Design Services - Progress Rail Services
Design Services - Progress Rail Services
Design Services - Progress Rail Services
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<strong>Design</strong> <strong>Services</strong><br />
Visit us online at:<br />
www.progressrail.com<br />
Cast Manganese Products Modelling,<br />
Methods and Metallurgy<br />
3D modelling and FEA allow us to engineer all of our products more<br />
efficiently. From CNC controlled pattern making for cast manganese<br />
crossings (frogs) to Failure Mode and Effect Analysis (FMEA) to determine<br />
weaknesses in design<br />
Our current engineering processes revolve around 3D modelling to<br />
generate LEAN products with highly analysed performance characteristics<br />
3D modelling interfaces directly with our Computer Numerical Controlled<br />
(CNC) machines to offer a superior and repeatable quality product<br />
The casting process itself is a well established and highly controlled<br />
process. This control stems, in part, from 3D modelling the molten shape<br />
and the molten metal flow to ensure cooling rates and other parameters<br />
are within known tolerances to produce a high quality product<br />
Within our South Queensferry and Midland foundries we have qualified<br />
metallurgical engineers and are members of the Cast Metal Federation<br />
Complex Cast Manganese Solutions<br />
Our design engineers are qualified to high standards and are able to<br />
solve complex geometrical alignment problems facing many of the<br />
world’s railways<br />
We undertake work regularly for London Underground and have also<br />
worked for various subterranean rail systems around the world where<br />
alignment is paramount. We have been involved in tunnel wall studies<br />
and modelling train paths to ensure clearance is within permitted levels<br />
Geometrical data is used to develop 3D models of cast manganese<br />
products and these models are used to create the wooden patterns used<br />
in the production of sand moulds for the casting process<br />
Molten Metal Modelling using Magma 5 Software<br />
Using Magma 5 software we simulate mould filling, solidification and<br />
cooling rates for different shape and complexity patterns<br />
This state-of-the-art analysis tool ensures that the molten metal witnesses<br />
directional solidification in order to eliminate the formation of shrinkage<br />
cavities within the casting<br />
We are also able to simulate metal entering the mould cavity using<br />
particle tracers, which move just like metal flow, allowing the identification<br />
and elimination of high and low velocities during mould filling which can<br />
lead to the formation of casting defects , oxide films and inclusions<br />
References<br />
Our <strong>Design</strong> <strong>Services</strong> team have undertaken work for customers in:<br />
• Commissioned <strong>Design</strong> and Standards work in the UK, USA and Australia<br />
• Trackwork and Cast Manganese Crossings (Frogs) designed and supplied to worldwide customers