling plan (normal) unless ‘mentioned otherwise. i) In case a quality plan is mentioned in the Purchase Order, Inspecting Engineer shall also take the same into consideration during inspection, and mention the same in Inspection Records. ii) In case purchase order mentions different drawing/specification, then that will be applicable. ‘vjincase the testing for mechanical test not possible at the final stage, Internal TC to be verified with traceabilty Stamp/seal complete offered lot after drawing samples for lablin-house testing and before leaving Important 4. Crocs chook original PO (Eithor in physical form or enline) 2. Do not undertake inspection elsewhere other than the place of inspection mentioned in PO. 3. Do not undertake inspection if quantity offered is less than quantity mentioned in call letter. 4, Do not inspect part quantity unless provided in PO or authorized by client. 5. the site. . Use check sheet for recording observations. In case of any ambiguity in PO/Specification/Drawing/QAP/Technical Spec. annexed with PO; the same shall be brought into the notice of vendor as well as CM for seeking necessary Clarification from Purchaser/Client. Prepared by- IE: PP ‘Checked by- Technical Cell: RKD. 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