CAST WHEEL IN INDIAN RLYS - Present Status

Shri Sanjeev Kishore, PCME, Rail Wheel Factory, Banglore

Devarshi Kumar Gaur, DyCCMT, Rail Wheel Factory, Banglore
INTRODUCTION:

In the early 1970s the Railway Ministry felt the necessity for setting up a new
specialized Production Unit for manufacture of rolling stock wheels and axles as import
substitute due to increasing demands. The ultimate objective was that Rail Wheel
Factory [RWF, formerly Wheel & Axle Plant] should be able to totally meet Indian
Railways requirement for standard wheels so that their import could be stopped.

An extensive study was made of the latest technology and equipment available globally
possibility of collaboration and foreign exchange requirement. Based on this study the
Rail Wheel Factory project was conceived in the mid 70s with IR deciding to adopt the
cast wheel technology developed by M/S Griffin Wheel CO., USA for wheel
manufacture. American Railroads have been using cast wheels for freight operations
while European Railways use forged wheels.

Adoption of cast wheel technology was found more suitable as the productivity of the
plant is higher and cost of production lower as compared to forged wheels. The net
saving in foreign exchange on wheel imports was estimated at Rs.8 Crores per annum.

The Planning Commission sanctioned the Rail Wheel Factory Plant project in 1978 at a
cost of Rs.146 Crores. Trial production commenced during 1983. Late Smt. Indira
Gandhi, the then Prime Minister of India formally commissioned the plant on 15
September 1984. To reinforce the fact that we belong to the Indian Railways Family and
to display our commitment to change with times, the factory was renamed as RAIL
WHEEL FACTORY on 15 February 2003.

During April 2013, RWF has been re-certified by M/s. Indian Register Quality System
(IRQS), with latest version of Integrated Management System (IMS) encompassing (1)
Quality Management System conforming to the standards of ISO 9001:2008, for
manufacture of wheels, axles and wheel sets, (2) Environment Management System to
the standards of ISO 14001:2004 & (3) Occupational Health and Safety Management
system to the standards of OHSAS 18001:2007, for all activities related to manufacture
of Wheel, Axle & Wheel sets, support activities such as Canteen, Hospital, Kendriya
Vidyalaya and maintenance infrastructure in township. The latest feather in cap added
by getting certification of IRIS.

Another Plant set up by Government of India named as Rail Wheel Plant is situated at
Bela, in Saran Distt. Of Bihar (India) in 2014 to meet the growing requirement of wheel
discs for the Indian Railways.
Railway Cast Wheels •

Railway wheel sets having a special parabolic profile is assembly of two wheels fixed to
the axle by interference fit and they rotate along with the axle, without any independent
relative movement as in the case of other automobile wheels. • These wheels are
provided with flange towards the inner side, which guide the wheels to travel on the rails
and does not allow it to fall down from the rails. Governing specification of cast wheel is
IRS R19/1993 pt-III.

Metallurgical Properties of Cast wheel (IRS R-19 Part III/93) B G Coaching

(a) Chemical Properties

Element IRS R-19-93 Part III Class A IRS R-19-93 Part III Class B
( coaching) (WAGON)
C 0.47 – 0.57 (+0.03/-0.02) 0.57 – 0.67 (+0.03/-0.02)
Mn 0.60–0.80(+0.03/-.03) 0.60–0.80 (+0.03/-0.03)
Si 0.15–0.70(+0.03/-.03) 0.15 – 0.70(+0.03/-0.03)
P 0.03 max (+0.005) 0.03 max (+0.005)
S 0.03 max (+0.005) 0.03 max (+0.005)
Cr 0.15 max (+0.05) 0.15 max (+0.05)
Ni 0.25 max (+0.05) 0.25 max (+0.05)
Mo 0.06 max (+0.02) 0.06 max (+0.02)
Cr+Ni+Mo 0.40 max 0.40 max
V Not specified Not specified
Cu Not specified Not specified
H2 3 ppm max. 3 ppm max.
N2 0.007 max 0.007 max
Mechanical and Metallographic Properties

Characteristics Rim Plate Rim Plate

UTS N/mm2 900 min 800 min 930 min 800min
Yield Strength 50% of 50% 50% of 50% UTS
N/mm2 min. UTS UTS UTS
El% min 5 7 4.5 7
Hardness range 255-320 277-341
BHN
Grain Size ASTM 6–8 06/08/19
Micro structure Fine Pearlite Fine Pearlite
Impact strength 10 -- -- --
J/mm2 (-20C)
Closure mm >1 >1
Sampling Size 1 in < 500 1 in < 1000

