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MFL Group
Workshop LiezenFounded in 1939
Privatized on 15 November 1994
750 employees at the headquarter in Liezen
1100 employees worldwide
Yearly turnover ~ 125 million Euros
Sales and Engineering Sawing and Milling Technology Maschinenfabrik Liezen und Gießerei GmbH Fabriksplatz 1, 4662 SteyrermühlAustria Phone: +43 3612 270 800Fax: +43 3612 270 830E-Mail: [email protected]
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Production branches
Main branches
Foundry
Sawing and milling technology
Mineral processing
Component manufacturing
Mechanical production
Subsidiaries
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Sawing and milling technology
SAWINGSingle cut sawing machines for tubes, billets, bars, rails and profiles
Layer sawing machines for tubes and profiles
Sawing machines for aluminium and steel plates
Sawing machines for steel slabs
Sawing machines for material inspection (sample saw)
MILLINGEdge milling machines for plates
Edge milling machines for stripes/coils
Milling machines for special profiles
Milling machines for the production of tensile tests
Welding seam processing machines for large diameter pipes
RAILRail sawing machines
Axle sawing machines
Combined rail sawing and drilling machines
Combined rail drilling and milling machines
Mobile and stationary rail milling machines
SPECIALRing splitting machines
Pipe beveling machines
Deep hole drilling machines
TOOLS Saw blades with exchangeable carbides
Milling tools
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Sawing technology
Overview
Layer sawing machines for tubes and profiles
Single cut sawing machines for billets, bars, rails and profiles
Sawing machines for steel and aluminium plates
Sawing machines for steel slabs
Sawing machines for material inspection (samples)
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Milling technology
Overview
Edge milling machines for plates
Edge milling machines for stripes / coils
Milling machines for special profiles
Milling machines for the production of tensile tests
Welding seam processing machines for large diameter pipes
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Rail technology
Overview
Rail sawing machines
Axle sawing machines
Combined rail sawing and drilling machines
Combined rail drilling and milling machines
Mobile and stationary rail milling machines
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Special machinery
OverviewRing splitting machines
Pipe beveling machines
Deep hole drilling machines
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Range of application
Seamless pipe mills
Single cut sawing machines for billets
Single cut sawing machines for tubes (Re-Cut)
Layer sawing machines for tubes
ERW pipe mills
Edge milling machines for plates
Welding seam processing machines for large diameter pipes
Pipe beveling machines
Spiral pipe mills Edge milling machines for stripes / coils
Profile production
Single cut sawing machines for profiles
Layer sawing machines for profiles
Milling machines for special profiles
Plate production
Sawing machines for aluminium plates
Sawing machines for steel plates
Forgings Single cut sawing machines for billets
Single cut sawing machines for squared material
Ring rolling mills
Single cut sawing machines for billets
Ring splitting machines
Sample shops
Sawing machines for material inspection
Milling machines for the production of tensile tests
Production of rails, wheels and axles
Rail sawing machines
Axle sawing machines
Combined rail sawing and drilling machines
Combined rail drilling and milling machines
Ship yards, Wind mill industry
Edge milling machines for plates
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Advantages Customized turnkey solutions
Combined and simultaneous cutting and drilling of rails
Horizontal and vertical adjustable drilling spindles
Temperature compensation to guarantee exact lengths under different temperature conditions
Guaranteed length tolerances for rails between 5 –120 m
Main dataProcessable rail dimensions: 200 x 220 mm
Number of drillers: 1 – 6 pcs.
Drilling diameter: 20 – 40 mm
Saw blade diameter: 660 mm
Tolerance of length: +/- 5 mm
Tolerance of hole distances: +/- 0,5 mm
RAIL SAWING AND DRILLING MACHINE
Advantages and technical data
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4 vertical clamping cylinders
4 horizontal clamping cylinders
fixed stopping edge
RAIL SAWING AND DRILLING MACHINE
Horizontal clamping device
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AdvantagesProcessing of round and slotted holes by one machine
Processing of slotted holes in vertical and horizontal direction
Precise chamfering within very close tolerances
Web detection to recognize rail markings
Exact length positioning by material feeding tongs
Manipulator for automatic tool changing
Main data Number of drilling stations: 1
Number of chamfering stations: 1
Round hole diameter: 20 – 40 mm
Slotted hole dimension: Ø 20 – 40 x variable
Chamfering angle: 30° / 45°
Chamfering tolerance: +/- 0,1 mm
RAIL DRILLING AND MILLING MACHINE
Advantages and technical data
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2
1
4
9
3
7
6
10
5
8DesignRail infeed – roller table
Drilling and chamfering unit
Manipulator – tool exchange
Material feeding tongs
Outlet roller table
Hydraulic aggregate
Operator station
Safety door – tool exchange
Switch cabinet
Stage
RAIL DRILLING AND MILLING MACHINE
Design
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Axle sawing machineHorizontal single cut sawing machine
Exact length cutting of axles
Fully automatic cutting, centering and face milling of axles
Cutting position head piece
Cutting position tail piece
AXLE SAWING MACHINE
Plant overview
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Short pitch corrugation
Defect of the rail head shape
Why to maintain rails?
To reach low maintenance costs for the complete track construction and the vehicles
To reach a high level of travel comfort
To comply with requirements set for environment protection; to reach a low noise level of railway transport
To ensure the safety of railway traffic
Near surface defects
RAIL MILLING MACHINE
Why rail milling?
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Kinds of rail profilingRail maintenance (removal of „geometric“ rail defects and near surface defects)
Profiling of new rails
Profiling of acoustic requirements
For use in main-line and underground systems
Operation sites for rail profiling Importance of no sparks, no dust, clearance, no removal of switches
RAIL MILLING MACHINE
Where and what to use for?
