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Transcript of Wheels PDF 2009
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WHEELS AND TYRES FOR RAILWAYS
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COMMITTED TO WHEELS
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KLW is the wheels brand ofglobal steel company Interpipe.Interpipe has more thanseventy years of experience inmanufacturing railway wheelsat the company’s renownedInterpipe NTRP mill inDnepropetrovsk, Ukraine. Thesewheels are supplied to thecustomers worldwide throughsales company KLW WheelcoSA (Switzerland). With annualproduction of over 600,000pieces, Interpipe NTRP hasa huge portfolio of over 200products. All the products havedistinctive KLW stamp insignia.
KLW global network is strongwith clients in 60 countrieson five continents. Years ofmanufacturing and supplyexperience enable KLW
to compete successfullyeverywhere where there is amajor railway operation. Asour company has evolved wehave gained over forty yearsof experience in partnershipwith railway operators incountries as far afield as Indiaand Australia as well as intraditionally large markets likeGermany and Russia.
Railway wheels and tyres
KLW is committed to providingthe highest quality railwaywheels according to thespecifications and requirementsof the customer, correspondingto strict international standards.Our products are guaranteedby the quality controland management systemcertified by TUV (Germany)corresponding to the norms ofDIN EN ISO 9002.
Quality control is enforcedat all stages of productmanufacturing – from steelmelting to the acceptance testof wheels and tyres. Our focuson reliability includes a widerange of measures includingreducing residual stress andincreasing durability as wellas using mechanical, chemical
and metallographic controlmeasures in the Interpipe NTRPCentral Laboratory.
High levels of investmentand R&D continue to bringsignificant benefits acrossthe design, development andproduction of our wheels. Thisallows us to achieve the bestresults for our customers across
all of the key mechanical andoperational properties as wellas life cycle costs.
Our product portfolio hasdeveloped rapidly over theyears as our business hasexpanded globally. Now weprovide an extremely widerange of railway wheelsand products to the highestinternational requirements,
including tyres.
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Tyres
Outside diameterØ D, mm
Inside diameterØ d, mm
Width of rimØ d, mm
Width of flangeØ h, mm
Mass, kg
690-1300 550-1100 80-150 15-50 100-600
Wheels
Outside diam-eterØ D, mm
Inside diameterØ d
1 , Ø d
2mm
Widthof rim H, mm
Diameterof hub Ø d, mm
Heightof hub L, mm
Diameter ofhole in hub Ød
0 , mm
Thickness ofdiskt
1 , t
2 , mm
Mass, kg
650-1269 600-1100 95-160 185-500 90-405 60-200 15-80 165-1050
Range of railway wheels and tyres
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AAR M 107/208ASTM A504ASTM A551ASTM A551-81BN 918277BS 5892 part 4BS 5892, part 3: 92
BS24IRS R 15-95IRS R 3403IRS R 19-93, parts 1-5ISO 1005
JIS E 5402KRS 2242-2107M4T 2000
Quality Management SystemISO 9001-2000 AAR M-1003
Our approvalsAAR – Freight & Locomotive Wheels DB – Freight Car Wheels
DB – Locomotive Wheels PKP – Freight Car Wheels
Railtrack – Freight Car Wheels SZ - Freight & Locomotive Wheels
ÖBB - Freight Car Wheels BZ - Freight & Locomotive Wheels
MOR-M-2001-2NF EN 10228-3NF F 01-111NF F 01-115NF F 01-131NF F 01-33PN-84
PN-84 H84027/06PN91/K91032PN-92PN-92/K91018 prEN 13262RSP #SM-55/2543SNCB A-12TJZL 01-98
TJZL 02-99TTS 094TTS 248UIC 810-1UIC 812-1UIC 812-3UNI 6102
The railway wheels and tyres are exported according to thespecifications and requirements of the Customer, the norms ofinternational standards, including:
List of standards
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Railway wheels shop includes:z Forging-rolling line for
production of wheels from650 to 1269 mm
z Forging-rolling for productionof tyres
z Mechanical finishing floor
z Heat treatment lines
z Shot blasting line
z Non-destructive testing
(ultrasonic, magneticand hardness testing)
z Finishing line
In 2002 -2007 Interpipeinvested in increase ofproduction capacities bybuilding new finishing andtesting lines, mechanicalhardening (ultrasonic, magnetichardness testing, geometrycontrol, mechanical operation).
As a part of its strategicinvestment program, Interpipehas purchased equipment for
the installation of a new full
profile line for railway wheelsmachining. The automated linewill include four RQQ machines,the complex of inter-machineequipment (systems for loadingand unloading of wheels).The expected capacity of theautomated line, which has self-operated control for full profilerailway wheel machining,is 100,000 finally machinedwheels per year.
