TURNING AND ROLL HARDENING MACHINE KJ 1840.02

Machine is designed for turning and roll- hardening journals and pre-wheel -mounting axle portions of wheel- sets in rail way car sheds, car repair- and building plants.

Design features

Wheel-set is to be jacked up on centers level and backed up by quills in the centers of RH and LH heads

Wheel-set is driven by rubber-coated friction roller in contact with wheel running surface.

Either carriage has front side slides with two-position holder (roller, cutter) and back side slide with hardening rollers.

Hydraulic pressure controllers located on slides allow smooth adjustment of forces on hardening rollers while hardening axle journals.

Roll-hardening process is to be controlled by handles on slides front side; gear shift, delivery of brake block and rubber-coated roller to wheel- by handles on front vertical bed wail ; other machine units are controlled by buttons on slides of LH and RH carriages.

Carriage apron mechanisms allow changing feeds during motion.

TECHNICAL SPECIFICATION
Parameters / Values
Height of centers, mm / 320
Max. length of axle to be machined / 2600
between centers, mm / -
Diameters of journal to be machined, mm / 90 and 240
Diameters of wheel on tread : / -
Min., mm / 850
Max., mm / 1050
Number of speed steps, nos. / 3
Number of carriages, nos. / 2
Speeds, rpm: / -
-wheel-set (tread diameter 1050 mm) / 57,130,232
Carriage operation feeds, mm/min / 56,78,115,162
Main drive motor power, KW / 11
Machine overall dimensions, mm: / -
-length / 5100
-width / 2900
-height / 1970
Machine weight, kg / 11 200

TURNING AND ROLL HARDENING MACHINE KJ 1844

For hardening of outside journals, fillets as well as pre-wheel mounting axle portions with swing rotation axis of some rollers.

Design features

The following components are mounted on machine bed:

1.Gear box: reducer for spindle rotation with different speeds.

2.LH- carriage: for roll hardening car axle journal.

3.RH- carriage: for hardening pre-wheel mounting axle portion and fillets and journal with swing of roller axis during roll hardening.

4.Jack: for lifting the axle from center axis level, swing on 180 degrees and lowering axle on centers axis.

5.RH- stock: includes rotating center and movable quill and intended for setting, clamping / unclamping axle.

Machine is furnished with sensor and movable stop for accurate setting of RH carriage with regard to journal fillet providing necessary quality of fillet roll hardening. Process accuracy is achieved in accordance with machine precision and rigidity specifications.

TECHNICAL SPECIFICATION
Parameters / Values
Height of centers, mm / 350
Max. length of axle to be machined , mm / 2200-2600
Diameters of journal to be machined, mm / 120 - 240
Diameters of wheel on tread :
Min., mm / .
Max., mm
Number of speed steps, nos. / 2
Number of carriages, nos. / 2
Carriage operation feeds, mm/min / 67-155
Main drive motor power, KW / 11
Machine overall dimensions, mm:
-length / 6100
-width / 3390
-height / 1970
Machine weight, kg / 14000

TURNING AND ROLL HARDENING MACHINE KJ 1843.02

Machine designed for roll hardening middle and wheel-mounting portion of rail road car axles.

Design features

Three front side and back side bodies with hardening rollers are secured on carriage slide inT-slots. Two pairs of rollers are located one against another with accuracy 0,2 mm. Feed andrapid travel of carriage- from hydraulic cylinder with infinitely speeds variation.

Feeds and fast carriage travel hydraulic cylinder is mounted in slide body and cylinder

connecting rod is fixed stable on the bed. During axle roll hardening oil from lubricating pump,

mounted on the slide, is delivered in pipes to working area of rollers. Machine is provided with

pressure controller for adjustment of length and force of axle rolling. Roll hardening process is

performed in semi-automatic mode.

