machine tools for railways

machine tools for railways

RAFAMET S.A. Comprehensive solutions, advanced technologies and cost efficient productivity now much more than ever before are obvious requirements that the right equipment supplier is expected to meet in order to help various industries to be successful, to stay competitive in this global manufacturing market. For more than a century, RAFAMET has served to meet the diverse needs of the metalworking industry. Today RAFAMET SA is one of the world s leading builders of innovative and productive machine tools. At the beginning of the twentieth century the foundry shops then existing began producing wheel lathes for machining railway wheel sets. This type of production continues up to the present day. Since then RAFAMET has developed its products to include special purpose wheel lethes for railways and multi-purpose heavy duty single and double column vertical turning and boring mills. Over the years the Company has become one of the largest suppliers of special purpose machine tools. It has manufactured more then 6000 heavy duty machines to date. These machine tools have been installed in more than 50 countries in the world. Whilst maintaining its traditional production, RAFAMET continues to develop new product lines, using the Company s own, engineering task force. Such a development, in recent years, has helped RAFAMET to be able to enter new manufacturing fi elds, i.e. bridge type milling machines, horizontal lathes, special machines, modular machining centres etc. Simultaneously RAFAMET has developed the customer service and support program. It s total commitment to customer satisfaction has become a daily routine for the entire RAFAMET s staff. Moreover RAFAMET has been working in the ISO 9001 Quality Assurance/Management Standard environment since 1996.

Table of contents UBF 112 N CNC Surface Wheel Lathe... 4 UFB 125 N CNC Wheel Lathe with Friction Drive... 5 UDA 125 N CNC Portal Wheel Lathe...6 UBE 112 N CNC Surface Wheel Lathe...7 UGL 80 N / UGD 150 N CNC Underfloor Wheel Lathes...8 UGE 150 N CNC Underfloor Wheel Lathe...9 KCM 150 N CNC Vertical Turning & Boring Mill...10 GMC 400 CNC Gantry Milling Machine...11 Our work is based on the ISO 9001 quality system, which is continuously being improved and our principal goal is the complete satisfaction of our Customers.

UBF 112 N CNC Surface Wheel Lathe Modern and fi eld-proven design providing economical machining of wheel sets in roll-in, roll-off system Fully automatic machining of new and worn wheel sets with axle boxes, gears and brake discs used in rail vehicles Compact and rigid design based on high grade iron castings ensuring both machine tool high geometrical stability and effi cient vibration damping System of automatic measurement of profi le wear and software optimizing all parameters of cutting process to minimize layer of material to remove Twin master-and-slave-type main drive provides high productivity and quality of wheel set machining Effi cient chip disposal system UBF 112 N Track gauge [mm] 1435 (1) Max. wheel set wheel tread diameter before machining [mm] 1120 or 1250 Min. wheel set wheel tread diameter before machining [mm] 700 or 830 Max. length of wheel set axle [mm] 2270 Min. length of wheel set axle [mm] 1910 Max. width of tyre [mm] 150 Max. weight of wheel set [x10 kn] 3 Power of motors of infi nitely variable rotation rates for main drive [kw] 56 (2 motors) Length [mm] 7220 Overall dimensions of machine tool Width [mm] 3000 Height [mm] 2160 Approximate weight of machine tool [x10 kn] 36 (1) Or another according to agreement Wheel set wheel profi le turning according to technological programme Wheel set wheel inner rim facing Tyre cutting to remove clamping ring Wheel set wheel outer rim facing Limit machining groove cutting Brake disc facing Wheel centre turning

UFB 125 N CNC Wheel Lathe with Friction Drive Designed for turning operations on new and worn railway rolling stock wheel sets in roll-in, roll-off system Fully automatic machining of new and worn wheel sets with axle boxes, gears and brake discs used in rail vehicles Compact and rigid design based on high grade iron castings ensuring both machine tool high geometrical stability and effi cient vibration damping System of automatic measurement of profi le wear and software optimizing all parameters of cutting process to minimize layer of material to remove Six independent rollers for main drive provides high productivity and quality of wheel set machining Coromant CAPTO quick change tools UFB 125 N Track gauge [mm] 1435 (1) Max. wheel set wheel tread diameter before machining [mm] 1250 Min. wheel set wheel tread diameter before machining [mm] 600 Max. length of wheel set axle [mm] 2800 Min. length of wheel set axle [mm] 1640 Max. width of tyre [mm] 150 Max. weight of wheel set [x10 kn] 3 Power of motors of infi nitely variable rotation rates for main drive [kw] 72 (6 motors) Length [mm] 6500 Overall dimensions of machine tool Width [mm] 3100 Height [mm] 2500 Approximate weight of machine tool [x10 kn] 25 (1) Or another according to agreement Wheel set wheel profi le turning according to technological programme Wheel set wheel inner rim facing Tyre cutting to remove clamping ring Wheel set wheel outer rim facing Limit machining groove cutting Brake disc facing Wheel centre turning

