Railroad Car Wheels Re-Turning

 

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ISCAR's Machining Solutions for Railroad Car Wheels Re-Turning

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ISCAR 's Machining Solutions for Railroad Car Wheels Re-Turning w w w. i s c a r. c o m

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Machining Technology Railroad car wheel re-turning can be found in every country where trains are used for passengers or freight transportation. It is most common for wheels to be re-turned on a dedicated portal wheel, universal lathe, or under floor lathes. Railroad Re-Turning Wheel The new tools for re-turning railroad wheels can machine the entire outer wheel profile in a single cut. They feature two cartridges with tangentially mounted inserts. Longitudinal turning is performed with a 30 mm long and 4 mm corner radius tangentially clamped insert, positioned with its long side against the machining direction. This insert can handle large cutting depths for roughing or semi-finishing applications, depending on the outer wheel condition.

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A 19 mm long and 4 mm radius tangentially clamped insert positioned perpendicularly to the larger insert is used to machine the rim zone, which becomes massively eroded and sometimes has cracks. Machining depth can range from 0.3 mm to 12 mm, depending on the wheel’s outer condition prior to re-conditioning. Large depths of cut are usually performed by several machining paths, in order to prevent heavy loads or poor insert life.

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Common Machines for Rail Wheel Re-turning Rail Wheel Re-turning Under Floor Wheel Lathe Conventional Wheel Lathe CNC Portal Wheel Lathe

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Toolholders and Cartridges for Under Floor Re-turning Lathes (Model 106 Thread Profile Machine) Assembly & Spare Parts PRWR/L 50-55 PRWR/L 177-CA-19 PRWR/L 175-CA-19 PRWR/L 175-CA-30 Designation LNMX 191940 LNMX 301940 Screw SR LCS 5 Lever LR 5 HW 3.0 Key

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Inserts & Tools LNMX 19/30 Tangentially Clamped Inserts for Railroad Wheel Re-Turning r l d1 W S Recommended Machining Data Dimensions IC8150 IC9150 IC8250 IC9250 Designation LNMX 191940-WF LNMX 191940-WM LNMX 301940-WM LNMX 301940-WR l 19.05 19.05 30.00 30.00 W 10.00 10.00 12.00 12.00 s 19.05 19.05 30.00 30.00 r 4.00 4.00 4.00 4.00 d1 6.35 6.35 6.35 6.35 (mm) 0.30-5.00 0.30-5.00 0.50-12.00 0.50-12.00 ap (mm/rev) 0.25-1.30 0.40-1.50 0.70-1.90 0.80-1.90 f l l l l l l l l l l l l l l l l LNMX 191940-WF For finishing operations LNMX 301940-WM For medium/ semi-finishing operations LNMX 191940-WM For medium semi-finishing operations LNMX 301940-WR For roughing operations

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PRWR/L Toolholders with Cartridges for Under Floor Re-turning Lathes (Model 106 Thread Profile Machine) 6° h1 87° h f b 84° l1 Right-hand shown h1 44.00 Designation PRWR/L 50-55 l1 210.00 f 55.00 h 50.00 b 55.00 Spare Parts Designation PRWR/L 50-55 Screw SS M6x1x16 Pin PIN D5x13 ap mm 12 10 8 6 4 2 0 0 0.5 19-WF 19-WM 30-WM LNMX 30-WR Material: Alloy steel Cutting speed: Vc=25-90 m/min 1.0 1.5 2.0 f mm/rev