TECHNICAL SPECIFICATION
Parameters / Values
Height of centers, mm / 320
Max. length of axle to be machined / 2600
between centers, mm / -
Diameters of journal to be machined, mm / 150 and 240
Diameters of wheel on tread : / -
Min., mm / -
Max., mm / -
Number of speed steps, nos. / 6
Number of carriages, nos. / 3
Speeds, rpm:
-wheel-set (tread diameter 1050 mm) / -
-spindle / 58,78,120,
160,216,335
Carriage operation feeds, mm/min / 12-1000
Main drive motor power, KW / 11
Machine overall dimensions, mm:
-length / 5600
-width / 2900
-height / 1970
Machine weight, kg / 9300

SPECIAL TYPE ROLL TURNING MACHINE MODEL KJ16277F3

Intended for machining complex linear-and curved- shaped surfaces of grooves on rolls for section mills in programming mode with constant cutting speeds with using CNC system.

The following operations are possible on this machine:

-semi-finish and finish roll groove sizing between centers;

-repair operations on used rolls between centers or in faceplate jaws of head-and tailstock.

The machine is used for finish and semi-finish machining rolls for rail-and-structural steel rolling mills in the metallurgical industry.

TECHNICAL SPECIFICATION
Parameters / Values
Max. roll diameter over carnage, mm / 1250
Max. distance between centers, mm / 5500
Max. weight of roll to be machined between centers, kg / 25 000
Spindle speeds regulation / Infinitely various, 2 steps
Spindle speeds, rpm / 1,0-225
Main drive motor power, KW / 110
Max. spindle torque, KNM / 90
Headstock faceplate diameter, mm / 1250
Tailstock faceplate diameter, mm / 1000
Outer diameter clamping range in faceplate jaws, mm / 210-830
Clamping force, KNM / 150
Number of carriages / 1
Number of simultaneously controlled coordinates (X, Z) / 2
Carriage operation feeds, mm/min:
-longitudinal (Z) / 0,05-500
-cross (X) / 0,05-500
Max carriage fast (setting) travels (X,Z), mm/min / 5
Feeds regulation / Infinitely
Positioning accuracy (accumulated deviation), micron:
-X / 30
-Z / 250
Max. cutting force P, KN / 120
Machine overall dimensions excl separately installed
units ±10% and electric cabinets, mm:
-length / 12 000
-width / 4000
-height / 2590
Max. machine weight excl. separately installed equipment, kg / 55 000
Max. weight of separately installed units, electric cabinets, kg / 3000
Sample geometrical shape accuracy:
-constancy of diameters in cross section, micron / 16
-constancy of diameters in any section, micron / 20
Surface roughness Ra as per COST 2789-73, micron, max / 1,6
Cutting tools : Modulus fast changeable tool system Coromant / Capto, Sweden

DEEP DRILLING AND BORING MACHINE MODEL KJ 2880

Configuration and design of the machine provide machining deep holes by carbide and high speed tools.

Feed and tool fast movements through slide feed drive from power rack of the bed or through screw of separate feed drive located at bed end.

Depending on purpose machine can be equipped with:

-boring tubes with- and without tool rotation;

-device for powered workpiece clamping in faceplate jaws;

-workpiece devices for centering in steady-rests;

-opened ,-closed and ring type steady rests;

-axial forces sensors;

-coolant delivery with washing out chips through boring tube and coolant supply to cutting area .

TECHNICAL SPECIFICATION
Parameters / Values
Diameters of workpiece holes, mm / 63-800
Max. length of workpiece, mm / As per
requirements of
customer
Max. weight of workpiece to be machined / 60
(when using steady-rests), t
Electric drive for workpiece heads and / 110/85
boring tube, KW
Feeds, mm/min / 4-4000
Feed force, kg / 12 500

CENTER DRILLING AND CUTTING MACHINE MODEL KJ 4254M

For two-side cutting off risers and center drilling wheel-set axles of rail-road transport.

Design features

Symmetric configuration in relation to its center axis.

Two bed plates mounted on machine bed.Setting on various lengths of axles to be machined- by displacement of RH- bed plate.

Bed-plates have guides on which slides with power units- saw cutting headstock and center-drilling head move.

Two clamps are mounted on each bed-plate: first one -for cutting, second one- for center drilling

Saw headstock has 6 spindle rotation speeds.Speed adjustment by triple switching unit and changeable gears.

