Rebuilding the wheelset flanges of locomotives by surfacing without wheeling out

Abstract

The most effective method to increase the surface life of wheel tires, the flange wear of which outpaces the growth of tire wear significantly, is surfacing of worn flanges of electric locomotive wheel sets. This method, in comparison with the restoration by turning and forming a profile configuration by reducing the thickness of the tire has undeniable advantages: flange surfacing combined with the shape of female profile minimizes the technological wear of the tire before its retirement; idle time of locomotives caused by the need of intermediate turning is eliminated; the costs of maintaining the machines for turning without removing the wheels and purchasing hard-alloyed cutting tools are decreased; wage savings are achieved. The work presents basic information on wheel sets, theoretical data on surfacing, analyzes previously used surfacing materials and provides metallographic studies of the surfaced material. The technology of flange surfacing without removing the wheels from under the electric locomotive was developed and described, that allows reducing the time spent on repair significantly. The use of alloyed surfacing materials instead of low-carbon ones allows reducing the time of surfacing and increasing the resistance to wear of wheel set flanges of traction vehicles. Efficiency of NP-18H1G1M.01 surfacing wire application for wear-resistant surfacing of tire flanges and increase of the overhaul cycle is shown. Increased wear resistance of electric locomotive wheel flanges surfaced with alloyed wire is confirmed by the production test data.