UDA 125 N CNC Portal Wheel Lathe High productivity of wheel set machining in both roll-in, roll-off and/or roll-through systems Fully automatic machining of new and worn wheel sets with axle boxes, gears and brake discs used in rail vehicles Compact and rigid design based on single-piece cast iron frame ensuring both machine tool high geometrical stability and effi cient vibration damping System of automatic measurement of profi le wear and software optimizing all parameters of cutting process to minimize layer of material to remove Twin master-and-slave-type main drive provides high productivity and quality of wheel set machining Effi cient chip disposal system UDA 125 N Track gauge [mm] 1435 (1) Max. wheel set wheel tread diameter before machining [mm] 1250 Min. wheel set wheel tread diameter before machining [mm] 660 Max. length of wheel set axle [mm] 2370 Min. length of wheel set axle [mm] 1645 Max. width of tyre [mm] 150 Max. weight of wheel set [x10 kn] 4,5 Power of motors of infi nitely variable rotation rates for main drive [kw] 100 (2 motors) Length [mm] 8400 Overall dimensions of machine tool Width [mm] 3825 Height [mm] 2840 Approximate weight of machine tool [x10 kn] 46 (1) Or another according to agreement Wheel set wheel profi le turning according to technological programme Wheel set wheel inner rim facing Tyre cutting to remove clamping ring Wheel set wheel outer rim facing Limit machining groove cutting Brake disc facing Wheel centre turning

UBE 150 N CNC Surface Wheel Lathe Modern and fi eld-proven design providing economical machining of heavy wheel sets in roll-in, roll-off system Fully automatic machining of new and worn wheel sets with axle boxes, gears and brake discs used in rail vehicles Compact and rigid design based on high grade iron castings ensuring both machine tool high geometrical stability and effi cient vibration damping System of automatic measurement of profi le wear and software optimizing all parameters of cutting process to minimize layer of material to remove Two main drive motors provide high productivity and quality of machining Effi cient chip disposal system UBE 150 N Track gauge [mm] 1435 (1) Max. wheel set wheel tread diameter before machining [mm] 1300 Min. wheel set wheel tread diameter before machining [mm] 700 Max. length of wheel set axle [mm] 2360 Min. length of wheel set axle [mm] 1890 Max. width of tyre [mm] 150 Max. weight of wheel set [x10 kn] 3 Power of motors of infi nitely variable rotation rates for main drive [kw] 100 (2 motors) Length [mm] 8700 Overall dimensions of machine tool Width [mm] 3650 Height [mm] 2600 Approximate weight of machine tool [x10 kn] 56 (1) Or another according to agreement Wheel set wheel profi le turning according to technological programme Wheel set wheel inner rim facing Tyre cutting to remove clamping ring Wheel set wheel outer rim facing Limit machining groove cutting Brake disc facing Wheel centre turning

