February 2025 Volume 7

EQUIPMENT & TECHNOLOGY

THE U.S. FORGER’S QUICK GUIDE TO TURNKEY RAILWAY LINES By Schuler Group

T here is a critical need for long-lasting railway wheels as the global railway industry evolves rapidly with increasing demands for high-speed and ultra-high-speed trains. Traditional cast wheels, historically, were the standard choice for railways due to their lower initial cost. However, cast wheels have proven insufficient for the demands of modern rail transport and are being replaced by forged monobloc wheels as a result. Forged wheels offer superior physical properties and greater durability under extreme conditions, making them ideal for the high-speed trains’ high loads, sharp bends, strong acceleration, emergency braking, and tremendous force transmission onto the tracks. Forged wheels exhibit better performance under extreme stress and require less frequent reworking compared to cast wheels. Advancements in forging technology have also reduced the cost differential between forged and cast wheels to the point where forged wheels are now embraced by countries all over the world— even for applications with lower speeds and loads. The U.S. is the soon-to-change exception to this global market adoption, presenting an opportunity for forgers to prepare for the inevitable shift to high-speed trains in the country. U.S. Market: A Missed Opportunity There are several reasons as to why the U.S. rail industry has been slower than the rest of the world in adopting the high-speed rail trend. There is a lack of necessary infrastructure to support high-speed trains and a lower population density that hinders the economic viability of rail transportation. There is also a vast differ ence in current rail speeds; the U.S. is capped at around 100 mph, while European and Asian countries have trains reaching speeds over 200 mph. This may be the current market status, but the landscape is changing. The U.S. is beginning to invest in high-speed rail infra structure, particularly on the West Coast, which could lead to a demand for forged railway wheels in the near future. Forgers looking to enter this market must prepare to minimize technolog ical risks and capitalize on new opportunities. The Forging Process The investment in forging technology for railway wheels is signifi cant, but essential, for producing high-quality forged wheels that meet the specific demands of high-speed rail. Forging produc tion lines are complex and require advanced forging equipment as well as machines for billet production, furnaces, heat treatment systems, and machining lines. The forging process involves several key stages:

• Heating the billet to approximately 1250° C (2282° F) • Descaling using high-pressure water

• Forging the preform in one or two stations • Rolling and calibrating the wheel shape • Piercing the central hole • Dimensional checks, often with lasers • Hot marking for identification Turnkey Forging Lines

U.S. forgers interested in the high-speed rail market will need to invest in several pieces of equipment to ensure a streamlined, efficient, and superior production process. A standard forging line includes: • A rotary hearth furnace for heating billets • A high-pressure water descaler for removing scale • One or two forging presses, with manipulators for centering and lifting billets • A wheel mill for expanding the preform to the required diameter • A piercing and shaping press to forge and calibrate the wheel to its final shape and pierce the central hole • A laser measuring machine for dimensional checks • A marking system for temporary or permanent identification • Five or six heavy-duty forging robots • One or more set(s) of die holders • Active (contact) dies for the individual wheel shapes • Die changing equipment (moving bolster or die change carts) • A safety system and master control system Schuler and parent company ANDRITZ can support U.S. forgers with advanced, turnkey railway wheel and axle forging lines.

FIA MAGAZINE | FEBRUARY 2025 24