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Questions and Answers
What is the primary purpose of rim quenching in the wheel manufacturing process?
What is the primary purpose of rim quenching in the wheel manufacturing process?
How long does a wheel remain in the draw furnace for tempering?
How long does a wheel remain in the draw furnace for tempering?
What is the purpose of hub cooling in the wheel manufacturing process?
What is the purpose of hub cooling in the wheel manufacturing process?
What is the typical pressure of the water used during the hub cooling process?
What is the typical pressure of the water used during the hub cooling process?
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What is a consequence of wheels having a rough, uneven surface after cooling?
What is a consequence of wheels having a rough, uneven surface after cooling?
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What is the primary heating method used in electric arc furnaces?
What is the primary heating method used in electric arc furnaces?
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What role does slag play during the melting process in electric arc furnaces?
What role does slag play during the melting process in electric arc furnaces?
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What is the typical temperature range during the melting procedure in an electric arc furnace?
What is the typical temperature range during the melting procedure in an electric arc furnace?
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What is the function of the oxygen lancing pipe during the melting process?
What is the function of the oxygen lancing pipe during the melting process?
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How does the electric arc furnace maintain the gap between its electrodes and the charge?
How does the electric arc furnace maintain the gap between its electrodes and the charge?
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Which of the following components is not part of the electric arc furnace structure?
Which of the following components is not part of the electric arc furnace structure?
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What is the capacity range of each electric arc furnace in the RWF wheel shop?
What is the capacity range of each electric arc furnace in the RWF wheel shop?
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At what temperature should full slag be removed during the process?
At what temperature should full slag be removed during the process?
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What is added to the slag if it is found sluggish during processing?
What is added to the slag if it is found sluggish during processing?
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What is the primary purpose of spectro-analysis in the testing process?
What is the primary purpose of spectro-analysis in the testing process?
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What material is added during carburisation if the carbon content is low?
What material is added during carburisation if the carbon content is low?
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Why is oxygen introduced during decarburisation?
Why is oxygen introduced during decarburisation?
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What is the average tapping temperature range for the melt?
What is the average tapping temperature range for the melt?
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What is the purpose of thoroughly mixing the bath during production?
What is the purpose of thoroughly mixing the bath during production?
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How long should the tapping process ideally take to minimize temperature loss?
How long should the tapping process ideally take to minimize temperature loss?
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What addition is made to the ladle after its preparation for the tapping process?
What addition is made to the ladle after its preparation for the tapping process?
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What is the primary purpose of the John Mohr Pit (JMP)?
What is the primary purpose of the John Mohr Pit (JMP)?
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How much Ferro-silicon can be added without draining metal?
How much Ferro-silicon can be added without draining metal?
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What temperature range is critical for immersing the Aluminum stars into the melt?
What temperature range is critical for immersing the Aluminum stars into the melt?
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What is the aim of adding 2 kgs of graphite powder to 20 MT of liquid metal?
What is the aim of adding 2 kgs of graphite powder to 20 MT of liquid metal?
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How long does it take for the ceramic pouring tube to be prepared for high temperature?
How long does it take for the ceramic pouring tube to be prepared for high temperature?
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What is sprinkled into the ladle to maintain temperature after the melt is poured?
What is sprinkled into the ladle to maintain temperature after the melt is poured?
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What is required for the pouring tube section preparation before using the ceramic pipe?
What is required for the pouring tube section preparation before using the ceramic pipe?
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Which element is increased by adding 3 kgs of Ferro-Manganese?
Which element is increased by adding 3 kgs of Ferro-Manganese?
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What does the controlled pressure pouring process in the casting process primarily achieve?
What does the controlled pressure pouring process in the casting process primarily achieve?
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What is the expected increase in manganese when adding 3 kgs of Silicon-Manganese?
What is the expected increase in manganese when adding 3 kgs of Silicon-Manganese?
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What is the maximum temperature range maintained in the rotary hearth furnace?
What is the maximum temperature range maintained in the rotary hearth furnace?
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Which type of fuel is used in the rotary hearth furnace?
Which type of fuel is used in the rotary hearth furnace?
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How long does each wheel remain in the furnace?
How long does each wheel remain in the furnace?
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What is the temperature of the wheel when it exits the furnace?
What is the temperature of the wheel when it exits the furnace?
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What drives the rotation of the hearth inside the rotary furnace?
What drives the rotation of the hearth inside the rotary furnace?
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What is the purpose of rim quenching?
What is the purpose of rim quenching?
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Which blower is used for combustion in the rotary hearth furnace with the highest rated static pressure?