Manufacturing Process:

Pressure poured cast wheels are being used in Indian by freight railroads .No other
methods are in practice for cast railroad wheels These wheels are manufactured in
high-volume, technically advanced, highly automated cast wheel manufacturing plants
at Yelahanka and Bela. Pressure poured cast wheels are used in India in all climates
from +40C to -40C, with axles loads of up to 25 metric tons, and such wheels are known
for their durability, dimensional consistency, superior rotundity, ability to resist severe
thermal loads from tread braking, and excellent service performance. Due to the
automated, high volume manufacturing methods utilized, the technical details of the
pressure pouring process itself, and soundness of the casting, these railroads enjoy a
favorable life cycle cost for wheels. Not only is the initial value proposition of the
pressure poured wheel outstanding for end users, but the durability of the wheel is well
known. This paper also described the extensive tests that were conducted on pressure
poured cast wheels with improved chemistry made of speed upto 110 km/hr.
Developed wheels:

RWF manufactured cast wheels of AV an MoV chemistry developed by RWF and IIT
Kanpur for speed upto 110kmph. After extensive trials and monitoring , RDSO, a
technical advisory body to Indian rlys, given the provisional clearances of using it Non-
AC coaches of Fiat Bogie at a maximum speed of 110Kmph as an alternative to forged
wheel. Further, RWF has manufactured some cast wheels for LHB coaches with TMRS
chemistry to run upto 130kmph. This TMRS chemistry has got much improved
metallurgical properties in compare to AV an MoV type. The RDSO clearance is still
awaiting to put these wheels into service.
COMPARISON OF PHYSICAL & CHEMICAL PROPERTIES OF IRS R-19 CLASS-A,
CLASS-AV, CLASS MoV & TMRS CAST WHEELS
R-19/93 IRS R-93 Part II
LHB LHB TMRS
Description Pt.III, Forged (LHB)
Class AV Class MoV
Class A Wheel
Chemical Properties(ladle analysis)
Carbon 0.47-0.57 0.47-0.57 0.47-0.57 0.43-0.47 0.52 max
Manganese 0.60-0.80 0.60-0.80 0.60-0.80 0.70-1.00 0.60 to 1.00
Silicon 0.15-0.70 0.15-0.70 0.15-0.70 0.50-0.70 0.15 to 0.40
Sulphur 0.03 max 0.03 max 0.03 max 0.030 max 0.025 max
Phosphorous 0.03 max 0.03 max 0.03 max 0.030 max 0.025 max
Nickel 0.25 max 0.25 max 0.25 max 0.25 max 0.25 max
Chromium 0.15 max 0.15 max 0.15 max 0.25 max 0.25 max
Molybdenum 0.06 max 0.06 max 0.07-0.15 0.05 max 0.06 max
Vanadium --- 0.10-0.16 0.10-0.16 0.11-0.15 0.15 max
Copper --- --- --- --- 0.20 max
Mechanical & Metallurgical Properties
Specified Achieved by Achieved by
Achieved by RWF
Description as per IRS RWF RWF
MAS-8
R-19 H.No.75795 H.No.84383
Tensile
900 (Rim) 1037.8 (Rim) 1019.6 (Rim)
Strength, 927 - 965
800 (Plate) 882.7 (Plate) 872.0 (Plate) 750-850
N/mm2
Elongation % 5 (Rim) 7.7 (Rim)
7.9 (Rim) 6.4 – 9.3 16 min
7 (Plate) 8.4 (Plate)
Yield Strength, 50% of 705.1 (Rim)
713.3 (Rim) 680 - 715 520 Min
N/mm2 UTS min 573.1 (Plate)
Impact
Strength, Average :17
10 min 15 15 14
Joules at 20oC Individual:12

Hardness, 241-320
255 -321 295 - 314 282 - 314 ---
BHN
Microstructure Fine
Fine Pearlite Fine Pearlite --- Fine pearlite
Pearlite
ASTM Grain
6-8 6 6 --- 6 or finer
size
Fracture Axial:62.97 Axial:69.72
Axial:51.24
toughness Not specified Not specified 6 or finer
Not Not specified
Mpa√m
specified
(maximum) Radial:69.30 Radial: 50.80 Radial: 77.48 Not
Not specified Not specified specified Should be ≥80
Challenges: