Bogie Information. Issue 1

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1 Bogie Information Issue 1

2 William Cook Rail Bogie Information Issue 1: 16 March 2017 Copyright William Cook Rail Ltd. All rights reserved. This document is protected by copyright and design right owned by William Cook Rail Limited. All rights conferred by the law of copyright conventions are reserved to the copyright owner. No part of this document may be used, disclosed, transmitted, copied, lent, sold, stored in any retrieval system of any nature or otherwise reproduced or circulated (in any form or by any means including electronically and whether or not transiently) without the express prior written consent of the copyright owner. General Contact Information: William Cook Rail Ltd Cross Green Leeds LS9 0DX England Tel. +44 (0) Web: For information about our company, please visit our website. Copyright 2017 William Cook Rail WCR Bogie Information

3 IN-HOUSE CAPABILITIES Design and Development CAD Modelling Solidification Simulation CNC Patternmaking 3D Rapid Prototyping Casting and Fabrication Stress-Relieving, Air and Inert Atmosphere Normalising, Tempering and Quenching Hot Wash De-Greasing, Shot and Sand Blasting Magnetic Particle, Ultrasonic and Radiographic Inspection Finite Element Analysis Fatigue Testing and Non-Destructive Testing Collision Damage Repairs, Fault Finding and Clash Testing Tooling Manufacture Machining CMM Metrology Laser Scanning Fabrication by qualified welders using the latest MIG and TIG welding equipment Dipping, Hand Painting, Spray Painting, Heated Drying Copyright 2017 William Cook Rail Page 1 of 29 WCR Bogie Information

4 PRO-ENGINEER DESIGN SOFTWARE Copyright 2017 William Cook Rail Page 2 of 29 WCR Bogie Information

5 MAGMASOFT Copyright 2017 William Cook Rail Page 3 of 29 WCR Bogie Information

6 CNC PATTERNMAKING Copyright 2017 William Cook Rail Page 4 of 29 WCR Bogie Information

7 IN-HOUSE MACHINING Correa HVM-50-MG Travelling Column Milling Machine Correa FOX-50: Machining Bogie Frames Copyright 2017 William Cook Rail Page 5 of 29 WCR Bogie Information

8 CMM METROLOGY Copyright 2017 William Cook Rail Page 6 of 29 WCR Bogie Information

9 ACCREDITATIONS AND APPROVALS ISO 9001:2008 Quality Management System Standard Certificate number: ISO 14001:2004 Environmental Management System Standard Certificate number: LRQ /B BS OHSAS 18001:2007 Occupational Health & Safety Management System Certificate number: LRQ /B EN , Certification Level CL1 Certificate number: TÜVNORD/15085/CL1/167/0A4/13 Deutsche Bahn Certificate number: IRIS Copyright 2017 William Cook Rail Page 7 of 29 WCR Bogie Information

10 CUSTOMERS Copyright 2017 William Cook Rail Page 8 of 29 WCR Bogie Information

11 SERIES 3 ELECTROSTAR BOGIE FRAME Copyright 2017 William Cook Rail Page 9 of 29 WCR Bogie Information

12 ELECTROSTAR FRAME END Copyright 2017 William Cook Rail Page 10 of 29 WCR Bogie Information

13 ELECTROSTAR FRAME END WITHOUT DAMPER BRACKET Copyright 2017 William Cook Rail Page 11 of 29 WCR Bogie Information

14 ELECTROSTAR TRAILER TRANSOM Copyright 2017 William Cook Rail Page 12 of 29 WCR Bogie Information

15 ELECTROSTAR CENTRE SECTION Copyright 2017 William Cook Rail Page 13 of 29 WCR Bogie Information

16 ELECTROSTAR BOGIE FRAME COMPLETE WITH AXLES BOXES AND BRAKE HANGERS Copyright 2017 William Cook Rail Page 14 of 29 WCR Bogie Information