TECHNICAL SPECIFICATION
Parameters / Values
Diameter:
-riser to be cut off, mm / 130-230
-wheel- mounting axle portion, mm / 140-270
Lengths of workpiece after cutting, mm / 1900-2650
Max length of riser to be cut, mm / 160
Centers axis height from base of bed-plates , mm / 1400
Cut saw spindle speeds, rpm / 3,15-12,55
Saw diameter, mm / 710
Machine overall dimensions, mm:
-Length / 6600
-width / 3800
-height / 2600
Machine weight, kg / 41000

LATHE MODEL 1K675F3

Design features

This machine is intended for machining various external surfaces.

Machine design provides automated machining complex curved-shaped workpieces.

Machine has four separated welded beds. Bed ways are hardened and ground. Two guide ways for carriage are hardened and provided with telescopic protection covering.

Chip disposal conveyer is installed between beds. Mechanical speed steps gear shifting by means of hydraulic cylinder.

Tailstock is intended for backing RH- face of workpiece to be machined.

Longitudinal- and cross feed drive from high torque DC motors with built-in brake through reducers with high precision gear transmissions with limited backlash.

Guide ways of cross slides are combined:

-on side surfaces roller bearings installed with pre-load.

-top and bottom ways are reinforced with synthetic antifriction material (filled fluoroplastic).

Cutting blocks of special design are fixed in flat tool holders with setting motorized movement. Block fixation with two wedge clampers.

TECHNICAL SPECIFICATION
Parameters / Values
Max diameter of workpiece to be machined, mm:
-over carriage / 1850
-over bed / 2550
Max length of workpiece to be machined, mm / 12500
Max weight of workpiece to be machined, kg / 100 000
Spindle speeds, rpm / 1-160
Feeds, mm/rev:
-longitudinal / 0,4-4000
-traverse / 0,4-4000
Main drive motor power, KW / 110
Machine overalls, mm:
-length / 23110
-width / 6020
-height / 3160
Machine weight, kg / 144000

TURNING AND ROLL HARDENING MACHINE KJ 1842.02

For turning and roll- hardening journals and pre-wheel mounting and wheel mounting axle portions of wheel- sets in railway car sheds, car repair- and building plants.

Design features

Axle is installed by crane in LH and RH stock centers. Rotation - by special chuck on headstock spindle.

Each of two carriages has front side slides with 2-position tool holder (roller and cuter) and back side slides with hardening rollers.

Hydraulic pressure controllers allow smooth adjustment of roller forces.

Roll-hardening process is controlled by handles on slides front side; gear shift- by handles on front vertical bed wall; other machine units are controlled by buttons on slides of carriages.

Carriage apron mechanisms allow changing feeds during motion.

Design provides high accuracy of journal processing for a long time.

TECHNICAL SPECIFICATION
Parameters / Values
Height of centers, mm / 320
Max. length of axle to be machined / 2600
between centers, mm
Diameters of journal to be machined, mm / 90 and 240
Diameters of wheel on tread :
Min., mm / -
Max., mm
Number of speed steps, nos. / 6
Number of carriages, nos. / 2
Speeds, rpm:
-wheel-set (tread diameter 1050mm) / -
-spindle / 58,78,120,160,
216,335
Carriage operation feeds, mm/min / 56,78,115,162
Main drive motor power, KW / 11
Machine overall dimensions, mm:
-length / 5100
-width / 2900
-height / 1970
Machine weight, kg / 1 1430

TURNING AND ROLL HARDENING MACHINE KJ 1841.02

For turning and roll- hardening journals of wheel- sets of rail road transport.

Design features

Machines can be used in rail road car sheds and in diesel loco plants.

Radius of hardening rollers for RH and LH carriages -19 mm, for central carriage- 9 mm.

Wheel-set is installed in the centers of LH and RH stocks by crane.

Wheel-set is driven by rubber-coated friction roller in contact with wheel running surface.

Machine is equipped with four individual carriages. Hydraulic system with original pressure regulator allows easy control of cross slides and pressure of hardening rollers on axle.

Carriage apron mechanisms allow changing feeds during motion of carriages.

