Rail Wheel Factory Overview

Podcast

Play an AI-generated podcast conversation about this lesson

Questions and Answers

What role do the hammers in the Long Forging machine have?

They convert billets into required shapes. (correct)

They measure the size of the forgings.

They transport billets to the machining lines.

They are used to cool down the billets.

What processes are the rough forged axles subjected to after end cutting?

Welding and assembly.

Drilling and grinding.

Heat treatment in normalizing and tempering furnaces. (correct)

Milling and polishing.

What is the purpose of precision borers in the wheel set assembly process?

To enhance the aesthetic finish of the wheels.

To inspect the structural integrity of the axles.

To determine the alloy composition of axles.

To ensure final bores have required interference with axles. (correct)

Which company supplied the highly automated wheel set assembly complex?

Simmons Machine Tool Corporation. Signup and view all the answers

What does RWF primarily convert into wheel sets?

Container and coaching axles. Signup and view all the answers

What is recorded automatically during the wheel pressing process?

Force required in pressing the wheels. Signup and view all the answers

What characteristic of RWF's manufacturing process minimizes human error?

Automated machining processes. Signup and view all the answers

What is a key feature of every product manufactured by RWF?

It is inspected and tested for reliability. Signup and view all the answers

Which of the following statements accurately describes the Rail Wheel Factory's manufacturing process?

Scrap steel is melted in an Electric Arc furnace. Signup and view all the answers

After the boring process, how are the wheels transported to the assembly complex?

Using automated conveyors. Signup and view all the answers

What is the planned capacity of the Rail Wheel Factory for manufacturing wheels?

200,000 wheels of various sizes. Signup and view all the answers

What type of machines are used in the axle machining lines at RWF?

CNC machines. Signup and view all the answers

In what year was the Rail Wheel Factory established?

1984 Signup and view all the answers

What is the primary purpose of the Spectrometer in the manufacturing process?

To ensure the correct chemistry of molten metal. Signup and view all the answers

What distinguishes the Rail Wheel Factory from other manufacturing units in the Indian Railways?

It was the first unit to receive ISO 9001:2008 accreditation. Signup and view all the answers

How long does it take to cast a wheel at the Rail Wheel Factory?

Every 1.5 minutes. Signup and view all the answers

What is the temperature to which blooms are heated in the Rotary Hearth Furnace?

1200 degree C. Signup and view all the answers

The casting process for wheels employs what kind of moulds?

Graphite moulds. Signup and view all the answers

What process follows the casting of wheels to ensure their quality?

Heat treatment and various inspections. Signup and view all the answers

What type of technology did the Rail Wheel Factory adopt for its wheel-casting process?

Controlled pressure pouring process. Signup and view all the answers

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.
Founded in 1984.
Previously known as the Wheel and Axle plant.
Renamed Rail Wheel Factory after becoming part of the Indian Railway Ministry.
Founded by C.K. Jaffer Sharief, the then Railway Minister.
First Indian Railways unit to receive ISO 9001:2008 accreditation.

Manufacturing Processes

Wheels: Uses cast steel technology using scrap steel from railway workshops.
Manufacturing capacity: 200,000 wheels, 100,000 axles, 70,000 wheel sets.
- Casting process using controlled pressure pouring technology, obtaining technology from M/s. Griffin Wheel Co., USA. Raw materials include scrap wheels, axles, and parts of railway bogies.
- Molten metal steel chemistry is determined via spectrometers.
- Casting into graphite molds, which are pre-heated, split, and the risers are detached.
- Heat treatment, cleaning, Magnaglo testing, Ultrasonic testing, and peening
- Machining focuses on precise boring of the central hub where the axle fits.
Axles: Converts steel blooms (raw steel) through forging, heat treatment, and machining processes.
- Blooms are heated to 1200°C in a Rotary Hearth Furnace, then transferred to a precision forging machine.
- Hammers shape the billets into the required axle form using CNC.
- Heat treatment in normalizing and tempering furnaces.
- Two CNC machining lines convert forgings into axles.
- Loco axles, BOX N, Coaching, and Container axles are also converted into wheel sets.
- Axles are generally sent to workshops for converting them to wheel sets.

Assembly and Quality Control

Automated Wheel Set Assembly: Highly automated assembly complex from Simmons Machine Tool Corporation, USA.
Automated Measurements: Wheel seat sizes of machined axles are measured, and wheels are bored based on these sizes for correct interference with the axles.
Automated Conveyors: Wheels and axles are carried through automated conveyors to the assembly complex, ensuring the correctness of pressing forces.
Automatic Force Recording: Pressing forces are recorded automatically, maintaining consistent assembly parameters.
Quality Control: Every product is manufactured per customer requirements, inspected, and tested to ensure reliability. Most machining processes are automated, reducing human error.

Studying That Suits You

Use AI to generate personalized quizzes and flashcards to suit your learning preferences.

Description

Explore the Rail Wheel Factory, a key manufacturing unit of Indian Railways located in Bangalore. This quiz covers its history, manufacturing processes, and production capabilities. Test your knowledge about its significant contributions to the Indian railway system.