CNC Pit Wheel Lathe Machine

CNC PIT WHEEL LATHE MACHINE
A Project report submitted in partial

fulfillment for the award of the degree of
BACHELOR OF
TECHNOLOGY IN
MECHANICAL
ENGINEERING (2020-2024)
Submitted by
A.RAM CHARAN 21X05A0302
D.JYOTHENDRA PAVAN 21X05A0310
G.BABU 21X05A0320
T.SHIVA 21X05A0357
Under the esteemed guidance of

Mr.Y BHIMAPPA
M.Tech (Ph.D)
ASSISTANT
PROFESSOR
Department of Mechanical Engineering
www.nrcmec.org
December – 2023
CERTIFICATE
This is to certify that the project report entitled “CNC PIT WHEEL
LATHE MACHINE” is the bonafide work done by A.RAM CHARAN,
21X05A0302, D.JYOTHENDRA PAVAN, 21X05A0310, G.BABU, 21X05A0320,
T.SHIVA, 21X05A0357, in partial fulfillment of the requirements for the award of
the degree of Bachelor of Technology in Mechanical Engineering, from Jawaharlal
Nehru Technological University Hyderabad, during the year 2020-2024.
Project Guide Head of the Department

Mr.Y BHIMAPPA Dr.M ASOHK KUMAR
M.Tech (Ph.D) Professor & Head
Department of Mechanical Engineering,
Department of Mechanical Engineering,
NARSIMHAREDDY ENGINEERING
NARSIMHAREDDY ENGINEERING
COLLEGE
COLLEGE
Maisammaguda, Kompally, Secunderabad.
Maisammaguda, Kompally, Secunderabad.
Submitted for the viva-voice examination held on:
External Examiner
DECLARATION
We A.RAM CHARAN, 21X05A0302, D.JYOTHENDRA PAVAN,

21X05A0310, G.BABU, 21X05A0320, T.SHIVA, 21X05A0357, hereby declare
that the Project Work entitled “CNC PIT WHEEL LATHE MACHINE” done
under the esteemed guidance of Mr.Y BHIMAPPA, Assistant professor,
Department of Mechanical and is submitted in partial fulfillment of the
requirements for the award of the Bachelor degree in Mechanical Engineering.
Date:
Place:
A.RAM CHARAN (21X05A0302)

D.JYOTHENDRA PAVAN (21X05A0310)
G.BABU (21X05A0320)
T.SHIVA (21X05A0357)
Cnc Pit Wheel Lathe
Machine
ACKNOWLEDGEMENT
This satisfaction that accompanies the successful completion of the task would be put
incomplete without the mention of the people who made it possible, whose constant
guidance and encouragement crown all the efforts with success. We avail this opportunity to
express our deep sense of gratitude and hearty thanks to Sri.J.Narasimha Reddy of NRCM,
for providing congenial atmosphere and encouragement. We would like to thanks Prof. G.
Kumaraswamy Rao, Director, Former Director &O.S. of DLRL Ministry of Defense, Dr. B.
Prasad Rao, L.P.S (Rtd). Director of Training & Placements, Industry Interface, and Former
Principal Secretary to Govt of TS, DGP of ACB, Commissioner of police, Hyderabad, and Dr.
R.Lokanadham , Principal for having provided all the facilities and support
We would like to thanks Mr.Y.Bhimappa, Academic me /C, Mr.S.Venkatesh, Admin I /C,
Mechanical Engineering for their expert guidance and encouragement at various levels of
our project.
We are thankful to our External Guide M.Subba rao , Mechanical Engineering for his
sustained inspiring guidance and cooperation throughout the process of this project. His
wish counsel and Suggestion are valuable. We express our deep sense of gratitude and
thanks to all the Teaching and nonteaching staff of our college who stood with us during the
project and helped us to make it a successful venture.
We place highest regards to our parents, our friends and well wishers who helped in making
the report of this project.
NARSIMHA REDDY ENGINEERING COLLAGE Department of Mechanical Engineering

