RAIL

TECHNOLOGY

MASCHINENFABRIK LIEZEN

UND GIESSEREI GMBH

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MFL Group

Workshop LiezenFounded in 1939

Privatized on 15 November 1994

750 employees at the headquarter in Liezen

1100 employees worldwide

Yearly turnover ~ 125 million Euros

Sales and Engineering Sawing and Milling Technology Maschinenfabrik Liezen und Gießerei GmbH Fabriksplatz 1, 4662 SteyrermühlAustria Phone: +43 3612 270 800Fax: +43 3612 270 830E-Mail: saegen.fraesen@mfl.atwww.mfl.at

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Production branches

Main branches

Foundry

Sawing and milling technology

Mineral processing

Component manufacturing

Mechanical production

Subsidiaries

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Sawing and milling technology

SAWINGSingle cut sawing machines for tubes, billets, bars, rails and profiles

Layer sawing machines for tubes and profiles

Sawing machines for aluminium and steel plates

Sawing machines for steel slabs

Sawing machines for material inspection (sample saw)

MILLINGEdge milling machines for plates

Edge milling machines for stripes/coils

Milling machines for special profiles

Milling machines for the production of tensile tests

Welding seam processing machines for large diameter pipes

RAILRail sawing machines

Axle sawing machines

Combined rail sawing and drilling machines

Combined rail drilling and milling machines

Mobile and stationary rail milling machines

SPECIALRing splitting machines

Pipe beveling machines

Deep hole drilling machines

TOOLS Saw blades with exchangeable carbides

Milling tools

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Sawing technology

Overview

Layer sawing machines for tubes and profiles

Single cut sawing machines for billets, bars, rails and profiles

Sawing machines for steel and aluminium plates

Sawing machines for steel slabs

Sawing machines for material inspection (samples)

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Milling technology

Overview

Edge milling machines for plates

Edge milling machines for stripes / coils

Milling machines for special profiles

Milling machines for the production of tensile tests

Welding seam processing machines for large diameter pipes

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Rail technology

Overview

Rail sawing machines

Axle sawing machines

Combined rail sawing and drilling machines

Combined rail drilling and milling machines

Mobile and stationary rail milling machines

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Special machinery

OverviewRing splitting machines

Pipe beveling machines

Deep hole drilling machines

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Range of application

Seamless pipe mills

Single cut sawing machines for billets

Single cut sawing machines for tubes (Re-Cut)

Layer sawing machines for tubes

ERW pipe mills

Edge milling machines for plates

Welding seam processing machines for large diameter pipes

Pipe beveling machines

Spiral pipe mills Edge milling machines for stripes / coils

Profile production

Single cut sawing machines for profiles

Layer sawing machines for profiles

Milling machines for special profiles

Plate production

Sawing machines for aluminium plates

Sawing machines for steel plates

Forgings Single cut sawing machines for billets

Single cut sawing machines for squared material

Ring rolling mills

Single cut sawing machines for billets

Ring splitting machines

Sample shops

Sawing machines for material inspection

Milling machines for the production of tensile tests

Production of rails, wheels and axles

Rail sawing machines

Axle sawing machines

Combined rail sawing and drilling machines

Combined rail drilling and milling machines

Ship yards, Wind mill industry

Edge milling machines for plates

RAIL SAWING AND

DRILLING MACHINE

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Advantages Customized turnkey solutions

Combined and simultaneous cutting and drilling of rails

Horizontal and vertical adjustable drilling spindles

Temperature compensation to guarantee exact lengths under different temperature conditions

Guaranteed length tolerances for rails between 5 –120 m

Main dataProcessable rail dimensions: 200 x 220 mm

Number of drillers: 1 – 6 pcs.

