Railway machining

How to use the tool

Selection mode: select part type, operation, cutting type, tool, coolant and priority. The system will check the compatibility of the parameters and issue a risk checklist with recommendations.

“Diagnostics” mode: click on the symptom (chips, craters, vibrations, etc.), specify the load and part - get the cause and a specific solution.

Features of processing railway parts

Railway parts are one of the most difficult objects to machine: high hardness, scale, shock loads during intermittent cutting and stringent requirements for profile accuracy.

Wheelset (ER7/ER8, GOST 10791, EN 13262): hardness 255–305 HB. Flanged turning is always an intermittent cut. Hardening and defects from use are possible. A rigid clamp and a viscous TV brand are required. alloy P40–P50.

Rail (900A/1100 MPa, EN 13674): hardness 260–360 HB, first pass on scale. The most abrasive material in the railway group. Reduce Vc by 20–30% for first pass, large feed. After removing the scale, the speed can be increased.

Crosspiece (Hadfield, steel 110G13L): the most difficult case. Manganese steel is riveted directly under the tool, the hardness of the crust reaches 450+ HB. You can't stop cutting. Only P40–P50, Vc ≤ 70 m/min, large feed.

Axle (EA1N/EA4T, EN 13261): softer than other railway parts (180–280 HB), but long cut → thermal expansion → size loss. For L/D > 8, a steady rest is required.

Diagnosis of common problems

Edge chipping: take a more viscous grade, add a T-land chamfer (0.1–0.2 mm), reduce Vc by 15–20%.

Notch wear: The scale/metal boundary or work hardening creates a jump in hardness. Periodically adjust the depth ap ±0.05 mm.

Vibrations: reduce offset to a minimum, increase fn, steady rest with thin axes.

Size care: thermal expansion or edge wear. Flood is required, change the plate until it is completely worn out.

Frequently Asked Questions

Can coolant be used with ceramics? No. Flood coolant on a hot ceramic plate - thermal shock and instant chipping. Ceramics only work in dry or air-cooled conditions.

What does “keep cutting” mean for Hadfield? Manganese steel hardens within seconds when the feed is stopped. The edge cuts into the hard crust and pricks. The only way out is with a smooth movement.

Selection of plates and tools for processing railway parts - call our technologists.