ZAIIMATUL

ZAIIMATUL
HUSNAA
HUSNAA M
M
12513062
12513062
METALURGI PEMBENTUKAN
LOGAM
TEKNIK METALURGI
INSTITUT TEKNOLOGI BANDUNG
2016

HOT FORGING FOR RAILWAY WHEEL BY

HYDRAULIC PRESS FORGING

OUTLINE
Introduction
Main Product
Manufacturing Process
Equipment Plant
Product Specification
Product Advantage
Summary
Reference

INTRODUCTION

Sales
: 1200
million
Employees : 5500
Customers:
Car
manufactures,
packaging,
Technological and global market leader in the metal forming
appliances,
minting, industry

MAIN PRODUCT

Shaft: Inconel (Al Ti

Si C S P)

Drive component: Al
Alloy

Wheel: Medium
Carbon Steel

MAIN PRODUCT
Medium Carbon Steel
Diesel Loco Wheel - IRS: R34/03***
Weight/piece, Wheel tread
kg

dia, mm

528

1097

Axle load, t

16.25

MANUFACTURING PROCESS

Billet
Loading

Finished
Forging

Billet
Cutting

Heating
Furnace

Upsetting

Start
Forging

High Pressure
Descalling

Piercing

MANUFACTURING PROCESS

Roll forming

UV-Magnetic
Testing

Trimmin
g

Machining

Stacking to reheating
furnace

CNC machining

EQUIPMENT PLANT

Billet
Cutter

Wheel

Rotary Hearth
Furnace

Hydraulic

Descaling
Press

Pneumatic

EQUIPMENT PLANT

CNC
Machine

Clamping and
Polishing
Machine

UV-Magnetic
Testing Machine

EQUIPMENT PLANT
1.
2.
3.
4.
5.
6.

Drive Head
Piston Rod
Slide
Upper Die
U-frame
Lower Die

Billet Cutter
1. Clamping Head
2. Saw blad
carriage
3. Saw blade
4. Machine bed
5. Power

Hydraulic forging press

160 kJ

EQUIPMENT PLANT
1. Liquid Sprayer
2. Monitor
System
3. Motor

1. Thrust Piece
2. Pneumatic
Spring

Pneumatic

3. Punch with
lubricant
4. Die

Magnetic
Tester

PRODUCT SPECIFICATION

C%
max

Mn%
max

0.57

0.60.85

Chemical
Composition
P%
S%
Si%
max

max

max

H (ppm)
max

0.03

0.03

0.15

2.5

Specification

Mechanical
Properties

IRS: R-34/03***

Diesel Loco
Wheel
IRS: R-34/03***

Yield Strength
(Min) MPa

Tensile
Strength MPa

%
Elongation

V-Notch impact
Toughness ( 20
CJ/cm2)

50% UTS

775-900

13-11 min

20 min

PRODUCT ADVANTAGE
Diesel Loco
Wheel
IRS: R-34/03***

Designed for use on rail track of

express train
Typically pressed onto an axle
and
mounted
directly
on
locomotive
Having high tensile stress to
resist RCF

SUMMARY
Schuler is a metal forming industry based in Germany
One of their product is medium carbon steel (Diesel Loco
Wheel-IRS: R-34/03***) wheel for railways wheel
The advantages of their product are higher Charpy V-notch
impact, higher %elongation, and higher tensile strength
improvingone problem may exacerbate other problems. It is
therefore necessary to prove by trialthat the demonstrated
improvements outweigh any deterioration in other properties.

REFERENCE
www.schulergroup.com (diakses tanggal 28 November 2016 pukul 17.52)
www.arrium.com (diakses tanggal 28 November 2016 pukul 19.02)