Podcast
Questions and Answers
What process is primarily used by the precision Long Forging machine to shape the billets?
What process is primarily used by the precision Long Forging machine to shape the billets?
What is the purpose of the heat treatment process in the forging process?
What is the purpose of the heat treatment process in the forging process?
How does Rail Wheel Factory ensure the quality of its products?
How does Rail Wheel Factory ensure the quality of its products?
What is the function of precision borers in the wheel assembly process?
What is the function of precision borers in the wheel assembly process?
Signup and view all the answers
What role does automation play in the machining process at Rail Wheel Factory?
What role does automation play in the machining process at Rail Wheel Factory?
Signup and view all the answers
What was the original name of Rail Wheel Factory before it was renamed?
What was the original name of Rail Wheel Factory before it was renamed?
Signup and view all the answers
How often is a wheel cast at RWF?
How often is a wheel cast at RWF?
Signup and view all the answers
What technology does RWF use for casting wheels?
What technology does RWF use for casting wheels?
Signup and view all the answers
What is the planned capacity of RWF for manufacturing axles?
What is the planned capacity of RWF for manufacturing axles?
Signup and view all the answers
What material is primarily used as raw material for manufacturing at RWF?
What material is primarily used as raw material for manufacturing at RWF?
Signup and view all the answers
What identification number did RWF receive as a quality certification?
What identification number did RWF receive as a quality certification?
Signup and view all the answers
In which year was Rail Wheel Factory founded?
In which year was Rail Wheel Factory founded?
Signup and view all the answers
At what temperature are steel blooms heated for axle production?
At what temperature are steel blooms heated for axle production?
Signup and view all the answers
Study Notes
Rail Wheel Factory (RWF)
- RWF is a manufacturing unit of Indian Railways
- Produces wheels, axles, and wheel sets for railroad wagons, coaches, and locomotives
- Located in Yelahanka, Bangalore, Karnataka
- Founded in 1984
- Formerly known as Wheel and Axle plant
- Renamed Rail Wheel Factory after coming under the Indian railway ministry board
- Started by C.K. Jaffer Sharief, the Railway Minister
- Commissioned to manufacture wheels and axles for Indian Railways
Manufacturing Process - Wheels
- Uses cast steel technology, utilizing scrap steel from Railways' workshops as raw material
- Manufacturing process involves melting scrap steel in an electric arc furnace
- Ensures correct metal chemistry using a spectrometer
- Cast in preheated graphite molds, with risers separated automatically
- Heat treatment, cleaning, Magnaglo testing, ultrasonic testing, peening, and rigorous inspection
- Precision boring of central hole for the axle
- Cast every 1.5 minutes
- Technology obtained from M/s. Griffin Wheel Co., USA
- Raw materials include scrap from used wheel sets, axles, and rail bogie parts
- Process meets wagon builders' and loose wheel requirements
Manufacturing Process - Axles
- Plant converts steel blooms into axles through forging, heat treatment, and machining
- Blooms are heated to 1200 degrees Celsius in a rotary hearth furnace
- Precision forging machines shape the blooms into axles, using CNC (Computer Numerical Control) technology
- Multiple hammers in forging machines to achieve required sizes
- Normalizing and tempering furnaces complete the heat treatment
- CNC machining lines convert forgings into axles
- Converts BOX N, Coaching, and Container Axles to wheel sets
- Loco axles are generally sent in rough-turned condition to production units and railway workshops
Automated Assembly
- Highly automated wheel set assembly complex supplied by Simmons Machine Tool Corporation, USA
- Wheel seat sizes of machined axles are measured, and wheels are bored according to these sizes
- Precision borers ensure interference fit with individual axles
- Automated conveyors carry wheels and axles through the assembly complex
- Pressing force is automatically recorded to maintain the set limits
Quality Control
- Every product is manufactured according to customer requirements
- Every product is inspected and tested for quality and durability
- Automated machining minimizes human error, ensuring superior product reliability
- Planned capacity: 200,000 wheels, 100,000 axles, 70,000 wheel sets
- Received ISO 9001:2008 accreditation
Studying That Suits You
Use AI to generate personalized quizzes and flashcards to suit your learning preferences.
Related Documents
Description
Explore the manufacturing processes of the Rail Wheel Factory (RWF), a key unit of Indian Railways located in Bangalore. This quiz covers the technologies and methods used in producing wheels and axles, focusing on the innovative use of scrap steel and advanced testing methods. Test your knowledge about RWF's history and production techniques.
