Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia
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Transcript of Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia
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by Craig Bishop
Engineering Manager
VAE Railway Systems Pty. Ltd.
Turnout Manufacture in Australia
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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
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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
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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.
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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
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Initial Requirements:
Actions needed prior to manufacture.
Technical clarification
Design requirements
Materials
Research and development
Timeframe / Delivery
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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**
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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
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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
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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
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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
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Examples
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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
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Typical Turnout Layout
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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
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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
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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
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Switch Assembly
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Video of CNC program prior to actual manufacture
CNC MACHINING
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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
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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
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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
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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
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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)
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Typical SNX Sections
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Typical Swing Nose Crossing
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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
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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
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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
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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
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Research & Development in Signalling
Points Machines
Operating Rodding
Locking Devices
Detection Systems
Hydraulic Systems
Monitoring Systems
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Steel In-bearer Sleepers
Spherolock operating system
In-bearer switch machines
Unistar Electro-Hydraulic Machine
Improvements currently in Track
These include:
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Improvement of existing components: KGO
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Manufacturers need to be addressing the future by the introduction of
new technology as part their program
For The Future:
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Plug and Play Turnouts
Turnout Panels Delivered
Directly to Site
For The Future:
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For The Future: The Complete System
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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:
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Typical cutting, drilling & bending drawing:
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Cutting
Typical Rail Saw
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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
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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
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Switches / Stockrail
CNC Machining
Multi Axis Head CNC Machines
CNC Machining and Milling (Modern Progression)
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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
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Single Head CNC Machining Dual Head CNC Machining
CNC Machining Videos
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Machining of manganese castings
Machining of block sets for switches and crossings
Machining of crossing rails and guarding rails
Other CNC Machining Capabilities
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Machining of Cast Crossings
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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
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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
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Welds checks identified in Green
Switch identification tags
Completion & sign off of switch quality
documents
Switch Complete
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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
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The crossing is assembled on plates
Check sheets are completed during the inspection and signed off by foreman
RBM Crossing Checking and Inspection
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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
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Swing Nose Crossings
Completed Crossings
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Completed Turnout Trial Assembly
60kg Turnout on concrete with RBM and guardrails
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Completed Turnout Trial Assembly - Operation
68kg Switch Assembly on concrete with
inbearers, M23A Machine and rodding
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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
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Forged Rail Lengths Up to 60 Metres
Forging
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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)
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Explosive Hardening
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Flash Butt Welding
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Flash Butt Welding Video
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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
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Routine testing
Sample welds done
periodically
Bend tests
Metallurgical testing
All Welds stored
electronically
Flash Butt Weld Testing
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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
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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
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THANK YOU
QUESTIONS?