Cnc Pit Wheel Lathe
Machine
ABSTRACT
CNC Under Floor Wheel Lathe is an automatic machine used for simultaneous re-profiling of
new or worn-out wheels of railway vehicles. It is capable of machining brake discs assembled
on wheel sets of rolling stock.
The machine is arranged in a pit. The wheel sets to be re-profiled are brought into the
machine via the supply rails or by crane. For re-profiling, the wheel sets are driven by friction
rollers pushing on the running surface. The high dynamic stiffness of clamped wheel sets
required to produce the highest possible machining precision is guaranteed by the radial
centering of the axle bearing box. Lateral positioning of the wheel set is executed by the use of
axial guide rollers. The machine is operated from a central control panel. Which enables the
operator to have constant access to all machine functions? During machining, the operator is
protected from flying chips. The automated machining takes most of the work from the
operator's hands, making the machine easy to operate.
The main objective of this paper is to "study on CNC machines for fabrication of rollers. This
paper also includes various processes like facing, turning, parting, drilling, boring and knurling
to improve production in order to decrease the production time and also to increase the
efficiency in conventional lathe and CNC machine by writing the program on CNC lathe.

Cnc Pit Wheel Lathe
Machine
CONTENTS
Chapter Page no
INTRODUCTION 1
LITERATURE REVIEW 2
1 HISTORY 8
1.1 CNC LATHE MACHINE 3
1.2 TYPES OF CNC MACHINE 4

1.2.1 SURFACE CNC WHEEL LATHE (YSL-08) 5
1.2.2 CNC UNDER FLOOR WHEEL LATHE (YUL-08) 6
1.2.3 CNC PORTAL WHEEL LATHE (YPL-01) 7
1.2.4 CNC TANDAM UNDERFLOOR WHEEL LATHE(YUL-12T) 8
2 CNC NEW GENERATION UNDER FLOOR WHEEL LATHE 9
2.1 TECHNICAL INFORMATION 10

3 MACHINE DESIGN AND FUNDAMENTAL 11
3.1 COMPONENTS OF CNC UNDER FLOOR WHEEL LATHEMACHINE 12
3.1.1COLUMN 13
3.1.2 DRIVER ROLLER ASSEMBLY 14
3.1.3 HOLD DOWN EQUIPMENT 15

3.1.4 AXLE BOX SUPPORT JACK 16
3.1.5 CNC PROFILE MACHINING SYSTEM 17
3.1.6 MEASURING SYSTEM 18

Cnc Pit Wheel Lathe
Machine
RAIL SYSTEM 19
HYDRAULICS 20
LUBRICATION 21
CONTROLS 22
AUTOMATIC CONVEYOR CHIP DISPOSAL SYSTEM 23

4 COMPONENTS USED IN OPERATION
23
CUTTING TOOL 24
WHEEL PROFILE 25
TYRE DEFECT GAUGE 26

5 WHEEL SET 27
RAILWAY WHEEL 28
DETAILS OF WHEEL SET 29
WHEEL GAUGE 30
BENT AXLE 31
WHEEL DIAMETER ON TREAD 32
WHEEL DEFECT 33
SHELLED TREAD 34
SHATTERED RIM 35
SPREAD RIM 36
THERMAL CRACK 37
HEAT CHECKS 5.3.6 DISC CRACK 38
365.3.7 LOOSE AXLE 39
WHEEL GAUGE 40
WHEEL TREAD DIAMETER 41
DIAMETER OF WHEEL USING ON BG STOCK WITH
CONDEMNING LIMIT 42
STEP SIZE OF WORN WHEEL PROFILE 43

Cnc Pit Wheel Lathe
Machine
STANDARD AND CONDEMNING 44
WHEEL DIAMETER 45
WHEEL CHANGING 46
6 SEQUENCE OF OPERATION 47
FLOW CHART OF SEQUENCE OPERATION 48
TABLE OF SEQUENCE OPERATION 49
MACHINING OF COACH/WAGON WHEELSET WITH WHEEL SET 50
MEASUREMENT SYSTEM
7 COMPARISION BETWEEN CONVENTIONAL MACHINE AND CNC MACHINE 51
8 ADVANTAGES AND DISADVANTAGES 52
9 CONCLUSION 53
REFERENCE

