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by Craig Bishop Engineering Manager VAE Railway Systems Pty. Ltd. Turnout Manufacture in Australia

Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

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Craig Bishop, Engineer Manager, VAE Railway Systems delivered the presentation at the RISSB’s 2013 Rail Turnouts Workshop. The RISSB’s National Rail Turnouts Workshop 2013 gives all those involved an in-depth forum to consolidate and share the latest technical information for rail turnouts. Drawing on industry expertise, the workshop features technical and practical presentations that address key turnout functions in an every-day operational context. For more information about the event, please visit: http://www.informa.com.au/railturnoutsworkshop13

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Page 1: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

by Craig Bishop

Engineering Manager

VAE Railway Systems Pty. Ltd.

Turnout Manufacture in Australia

Page 2: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia
Page 3: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

To provide an insight into the key issues in the

manufacture and supply of turnouts:

The contractual issues that must be addressed

Before During After

The design and development functions to meet

specifications

The manufacturing and inspection processes

Final Processing, Quality, Dispatch

Page 4: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

I. Background

II. Requirements

Technical / Design / Materials / R & D

III. Manufacture of Turnouts & Components

Process’s (Drill / Bend / Machine / Weld)

Tooling

Assembly (Switches / Crossing / Components)

IV. Special Manufacturing Process’s

Flashbutt welding / Explosive Hardening

V. Testing and Quality Assurance

VI. Conclusions

Page 5: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia
Page 6: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Manufacturing In Australia

There are only a few specialised suppliers that can manufacture

& supply turnout assemblies in Australia.

The industry is very specialised, with employees usually trained

in house or from people with railway backgrounds.

Traditionally turnouts were supplied only to the Rail Systems to

their designs.

Experience in Turnout knowledge is decreasing with allot of new

designers, consultants & contractors.

Allot of contracts are by tender with contractual conditions and

a technical specification.

Many of the supply contracts are also performance based and

will require new designs with defined benefits.

Page 7: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Manufacturing & Supply in Australia (The supply of turnouts is varied and complicated with many requirements that

affect manufacture)

Customer specific

Package Supply

Partial or complete assemblies

Variance in contract specifications

Quantity of Turnouts

Gauge required or dual gauge

Specialised materials involved

Rail size, many options

Expansion Switch

Page 8: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia
Page 9: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Initial Requirements:

Actions needed prior to manufacture.

Technical clarification

Design requirements

Materials

Research and development

Timeframe / Delivery

Page 10: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

In the Beginning:

Is there special turnouts required (Not Standard)

Are there existing designs available

Complete supply, partial supply or just components

What are the long leadtime components/ specialised

components

Are there type approvals required and are drawings required for

customer approvals and manufacture

What installation & maintenance information required

**Generally due to the number of variations it is necessary to

complete a separate work order or materials list for each turnout

to cover all the specific purchased and manufactured parts**

Page 11: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

How does the manufacturer

ensure that the product will

be configured correctly for

the customers needs?

Use an Identification Sheet

Review specifications

Ask questions up front

Clarify anything that is uncertain

Identification sign off sheet

Page 12: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Major items that cause delays: What is to be supplied (Scope)

Handing of turnouts

Rail type

Inbearers/ concrete / Timber / Steel

Positions of GIJ’s (if required)

Type of operation of the turnout

Switch Machine Specs & location

Special designs (long leadtime)

Complex Dual Gauge Turnouts

Rail Rolling Mill – Leoben, Austria

Page 13: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Additional functions that now form part of the

manufacturing process:

Trying to standardise designs between customers

Fitting new designs to specific areas (civil interface)

Approval drawings

Weight and length calculations (lifting information)

Assembly and Maintenance documentation

Page 14: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Crossovers

Scissors Crossovers

Flexed Turnouts

Simiflexure

Contraflexure

Dual Gauge Turnouts

Diamonds

Mixed Gauge Diamonds

Lap Beams Diamonds

Double Slips

Single Slips

Expansion Switches

Specialised Trackwork

QR - Roma Street Flexed Scissors Crossover

Page 15: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Examples

Page 16: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Design Requirements for manufacture Layout drawings

Manufacturing or details drawings

Individual drawings for CNC programs

Drawings for specialised components

Modeling of components

Checking of all drawings (Quality Assurance for design)

Drawings and documentation submitted for approval

Technical purchase information and details for suppliers

**Some special designs may

contain up to 25 drawings to

complete for manufacturing**

Jointless Boltless Managanese

Cast Crossing (Monoblock)

- 3D Model for casting

Page 17: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Typical Turnout Layout

Page 18: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Supporting design functions required

Ensure interfaces of disciplines (Civil / Mechanical / Electrical)

Concrete bearer coordinates and drawings for Suppliers

The design and supply of operating rodding

Special components (example. Castings)

