Training report

Industrial Training Report
1
SUMMER TRAINING REPORT
Industrial training at:-
Carriage and Wagon Workshop,
Northeast Frontier Railway,
New Bongaigaon, Assam
Submitted in partial fulfillment of the requirements of the degree of
B.TECH
MECHANICAL ENGINEERING
By
SUMIT KUMAR
2ND Year (4th semester)
Institute of Engineering & Management, Kolkata
Dated :- 16th July, 2016

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CERTIFICATE
This is to certify that SUMIT KUMAR, from Institute Of
Engineering & Management, Kolkata has undergone
training in the “Carriage and Wagon Workshop of Northeast
Frontier Railway at New Bongaigaon, Assam” for a period of 15
days from 1st July 2016 to 16th July 2016, under my guidance.
His performance was satisfactory so as to fulfill all the
requirements for successful completion of the training.
Date: - __________________ _______________________

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ACKNOWLEDGEMENT
Iwould like to express my sincere gratefulness and profound
gratitude to NORTHEAST FRONTIER RAILWAY for providing
an opportunity to undergo our summer training in “Carriage
and Wagon Workshop, New Bongaigaon”
I bear immense pleasure in expressing my gratitude and
thanks to all the Senior Section Engineers (SSE) of respective
shops for their honest teaching, practical demonstration,
guidance and suggestion in respective shops.
Furthermore, I would like to acknowledge with much
appreciation the crucial role of the staffs, who gave us the
permission to use all required equipments and the necessary
materials during our training period.
This training wasn't possible if HOD of mechanical department
MR ARUN KUMAR BAR OF IEM,KOLKATA wouldn't have
allowed us in the first place, so thanks to him as well.

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CONTENTS
1. Introduction
1.1 Training objectives
2. Company profile
2.1 History of workshop
2.2 Activities of the workshop
3. Shop description
3.1 Wheel turning shop
3.2 Roller bearing shop
3.3 Machine shop
3.4 Bogie repair shop
3.5 Wagon repair shop
3.6 Air brake section
3.7 Carriage lifting shop
4. Conclusion

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1. INTRODUCTION
Indian Railways is an Indian state owned enterprise, owned
and operated by the government of India through the Ministry
of Railways.
It is one of the largest railway networks comprising 115,000
km of track over a route of 65,436 km and 7,172 stations
Railway was first introduced to India in the year 1853 from
Bombay to Thane. In 1951 the systems were nationalized as
one unit.
Indian railways are the world's 7th largest commercial or
utility employer by number of employees with over 1.307
million employees.
Railways first entered Assam in 1881 when the Assam railway
and trading company began the construction of 65km long
meter gauge (MG) line from Dibrugarh to Makum collieries in
Margherita for the sole purpose for transporting tea and coal.
The Northeast- frontier was formed on 15th January 1958 with
the aim to give greater impetus to the development of
Northeast with its HQ at Maligaon.
It is divided in 5 division viz Alipur division, Lumbding
division, Rangiya division, Katihar division & Tinsukia division.

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1.1 TRAINING OBJECTIVES
 To understand the manufacturing and repairing of rail
coaches and wagon.
 To observe and acquire knowledge about
different Mechanism dealing with various machines.
 To apply the theoretical technical knowledge on real
industry application.
 To build a good communication skill with group of
workers and learn to learn proper behavior of corporate
life in industrial sector.
 To build the strength, team work spirit and self confidence
in students life.
 To enhance the ability to improve students creativity skills
and sharing ideas

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2. COMPANY PROFILE

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2.1 WORKSHOP OVERVIEW

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General Data

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2.2 Activities of workshop
COACH :-
 POH of BG AC, NON-AC and DEMU Coaches.
 Repair of Accident involved damaged coaches and special repair coaches.
 Modification as recommended by railway board & RDSO to improve the reliability of
safety and better passenger’s amenities.
 Refurbishing/Rehabilitation of BG coaches.
 Conversion of conventional air brake coaches to bogie mounted air brake coaches.
WAGON:-
 POH of BTPN, all types of BCN Wagon s, DBKM, BRN, BOBYN and brake van.
MANUFACTURING & REPAIRING:-
 Manufacturing and fabrication of components and subassemblies of BG coach and
wagon.
 Manufacturing of new wheel set for BG & NG rolling stock and motive power.
 Heat treatment, reclamation and testing of critical safety items like screw coupling,
bolster suspension hanger, draw gear equipment and testing of chain and rope.
 Shot blasting, magnaflux testing to detect crack and load testing of all types of C&W
springs.
 Phosphating of In-house manufactured component like long beam, bottom side wall
sheet etc.
METALLURGICAL & CHEMICAL LABORATORY:-
 Non destructive testing including ultrasonic testing of axles & wheels.
 Hardness testing of wheel.
 Chemical analysis, micro & macro analysis and physical testing of ferrous and non
ferrous components and materials.
MAINTENANCE:-
 The workshop undertakes in house preventive maintenance and brake down attention
of machinery, plants and equipment both for mechanical and electrical.
 Power supply for workshop and colony.

