Design Services - Progress Rail Services

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Switches, Crossings and Turnout Design We have a dedicated team of graduate and Chartered Engineers from mechanical, metallurgical and electrical backgrounds. We support our engineers in their membership of the IMechE and industry specific professional bodies Mechanical Analysis We assess product life cycle and expected performance, operation and maintenance requirements using a combination of classical mechanical analysis, Finite Element Analysis (FEA), practical testing and empirical data from over 100 years of manufacturing experience We undertake work for our own process and product development, but also deliver commissioned work for various clients in the UK and overseas We consider risk management a fundamental aspect of good design and follow ‘yellow book’ engineering safety management principles at the appropriate level for all product developments We design products using state-of-the-art 3D CAD software, considering mechanical integrity, potential failure modes and human interaction aspects before progressing to prototyping and testing Switch Performance Optimisation Our in house analysis tools allow us to fine tune the flexural behaviour of switches, minimising the thrust requirements and optimising the location and quantity of drive points. This process minimises the work done by the points operating equipment whilst ensuring closed switch fit and free wheel clearance are satisfactory under all operating conditions We also model customer’s current problems and derive mathematical models demonstrating the root causes and the potential remedies All of our products are supplied with operation and maintenance guidelines, developed with the end user in mind New Product Development The demands on the rail infrastructure continue to increase with faster trains and increased occupancy. To support this we are constantly driving ourselves to develop new products and allow our customers to meet these demands
Design Services Visit us online at: www.progressrail.com Cast Manganese Products Modelling, Methods and Metallurgy 3D modelling and FEA allow us to engineer all of our products more efficiently. From CNC controlled pattern making for cast manganese crossings (frogs) to Failure Mode and Effect Analysis (FMEA) to determine weaknesses in design Our current engineering processes revolve around 3D modelling to generate LEAN products with highly analysed performance characteristics 3D modelling interfaces directly with our Computer Numerical Controlled (CNC) machines to offer a superior and repeatable quality product The casting process itself is a well established and highly controlled process. This control stems, in part, from 3D modelling the molten shape and the molten metal flow to ensure cooling rates and other parameters are within known tolerances to produce a high quality product Within our South Queensferry and Midland foundries we have qualified metallurgical engineers and are members of the Cast Metal Federation Complex Cast Manganese Solutions Our design engineers are qualified to high standards and are able to solve complex geometrical alignment problems facing many of the world’s railways We undertake work regularly for London Underground and have also worked for various subterranean rail systems around the world where alignment is paramount. We have been involved in tunnel wall studies and modelling train paths to ensure clearance is within permitted levels Geometrical data is used to develop 3D models of cast manganese products and these models are used to create the wooden patterns used in the production of sand moulds for the casting process Molten Metal Modelling using Magma 5 Software Using Magma 5 software we simulate mould filling, solidification and cooling rates for different shape and complexity patterns This state-of-the-art analysis tool ensures that the molten metal witnesses directional solidification in order to eliminate the formation of shrinkage cavities within the casting We are also able to simulate metal entering the mould cavity using particle tracers, which move just like metal flow, allowing the identification and elimination of high and low velocities during mould filling which can lead to the formation of casting defects , oxide films and inclusions References Our Design Services team have undertaken work for customers in: • Commissioned Design and Standards work in the UK, USA and Australia • Trackwork and Cast Manganese Crossings (Frogs) designed and supplied to worldwide customers
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Design Services - Progress Rail Services

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