UGL 80 N / UGD 150 N CNC Underfloor Wheel Lathes Designed to machine wheel sets of light railway vehicles in situ, mounted on single bogie or dismantled off bogie. Fully automatic machining of wheel sets used in light rail vehicles Compact and rigid design based on high grade iron castings ensuring both machine tool high geometrical stability and effi cient vibration damping System of automatic measurement of profi le wear and software optimizing all parameters of cutting process to minimize layer of material to remove Four independent rollers for main drive provide high productivity and quality of wheel set machining Coromant CAPTO quick change tooling (UGL 80 N) Effi cient chip disposal system UGL 80 N UGD 150 N Track gauge [mm] 1435 (1) 1435 (1) Max. wheel set wheel tread diameter before machining [mm] 700 1500 Min. wheel set wheel tread diameter before machining [mm] 400 520 Min./ Max. width of tyre [mm] 90 / 135 90 / 135 Max. load of wheel set on Clamped by outer axle boxes 10 15 rails [x10kn] Clamped in centres 6 6 Min. load of vehicle on one wheel set without necessity of holding down [x10kn] 12 Power of motors of infi nitely variable rotation rates for main drive [kw] 25 (4 motors) 44 (4 motors) Total power installed [kw] 73 85 Overall dimensions of machine tool Length [mm] 6000 5300 Width [mm] 1950 1900 Height [mm] 1330 (2) (2) 2100 900 (4) 1050 (3) Approximate weight of machine tool [x10 kn] 12 22 Wheel set wheel profi le turning according to technological programme Wheel set wheel inner and outer rim facing Brake disc facing (1) Or another according to agreement (2) Height from base bottom to fl oor level (3) Height from fl oor level to max. extended holding down device column (4) Height from fl oor level to max. extended tailstock

UGE 150 N CNC Underfloor Wheel Lathe Designed to machine wheel sets of vehicles in situ, mounted on single bogie or dismantled off bogie Fully automatic machining of wheel sets used in heavy rail vehicles Compact and rigid design based on high grade iron castings ensuring both machine tool high geometrical stability and effi cient vibration damping System of automatic measurement of profi le wear and software optimizing all parameters of cutting process to minimize layer of material to remove Four independent rollers for main drive provide high productivity and quality of wheel set machining Effi cient chip disposal system UGE 150 N Track gauge [mm] 1435 (1) Max. wheel set wheel tread diameter before machining [mm] 1500 Min. wheel set wheel tread diameter before machining [mm] 600 Min./ max. width of tyre [mm] 90 / 150 Clamped by outer axle boxes 30 Max. load of wheel set on rails [x10 kn] Clamped in centres 6 Min. load of vehicle on one wheel set without necessity of holding down [x10 kn] 12 Power of motors of infi nitely variable rotation rates for main drive [kw] 60 (4 motors) Total power installed [kw] 95 Overall dimensions of machine tool Length [mm] 5350 Width [mm] 1960 Height [mm] 2150 (2) 900 (3) Approximate weight of machine tool [x10 kn] 26 Wheel set wheel profi le turning according to technological programme Wheel set wheel inner and outer rim facing Brake disc facing (1) Or another according to agreement (2) Height from base bottom to fl oor level (3) Height from fl oor level to max. extended holding down device column

KCM 150 N CNC Vertical Turning & Boring Mill Single-column Vertical Turning and Boring Mill specifi cally designed to machine railway wheels Fully automatic machining of wheels Compact and rigid design based on high grade iron castings ensuring both machine tool high geometrical stability and effi cient vibration damping Six point self-centering chuck Five position automated tool holder changer for each rail head ISO, CAPTO, KM or other tooling system Effi cient chip disposal system Complete machining of solid wheel (in two operations) Wheel hub hole rough and fi ne boring Tyre boring Wheel centre machining Table Main drive KCM 150 N Table diameter [mm] 1500 Max. tread diameter of solid wheel [mm] 1250 Min. diameter of solid wheel hub hole [mm] 145 Number of automatic chuck jaws [pcs] 3 Max. weight of workpiece [x10kn] 6 Power of main drive motor (S1/S6) [kw] 55 / 75 Number of ranges of table rotation rates 2 Max. rotation rates of table [rpm] 250 (1) Cross-rail Max. turning height (from table surface to ram face) [mm] 700 Rail head & ram Positioning Ram travel [mm] 700 Rapid travel rate X and Z axes [mm/min] 6000 Range of working feeds of X and Z axes [mm/min] 0.1 to 2000 Ram cross section [mm] 250 x 250 Mar accuracy of X axis (L = 1000 mm) [mm] 0.015 (2) Mar accuracy of Z axis ( L= 1000 mm) [mm] 0.015 (2) RPmax repeatability of X axis (L = 1000 mm) [mm] 0.012 RPmax repeatability of Z axis (L = 1000 mm) [mm] 0.012 Overall dimensions Length [mm] 5080 of machine Width [mm] 5616 tool Height [mm] 4500 Approximate weight of machine tool [x10kn] 21 (1) Note! Max. rotation rate of table depends on work piece load and balance (2) - When measuring scales are applied (option), positioning accuracy is following: X axis - 0.010 mm / 1000 mm, Z axis - 0.007 mm / 1000 mm