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3. SHOP DESCRIPTION

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3.1 WHEEL TURNING SHOP (WTS)
A train wheel or rail wheel is a type of wheel specially designed for
use on rail tracks. A rolling component is typically pressed onto an
axle and mounted directly on a rail car or locomotive or indirectly
on a bogie, also called a truck. Wheels are cast or forged (wrought)
and are heat-treated to have a specific hardness. New wheels are
trued, using a lathe, to a specific profile before being pressed onto an
axle. All wheel profiles need to be periodically monitored to ensure
proper wheel-rail interface. Improperly trued wheels increases
rolling resistances, reduces energy efficiency and may create unsafe
operation. A railroad wheel typically consists of two main parts :-
the wheel itself and the tire (or tyre) around the outside. A rail tire is
usually made from steel, and it’s typically heated and pressed onto
the wheel, where it remains firmly as it shrinks and cools.

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Machines available in the Wheel Turning Shop
1. Wheel Turning Lathe (MG)
2. Wheel Turning LATHE (BG)
3. Axle Journal Turning and Burnishing Lathe (AJTB)-(MG)
4. Axle Journal Turning and Burnishing Lathe (AJTB)-(BG)
5. Centre Lathe ( Super cut centre lathe )
6. Vertical Turret Lathe
7. CNC Surface Wheel Lathe
8. Surface Wheel Lathe
9. CNC Wheel Press Machine 500T (Electro-pneumatic)
10. Wheel Press Machine 500T
11. Universal Axle Journal Turning and Burnishing Lathe
Description of some of the various machines used in
machine shop –
1. Wheel Turning Lathe :-
A Lathe machine for turning wheel set having a common axis,
comprising two headstock fitted with one four jaw hydraulic
chuck on each headstock. It is a special type of lathe. It has two
tool post for holding two tools for turning the two discs on the
wheel set simultaneously. It has two control panels which
facilitate to control the two tool post separately. The machine is
hydraulic operated.

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2. Axle Journal Turning and Burnishing Lathe (AJTB Lathe):-
It is a rigid machine capable of turning and burnishing of inboard
and outboard journal of axles of wheel set. The machine is built on
rigid cast iron tailstocks on either ends. One or two tool posts in
cast construction are provided for turning and burnishing
operation. Wheel set is held between heavy duties, precision
revolving centers and is driven by suitably infinitely variable
speed try.

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3. Wheel Press Machine:-
It is used for removing wheels that are already fitted to axles and
also for fitting wheels in axles whose wheel seat diameter is
greater than wheel bore diameter. For easy fitting of axle with
wheel are mixture of linseed powder Molybdenum bi-sulphate is
smeared on the wheel seat diameter of axle for different axle
types different force for pressing is needed.
4. CNC Surface Wheel Lathe:-
It is extremely rigid and fully automatic machine for simultaneous
profiling of new or wore out wheels of railway wheel set equipped
with dial CNC toolpost. The machine is fully flexible to turn any
wheel profile. It is equipped with CNC control measurement
system for economical depth of profile selection. It is capable of
machining inside and outside face of wheel as well as break disc
with automatic loading and unloading of wheel set.

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5. Vertical Turret Lathe:-
It is the same machine as mentioned in machine shop, only
difference is here that here is rotating table are bigger in size to
hold the disc of all size of the wheel set. It has the facility of
programmable logic control (PLC).