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cutting Data Grade Recommendation High P IC8150 CVD coating. Features excellent thermal stability, resistance to chipping and plastic deformation. Recommended for high speed machining of steel at stable or slightly unstable conditions. A very hard substrate with a cobalt enriched layer, improved MTCVD TiCN and a thick alpha Al2O3 Speed IC9150 Excellent thermal stability and resistance to chipping and plastic deformation. Recommended for high speed machining of steel at stable conditions. A hard substrate with a cobalt enriched layer, MTCVD TiCN and alpha Al2O3 CVD coating. IC8250 alpha Al2O3 CVD coating. Recommended for general use machining of steel in a wide range of conditions, featuring high toughness and resistance to chipping and plastic deformation. A tough substrate with a cobalt enriched layer combined with improved MTCVD TiCN and a thick Low IC9250 CVD coating. Recommended for general use machining of steel in a wide range of conditions, featuring high toughness and wear resistance. A tough substrate with a cobalt enriched layer combined with MTCVD TiCN and a thick alpha Al2O3 Cutting Data Recommendations C B A Cutting data by area: Area A B C Vc 30 - 70 m/min 50 - 100 m/min 50 - 100 m/min f 0.3 - 1.8 mm/rev 0.5 - 2.0 mm/rev 0.5 - 2.0 mm/rev In case of worn wheels with skid flats, built-up, shelled tread or thermal cracks - ISCAR recommends reducing the cutting speed to the minimum recommended. High carbon wheels should be machined at the low range of our cutting speed recommendations. Feed should be optimized within our recommended range per chipformer and actual chip formation. Depth of cut according to chipbreaker geometry: WF WM WR 0.3 - 3.5 mm 1.5 - 7.0 mm 3.0 - 12 mm

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Chip Formation at the Rim Curve Competitor ISCAR ✘ ✔ One of the common problems in wheel re-turning is chip formation during the back turning operation at the rim zone. The new WM chipformer (on the 30 mm insert) has been specifically designed to prevent long chip formation during rim turning.

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Test Reports TEST No. 1 Part name: Railway wheel Material: Alloy steel Machine manufacturer: RAFAMET-under floor Coolant method: None ISCAR Insert type Carbide grade Cutting speed (m/min) Part diameter (mm) Feed per revolution (mm/rev) Feed mm/min Depth of cut (mm) Length of cut (mm) x3 Number of edges per insert Number of parts per edge LNMX 191940-WM IC8150 24 870 1.88 16.51 5 330 8 72 24 870 0.98 8.61 5 330 8 40 Competitor 131 116 TEST No. 2 Part name: Railway wheel Material: Alloy steel Machine manufacturer: Hegenscheidt-under floor Coolant method: None ISCAR Insert type Carbide grade Cutting speed (m/min) Part diameter (mm) Feed per revolution (mm/rev) Depth of cut (mm) Length of cut (mm) x3 Number of edges per insert Number of parts per edge LNMX 191940-WM IC8250 65 837 0.94 3.5 135 4 31 65 837 0.94 3.5 135 4 12 Competitor