GMC 400 CNC Gantry Milling Machine Designed to machine complex work pieces within working envelope of 11.000 x 3.200 x 2.500 mm. It can be tailored to satisfy requirements of machining of railway bogie frames. 3D milling Drilling Reaming Boring Threading, envelope threading (helical motion) in all machining planes, i.e. XY, YZ, and XZ Machine tool major members are: Two parallel bed ways with a table plate equipped with the table geometry adjustment systems Moving portal (Gantry) housing a cast iron cross rail Milling rail head with a forged steel ram Application of CNC system enables automatic and effi cient machining according to a technological programme. The ram spindle is provided with ISO 50 taper enabling automatic tool clamping & releasing and cooperating with a tool magazine. Right angle powered tool head is equipped with ISO 50 spindle enabling automatic tool clamping and releasing. GMC 400 CNC Plate surface [mm] 3200 x 8000 Bed ways length [mm] 11000 Travel of Gantry along bed ways (X axis) [mm] 8000 Travel of rail head along cross rail (Y axis) [mm] 4300 Ram travel [mm] 1500 Clearance between columns [mm] 4000 Max. distance between spindle face of ram and plate surface [mm] 2500 Ram cross-section [mm] 450 x 450 Max. power of main drive motor at ratio i=1 for Max. power of main drive motor at ratio i=5 for Max. rotation rates of main drive S1 [kw] 64 S6 [kw] 70 S1 [kw] 55 S6 [kw] 66 At ratio i = 1 [rpm] 3000 At ratio i = 5 [rpm] 750 Max. torque of main drive At ratio i = 1 [rpm] 820 spindle At ratio i = 5 [rpm] 3500 / 4200 Admissible local load of plate [x10 kn / 1 sq m] 5 Max. weight of work piece [x10 kn] 50 Length [mm] 13300 Overall dimensions of machine tool Width [mm] 9500 Height [mm] 8500 Approximate weight of machine tool [x10 kn] 120

RAFAMET product lines Besides the Portal Milling Machines, RAFAMET develops the following product lines: Vertical Turning & Boring Mills vertical turning & boring mills Horizontal Lathes horizontal lathes Portal Milling Machines portal milling machines Machine Tools for Shipbuilding Industry shipbuilding industry machine tools for

RAFAMET S.A. RAFAMET is one of the worldwide leading companies designing and manufacturing medium- and large-size heavy-duty machine tools. Engineering & programming From concept through design & analysis to fi nal implementation, RAFAMET strong engineering & programming task force equipped with 33 Workstations with Solid Edge, AutoCAD, and Prelude CAD Software has the expertise in developing engineering solutions and software programs tailored to meet specifi c needs of wide variety of metalworking industries. Own foundry To ensure required productivity rate and top quality of machined surfaces in the same time, major members of our machine tools are made as heavily-ribbed box-type iron castings providing excellent rigidity and vibration damping of main structures even when machining at high cutting parameters. Grey iron: 0.1-40 ton piece Ductile iron: 0.1-15 ton piece Overall dimensions: 10000 4000 3000 mm Pattern making, moulding, heat treatment, laboratory Contract machining As a machine tool builder having great metalworking experience, RAFAMET off ers customers a contract machining capability. Our stock of machine tools can handle cast iron, forged and fabricated workpieces weighting up to 60 tons within working envelope of 14000 3600 3600 mm. Service & technical support At RAFAMET, we not only build quality machines, we also provide training, service, and support to keep them in peak operating condition. During installation, operators and maintenance staff receive a specifi c training on how to use and maintain the machine in order to ensure its best performance and a fault-free operation. The English / German / Russian speaking servicemen having great skills in CNC machine tools are ready to assist our customers in case of any need. RAFAMET machine tools users have at their disposal dedicated ISDN-based remote diagnostics facility able to communicate with the machines control systems for immediate fault recognition and reporting.

Warsaw Katowice RAFAMET Machine Tools ul. Staszica 1, 47-420 Kuźnia Raciborska, Poland tel. +48 32 419 11 11, fax +48 32 419 13 66 www.rafamet.com