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3.2 ROLLER BEARING SHOP
Operation in Roller Bearing Shop :-
1. Bearing Extraction :- opening of Roller Bearing & Axle box housing
using Cartridge Taper Roller Bearing (CTRB) mounting and dismounting
hydraulic press.
2. Bearing & Axle box Cleaning Plant :-
a) Bearing Cleaning Plant :-
Unclean
Bearing
Centrifuge
Machine
Bearing
loaded in
parallel in
loading
station
manually
Automatic
movement of
Pallet to
washing booth
Automatic
door closing
Spray
Washing
operation
ORION-355
Spray rinsing
operation
ORION-334
Spray rust
prevention
ORION-500
Automatic
door closing
Automatic
movement of
pallet to
unloading
manually
Cleaned
bearing
unloaded
manually

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b) Axle Box cleaning plant :-
Step 1 :- Tank 1/2 :- Uncleaned box- Axle box is kept in this tank which
Contains caustic soda (NaOH) in definite
proportion.
 Tank Capacity – 5400 ltrs
 Operating temperature – 70-90 degree Celsius
 Duration – 1hr 20 minute
 Chemical used- COROLIN 35R :- 60g/ltr= 325 kg
COROLIN 40LR :- 10ml/ltr= 54 ltrs
Step 2 :- Blast Room :- Washing of axle with water at high and low
water jet.
Step 3 :- Detergent Wash Tank :- Washing of axle box with Detergent
at High Temperature.
 Tank Capacity :- 1650 ltrs
 Operating Temperature :- 50 to 70 degree Celsius
 Chemical used :- COROLIN 201R- 25g/ltrs= 41 kg
Step 4 :- Hot pre-rinse tank- Rinsing of Axle Box at high temperature
 Operating Temperature – 50 to 70 degree Celsius
Step 5 :- Hot Rust Inhibitor Rinsing Tank – spraying of chemicals to
prevent rusting
 Operating Temperature – 50 to 70 degree Celsius
 Chemical used – COROFIL SR = 16 ltrs
Step 6 :-Hot Air Dryer Tank – spraying of hot air to dry the axle box.

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3. Bearing Inspection And Zyglo Testing :-
Bearing inspection includes-
 Checking the defects and flaws by normal eye.
 Checking for any indent in the bearing.
 Checking whether the spherical roller is moving freely or not.
ZYGLO TESTING :- Zyglo testing is a preferred penetrant inspection method
for the extremely sensitive fluorescent detection of cracks and surface
discontinuities in ferrous & non ferrous materials using zyglo testing machine.
The steps for zyglo testing are as follows :-
Step 1 :- Apply Penetrant glowcheck PEE-30 on the roller.
Step 2 :- Drip Station :- drain out the penetrant in drip station.
Step 3 :- Rinse Station :- clean the roller by hot and cold water.
Step 4 :- Drying Station :- dry the roller in drying station.
Step 5 :- Developer Station :- apply dry developer powder.
Step 6 :- Inspection Station :- inspection is done under ultraviolet ray. If any
cracks exits, it can be seen in the form of zig-zag line of green color.
4. Bearing and axle box mounting :-
Preheating and then fitting of roller bearing into wheel axle.

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3.3 MACHINE SHOP
Operations performed at machine shop –
 Turning of various semi finish axles & axle end drilling and tapping.
 Conversion of various axles viz. BG wagon to MG wagon, BG-DSL to MG-DSL,
Fricon to MG ICF.
 Machining of rear cover and front cover (MG & BG) 9”x4 ½ bearing.
 Machining of buffer plunger face plate and body under frame head stocks.
 Manufacturing of various items required for carriage and wagon POH.
 Manufacturing of various items as per divisional work order.
Machines available in Machine Shop –
1. High speed precision lathe
2. Centre lathe
3. Universal milling machine
4. Medium duty milling machine
5. Heavy duty milling machine
6. Double ended heavy duty pedestal grinder
7. Tool & cutter grinding machine
8. Surface grinder machine
9. Pillar drill machine
10. Universal radial drilling machine
11. Radial drill machine
12. Engraving machine
13. Shaping machine
14. Power hacksaw
15. Planer machine
16. Vertical turret lathe/ boring
17. CNC axle turning lathe
18. Axle facing & drilling machine

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19. Axle end drilling & tapping machine
20. Universal horizontal boring machine
21. Axle turning lathe
22. Slotting machine
23. CNC horizontal boring & milling machine
24. Cylindrical axle grinding machine
25. Power drill machine
26. Capstan lathe
27. Profile cutting machine
Description of some of the various machines used in machine
shop –
1. CENTRE LATHE :-
 The centre lathe is a machine tool that rotates the workpiece on its axis to
perform various operations such as cutting, sanding, knurling, drilling,
deformation, facing, turning, with tools that are applied to the workpiece to
create an object with symmetrical about an axis of rotation. These lathes
may be operated directly by people or computerized numerical control
(CNC) that has been programmed to carry out a particular task.