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ISCAR LTD. Headquarters Tefen 24959, Israel Tel + 972 (0)4 997 0311 Fax + 972 (0)4 987 3741 www.iscar.com headquarter@iscar.co.il Argentina ISCAR TOOLS ARGENTINA SA Monteagudo 222 1437 Buenos Aires Tel + 54 114 912 2200 Fax + 54 114 912 4411 admin@iscararg.com.ar Australia Headquarters and Technical Centre Norwest Business Park 30 Brookhollow Avenue Baulkham Hills NSW 2153 Australian Technical Training Centre Bell Street, Preston, Victoria, 3072 Tel + 61 (0) 2 8848 3500 Fax + 61 (0) 2 8848 3511 iscaraus@iscar.com.au www.iscar.com.au Austria ISCAR AUSTRIA GmbH Im Stadtgut C 2 A-4407 Steyr-Gleink Tel + 43 7252 71200-0 Fax + 43 7252 71200-999 office@iscar.at www.iscar.at Belarus JV ALC “TWING-M” Slutskaya str. 3, 223056 v. Sennitsa Minsk district Tel +375 17 506-32-38 +375 17 506-33-31/65 Tel/Fax +375 17 506-32-37 info@twing.by www.twing.by, www.iscar.by Belgium n.v. ISCAR Benelux s.a. 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Head Office 15th Floor, Senri Asahi Hankyu Building 1-5-3, Shinsenri-Higashimachi Toyonaka-Shi, Osaka 560-0082 Tel + 81 6 6835 5471 Fax + 81 6 6835 5472 iscar@iscar.co.jp www.iscar.co.jp Macedonia (Representative Office) Londonska 19/4 MK-1000 Skopje Tel +389 2 309 02 52 Fax +389 2 309 02 54 info@iscar.com.mk Mexico ISCAR DE MÉXICO, S.A de C.V. Fray Pedro de Gante 15 Col. Cimatario Querétaro, Qro. C.P. 76030 Tel + 52 (442) 214 5505 Fax + 52 (442) 214 5510 iscarmex@iscar.com.mx www.iscar.com.mx The Netherlands ISCAR NEDERLAND B.V. Postbus 704, 2800 AS Gouda Tel + 31 (0) 182 535523 Fax + 31 (0) 182 572777 info@iscar.nl www.iscar.nl New Zealand ISCAR PACIFIC LTD. 1/501 Mt. Wellington Hwy. Mt. Wellington Auckland Tel + 64 9 5731280 Fax + 64 9 5730781 iscar@iscarpac.co.nz Poland ISCAR POLAND Sp. z o.o. ul. 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IOC, Motnica 14 SI-1236 Trzin Tel + 386 1 580 92 30 Fax + 386 1 562 21 84 info@iscar.si www.iscar.si South Africa ISCAR SOUTH AFRICA (PTY) LTD. 47 Lake Road Longmeadow Business Estate - North Extension 7, Modderfontein, Edenvale, Gauteng P.O. Box 392 Longmeadow Business Estate - North 1609 ShareCall 08600-47227 Tel +27 11 997 2700 Fax +27 11 388 9750 iscar@iscarsa.co.za www.iscar.co.za South Korea ISCAR KOREA 304 Youggye-Ri, Gachang-myeon Dalsung-gun, Daegu 711-860 Tel + 82 53 760 7590 Fax + 82 53 767 7203 koss@taegutec.co.kr www.iscarkorea.co.k Spain ISCAR IBERICA SA Parc Tecnològic del Vallès Avda. Universitat Autònoma 19-21 08290 Cerdanyola-Barcelona Tel +34 93 594 6484 Fax +34 93 582 4458 iscar@iscarib.es www.iscarib.es Sweden ISCAR SVERIGE AB Kungsangsvagen 17B Box 845 751 08 Uppsala Tel + 46 (0) 18 66 90 60 Fax + 46 (0) 18 122 920 info@iscar.se www.iscar.se Switzerland ISCAR HARTMETALL AG Wespenstrasse 14 CH 8500 Frauenfeld Tel + 41 (0) 52 728 0850 Fax + 41 (0) 52 728 0855 office@iscar.ch www.iscar.ch Taiwan ISCAR Taiwan Ltd. 395, Da Duen South Road, Taichung 408 Tel +886 (0)4-24731573 Fax +886 (0)4-24731530 iscar.taiwan@msa.hinet.net www.iscar.org.tw Thailand ISCAR Thailand Ltd. 57, 59, 61, 63 Soi SamanchanBabos Sukhumvit Rd. Phra Khanong, Khlong Toey Bangkok 10110 Tel + 66 (2) 7136633-8 Fax + 66 (2) 7136632 iscar@iscarthailand.com Turkey ISCAR Kesici Takim Tic. Ve Iml. Ltd. Sti. Gebze Organize Sanayi Bölgesi (GOSB) Ihsan Dede Cad. No: 105 Gebze / Kocaeli Tel + 90 (262) 751 04 84 (Pbx) Fax + 90 (262) 751 04 85 iscar@iscar.com.tr www.iscar.com.tr Ukraine ISCAR UKRAINE LLC Volgodonska str., 66 02099 Kiev Tel/fax +38 (044) 503-07-08 iscar_ua@iscar.com www.iscar.ru United Kingdom ISCAR TOOLS LTD. Woodgate Business Park Bartley Green Birmingham B32 3DE Tel + 44 (0) 121 422 8585 Fax + 44 (0) 121 423 2789 sales@iscaruk.co.uk www.iscaruk.co.uk United States ISCAR METALS INC. 300 Westway Place Arlington, TX 76018-1021 Tel + 1 817 258 3200 Tech Tel 1-877-BY-ISCAR Fax + 1 817 258 3221 info@iscarmetals.com www.iscarmetals.com Vietnam ISCAR VIETNAM (Representative Office) Room D 2.8, Etown Building, 364 Cong Hoa, Tan Binh Dist., Ho Chi Minh City Tel +84 38 123 519/20 Fax +84 38 123 521 iscarvn@hcm.fpt.vn “As part of Iscar’s ongoing effort to improve its products, it reserves the right to make changes to any of the products appearing in this publication, without prior notice.” © ISCAR LTD. All rights reserved 01/2012_R 7861573

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