ST Ts RAIL WHEEL FACTORYTo become a renowned global leader in the Business of developing and manufacturing cast steel railroad wheels, Precision forged axles ond immacuiately Gssembled wheel sets. +s To emerge as a unique global center for design, development and manufactur excellence of our products throug onlinuous improvement by upgrading our ually, reliobiity, dependabilily and vole ‘dation in a deliberate and proactive manner To perennially enceavour to sustoin excellence: in customer satisiaction by consistently exceeding ther expectations, To develop our human capital by constant enhancement of ther technical, managerial & innovative capabilies. To promote ethical business practices ond values in the fue spit of corporate governance:In the era of foreign quality dominance, one Indian company was founded as import substitution, The Rail Wheel Factory (RWF) was set up in 1978 to ensure that Indian Railways get the world’s best products. The standard of its wheels, axles and wheel sets places RWF among the most quality conscious companies of the world. RWF stands for total quality, environment awareness and customer orientation. It proudly holds the masthead, "MADE IN INDIA", high among the rest of the world,ins bata represents on td 0 rage a ho SHAPING THE FUTURE CREATING HISTORY Product Range RWF is the only integrated plant in the world undertaking manufacture of cost wheels, forged axles and assembly of whee! sets for aiload applications, Under one roof. Through the process of continual improvement and updating of technology, the Plant has, over the years, developed an impressive portfolio of products, unsurpassed worldwide, The products manufactured by RWE mee! the stringent requirements of indian Railway Stanclards (RS) for various applications. The wheels and exies conform fo the Association of American Railroads (AAR) specification M-208 and M- 101 respectively Wheels RWF manufactures a parabolic deep-dish design of cast stee! wheels. The diameters of the wheel produced on a regular basis range from 725 mm. 10 1100 mm. WE also has the capabilly to produce other sizes of wheels to suit customer requirements. For users of forged wheels, RWF offers suppor for design (ond manufacture of equivalent cast steel whee: meeting with the customers requirements of physical and chemical properties.Tey APERSONAL COMMITMENT Quality Assurance Plan RWF constantly sves to bull successful and lasting relationships with its customers by consistently exceeding their expectations, as measured by the quality, reliability and value of its products and services. Quality begins at the design stage ilsell fo meet the qualty and end use requirement of the product. For brought out items, vendors are caretuly selected after due process of evaluation auallt fo ascertain thek capabilly and credentials for supply of required raw materials, fo meet the exaciing specifications. Allincoming raw material subjected to meticulous inspection, The Qualily Assurance Plan includes regular process audits to ensure that the laid down porameters are being met. Rigorous stage and final inspections are Conducted for assurance that the final pradue! fully conforms t0 the ‘customer requirements, Slage inspection of wheels * Chemical composition ofiquid metal before casting * Determination of hydrogen concentration in iquid steel Lung hycrogen determinater. «Inspection or surface faws usng Magnet wen '* Detection of subsurtace flaws using Ultrasonic Testing (UT) fechniques ‘= BHN Hardness Particle Testing 1 Warpage tes! to ensure fatness {Final inspection for dimensional accuracies of plate, hub, Fim, ead and diometer ‘© Closute test and micro examination on every S00 whee! GLOBAL Ine gov bio he at of Navgatann heme Sin, 500 ane oI NAVOATH one NOY: eecH re Quy wroH rea Stage Inspection of Axles © Chemical Compostion and vsualulraxonic ests on blooms before forging + Macro ane micro properties of forged axles. # 100% uitrsonic and magnetic parce testing * Measurement of pitch circle ciameter, journal diameters, topped holes and ovatty © Measuring the surlace trish, © Racial scanning of axes willbe started shorty inne with UC requirements Final inspection of Wheel-sels # 100% check o track gauge, whee! otset and topped holes + Check on tne graph records of whee! mounting pressures. {+ Ensuting protective packoging Ggais! physical and vironmental damage Measuring equipments used for process control are regularly Colibrated, ensuing traceobilly 1 netional/international standards Each product leaves the Plant with « Qualily Assurance Cortificate and caries @ warranty against manufacturing defects. his ensures product traceabilty, RWF is certiiod 0 ISO 9001 : 2000 standard for is Qualify Management System,Product Development RWE products have been developed consultation with the Indian Roilwoys centralized RED Wing i. hy, Design & Standards Orgenisation of Lucknow, RIWF is equipped with on R&D Laboratory, complete with Finite Element Analysis ond. strass ‘nals capabiliies with ANSYS sofware, for developing diferent whee! ond oxle pros. While modeling various products RWF strictly follows AAR & UIC procedures, which detals the loode, ed lls ond st on $-660 for use on Reilroods. Critical products have also been ‘evaluated by TTC!, USA. standard specifica rade wheels being used by AAR. These whee Ine. (TTC), USA. Ht was found hat th Yonce and fracture toug) found to be superior fo the equivalent by the Indian RaitwoyWheel manufacturing process WF uses virgin scrap. mainly consisting of used wheels returned from the railways. The scrap is melted in three electtic arc furnaces. The process is closely monitored in a state-of-the-art laboratory, equipped with a spectrometer for instantaneous sample results, allowing precision control of the molten steel ‘chemistry It's thus ensured that the molten steel meets the desired specification before the metalis tapped in the ladle for pouring Cast steel deep dish parabolic wheels of various sizes are manufactured using the patented bottom pressure pouring fechnique of M/s Giifin Wheel Corporation, USA. In this process, the ladle containing molten steel is placed