Wheels PDF 2009

7/27/2019 Wheels PDF 2009

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WHEELS AND TYRES FOR RAILWAYS

7/27/2019 Wheels PDF 2009


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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]

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Wheels PDF 2009