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2. CNC AXLE TURNING LATHE :-
 Computerized numerical control (CNC) lathes are rapidly replacing the
older production lathe due to their ease of setting, operation, repeatability
and accuracy. They are designed to use modern carbide tooling and fully
used modern processes. The part may be designed and the tool paths
programmed by the CAD/CAM process or manually by programmer. This
lathe has a three jaw hydraulic chuck with a turret cutter which can hold
twelve cutters at a time.
3. POWER DRILL MACHINE :-
 It is used for handling medium sized work piece, heavy medium speed,
available both power and hand feeding arrangement. It is an upright
drilling machine in round type where the column is round in section. It has
360 degree arrangement of rotation about the column under the spindle. It
can drill up to 50mm diameters.

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4. SHAPER MACHINE :-
 A Shaper is a type of machine tool that uses linear relative motion between
the workpiece and a single-point cutting tool to machine a linear tool path.
It works on quick-return mechanism. It can cut curves, angles and many
other shapes. Its movement is very simple but can produce a variety of
work.
5. UNIVERSAL HORIZONTAL BORING MACHINE :-
 A horizontal Boring Machine is a machine tool which bores holes in a
horizontal direction. It has its spindle parallel to the ground and work
table. The table of horizontal bore machine has accurate guide ways to
move the table in two perpendicular direction. This machine is further
modified in the machine shop for performing horizontal tapping.

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6. CNC PROFILE CUTTING MACHINE :-
 CNC profile cutting machine is an economical portable light weight CNC
cutting machine to cut complex shapes of high quality with oxy-fuel and
plasma cutting. The machine can be programmed to cut any plane shape
parts composed of beeling and arc, which are same as large gantry cutting
machines. It can be programmed to cut parts directly, and also can be
operated by using G-code generated by CAM program, and then be
transferred to the machine via its USN port.
7. PLANER MACHINE :-
 The planer is a machine tool designed to produce plane and flat surface on
a work piece which is too large or too heavy. The work piece is securely
fixed on a table called platen, and it reciprocates horizontally against a
single edged cutting tool. The surface machined may be horizontal , vertical
or at an angle.

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3.4 BOGIE REPAIR SHOP (BRG)
This shop deals with the maintenance and repairing of Bogies.
A bogie is a chassis or framework carrying wheels attached to a
vehicle, thus serving as a modular sub assembly of wheels & axles. The
bogies being manufactured by ICF/RCF have been accepted as a
standard of Indian railways.
Key components of a bogie include :-
 Bogie frame :- This can be of inside frame type where the main
frame and bearing are between the wheels, or (more commonly)
of outside frame type where the main frame and bearing are
outside the wheels.
 Suspension :- To absorb shocks between the bogie frame and the
rail vehicle body. Common types are coil springs or rubber
airbags.
 At least one wheelset composed of an axle with bearing and a
wheel at each end.
 Axle box suspension absorbs shocks between the axle bearing
and the bogie frame and axle bearing to permit up-and-down
movement, and sliders to prevent lateral movement. A more

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modern design uses solid rubber springs.
 Brake Equipment :- Two main types are used : Brake shoes that
are pressed against the tread of the wheel, and disc brakes and
pads.
 In powered vehicles, some form of transmission, usually
electrically powered traction motors or a hydraulically powered
torque converter.
Types of Bogies
1. IRS Bogie
2. SCHLIEREN Bogie
3. MAN-HAL Bogie
4. ICF all coiled bogie
5. IR 20 Bogie
6. FLAT Bogie
Bogie general arrangement

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Bogie Repair Step
CHANGEABLE ITEMS FOR COACH BOGIE :-
1. Rubber packing ring (T-0-1-632)
2. Guide ring (T-0-1-635)
3. Guide bush
4. Circlip for dash pot guide bush
5. Side bearer oil
6. Dash pot oil
7. Break gear bushes
8. Break shoe key
9. Shoe adjuster assembly
Bogie
Dismantling
Station
Bogie cleaning
station (BOSCH
TANK)
Bogie scrapping
and painting
station
Bogie
component
repair station
Bogie fitting
station
Bogie
assembling on
wheels
Bogie load
testing and final
dispatch

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3.5 WAGON REPAIR SHOP
This shop deals with the repairing & maintenance of wagons and their
trolleys.
Wagon :-
A vehicle used for transporting goods or peoples or another specified
purpose is called wagon. A variety of wagon types are in use to handle
different types of goods but all goods wagon in a regional network
typically have standardized coupler and other fittings such as hoses for
air brakes, allowing different wagon types to be assembled into trains.
Types Of Wagons :-
Types Lifting capacity
(ton)
Capacity(m^3) Use
Closed wagon 68 120-128 Transport packed
goods
Semi wagon 70 73 Transport bulky
materials loaded
from top
Platform/universal 71 - Transport large
cargo &
machinery
Hopper 68 90-120 -
Dump car wagon 105 50 Transport bulky
materials
Transporter 55-120 - Mainly for
transporting large
cargo
Tank 60-66 73 Transport liquid
products