Which blower is used for combustion in the rotary hearth furnace with the highest rated static pressure?
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What medium is used during the quenching process?
What medium is used during the quenching process?
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What is the total number of wheels accommodated in the furnace at one time?
What is the total number of wheels accommodated in the furnace at one time?
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What happens to the outer portion of the wheel during movement on rails?
What happens to the outer portion of the wheel during movement on rails?
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Study Notes
Wheel Shop Process Overview
- The Wheel Shop is the initial unit in the Rolling Wheel Factory (RWF).
- Wheels average 500 kg in weight.
- Eight different wheel types are produced, each with varying compositions, requirements, and dimensions.
- Scrap yard metals are recycled and combined with new materials to create the correct wheel composition.
- The Wheel Shop is divided into three main divisions: Melting, Moulding, and Finishing (WFPS).
Melting Process
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Scrap Conditioning: The process begins with scrap preparation.
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Scrap types include rejected wheels, rejected axles, used axles/worn-out wheels, and machining chips.
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Different scrap types are crucial in the electric arc furnace, as heat distribution isn't uniform.
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The arrangement of scrap in the furnace helps prevent fire, bridging, and collapse.
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Charging of Scrap: Adding scrap, lime, calcined lime, and coke/graphite to the furnace. -Electromagnets are used to lift and place scrap in the furnace.
- The process involves electric arc furnaces designated as A, B, and C.
- Furnace capacities range from 20-23 metric tons.
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Brief Procedure: -Electrodes lower and an arc is struck between electrodes and scrap for 45-55 minutes.
- Maintaining gap between electrodes and scrap controls the arc.
- Oxygen lancing is used for scrap cutting, with temperatures between 1650-1700°C. -Slag is formed, floating on top to protect the melt and furnace roof -Removal of slag is done using dolomite.
Melting of Scrap
- The Electric Arc furnace is crucial for heating charged materials.
- Refractory-lined vessels with retractable roofs allow for graphite electrode entry.
- Furnace split into three sections (shell, hearth, roof).
Spectro-Analysis
- Testing samples to analyze metal composition for wheel manufacturing.
- Samples are solidified metal obtained from an electric arc furnace.
- Accurate wheel composition is essential.
Carburisation/Decarburisation
- Testing the composition of metals (C, Si, Mn) in the melt.
- Adjusting material additions (like graphite) to reach the required percentage.
- This adjustment is done by carburization or decarburization, based on the carbon content.
Tapping
- Pouring the molten metal from the furnace into ladles.
- This involves tilting the furnace base.
Other Processes in Wheel Manufacturing
- Moulding Room: The Controlled Pressure Pouring process uses a graphite mould, ladle, & refractory structure.
- John Mohr Pit (JMP): Cooling, temperature measurement, and melt composition adjustments.
- Sprue Washing: Cleaning melted material channels from sprue, runner, and riser sections.
- Hub Cutting: Using oxygen and LPG gas flame in a hub cutting machine, this process trims the wheel hub to the correct size, using an 188mm diameter and pilot hole.
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Normalizing: Heating the metal above the critical temperature, holding it for time, and then cooling it.
- This process uses a seven-zone rotary hearth furnace.
- Temperature is maintained between 890-960 °C, 90 minutes/wheel.
- Quenching and Tempering: Applying rapid cooling to increase the hardness. This is to increase rim portion hardness to 5-8mm thickness. Water temp is 18-35 °C.
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Hub Cooling: Hardening the hubs by quenching in water jets.
- Using 3 regions to cool -- upper, middle, and inner portion -- for 45 seconds each.
- 2.5 kg/cm squared water pressure
- Apex Grinding: Removing extra metal from the casting along the parting line.
- Cleaning: Removing dust, ash, and scales from the wheels.
- Magnaglo Testing: Detecting surface cracks using fluorescent magnetic particles.
- Ultrasound Testing: Detecting interior defects using ultrasonic waves.
- Warpage Testing: Identifying and measuring wheel warpage to ensure quality and suitability
- Shot Peening: Improving the mechanical properties of the wheel through compressive residual stress (cold working method)
Wheel Final Process Shop (WFPS)
- Cleaning: Ensuring even surface, removing any impurities, and prepping for further tests.
- Additional processes: including Apex grinding to remove excess material from casting, using a multiple roto-blast system to increase surface cleaning.
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Description
This quiz covers the Wheel Shop process in the Rolling Wheel Factory, detailing the various divisions such as Melting, Moulding, and Finishing. It explores the significance of different scrap materials and their role in the melting process. Delve into how wheels are produced, including the importance of composition and recycling.