Drilling diameter: 20 – 40 mm

Saw blade diameter: 660 mm

Tolerance of length: +/- 5 mm

Tolerance of hole distances: +/- 0,5 mm

RAIL SAWING AND DRILLING MACHINE

Advantages and technical data

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4 vertical clamping cylinders

4 horizontal clamping cylinders

fixed stopping edge

RAIL SAWING AND DRILLING MACHINE

Horizontal clamping device

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Rail sawing and drilling machineSSB 700 E55/90

RAIL SAWING AND DRILLING MACHINE

Plant overview

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Machine layout

Sawing unit

Drilling unit

RAIL SAWING AND DRILLING MACHINE

Machine layout

RAIL DRILLING AND

MILLING MACHINE

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AdvantagesProcessing of round and slotted holes by one machine

Processing of slotted holes in vertical and horizontal direction

Precise chamfering within very close tolerances

Web detection to recognize rail markings

Exact length positioning by material feeding tongs

Manipulator for automatic tool changing

Main data Number of drilling stations: 1

Number of chamfering stations: 1

Round hole diameter: 20 – 40 mm

Slotted hole dimension: Ø 20 – 40 x variable

Chamfering angle: 30° / 45°

Chamfering tolerance: +/- 0,1 mm

RAIL DRILLING AND MILLING MACHINE

Advantages and technical data

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2

1

4

9

3

7

6

10

5

8DesignRail infeed – roller table

Drilling and chamfering unit

Manipulator – tool exchange

Material feeding tongs

Outlet roller table

Hydraulic aggregate

Operator station

Safety door – tool exchange

Switch cabinet

Stage

RAIL DRILLING AND MILLING MACHINE

Design

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RAIL DRILLING AND MILLING MACHINE

Plant overview

AXLE SAWING

MACHINE

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Axle sawing machineHorizontal single cut sawing machine

Exact length cutting of axles

Fully automatic cutting, centering and face milling of axles

Cutting position head piece

Cutting position tail piece

AXLE SAWING MACHINE

Plant overview

RAIL MILLING

TECHNOLOGY

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Short pitch corrugation

Defect of the rail head shape

Why to maintain rails?

To reach low maintenance costs for the complete track construction and the vehicles

To reach a high level of travel comfort

To comply with requirements set for environment protection; to reach a low noise level of railway transport

To ensure the safety of railway traffic

Near surface defects

RAIL MILLING MACHINE

Why rail milling?

2323

Wheel-Burn Corrugations Rail batter Riffles

RAIL MILLING MACHINE

Rail defects

2424

Head checks

RAIL MILLING MACHINE

Rail defects

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Kinds of rail profilingRail maintenance (removal of „geometric“ rail defects and near surface defects)

Profiling of new rails

Profiling of acoustic requirements

For use in main-line and underground systems

Operation sites for rail profiling Importance of no sparks, no dust, clearance, no removal of switches

RAIL MILLING MACHINE

Where and what to use for?

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Processing of the rail head in one working pass

High finished meter performance per hour300 m/h - 2.000 m/h

0.083 – 0.56 m/s

High metal removal rate on the top and on the gauge corner of the rail

High accuracy of the milled rail head profileTransverse ≤ ± 0,2 mm

Longitudinal ≤ ± 0,01 mm

For wave lengths 10 – 30 / 30 – 100 mm

No need for grinding finishing

Environmentally friendly working processNo sparks / no dust / noiseless

Clearance free working processNo need to remove and reinstall switches

No limitations for works in tunnels, open-bridges and slab tracks

High capacity of milling swarf container –from 6 to 8 km milled track

Certificated for works on German high-speed traffic lines (300 km/h)

RAIL MILLING MACHINE

Advantages of milling process

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Milling units

Milling tool

Main electric cabinet

Chip compressor

Chip container

Operator station

Generator

Operator station

RAIL MILLING MACHINE

Design (Example SFU 04)

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RAIL MILLING MACHINE

Rail milling machine SFU 04

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Milling parametersMilling stations per rail each with an automatic rail detection system and an extraction system for milling swarf 2

Tool diameter 1.320 mm (1400 SF04)

Cartridges on each tool (7 straight and 2 radius each) 60

Number of blades per plate straight radius

84

Normal pressure angle of the tool 2,44 °

Residual waviness 0,0047 mm

Milling depth at the surface in one pass / miller 0,3 – 1,0 mm

Milling depth at the running edge in one pass / miller 0,3 – 3,0 mm

Milling performance 300 – 2000 m/h

Accuracy transverse profile ≤ ± 0,2 mm

Accuracy longitudinal profile at wave lengths 10 – 300 mm ≤ ± 0,01 mm

Accuracy longitudinal profile at wave lengths 300 – 1000 mm ≤ ± 0,10 mm

Possible tool change from inside and outside

RAIL MILLING MACHINE

Milling parameters SFU 04

3030

Unique milling conceptRemoval 3 mm running surface per miller

Removal 6 mm running edge per miller

High productivity

No sparks

No dust

Modular concept

24h working possible

RAIL MILLING MACHINE

Rail milling machine RFP 1

3131

Technical dataTrain weight, ton 300 3%

Train length 66,430

Maximum track climb in operating mode, ‰ 30

Minimum radius covered during milling of curves, m: 150

Speed of RFP-1, km/h:

Self-operation, not greater than 100

In measurement mode 0.5...1.8

In milling mode 0.5…1.8

Number of milling units, pcs. 4

Removal of metal per pass during milling:

Rolling surface of rail head, mm 0.3 … 3.5

Rolling edge 0.3 ... 8.0

RAIL MILLING MACHINE

Technical data RFP 1

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Milling parametersMilling stations per rail each with an automatic rail detection system and an extraction system for milling swarf 2

Tool diameter 1400

Cartridges on each tool (7 straight and 2 radius each) 6 / 1

Number of blades per plate straight radius

82

Normal pressure angle of the tool 2,37°

Residual waviness 0,0045

Milling depth at the surface in one pass / miller 0,3 – 3,5

Milling depth at the running edge in one pass / miller 0,3 – 8

Milling performance 300 – 2000 m/Std.

Accuracy transverse profile ≤ ± 0,2 mm

Accuracy longitudinal profile at wave lengths 10 – 300 mm ≤ ± 0,01 mm

Accuracy longitudinal profile at wave lengths 300 – 1000 mm ≤ ± 0,10 mm

Possible tool change from inside and outside

RAIL MILLING MACHINE

Milling parameters RFP 1

3333

Milling module SF-1/SF-2Control cabinet

Milling units

Compressors for supply of chippings

SF-2 – additional diesel-generator set for utility

SF-1 – sleeping compartment for 4 persons

Pull and energy module2 diesel sections with installed diesel generator sets

Brake compressor

Hopper box for chippings

Transporters for unloading chippings

RAIL MILLING MACHINE

Design RFP 1

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DQM traverse profile measurement after milling

RAIL MILLING MACHINE

Milling result

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RM 1200 D longitudinal profile measurement after milling for different wave lengths

Calculation of waviness

Milling tool diameter D mm 1400Removal rate, constant mm 0.6Feed per tooth fz mm 5.0Pressure angle º 2.37Waviness h mm 0.0045

RAIL MILLING MACHINE

Milling result

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RAIL MILLING MACHINE

Milling result

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RAIL MILLING MACHINE

Milling chips

3838

RAIL MILLING MACHINE

Increased life time

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Each milling unit consists of:

Main drive

Main body, milling gear with tool fitting

Milling tool

Hydro mechanically height copying with cutter in feed mechanism

Electro mechanically copying device with cutter in feed mechanism for horizontal movement Automatic emergency lifting device

Transport locking system

Local electric terminal box

Lubrication

Spray lubrication

RAIL MILLING MACHINE

Milling units

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RAIL MILLING MACHINE

Milling units

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Advantages of the MFL tool system

All block cassettes can be exchanged in case of a crash

Number of cutters per insert tip 8 (straight)

Tools with sole plates have the advantage that the rail profile can be adjusted more exactly

By exchange of the block cassettes different rail profiles can be processed

With the new designed tools up to the double life time can be obtained.

RAIL MILLING MACHINE

Milling tool

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Milling tool

Inlet suction device, suction shoe

Venturi nozzle

Compressor

Inlet chip container

Screw conveyor

Cross transport conveyorBelt conveyor

RAIL MILLING MACHINE

Chip collection device

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Chip conveyor

Chip transport system

Venturi nozzle

RAIL MILLING MACHINE

Chip collection device

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PERFECTION IN ALL AREAS

MASCHINENFABRIK LIEZEN

Maschinenfabrik Liezenund Gießerei GmbH

Sawing and milling technology

Fabriksplatz 1, 4662 SteyrermühlAustriaPhone: +43 3612 270 800Fax: +43 3612 270 830E-Mail: saegen.fraesen@mfl.at

www.mfl.at