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Processing of the rail head in one working pass
High finished meter performance per hour300 m/h - 2.000 m/h
0.083 – 0.56 m/s
High metal removal rate on the top and on the gauge corner of the rail
High accuracy of the milled rail head profileTransverse ≤ ± 0,2 mm
Longitudinal ≤ ± 0,01 mm
For wave lengths 10 – 30 / 30 – 100 mm
No need for grinding finishing
Environmentally friendly working processNo sparks / no dust / noiseless
Clearance free working processNo need to remove and reinstall switches
No limitations for works in tunnels, open-bridges and slab tracks
High capacity of milling swarf container –from 6 to 8 km milled track
Certificated for works on German high-speed traffic lines (300 km/h)
RAIL MILLING MACHINE
Advantages of milling process
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Milling units
Milling tool
Main electric cabinet
Chip compressor
Chip container
Operator station
Generator
Operator station
RAIL MILLING MACHINE
Design (Example SFU 04)
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Milling parametersMilling stations per rail each with an automatic rail detection system and an extraction system for milling swarf 2
Tool diameter 1.320 mm (1400 SF04)
Cartridges on each tool (7 straight and 2 radius each) 60
Number of blades per plate straight radius
84
Normal pressure angle of the tool 2,44 °
Residual waviness 0,0047 mm
Milling depth at the surface in one pass / miller 0,3 – 1,0 mm
Milling depth at the running edge in one pass / miller 0,3 – 3,0 mm
Milling performance 300 – 2000 m/h
Accuracy transverse profile ≤ ± 0,2 mm
Accuracy longitudinal profile at wave lengths 10 – 300 mm ≤ ± 0,01 mm
Accuracy longitudinal profile at wave lengths 300 – 1000 mm ≤ ± 0,10 mm
Possible tool change from inside and outside
RAIL MILLING MACHINE
Milling parameters SFU 04
3030
Unique milling conceptRemoval 3 mm running surface per miller
Removal 6 mm running edge per miller
High productivity
No sparks
No dust
Modular concept
24h working possible
RAIL MILLING MACHINE
Rail milling machine RFP 1
3131
Technical dataTrain weight, ton 300 3%
Train length 66,430
Maximum track climb in operating mode, ‰ 30
Minimum radius covered during milling of curves, m: 150
Speed of RFP-1, km/h:
Self-operation, not greater than 100
In measurement mode 0.5...1.8
In milling mode 0.5…1.8
Number of milling units, pcs. 4
Removal of metal per pass during milling:
Rolling surface of rail head, mm 0.3 … 3.5
Rolling edge 0.3 ... 8.0
RAIL MILLING MACHINE
Technical data RFP 1
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Milling parametersMilling stations per rail each with an automatic rail detection system and an extraction system for milling swarf 2
Tool diameter 1400
Cartridges on each tool (7 straight and 2 radius each) 6 / 1
Number of blades per plate straight radius
82
Normal pressure angle of the tool 2,37°
Residual waviness 0,0045
Milling depth at the surface in one pass / miller 0,3 – 3,5
Milling depth at the running edge in one pass / miller 0,3 – 8
Milling performance 300 – 2000 m/Std.
Accuracy transverse profile ≤ ± 0,2 mm
Accuracy longitudinal profile at wave lengths 10 – 300 mm ≤ ± 0,01 mm
Accuracy longitudinal profile at wave lengths 300 – 1000 mm ≤ ± 0,10 mm
Possible tool change from inside and outside
RAIL MILLING MACHINE
Milling parameters RFP 1
3333
Milling module SF-1/SF-2Control cabinet
Milling units
Compressors for supply of chippings
SF-2 – additional diesel-generator set for utility
SF-1 – sleeping compartment for 4 persons
Pull and energy module2 diesel sections with installed diesel generator sets
Brake compressor
Hopper box for chippings
Transporters for unloading chippings
RAIL MILLING MACHINE
Design RFP 1
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RM 1200 D longitudinal profile measurement after milling for different wave lengths
Calculation of waviness
Milling tool diameter D mm 1400Removal rate, constant mm 0.6Feed per tooth fz mm 5.0Pressure angle º 2.37Waviness h mm 0.0045
RAIL MILLING MACHINE
Milling result
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Each milling unit consists of:
Main drive
Main body, milling gear with tool fitting
Milling tool
Hydro mechanically height copying with cutter in feed mechanism
Electro mechanically copying device with cutter in feed mechanism for horizontal movement Automatic emergency lifting device
Transport locking system
Local electric terminal box
Lubrication
Spray lubrication
RAIL MILLING MACHINE
Milling units
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Advantages of the MFL tool system
All block cassettes can be exchanged in case of a crash
Number of cutters per insert tip 8 (straight)
Tools with sole plates have the advantage that the rail profile can be adjusted more exactly
By exchange of the block cassettes different rail profiles can be processed
With the new designed tools up to the double life time can be obtained.
RAIL MILLING MACHINE
Milling tool
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Milling tool
Inlet suction device, suction shoe
Venturi nozzle
Compressor
Inlet chip container
Screw conveyor
Cross transport conveyorBelt conveyor
RAIL MILLING MACHINE
Chip collection device
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PERFECTION IN ALL AREAS
MASCHINENFABRIK LIEZEN
Maschinenfabrik Liezenund Gießerei GmbH
Sawing and milling technology
Fabriksplatz 1, 4662 SteyrermühlAustriaPhone: +43 3612 270 800Fax: +43 3612 270 830E-Mail: [email protected]
www.mfl.at
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