in a pouring tank, segled with an airight cover. Ai is forced into this sealed pouting tank, pushing the molten steel through @ ceramic pouring tube into @ graphite mould, which is automatically positioned to receive the metal The controlled rate at which metal is filed into the mould results in close tolerances with a surface finish that eliminates nearry all surface re-conaiiioning and machining. The graphite moulds are machined to close tolerances using a form tool to obtain the desired profile, After pouting, the mould is spit and the wheels transferred fo © hot wheel kin for cooling under controlled conditions. A process called sprue washing using graphite electrodes removes the riser stubs. A unique number is hot stamped on each wheel to enable traceabilly. The hub Is gas-cut and the wheels normalised in a rolary hearth fumace. The wheel fim is quenched to attain the desired rim hardness values ater which they are tempered in a draw furnace and then allowed fo cool fo an ambient lemperature before being sent for final processing. In the final processing, the apex of the wheels are ground for fin femoval and blasted with stae! shots, Wheels are then subjected fo Magnetic Particle Test to locate surface defects and Ulrasorically tested for internal soundness. The hardness value of the rim is checked and recorded by an online automatic BHN testing machine. The whee's are further checked fo ensure that warpage is within | mm, The wheels are then shot-peened to limprove the surface hardness and bored in a precision auto boring machine to mee! the precise requirements for ‘assembly/aispatch. It is then sent for final inspection to the ‘uaity depariment, which checks various physical dimensions ‘and gives a final approval. The entire process of wheel movement rom station to station is carried out in a numerically controlled automatic assembly ine with minimum hurnan intervention,— Axle manufacturing process Ades are manulacked to various szes and specification Blooms fo the desired specification are procured from leading integrated steel plantsin sizes specified fo obtain the desited reduction ratios. The blooms are thoroughiy inspecied forthe chemical compostion and micro/macre properties before they are taken up for forging Bilots are cut to required unit lengths and heated ino rolary hearth fuace to forging temperatures. The heated billets are then transferred 10 a CNC controlled precision Long Forging Machine procured trom M/s GFM. Aust The advantage of the precision forging processis minimed machining allowance, leading fo reduced wastage, The fish fail ends of the forged axles ore gas cu! and the ‘axles ho! stomped with a urique number. The forged cles ‘fe then normalised in a walking beam fumace, followed by ait-cookng ond fempering. For ales meant for racton applications, where higher tense srength andl hardness istequied, he axles are quenched after normalsing using polymer quenchant, Samples are drawn from each balch ‘ond checked for physical and metallurgical properties tested before being taken up for machining, The machining line is again a completely automated system with integrated engineering for material transfer from one station to another. The various machining stages include end miling, cup turning and centering: rough, semifinish and finish turning, burishing of wheel dilling and tapping of axle end holes, grinding of axle journal and dust guards. During the course of machining cycle, all axles are Ultrosonically checked for intemal flaws Gnd Magnetic Particle Testing is done to detect any surface flaws, RWF is procuring a radial scanning equipment fo undertake radial probing of the axles required {5 per UIC standards Wheel-set assembly WF hos the unique distinction of being one of the few plants worldwide which, besides loose wheels and ‘axles, is capable of supplying assembled wheel sets to customers. RWF has Iwo uly automated whet ‘asiembly complexes, which can assemble a wide specirum of wheel sels. In the assembly complex, the wheel seal diameter of the axles is measured electronically dnd the data transferred to precision borers, where a wheel pair, with tread diameter within 0.5 mm, is bored to get correct the interlerence iit he wheels are then pressed on the axle in @ 300 ton pres: under controlled conditions to form a perfect ‘assembly in respec! of track gauge, offset of the wheels trom axle center, mounting pressure etc The assembled wheel sels are inspected for all parameters. The wheel sels are given a profeciive coating, Painted and packed before being cleared for shipment Io protect them from physical and environmental damage during transi.ADMIRED EVERYWHERE About the Company ‘The Indion Reilways is one ofthe largest rail networks in the world under a single management, The nelwork covers ‘over 1,00,000 km of Multi quage tracks. The rolling stock flet consists of over 8,000 locomotives, 50,000 passenger cars ond 2,00,000 freight cars. Rail Wheel Factory (formerly know as Wheel & Axle Plant), located inthe {garden cy of Bangalore in Southern India, is @ Production Unit under the Indian Railways. RWF largely meets the Indian Railways’ requirement of wheels, axles and whee! sets ond, ina way, moves the nation. The space capacity ‘ovcilable is utlized profitably 1o meet the domestic demands of non-Rallway customers o: well os export WF is deeply conscious of the need to be © learning organization and of its obligation fo sociely in general. The Plant consistenly endeavors to enhance is intellectual capital through well-planned training schemes for al its ‘employees. I is commited to ensure sustainable development by using the right process / material / technology, the provision ofa safe and healthy environment, the conservation of resources and proper wasle management. Mejor initiatives token by RWF towards environment management have led fo cerification of the Plant ond the Colony to ISO 14007 : 2004 standard for Environment Management System sangaioe |Chief Public Relations Officer RAIL WHEEL FACTORY Yelahanka, Bangalore - 560 106 India. Tel: +91-80-28460326 Fax: +91-80-28460492 e-mail: secyrwi@yahoo.com www.rwfindla.gov.in