Rail Wheel Factory Flow Process Chart - Axle PDF

# RAIL WHEEL FACTORY ## Flow Process Chart - AXLE | Stage | Description...

# RAIL WHEEL FACTORY ## Flow Process Chart - AXLE | Stage | Description | | ---------------------------------- | ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------ | | BLOOMS | | | BILLET CUTTING | 287 X 300 X 343 (mm) | | BILLET HEATING (RHF) | Rotary Hearth Furnace, 980-1050°C. | | FORGING | LFM 8 Ton (Forging press 3600 Ton) | | END CUTTING | OXY-LPG - High propane gas cut | | NUMBER STAMPING | | | COOLING BED | Air cooled (Internal Stress Removed) | | NORMALISING | Uniform fine grain structure & Bake, It less brittle Improve machining. 20-50°K above UCLF. Soak for 1 hour then Air cooliny, Smaller gran give tougher & more ductile material. | | INT. COOLING | Intermediate cooling bed at 650°C to improve machining. | | TEMPERING | 650°C (for Machinability), Allows heat to enter | | STN 1 END MILLING, CUP TURNING & CENTERING | 'A' MIC Shop | | ULTRASONIC TEST | | | STN 2 CNC ROUGH TURNING | | | USL RADIAL SCANNING M/C | | | SPM MACHINE DRILLING, TAPPING & RE CENTERING | 'B' MIC Shop | | 2-CNC LATHES | | | CYLINDRICAL GRINDING MACHINE | | | MPT | | | MEASURING STATION | | | WHEEL, WHEEL HUB BORING | | | ASSEMBLY | | | INSPECTION | | ## Flow Process Chart - WHEEL - **SCRAP CHARGING** - **EAF-1, EAF-2, EAF-3** - **MELTING** - **SPECTRO ANALYSIS** - **JMP-1, JMP-2** - **POURING STN** - **MOULD SPLIT** - **CONTROLLED COOLING IN HOT WHEEL KILN** - **SPRUE WASH** - **CHIPPING STN** - **NUMBER STAMPING** - **HUB CUTTING** - **NORMALISING** - **RIM QUENCHING** - **TEMPERING** - **HUB COOLING** - **AIR COOLING** - **STACK YARD** - **WHEEL LOADING** - **APEX GRINDING** - **SHOT BLASTING** - **MAGNAGLO INSP. - 181A** - **ULTRASONIC INSP.** - **BRINELL HARDNESS** - **WHEEL GRINDING STATIONS** - **XC WHEELS** - **VTL** - **WHEELS MARKED FOR M/C MACHINING** - **PASSED WHEELS** - **WARPAGE TESTING** - **SHOT PEENING** - **HUB BORE MACHINING** - **FINAL INSPECTION** - **STOCK** - **LOOSE ROUGH BORED WHEEL PRODUCT TO AXLE ASSEMBLY FOR WHEELSETS** - **LOOSE ROUGH BORED WHEEL DESPATCH TO CUSTOMER** ## Notes - Oby high propere gas cut & Band Jaw (Pocheata zone, Heating Lan, soaking) - LF (270 Smallmin) - Love ante al quenched to stre mech. Probestre - Polyoner quenching thrid (fraud heat जारी है) - INT Cooاعند samp QUENCHING - * FOR LOCO AXLES POLYMER QUENCHING DONE & FOLLOWED BY TEMPERING, FOR OTHER AXLES ONLY NORMALISING IS DONE. - Forged axle of maching allovan 12-150 है। - Cup terning is done at Journal orca for agrop to hold the apl - STN.1 END MILLING, CUP TURNING & CENTERING - ULTRASONIC TEST - STN.2 CNC ROUGH TURNING - USL RADIAL SCANNING M/C - SPM MACHINE DRILLING, TAPPING & RE CENTERING - 2-CNC LATHES - CYLINDRICAL GRINDING MACHINE - MPT - MEASURING STATION - WHEEL, WHEEL HUB BORING - ASSEMBLY - INSPECTION - **By gas Cutting** - **temp het Buc 200c** - **QUENCHING** - * FOR LOCO AXLES POLYMER QUENCHING DONE & FOLLOWED BY TEMPERING, FOR OTHER AXLES ONLY NORMALISING IS DONE. - **BLOOMS** - **BILLET CUTTING** - **BILLET HEATING (RHF)** - **FORGING** - **END CUTTING** - **NUMBER STAMPING** - **COOLING BED** - **air coding** - **NORMALISING** - **INT COOLING** - **TEMPERING** - **980-1050°C Heat (6hrs) in Hearth Funhan (Load-3600 Ton Hamnery 770 shoveffwin** - **'A' MIC SHOP** - **STN.1 END MILLING, CUP TURNING & CENTERING** - **ULTRASONIC TEST** - **STN.2 CNC ROUGH TURNING** - **USL RADIAL SCANNING M/C** - **SPM MACHINE DRILLING, TAPPING & RE CENTERING** - **2-CNC LATHES** - **CYLINDRICAL GRINDING MACHINE** - **MPT** - **'B' MIC SHOP** - **650°C (for machinability) Allows heat to enter** - **STN.1 END MILLING, CUP TURNING & CENTERING** - **ULTRASONIC TEST** - **STN.2 CNC - ROUGH TURNING** - **SPM MACHINE DRILLING, TAPPING & RECENTERING** - **3-CNC FINISH TURNING JOURNAL, DUST GUARD, WHEEL SEAT & BODY. BURNISHING W/S.** - **CNC-GRINDING JOURNAL, DUST GUARD** - **MPT** - **USL RADIAL SCANNING MIC** - **→ magnetic Pariticle (Ultrasonic terl** - **MEASURING STATION** - **WHEEL, WHEEL HUB BORING** - **ASSEMBLY** - **INSPECTION** - **Continuous casting Roll** - **DYLINEID** - **CHD** - **DRN KIRAN** - **DY.CMEMFG**