A case story of indigenisation & engineering accuracy of 8052224 bush component of the coolant water pump of EMD engines 567, 645 & 710
The Problem
Water leakage in the coolant water pump of the engine.
The Challenge
Achieving a flatness of within 2 microns on this internal face of the rotary joint bush component.
Our Approach
Our team delved into process engineering, machine design, material analysis, and prototyping.
Our Process
Before machining, we conducted a material study of the high nickel cast iron. The lapping process involved placing the bush component in a customized tool with abrasives and lubrication. Precise pressure control ensured uniform material removal and flatness. Iterative calibration adjusted parameters for micron-level accuracy. Real-time metrology tools, including laser interferometry and CMMs, maintained stringent tolerances.
Our Work
We engineered a highly specialized internal lapping tool that consistently maintained optimal contact, achieving a flatness target on every bush component, resulting in a remarkable 100% success rate.
The Result
This technical accomplishment played a pivotal role in resolving the water pump leakage issue. With the newly optimized water pump assembly, approximately 300 units underwent field trials in locomotive engines for five months. The results were outstanding, with no reported water leakage incidents. The end users, including Indian Railways, expressed their satisfaction.
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