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Questions and Answers
What year was the Rail Wheel Factory (RWF) founded?
What year was the Rail Wheel Factory (RWF) founded?
Which technology is used in the manufacturing of wheels at RWF?
Which technology is used in the manufacturing of wheels at RWF?
How often is a wheel cast at the RWF?
How often is a wheel cast at the RWF?
What is the planned capacity of RWF for producing wheels annually?
What is the planned capacity of RWF for producing wheels annually?
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Which process is used for scrap steel in wheel manufacturing at RWF?
Which process is used for scrap steel in wheel manufacturing at RWF?
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How frequently does RWF produce an axle?
How frequently does RWF produce an axle?
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What accreditation did RWF receive as the first unit of Indian Railways?
What accreditation did RWF receive as the first unit of Indian Railways?
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What is the main raw material used in the production of wheels at RWF?
What is the main raw material used in the production of wheels at RWF?
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Which company provided the technology for the controlled pressure pouring process at RWF?
Which company provided the technology for the controlled pressure pouring process at RWF?
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What is the temperature to which steel blooms are heated in the Rotary Hearth Furnace at RWF?
What is the temperature to which steel blooms are heated in the Rotary Hearth Furnace at RWF?
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What process is used by the Forging Machine to shape the billets?
What process is used by the Forging Machine to shape the billets?
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What treatments do the rough forged axles undergo after end cutting?
What treatments do the rough forged axles undergo after end cutting?
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Which type of axles does Rail Wheel Factory convert to wheel sets?
Which type of axles does Rail Wheel Factory convert to wheel sets?
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What is the condition in which loco axles are generally sent to the production units?
What is the condition in which loco axles are generally sent to the production units?
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Which company supplied the automated wheel set assembly complex?
Which company supplied the automated wheel set assembly complex?
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How are the wheel sizes adjusted to fit the machined axles?
How are the wheel sizes adjusted to fit the machined axles?
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What ensures that the pressing force of the wheels is within laid down limits?
What ensures that the pressing force of the wheels is within laid down limits?
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What is emphasized about the manufacturing process at Rail Wheel Factory?
What is emphasized about the manufacturing process at Rail Wheel Factory?
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What is ensured through inspection and testing of every product at RWF?
What is ensured through inspection and testing of every product at RWF?
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What does CNC stand for in the context of the manufacturing process?
What does CNC stand for in the context of the manufacturing process?
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Study Notes
Rail Wheel Factory (RWF)
- RWF is a manufacturing unit of Indian Railways, producing wheels, axles, and wheel sets for railroad wagons, coaches, and locomotives.
- Located in Yelahanka, Bangalore, Karnataka, India.
- Established in 1984.
- Renamed from Wheel and Axle Plant after becoming part of the Indian Railway ministry.
- Started by C. K. Jaffer Sharief, the then Railway Minister.
- Uses cast steel technology in wheel manufacturing.
- Recycles scrap steel from railway workshops for raw materials.
- Produces wheels, axles, and wheel sets.
- Planned capacity to manufacture 200,000 wheels, 100,000 axles, and 70,000 wheel sets.
- First Indian Railways unit to receive ISO 9001:2008 accreditation.
Wheel Manufacturing Process
- Wheels are cast every 1.5 minutes using a controlled pressure pouring process.
- Raw materials include scrap from old wheel sets, axles, and rail bogie parts.
- Scrap is melted in an electric arc furnace; steel chemistry is checked using a spectrometer.
- Molten steel is cast into pre-heated graphite molds.
- Risers are automatically separated from the cast wheels.
- Wheels undergo heat treatment, cleaning, Magnaglo testing, ultrasonic testing, peening, and inspection.
- Precision boring of the central hub is the only machining required.
Axle Manufacturing Process
- Axles are produced every 5 minutes via forging, heat treatment, and machining.
- Steel blooms are heated in a rotary hearth furnace up to 1200°C.
- Forged into the correct shapes using multiple-hammer forging machines.
- CNC-based machining.
- Normalizing and tempering.
- Machinery converts forgings into axles.
Wheel Set Assembly
- RWF has a highly automated wheel set assembly complex (Simmons Machine Tool Corp., USA).
- Wheel seat sizes are measured on machined axles.
- Axles are bored according to the wheel seat sizes.
- Wheels and axles are automatically pressed together using conveyors.
- Force is monitored to remain within limits.
Quality Control
- Every product is manufactured according to customer requirements.
- Each product is inspected and tested to ensure longevity and reliability.
- Automation minimizes human error in machining processes.
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Description
Explore the Rail Wheel Factory, a key manufacturing unit of Indian Railways located in Bangalore. This quiz covers its establishment, production capabilities, and the innovative processes used in wheel manufacturing. Test your knowledge on this crucial aspect of rail transport in India.
