production lines rail forging linechallenge of rail forging forging of train rail ends is vital for...

State of the Art• Highcapacity:4-8rails/hour

• Save75%ofmanpower

• Save65%onmilling

• Savemorethan50%energy

• Savepostheattreatment

• Hardnessofrailheadsameorbetterthantheinputrail

• Machiningonlyonrailheadandunderfoot

• ReducedHazardZone(HAZ)

• Decarburizationreducedtoaminimum

Production Lines

Rail Forging LineForging to Net Shape

FORGING PRESS5,000tonshydraulicpresswithforgingdies

HEATINGSystemforautomaticheatingofrails

RAIL MANIPULATORSFourcomputer-controlledmanipulatorslift,turnandmoverailsthroughtheentireprocess

RTS PANELOperatorPanelforRailTransferSystem

LUBRICATION

INPUT SECTIONHoldsuptofiverails,readyforpick-up

OUTPUT SECTIONFinishedrails,readyforpick-upandstoring

ADVANCED DIES AND PRESSHighlyspecializedforgingequipment

MANIPULATOR FOR RAIL HANDLING5-axismanipulatorwithservo

Version 1.0 · February 2013

Hydraulico as

Raadhusgade 87 DK-8300 Odder Denmark

Tel.: +45 8780 2000 Fax: +45 8780 0304

info@hydraulico.com

Watchvideodocumentationandfindmoreinformationatwww.hydraulico.com

A Complete Solution: Rail ForgingThesystemincludesa5,000tonpresswithspeciallydevelopeddies,heatingandanadvancedcomputer-controlledRailTransferSystem–thiscanboostproductivitysignificantly!

Challenge of rail forging

Forgingoftrainrailendsisvitalforensuringadurable,smoothandsafeshiftingofrailsinrailwaycrossings.However,forging–i.e.formingofpre-heatedobjects–posesseveralchallengestobothpressanddietechnologies.

Forseveralyears,Hydraulicohasbeenworkingintenselyonrefiningthetechnologiesinvolvedintransitionforgingsfromassymetricthickwebrailstothesymmetricrailsection.

Controlling the final shape of forged railsThedesignofthediesisanimportantparametertoperfectthefinalshapeoftheforgedrail.

Hydraulicobenefitsfromadvancedsimulationthathasbeenspeciallydevelopedtodefinethediedesignforoptimumshapeandminimizecostfromdiewear.

Computer simulationsDetailedanalysisofforgingprocesssimulationshasproducedmanyimportantdataforthedesignofforgingdies.

Fast production cycles

TheRailForgingSystemhasfourmanipulatorsthatoperateinperfectcoordination,andthesystemcompletes5-8railsperhour.Eachrailisonlyheatedonce,savingconsiderableamountsoftimeandenergyinthecompleteprocess.

Allforgingoperationsareconductedwithin90seconds,eliminatingtheneedforanextraheating.

Built-in flexibility

Processsurveillanceandcontrolisobtainedviacustomizedcomputersoftware.EveryfunctionaldetailintheRailForgingSystemisprogrammable,andmaybechangedinordertoadapttodifferenttasks,oralternativeproductions.

Other benefits

• Fullyintegratedhandlingofrail,railheating,dieheating,lubrication,forgingandflashremoval

• Thesystemcanhandleraillengthsfrom3metersupto24metersormore

• Documentedprocessparameters:Temperature,pressforce,andcycletime

• Quickdiechange

• Programswithallparametersarestoredforre-use

Reference

HydraulicohasmanufacturedRailForgingSystemstomanufacturersinChina,India,EUandCIS.

Hydraulico presses and production lines are at work around the globe. You will find local representatives in more than 16 major countries worldwide.