Machine bed has attachable and adjustable guides with setting up parallel machine centers axis.

TECHNICAL SPECIFICATION
Parameters / Values
Height of centers, mm / 320
Max. length of axle to be machined / 2600
between centers, mm
Diameters of journal to be machined, mm / 120 and 240
Diameters of wheel on tread :
Min., mm / 850
Max., mm / 1250
Number of speed steps, nos. / 3
Number of carriages, nos. / 3
peeds, rpm:
-wheel-set (tread diameter 1 050mm) / 57,130,232
Carriage operation feeds, mm /mm / 56,78,115,162
Main drive motor power, KW / 11
Machine overall dimensions, mm:
-length / 5400
-width / 2900
-height / 1970
Machine weight, kg / 15000

WHEEL-SET MILLING MACHINE MODEL KJ 20TF1

This machine is designed for reprofiling used worn-out wheel tyres for rail road transport without rolling out wheel sets from under locomotive. Two wheel- sets can be machined simultaneously on this machine. The tyre of single wheel- set can be machined with rolling out it from locomotive.

Design features

Machine is to be installed under foundation rails in closed room with heating and ventilation systems. Loco moves over machine at green light signal.

Wheel- sets are loaded on machine to milling operation position by means of auxiliary winch and four machine rollers.

Two milling cutters are safely centered in wheel-set axle seats by two centering heads.

Simultaneous high-speed machining of two wheel-set tyres by shaped milling cutters provides obtaining precise profile, out-of-roundness and equality of wheel diameters on tread in accordance with high up-to-fate requirements for restoration of working shaped profile of wheels under locomotive.

Small size chips are easy to dispose.

Machine remote control system is automated by means of electric and hydraulic units and all main operations are performed by pressing buttons or switches on control desk. For easy control the desks are duplicated in two places.

Full milling process of two wheel tyres is performed within one wheel-set revolution under locomotive.

TECHNICAL SPECIFICATION
Parameters / Values
Rail road gauge, mm / 1520 (1524)
Diameters of wheel- sets to be / 850 - 1350
machined on tread, mm
Axle length of wheel- set to be machined, mm / 2200 - 2600
Milling spindles speeds, (infinitely variable / 40 - 160
regulation), rpm
Main drive motors, KW / 30x2
Accuracy of positioning as per coordinate axes,
micron:
-X-axis / 100
-Y-axis / 100
Circular working feeds of driving rollers / 25 - 500
(infinitely variable regulation), mm/ min
Machine overall dimensions, mm
-length / 6550
-width / 6400
-height / 3300
Machine weight, kg / 37472

DUPLICATING LATHE MODEL KJ 1833

For semi-finish machining axles of wheel sets for rail road transport: cars, locos etc.

Machine operation control: PC-system

Machining: by two hydraulic duplicating carriages in one workpiece setting

TECHNICAL SPECIFICATION
Parameters / Values
Max. diameter of workpiece to be machined
over carriage, mm / 300
Min. diameter of workpiece to be machined
over carriage when clamping in face chuck, mm / 120
Length of axle, mm:
-max / 2700
-min / 2100
Cross section of tool holder, mm / 40x40
Spindle speeds, rpm: / 100-500
Operation longitudinal feeds, mm/min / 25-315
Rapid carriage setting travels mm/min / 4000
Main drive, KW / 45
Machine overalls, mm
-length / 6000
-width / 2400
-height / 2600
Machine weight, kg / 27000

BAR CENTERLESS LATHE MODEL 9A350F1

Designed for removal of defective and decarburized layer from surfaces of hot rolled round bars made of carbon-, tool-, stainless-, alloy-and bearing steels with GB =50-120 kgf/mm2.

Machine is intended for installation for finishing rolled metal materials in rolling mills of metallurgical plants.

Machine also includes:

-Cutting head for all range of bars to be machined with changeable slides;

-Machine bed setting up leveling shoes;

-Assembly drawing for preparation of foundation.