Production facilityInterpipe NTRP
Key facts:1935 - the first railway wheel rolled off the
production line in starting one of themost absorbing stories of modernindustrial times
1970 - Interpipe NTRP wheel shop producedits 10 millionth railway wheel just 35years after the first one had rolled offthe production line
1979 - the company started to supply wheelsacross Eastern Europe
1987 - new purpose-built railway wheels andtyres shop, which started to producerailway tyres
1991 - the KLW brand entered the Indianmarket
1996 - the first wheels were supplied in China
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Steel for the production ofrailway wheels and tyres ismelted in the open-hearthfurnaces with the charge of 250tons and tapping in two ladles.High quality characteristicsof steel are provided by thesubsequent processing at theout-of-furnace complex of steeltreatment. The ladles withmetal are delivered in turn tothe unit furnace-ladle, wherethe metal finishing and refiningtakes place. Steel blowing inthe ladle by argon along withthe refining process providefor the sulphur content in the
finished metal equal to 0.010%phosphorus – 0.015% and less,and uniform distribution ofanother elements. Degassingprocess is effected by meansof removing the hydrogen,nitrogen, oxygen dissolved inmetal at the vacuum degassingset simultaneously with argonblowing. Hydrogen content insteel is within the limits up to 2ppm.
Steel Making Process
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The Technology of the Production of Railway Wheels
1 2 3 4
Open-hearth furnace Ladle Ladle-furnace Vacuumdegassing set
5 6 7 8
Bottom pouring Notching and breaking ofingot into initial billets
Billets inspectionand repairing
Billets heating in therotary furnace
9 10 11 12
Hydroscaling of cinder Open forging on thepress MN
Closed forging on thepress MN
Punching on the pressMN
13 14 15 16
Wheel rolling on therolling mill
Wheel calibration on thepress / MN andpiercing of central hole
Intermediate coolingand anti-flokingisometric holding
Cooling of the wheelin open air
17 18 19 20
Machining Wheels heating Rim quenching Tempering in pit in thefurnaces
21 22 23 24
Adjustable cooling CNC machining,imbalance checking
Automated non-destruc-tive control (ultrasonictest, magnetic particleinspection etc)
Wheels inspection andmeasuring, hardnessdetermination
25 26
Testing of mechanicaland other propertieson the samples
Storage
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The Technology of the Production of Railway Tyres
1 2 3 4
Open-hearth furnace Ladle Ladle-furnace Vacuumdegassing set
5 6 7 8
Bottom pouring Notching and breaking ofingot into initial billets
Billets inspectionand repairing
Billets heating in therotary furnace
9 10 11 12
Hydroscaling of cinder Open forging on thepress MN
Weighing Punching andclosed piercing
13 14 15 16
Piercing Rolling on oneor two mills
Marking Hot dressing
17 18 19 20
Thermal treatment(anti-flocking, hardeningwith temperingor normalizing)
Non-destructive control(hardness, ultrasonictest)
Selection of the samplesand holding of all testingon the samples
Inspection and measur-ing
21
Storage
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High quality characteristics ofthe products correspondingto the requirements ofinternational standards, areguaranteed by the systemof quality control andmanagement certified bythe firm TÜV (Germany) forcorrespondence to the normsof DIN EN ISO 9002.
Quality control is effected
at all the stages of productmanufacturing – from steelmelting to the acceptance testof the wheels and tyres:
z
Control of the chemicalcomposition of raw-materials, steel duringmelting process, readyrolled-stock is effected onthe spectrometers “Polyvac2000” type
z Control of hydrogen contentin liquid steel is effectedbefore and after vacuumdegassing using sound
determination by “HYDRIS”device of company “HeraeusElecro-Nite”
z Control of nitrogen, oxygen,hydrogen content isperformed at the devicesPH-402 and TS-236 of thefirm “Leco”
z 100% automated Ultrasonictest as well as magneticparticle of ready products,
is effected to determine thepresence of internal defectsinspection
z Control of the hardnesson the rim surface of thewheels and tyres is realizedduring the production usingdurometer of “EMCO”company
z
Metal testing forelongation is realized at themachine UTS-600-1 withmicrocomputer control andautomatic registration ofparameters and printing-outof the results
z Pendulum testing impactmachine Psd 50/15 of “WpmWerkstoffprufmaschinenGmbH” company is used
to determine the impactstrength of steel
z The determination of steeltoughness K1C accordingto the ASTM-E 300 iseffected on the universalcomputerized testingmachine “Hydropuls Sinus250” by company “CarlSchenk”
z By the request of thecustomers the testing ofwheels and tyres by thefalling weight or staticcompression, as well asthe control of micro – andmacro structure and natureof stresses are made by theup-to-date methods
Products Quality Control
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Countries supplied to:Argentina Croatia Kenya Romania TurkeyArmenia Egypt Kirghizstan Russia TurkmenistanAustralia Finland Korea, North South Africa UkraineAustria France Korea, South Slovakia United KingdomAzerbaijan Georgia Latvia Slovenia UruguayBangladesh Germany Lithuania Spain USABelgium Greece Macedonia Sri-Lanka UzbekistanBrazil Hungary Malaysia Sweden VietnamBulgaria India Mauritania Switzerland Yugoslavia
Byelorussia Indonesia Moldova Tajikistan ZambiaCanada Iran Poland TanzaniaChile Italy Netherlands ThailandChina Kazakhstan Norway Tunisia
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SETTING THE WORLD IN MOTION
, Via Generale Guisan, P.O. Box CH- Paradiso-Lugano, Switzer landPhone + Fax + E-mai l : [email protected]