17 METRO LOS TEQUES BOLSTER Copyright 2017 William Cook Rail Page 15 of 29 WCR Bogie Information

18 CONVERSION OF FABRICATION TO MACHINED CASTING ALSTOM Metro Los Teques Bolster Original diagram of fabricated plate bolster (highlighted in yellow). Developed from fabricated component to 3 piece cast steel assembly, pre-machined by William Cook ready for welding and final machining. Copyright 2017 William Cook Rail Page 16 of 29 WCR Bogie Information

19 CONVERSION OF FABRICATION TO MACHINED CASTING ALSTOM Metro Los Teques Bolster The 3 piece pre-machined assembly ready for welding. The 3 piece welded assembly at Alstom. The 3 piece finished assembly at Alstom. The 3 piece welded assembly in position on the train. Copyright 2017 William Cook Rail Page 17 of 29 WCR Bogie Information

20 STADLER - END BEAM Copyright 2017 William Cook Rail Page 18 of 29 WCR Coupler Information

21 CONVERSION OF FABRICATION TO MACHINED CASTING STADLER End Beam Existing fabricated design showing three separate components. One piece casting design. One piece casting, fully machined. Magmasoft Validation and Simulation Predicts potential internal defects. Predicts potential contraction and distortion. CNC Patternmaking Finished Product Copyright 2017 William Cook Rail Page 19 of 29 WCR Coupler Information

22 CONVERSION OF FABRICATION TO MACHINED CASTING ALSTOM Suspension Pot CAD Model Finished Machined Casting Copyright 2017 William Cook Rail Page 20 of 29 WCR Coupler Information

23 DEVELOPED FROM PRIMARY CONCEPT AS SUGGESTED BY BOMBARDIER Initial design by Bombardier CAD Modelled by William Cook William Cook Magmasoft Simulation Un-machined Casting Finished Machined Casting Copyright 2017 William Cook Rail Page 21 of 29 WCR Coupler Information

24 PRODUCT DEVELOPMENT BOMBARDIER Flexx Eco Frame Casting Design Proposal - Bogie Frame 7 piece cast steel frame with cast or forged ends Side Frame outer view Copyright 2017 William Cook Rail Page 22 of 29 WCR Coupler Information

25 PRODUCT DEVELOPMENT BOMBARDIER Flexx Eco Frame Casting Design Proposal - Bogie Frame Flexx Eco Cast Transom 7 piece Frame, pre-machined and ready for fabrication Copyright 2017 William Cook Rail Page 23 of 29 WCR Coupler Information

26 PRODUCT DEVELOPMENT BOMBARDIER Flexx Eco Frame Hybrid Proposal: Cast Sideframe, Fabricated Transom Motor Frame Assembly, complete (top) Existing, Fabricated, Crossrail, Motor Frame. Spring Pots and Fabricated Transom to be retained. Minor Brackets and Fittings to be welded on. Copyright 2017 William Cook Rail Page 24 of 29 WCR Coupler Information

27 PRODUCT DEVELOPMENT BOMBARDIER Flexx Eco Frame Hybrid Proposal: Cast Sideframe, Fabricated Transom Full Assembly Copyright 2017 William Cook Rail Page 25 of 29 WCR Coupler Information

28 PRODUCT DEVELOPMENT BOMBARDIER Flexx Eco Frame Gearbox Bracket Detail Gearbox Bracket Copyright 2017 William Cook Rail Page 26 of 29 WCR Coupler Information

29 BOMBARDIER TRANSPORTATION Crossrail, Gearbox Bracket Gearbox Bracket Copyright 2017 William Cook Rail Page 27 of 29 WCR Coupler Information

30 STADLER AXLEBOX BODY Copyright 2017 William Cook Rail Page 28 of 29 WCR Coupler Information

31 FINANCIAL INFORMATION 2015/2016 Group Sales: 50 Million Group Net Assets: 58 Million Employees: 450 Copyright 2017 William Cook Rail Page 29 of 29 WCR Coupler Information

Coupler Information. Issue 2

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