MACHINE IS COMPLETED WITH
FOLLOWING UNITS
Description / Nos.
Machine bed / 1
Spindle headstock / 1
Feeding rollers unit / 1
Supporting rollers unit / 1
Centering rollers unit / 1
Feeding rollers drive / 1
Slide / 1
Pulling rollers unit / 1
Loading unit / 1
Feeding roller conveyer / 1
Unloading unit / 1
Support truck / 1
Cooling station / 1
Hydraulic drive station / 1
Electric equipment / 1 complete set
TECHNICAL SPECIFICATION
Parameters / Measur. unit / Values
Bar diameter to be machined / Mm / 125-360
Machined bar diameter / Mm / 115-350
Bar lengths / Mm / 4500-12000
Max. depth of layer to be cut off (for one / side) Mm / 2-6
Cutting head speeds / Rpm / 20-300
Operation feeds / Mm/min / 2000-6000
Main drive motor power / KW / 250
Machine overalls
(to be agreed when designing): / Mm
-length (depending on length of bars
to be machined- 6000 / 36000
-9000 / 54000
-12000 / 60000
-width / 13000
-height / 4500
Machine weight (for bars to be / Kg / 190000
machined 9000 mm)
Finish surface roughness Ra / Micron / 6,3
Voltage / V / 380/220
Frequency / Hz / 50
Approximate productivity for 120mm, / Kg/h / 18000
steel grade 45, min. L=6000
Machine assembly / By units

BAR CENTERLESS LATHE MODEL 9A330F1

Intended for removal of defective and decarburized layer from surfaces of hot rolled round bars made of carbon-, tool-, stainless-, alioy-and bearing steels with GB=50±120kgf/mm2 .

MACHINE IS COMPLETED WITH
FOLLOWING UNITS
Description / Nos.
Machine bed / 1
Spindle headstock / 1
Feeding rollers unit / 1
Supporting rollers unit / 1
Centering rollers unit / 1
Feeding rollers drive / 1
Slide / 1
Pulling rollers unit / 1
Loading unit / 1
Feeding roller conveyer / 1
Unloading unit / 1
Cooling station / 1
Hydraulic drive station / 1
Electric equipment / 1 complete set
TECHNICAL SPECIFICATION
Parameters / Measur. unit / Values
Bar diameter to be machined / Mm / 53-165
Machined bar diameter / Mm / 50-160
Bar lengths / Mm / 3000-12000
Spindle speeds / Rpm / 30-510
Operation feeds / Mm/min / 140-4000
Main drive motor power / KW / 200
Machine overalls:
-length (as per length of bars to be machined) / Mm / 30000
42000
54000
-width / 7500
-height / 2400
Machine weight / Kg / 90000
Finish surface roughness Ra / Micron / 6,3
Voltage / V / 380/220
Frequency / Hz / 50

CNC-LATHE MODEL KJ16274F3

This machine- tool is designed for machining rotation- type parts.

Machine is furnished with contour type CNC-system providing machining curve-shaped profiles, threading, spiral cutting with high accuracy in automatic mode as per program.

Machine bed is steel welded structure, 4 guide ways are hardened and ground.

Two front-side bed guide ways are designed for carriage travel. These guide ways have telescopic protection covering. Open-type steady rest is installed on three guide ways. In this case on steady rest installation area telescopic covering is to be removed.

Carriage is designed for providing required accuracy of machining parts with complicated curve- shaped profile.

Longitudinal (Z-axis) and cross ( Xaxis) drives from high torque DC motors through reducers with high precision gears. End link of X- feed drives is screw- rolling nut transmission, Z-axis: rack transmission with backlash compensation. Z-slide guides are reinforced with synthetic antifriction material. Carriage slide guides ways (X-axis) -with rolling type bearings. Cutting blocks of special design are fixed in flat cutter holders.

Headstock has non- parting spindle bearings for higher rigidity. Two mechanical speed steps are provided with kinematics chain containing high precision gear drives and roller bearings. Drive with DC-motor adjustable with constant power at 1500-315 rpm and at 315-35 rpm- with constant torque.

Machine is furnished with contour type CNC system SINUMERIK 840D. Automated lubrication system for all mechanisms of loaded units.