Bill of materials for manufacture

Quality control / checksheets

Loading and Dispatch documentation

Interface between operating

equipment & Swing Nose

Crossing

- Modelled to check interfaces

Page 19: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

New Turnouts / Switch & Crossing Designs Require: Geometries to meet speed and axle loads

wheel profiles to check overrunning conditions & transfer areas

Machining angles, machining process’s and special tooling

CNC modelling for machining components

Drilling positions and bolting arrangements

Guarding of crossings and flange ways widths

Crossing materials and hardness requirements

Bearer type: timber / concrete / steel / polymer

Plating, fastening and materials to suit nominated loads

Page 20: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Conventional full depth switch

Tangential switch with asymmetrical rail

Pivot heel switches

Fixed heel switches

Secant switch (non tangential)

KGO tangential switch (new technology)

Typical Turnout Switch Designs

Tangential Switch Section Conventional Switch Section

Page 21: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Switch Assembly

Page 22: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Video of CNC program prior to actual manufacture

CNC MACHINING

Page 23: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

www.rissb.com.au

5

15 18

10

24

50

30 35

150

40

100

22,5 10

200

180

160

140

120

100

Moveable high performance Swing Nose crossings

Weldable into-track cast Manganese crossings

With cast inserts

Weldable into-track cast manganese

crossings, prehardened

Compound crossings with manganese-point and

head Hardened wing and vee rails

Fabricated crossings, bolted or with welded main and

counter point

annual load [MGT]

axle load [t]

sp

eed

[km

/h]

Crossing Types & Application

Page 24: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Manganese Nose

Head Hardened

Wing Rails

SG iron Or Steel

Blocks

Head Hardened Heel Rails

Flash Butt Welded To

Manganese Nose

Huck Bolts

Elements of Compound Crossing

Page 25: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Standard Carbon Or

Head Hardened Rail

Manganese Insert

Machined Top And Bottom

Graduated Explosive Discharge

Hardened

Flash Butt Welded Heel Rails To

Manganese Insert

Submerged Arc Welded

Heels

SG Iron Blocks

Huck Bolts

Elements of Welded Heel Rail Bound Crossing

Page 26: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Base And Top Face

Fully Machined

Flash Butt Weld With VAE

Austenitic Interface Process

Graduated Explosive Depth

Hardened Transition Faces

All 4 legs welded onto casting The

crossing assembly has no bolt holes

Elements of Monoblock (JBM) Crossing

Page 27: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Swing nose crossing designs are supplier specific

Very complex to design

Each manufacturer has developed a SNX to suit their own, and

customer requirements

A swing nose crossing is dependent upon the loads, type of

operating system and the sleeper geometry

Are used for specific requirements, heavy haul, noise reduction

Require special rollers

Require signalling interface

Swing Nose Crossing Design (Moveable Point Frog)

Page 28: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Typical SNX Sections

Page 29: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Typical Swing Nose Crossing

Page 30: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Special Component Design

Material finishes: Attention to detail

Ensuring all sharp edges are removed

Stress elimination Development of new parts

Stress considerations

Finite element analysis

Risk assessment

Page 31: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Materials used are very dependent upon the specification and

the references to other Standards.

Manufacturers and suppliers must manufacture to the standards,

specifications and certify their products.

Items such as:

→ Manganese castings with heat details and metallurgical tests.

→ Glued insulated joints with alignment and electrical testing.

→ Switch machines by serial numbers.

→ Operating rodding sets by compliance numbers.

Material Specifications and Availability

Page 32: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Currently R & D forms an important part of the manufacturing process

Most new proposals are submitted by manufacturers to improve

performance or reduce costs (life cycle costing)

Where new products and proposals are offered the manufacturer

becomes responsible to provide all the technical documentation,

manuals and on site training

Type approvals and associated documentation

There are also on-going programs to improve the performance of

existing products

Research & Development in Manufacturing

Page 33: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Ongoing developments occurring:

Reduction in Life cycle costs in new and existing

products

Rail metallurgy and hardness investigations

Component developments (Plating, switch

rollers, snx rollers)

Improved manufacturing techniques

THE ULTIMATE GOAL

Reductions in assembly and installation times,

with reduced maintenance cycles

LCC

Page 34: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Research & Development in Signalling

Points Machines

Operating Rodding

Locking Devices

Detection Systems

Hydraulic Systems

Monitoring Systems

Page 35: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Steel In-bearer Sleepers

Spherolock operating system

In-bearer switch machines

Unistar Electro-Hydraulic Machine

Improvements currently in Track

These include:

Page 36: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Improvement of existing components: KGO

Page 37: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Manufacturers need to be addressing the future by the introduction of

new technology as part their program

For The Future:

Page 38: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Plug and Play Turnouts

Turnout Panels Delivered

Directly to Site

For The Future:

Page 39: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

For The Future: The Complete System

Page 40: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia
Page 41: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Cutting and Drilling

Bending / Pressing

Machining (Planing / Milling & CNC)

Fabrication & welding of components

Specialised processes

Assembly of some components

QA checking of components & assemblies

Dispatch documentation

Introduction of the Manufacture Processes:

