Consumables for Wheel Shop PDF

30 Consumables for Wheel Shop The consumables used in the wheel shop can be either used directly to manufacture the wheels (eg: Coke/Grahite, Ferro-silicon, etc.) or indirectly used to help manufacture the wheels Consumable Name: Asbestos Gasket Application/ Job requirement: Asbestos...

30 Consumables for Wheel Shop The consumables used in the wheel shop can be either used directly to manufacture the wheels (eg: Coke/Grahite, Ferro-silicon, etc.) or indirectly used to help manufacture the wheels Consumable Name: Asbestos Gasket Application/ Job requirement: Asbestos Gasket is used as a sealant between drag and pouring tube in casting of railway cast steel wheel to prevent bleeding of liquid steel. One asbestos gasket is used for casting each wheel. Consumable Name: Ingate Sleeves Application/ Job requirement: The Clay Graphite Tapered Ingate Sleeve shall be fired/baked in controlled reducing atmosphere. The kilns shall have control mechanism to achieve uniform heating at a controlled rate as established by the manufacturer’s firing schedule. The Clay Graphite Tapered Ingate Sleeves have to be encased in a suitable medium like graphite, calcined petroleum coke or similar during firing so as to avoid oxidation. During the mould assembly for casting steel railway wheels, the Clay Graphite Tapered Ingate Sleeve is required to be fixed in the graphite drag against the taper at a pressure of 52-56 kg/cm2 and ingate sleeve is retained in position using  31 ingate-retaining ring. As the mould is reused, after each casting the ingate is reamed using grinding stone for proper seating of the clay graphite stopper in the stopper seat. Consumable Name: Ceramic Pouring Tube Application/ Job requirement: The pouring tube is assembled with pressure Pouring Tank cover. The molten metal rises through the pouring Tube into the mould by means of controlled pressure (35psi max.) pouring technique. Consumable Name: Pouring Tube Glaze Application/ Job requirement: The pouring tube glaze is used as a coating applied to the ceramic pouring tube by dipping the tube in it to fill the pores of the tube and make the tube air tight. Consumable Name: Clay Graphite Stopper Application/ Job requirement: The Clay Graphite Stopper, made of clay graphite, is used to prevent the back flow of molten metal after pouring the metal into the mould. The stopper with pipe assembly is set with cope on the required height and used for the manufacture of cast steel wheels. Molten metal rises through the gap available between the stopper and mould box by means of pressure pouring technique. Once the metal rises to the required height of risers the Clay Graphite Stopper is pressed down for closing the molten metal incoming port by Pneumatic cylinders. Consumable Name: Calcined Lime Application/ Job requirement: This Calcined Lime is used as flux for making slag in the steel making process through Electric Arc Furnace melting practice. Consumable Name: Ferro Silicon Application/ Job requirement: Ferro Silicon is used as a ladle addition to the liquid Steel tapped from the Electric Arc Furnace. Final chemistry with respect to Silicon is achieved suitably for casting of Railway steel wheels.  32 Consumable Name: Silico Manganese Application/ Job requirement: Silico Manganese is used as a ladle addition to the liquid steel manufactured in Electric Arc Furnace steel making practice. Final chemistry with respect to Manganese and partly Silicon is achieved suitably for casting of Railway steel wheels. Consumable Name: Ferro Manganese Application/ Job requirement: Ferro Manganese is used as furnace addition in the making of steel from Electric Arc Furnaces for casting of Railway steel wheels. Consumable Name : Graphite Powder/ Granule Application/ Job requirement: Graphite Powder/Granules is used in the Electric arc Furnace at RWF, steel scrap is melted for casting of railway wheels. During the course of melting, Graphite Granules are added to maintain the carbon content in the steel. Consumable Name: Magnaglo Powder Application/ Job requirement: Magnaglo powder is a dry, free flowing, speckled brown and white magnetic powder which fluoresces bright yellow-green under black light (wave length of 365 nanometres). Magnaglo powder is intended for  33 use in high sensitivity wet method magnetic particle inspection using water as suspension vehicle. It is used to locate fine surface and sub-surface discontinuities such as cracks, inclusions, seams, shrinkage porosity, tears, laps flakes etc., in cast steel wheels for Rail road application. Consumable Name : Fused Silica Powder Application/ Job requirement: Fused Silica Powder is used for the preparation of spray for graphite moulds. It should serve as an emulsion stabilizer, suspending agent, film former, binder and organic gum modifier, when added with other additives of CMC and veegum to prepare mould spray. Consumable Name: Steel Shots Application/ Job requirement: The steel shots are used for cleaning and peening of the Cast steel wheels of hardness of 255 to 363 BHN.  34 Wheel Shop Specifications Average Wheels Cast Per Day 720 706 704 700 680 660 Average wheels cast per day 641 640 620 600 13-14 14-15 15-16 Average Heats Per Day 22.75 22.62 2013-2014 2014-2015 20.79 2015-2016  35 Good Wheels Per Day 670 656 660 650 640 630 616 620 610 Good Wheels Per Day 594 600 590 580 570 560 13-14 14-15 15-16 Wheel Rejection % 5.93 6.083 15-Apr 6.13 7.51 15-May 15-Jun 7.31 15-Jul 15-Aug