Rail Wheel Factory Process Charts

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Questions and Answers

Which of the following methods is used for cooling the forged part?

Water Cooling

Vacuum Cooling

Oil Cooling

Air Cooling (correct)

Which of the following processes is used to create a uniform fine grain structure in the forged part?

End Cutting

Normalising (correct)

Forging

Cooling Bed

What is the capacity of the forging press used in the process?

20 Ton

50 Ton

3600 Ton (correct)

8 Ton

What is the purpose of the 'Normalising' treatment?

To improve the machinability of the material (A) Signup and view all the answers

Which of the following methods is used for cutting the end of the forged piece?

Oxy-LPG Cutting (D) Signup and view all the answers

In which station does the machining process begin?

STN.1 END MILLING, CUP TURNING & CENTERING (A) Signup and view all the answers

What is the purpose of cup turning in the process?

To create a groove to hold the axle (C) Signup and view all the answers

Which of the following is a type of heat treatment used for Loco axles?

Polymer Quenching (B), Tempering (C) Signup and view all the answers

Which of the following machines are used in the process for both rough and fine turning?

2-CNC LATHES (A) Signup and view all the answers

What is the temperature used for heating the metal during the process?

200 degrees Centigrade (C) Signup and view all the answers

Which of the following processes is used to ensure the uniform fine grain structure of the forged part?

Normalising (B) Signup and view all the answers

Which process is used to prepare billets before forging?

BILLET HEATING (RHF) (C) Signup and view all the answers

What is the purpose of the 'A' MIC Shop's 'STN. 1 END MILLING, CUP TURNING & CENTERING' stage?

Preparing the forged piece for the next stage of machining. (B) Signup and view all the answers

What is the purpose of the 'USL RADIAL SCANNING M/C' used in the process?

To identify and detect internal defects in the forged part. (B) Signup and view all the answers

What is the significant difference between the 'A' MIC Shop and the 'B' MIC Shop?

'A' MIC Shop focuses on rough machining while 'B' MIC Shop handles finish machining. (D) Signup and view all the answers

Which of these processes involves heating and soaking?

Band Jaw (B) Signup and view all the answers

What is the purpose of 'LF (270 Smallmin)'?

Specifying a processing time (A) Signup and view all the answers

Which stage indicates the wheels have passed inspection and are ready for further processing?

Passed Wheels (D) Signup and view all the answers

What type of specialized equipment is used for 'HUB BORE MACHINING'?

VTL (D) Signup and view all the answers

Which process helps to increase the durability of the wheels?

SHOT PEENING (C) Signup and view all the answers

Which of the following is used to measure the radial dimensions of the forged part?

USL Radial Scanning Mic (B) Signup and view all the answers

What is the purpose of the 'MPT' within this process?

To apply lubricating oil during forging (A) Signup and view all the answers

What is the standard size of a billet used in the axle production process?

287 X 300 X 343 (mm) (A) Signup and view all the answers

What is the approximate target temperature range for heating the billets in the Rotary Hearth Furnace?

980 - 1050 °C (D) Signup and view all the answers

Which stage in the axle production process is NOT related to the billet's initial preparation and heat treatment?

AXLE FORGING (B) Signup and view all the answers

What is the primary function of the Rotary Hearth Furnace?

To heat the billets to a specific temperature for further processing (C) Signup and view all the answers

What does the acronym 'RHF' stand for in the context of the flow chart?

Rotary Hearth Furnace (D) Signup and view all the answers

Study Notes

Rail Wheel Factory Flow Process Charts

Flow Process Chart - Axle: This chart outlines the steps in manufacturing railway axles.
- Raw materials (billets) are heated, cut, and numbered.
- Forging and tempering stages follow.
- Processes like rough and finish turning, drilling, tapping, and re-centering occur.
- Cylindrical grinding and various quality checks (e.g., ultrasonic tests) are performed.
- Axles are measured and assembled.
Flow Process Chart - Wheel: This chart details wheel production.
- Scrap charging, melting, pouring processes happen.
- Wheel rims are quenched and cooled.
- Number stamping and hub cutting take place.
- Normalizing, wheel grinding, shot blasting, and hardness testing occur.
- Quality checks and final assembly conclude the procedure.
Key Processes: Processes like forging, quenching, tempering, and various machining operations (e.g., turning, grinding, drilling) are crucial in both charts.
Quality Control: Methods like ultrasonic testing, magnetic particle inspection & others are used for verifying axle and wheel quality.
Material Specifications: Billets are heated to temperatures between 980-1050°C. Different quenching and tempering methods occur, depending on the alloy used. Precise dimensions are critical.
Machine Types: The processes utilize specialized machines like rotary hearth furnaces, forging presses, lathes, cylindrical grinding machines, CNC machine tools and more.
Terminology: Various specialized terms related to metalworking, quality control, and railway engineering are used throughout the documents.

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Description

This quiz explores the flow process charts for manufacturing railway axles and wheels. It covers each step from raw materials to final assembly, detailing critical processes such as forging, quenching, and various machining operations. Test your knowledge on the intricate procedures involved in rail manufacturing.