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NATURE OF REPAIRS REQUIRED IN WAGON
1. Corrosion of panels, floor plates & roof sheets.
2. Puncturing of panels due to improper loading inadequately
secure consignment or deliberately tempering.
3. Bulging of ends due to shifting of loads.
4. Tearing of panels, fracture of stanchions and shearing of rivets
due to several impacts & shifting of loads.
5. Corrosion of end floor angles.
6. Bulging of side usually occur after a prolonged period in service.
7. Slackening of rivets due to combined effect of ageing, corrosion,
wear & tear.
8. Weakening of welded joints.
9. Damages due to mechanical loading & unloading.
10.Repair of doors & door fittings (for MS wagons).
Different types of wagon in figure :-

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3.6 AIR BRAKE SECTION
Introduction :-
Brakes applied with the help of air are called air brakes & the system is
actuated to apply this phenomena is known as air brake system. An air
brake system is a conveyance breaking system actuated by
compressed air. Modern trains rely upon a fail-safe air brake system
that is based upon a design presented by George westing house on
March 5,1872.
Components of Air Brake system :-
1. Distributor valve
1.1 C3W
1.2 KE
1.3 P4a
2. Brake cylinder
3. Control Reservoir
4. Auxiliary reservoir
5. Isolating cock
6. Dirt collector
7. Cut-off angle cock
8. Hose coupling
9. Non-return valve with choke
10. Passenger emergency valve
11. Pilot valve
12. Guard emergency valve
13. Pressure gauge
14. Slack adjuster

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Principle of operation of Air Brake System :-
There are 3 stages in Air Braking System
1. Charging :-
1.1 Compressed air of 5 kg/cm^2 is supplied through brake
pipe(BP) from engine.
1.2 Control Reservoir (CR) & Auxiliary Reservoir (AR) is charged
to 5 kg/cm^2 through distributor valve (DV).
1.3 Brake cylinder (BC) is in released condition in this stage.
2. Application :-
2.1 BP pressure is dropped by driver using A9 valve or by guard
using guard emergency valve (or passenger using passenger
alarm chain).
2.2 AR & CR is disconnected from BP and DV. AR air is connected to
BC line through pressure limit gauge of DV.
2.3 BC get operated i.e. piston moves out and brake gets applied.
3. Release :-
3.1 BP pressure is raised to 5 kg/cm^2 by driver.
3.2 AR line is disconnected from BC line by DV.
3.3 BC line is opened to atmosphere through release choke in
the DV.
3.4 Piston in the BC is pushed in by the retention spring as
compressed air gets exhausted from BC.

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Testing of Air Brake Equipments :-
Most important test in the air brake system is Distributor valve test.
It contains 8 stages/steps.
1. Leakage test
2. Charge time
3. Sensitivity & Insensitivity test
4. Release characteristics of DV
5. over charge protection
6. Automatic release test
7. Automatic release valve closing
8. Graduated application & release test
Block diagram of Air Brake Equipment

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3.7 CARRIAGE LIFTING SHOP
In this shop the body is separated from the bogie. This can be done
only when the connecting pipes and the lighting wires are
disconnected from the bogie to the body. After that the body is
repaired as per requirement. Some of the parts which normally get
repaired or replaced are the footsteps, buffer, sole bar, pillar, screw
coupling, air brake.

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CONCLUSION
In review of this training has been an excellent and rewarding
experience. We had the huge advantage as engineers to practice a
profession, the application of which has no boundary and it is
extremely beneficial to discover how engineers from different fields
find solutions, face problems that occurs in various situations with
different capabilities.
The only chance that an undergraduate has to have this experience is
the industrial training period. I feel I got the maximum out of that
experience. Also I learnt the way of work in an organization, the
importance of maximum commitment, the importance of punctual, and
the importance of team spirit. In my opinion, I have gained lots of
knowledge and experience needed to be successful in a great
engineering challenge, as in my opinion, Engineering is after all a
challenge not a job.
The skills I acquired in the field and behind the desk were extremely
and embellished by a marvelous experience.
It was a pleasant training environment. I thank to this reputed
organization for helping me whole heartedly.

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REFERENCES
1.Wikipedia- about carriage and wagon
2.Daily Dairy
3.http://www.google.co.in/
4.http://www.books.google.co.in/

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