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Questions and Answers
What is the primary product manufactured at Rail Wheel Factory (RWF)?
What is the primary product manufactured at Rail Wheel Factory (RWF)?
In which year was the Rail Wheel Factory (RWF) founded?
In which year was the Rail Wheel Factory (RWF) founded?
What technology does RWF employ for manufacturing wheels?
What technology does RWF employ for manufacturing wheels?
How often is a wheel cast at RWF?
How often is a wheel cast at RWF?
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What is used as raw material for wheel production at RWF?
What is used as raw material for wheel production at RWF?
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What accreditation did RWF achieve first among Indian Railways units?
What accreditation did RWF achieve first among Indian Railways units?
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Which process is used to melt the steel for wheel production?
Which process is used to melt the steel for wheel production?
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How long does it take to produce an axle at RWF?
How long does it take to produce an axle at RWF?
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What type of testing is performed on the wheels produced at RWF?
What type of testing is performed on the wheels produced at RWF?
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What heating temperature is used in the Rotary Hearth Furnace for axles?
What heating temperature is used in the Rotary Hearth Furnace for axles?
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What is the primary function of the Long Forging machine?
What is the primary function of the Long Forging machine?
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What processes do the forged axles undergo after end cutting?
What processes do the forged axles undergo after end cutting?
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Where is the machining of axles performed at Rail Wheel Factory?
Where is the machining of axles performed at Rail Wheel Factory?
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What is the purpose of the precision borers in the process?
What is the purpose of the precision borers in the process?
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What happens to loco axles after they are rough turned?
What happens to loco axles after they are rough turned?
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What is the significance of the pressing force being recorded automatically?
What is the significance of the pressing force being recorded automatically?
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Who supplied the wheel set assembly complex at Rail Wheel Factory?
Who supplied the wheel set assembly complex at Rail Wheel Factory?
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What is a key benefit of automation in the machining process at Rail Wheel Factory?
What is a key benefit of automation in the machining process at Rail Wheel Factory?
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What does the Rail Wheel Factory ensure with every product manufactured?
What does the Rail Wheel Factory ensure with every product manufactured?
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What type of axles does Rail Wheel Factory convert into wheel sets?
What type of axles does Rail Wheel Factory convert into wheel sets?
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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.
- Founded in 1984, formerly known as Wheel and Axle Plant.
- Renamed Rail Wheel Factory after coming under the Indian Railway ministry.
- Started by C. K. Jaffer Sharief, the then Railway Minister.
- Uses cast steel technology in wheel manufacturing.
- Raw material is scrap steel from Railways' workshops.
- Manufactures wheels, axles, and wheel sets.
- Designed with minimal scrap contributing to human errors.
- Production capacity: ~200,000 wheels, ~100,000 axles, ~70,000 wheel sets.
- First Indian Railways unit to receive ISO 9001:2008 accreditation.
Wheel Manufacturing Process
- Wheels are cast every 1.5 minutes.
- Technology from M/s. Griffin Wheel Co., USA.
- Raw materials include scrap wheels, axles, and rail bogie parts.
- Scrap steel is melted in an Electric Arc furnace.
- Molten steel's chemistry is checked using a Spectrometer.
- Cast in graphite molds (pre-heated and sprayed).
- Risers are separated after a set time.
- Undergoes heat treatment, cleaning, Magnaglo testing, ultrasonic testing, peening, and inspection.
- Precision boring of central hub (for axle fitting).
- No machining required, except for the central hole.
Axle Manufacturing Process
- Axles are manufactured every 5 minutes.
- Process involves forging, heat treatment, and machining.
- Steel blooms are heated in Rotary Hearth Furnace (up to 1200°C).
- Precision forging using multiple hammers.
- Forged axles undergo heat treatment (normalizing and tempering).
- CNC machining lines convert forgings into axles.
Wheel-Axle Assembly and Quality Control
- RWF has an automated wheel set assembly complex (Simmons Machine Tool Corp., USA).
- Wheel seat sizes of machined axles are measured and bored for precise fit.
- Automated conveyor system for assembly.
- Pressing force for assembly is automatically controlled.
- Each product is manufactured to customer's specifications and inspected thoroughly.
- Automated machining processes minimize human errors.
- Wheel and axles are typically delivered to production facilities in rough turned condition.
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Description
Explore the history and manufacturing processes of the Rail Wheel Factory (RWF), an essential unit of Indian Railways located in Bangalore. Learn about its production capabilities, technological advancements, and its significance in the railway sector since its establishment in 1984.