Page 42: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Typical cutting, drilling & bending drawing:

Page 43: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Cutting

Typical Rail Saw

Page 44: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Adjustable positioning supports

Centre pressing with hydraulic rams

Performance is dependent upon

operator experience

Press Drill

Typical Bending Press 200 Tonne Capacity

Hydraulic Clamping

Laser measuring of rails

Drilling tools with inserts

Air or lubricant cooled

Hydraulic Drilling Machine

Page 45: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

The original method of machining long lengths

The process is time consuming

Additional time is used for

positioning & clamping of setups

May require a number of setup

changes

Drilling and milling must be

scheduled to be done on other

machines

Planing and Machining

Page 46: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Switches / Stockrail

CNC Machining

Multi Axis Head CNC Machines

CNC Machining and Milling (Modern Progression)

Page 47: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Specialised tooling requirements for CNC milling

machines:

Designed and manufactured to suit respective machines

Most tools have a large number of inserts

For switch machining two tools can be used

Machine Tooling

Page 48: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Single Head CNC Machining Dual Head CNC Machining

CNC Machining Videos

Page 49: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Machining of manganese castings

Machining of block sets for switches and crossings

Machining of crossing rails and guarding rails

Other CNC Machining Capabilities

Page 50: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Machining of Cast Crossings

Page 51: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Large numbers of fabricated plates

Many are individual

Standard plates are made in jigs or

from cast material

All others are fabricated

Plating checks to ensure all plates

are stamped correctly and made to

drawings

Plating Manufacture

Page 52: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Assembled on Jigs

Plating assembled in position

Rollers added (If required)

Switch fit & dimensional tolerances checked

Operating equipment checked (If required)

Switch fit check

Switch Assembly Checking

Page 53: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Welds checks identified in Green

Switch identification tags

Completion & sign off of switch quality

documents

Switch Complete

Page 54: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Important factors for checking crossings:

Alignment

Crossing length

Flangeway width and depth

Throat openings

End openings

Nose Ramping / Transfer areas

Block fit up and glued (if necessary)

Plates fitted and in correct position

Crossing Checking

Page 55: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

The crossing is assembled on plates

Check sheets are completed during the inspection and signed off by foreman

RBM Crossing Checking and Inspection

Page 56: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Compound

Crossing

Welded Heel

RBM Crossing

Monoblock

Crossing

Compound

Crossing

Welded Heel

RBM Crossing

Compound

Crossing

Welded Heel

RBM Crossing

Compound

Crossing

Welded Heel

RBM Crossing

Compound

Crossing

Completed Crossings

Page 57: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Swing Nose Crossings

Completed Crossings

Page 58: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Completed Turnout Trial Assembly

60kg Turnout on concrete with RBM and guardrails

Page 59: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Completed Turnout Trial Assembly - Operation

68kg Switch Assembly on concrete with

inbearers, M23A Machine and rodding

Page 60: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia
Page 61: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Forging of Asymmetric rail to standard rail sections

Forging of rail to different rail sections (junction rails)

Explosive depth hardening of manganese castings

Hardening of non head hardened rails

Flash Butt welding

→ Rail to Rail welding

→ Rail to rail with manganese

→ Vee rails to manganese

Specialised Process’s Associated with Manufacture

Page 62: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Forged Rail Lengths Up to 60 Metres

Forging

Page 63: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Procedures for EDH hardening

Casting setout on course surface base

Glue sheet explosive to casting

Explode casting

Process can be done up to 3 times (3 shots)

Check hardness is within 350 to 415 BHN

Check casting for any damage or cracks

Explosive Hardening

Used specifically for manganese as manganese

has good work hardening properties, but an initial

low hardness (220 BHN)

Page 64: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Explosive Hardening

Page 65: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Flash Butt Welding

Page 66: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Flash Butt Welding Video

Page 67: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia
Page 68: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Manufacturing:

Subcomponents and plating assembly checksheets

Fitting and assembly of major components

Assembling and checking to specified tolerances

Material traceability

Logistics, Dispatch and Documentation

Packing and dispatch documents

Logistics documentation and delivery

Weights and craning points

Dispatch & Documentation

Page 69: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Routine testing

Sample welds done

periodically

Bend tests

Metallurgical testing

All Welds stored

electronically

Flash Butt Weld Testing

Page 70: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Magnetic Particle Testing

Hand Welds

Dye Penetrant Testing

Sub Arc Welds / Flash Butt Welds

Ultrasonic Testing

Level 1 & Level 2 testing

Testing of FBW

Non Destructive Testing

Page 71: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Provided an understanding of the core elements in

the manufacture and fabrication of turnouts

The involvement of contractors and Railway systems

to achieve a positive outcome for the supply of

turnouts into the rail industry

Turnout manufactures are trying to deliver the most

suitable, cost effective solution over the lifecycle of

the product

Page 72: Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

THANK YOU

QUESTIONS?