Cnc Pit Wheel Lathe
Machine
LIST OF FIGURES
Figure page no
Fig (i) CNC MACHINES USED TO BE AS BIG SIZE OF ROOM 3
Fig (ii) PARTS OF A CNC LATHE MACHINE 3
Fig (iii) CNC SURFACE WHEEL LATHE 5
Fig (iv) CNC UNDER FLOOR WHEEL LATHE 5
Fig (v) CNC PORTAL WHEEL LATHE 6
Fig (vi) CNC UNDER FLOOR WHEEL LATHE MACHINE 7
Fig (vii) CNC UNDER FLOOR WHEEL LATHE ASSEMBLY 10
Fig (viii) COLUMN 11
Fig (ix) DRIVER ROLLER 12
Fig (x) HOLD DOWN EQUIPMENT 13
Fig (xi) AXLE BOX SUPPORT JACK
Fig (xii) CNC PROFILE MACHINING SYSTEM 14
Fig (xiii) SERVO MOTOR 15
Fig (xiv) MEASURING UINT 15
Fig (xv) MEASURING PROBE OF THICKNESS 16
Fig (xvi) MEASURING PROBE OF DIAMETER 17
Fig (xvii) RAIL SYSTEM 18
Fig (xviii) HYDRAULICS PORTAL 19
Fig (xix) OIL LEVEL INDICATOR 19
Fig (xx) OIL LEVEL GAUGE 19

Cnc Pit Wheel Lathe
Machine
Fig (xxi) LUBRICATION 19
Fig (xxii) CNC CONTROLED MONITOR 20
Fig (xxiii) CHIP CONVEYOR SYSTEM 21
Fig (xxiv) DIMENTION OF CUTTING TOOL 22
Fig (xxv) CUTTING OPERATION 22
Fig (xxvi) BEFORE AND AFTER OPERATION 22
Fig (xxvii) DIFFERENT TYPES OF PROFILE 23
Fig (xxviii) TYRE DEFECT GAUGE 24
Fig (xxix) ICF COACH WHEEL 28
Fig (xxx) LHB COACH WHEEL 28
Fig (xxxi) BOXN WHEEL 29
Fig (xxxii) WHEEL PARTS 29
Fig (xxxiii) TYRE 30
Fig (xxxiv) WHEEL SET 31
Fig (xxxv) WHEEL DIAMENSION 31
Fig (xxxvi) SHELLED TREAD 32
Fig (xxxvii) SHATTERED RIM 33
Fig (xxxviii) SPREAD RIM 33
Fig (xxxix) THERMAL CRACK 34
Fig (XL) HEAT CHECKS 34
Fig (XLI) DISC CRACK 35
Fig (XLII) WHEEL GAUGE 36

Cnc Pit Wheel Lathe
Machine
LIST OF TABLES
Table Page no
2.1 TECHNICAL INFORMATION 8
5.4 WHEEL GAUGE 36
DIAMETER OF WHEEL USED ON BG STOCK WITH
CONDEMNING LIMIT 37
STEP SIZE WORN PROFILE 37
STANDARD AND CONDEMNING LIMIT 38
WHEEL DIAMETER 38
WHEEL CHANGING 39
TABLE OF SEQUENCE OPERATION 40
MACHINING OF COACH/WAGON WHEELSET WITH
WHEEL MEASUREMENT SYSTEM 41

Cnc pit wheel lathe machine
Chapter 1
Introductio
There are lot of technological advancement in CNC machine, there are several types of CNC
machines in railway department such as CNC Under Floor wheel lathe, CNC Surface wheel lathe,
CNC Portal Wheel lathe, Wheel Press, CNC Vertical Turning & Boring Machine etc are used for
Turning operation done on
Coaches, Wagons, Trams, Metros etc...
The CNC under Floor Wheel Lathe is an automatic machine used for simultaneous re- profiling of
new or worn-out wheels of railway vehicles. It is capable of machining brake discs assembled on
wheel sets of rolling stock. Every machine tool needs a certain amount of attention for continuous and
satisfactory service. The machine is designed as a two-column construction, Both machine columns
are erected on a common foundation frame. The machine stands in a pit below the feed rails. A
section of these rails is hydraulically pushed out of the range of the machine before a wheel-set is
processed. A wheel set is profile without its being removed from the vehicle.
Computer Numerical Control refers to manipulating traditional machines by theuse of computer
system. CNC machining has become common as the use of computers has increased in industrial
manufacturing processes. Conventional industrial equipment like center lathes, routers, drills and
millers are now operated through computer to achieve better control. On the surface, it may seem like
a simple computer is controlling the machine, but the unique software and control is what really sets
the system apart in CNC machining.
The design is loaded into the computer which is attached to the CNC machine. The computer changes
the design into a special code that controls the way CNC cuts and shapes the material. Computer
numerical control (CNC) then is when precisely coded instructions are sent to a microprocessor in the
control system of a machining tool, enabling an enhanced level of precision and consistency. When
people today talk about CNC, they almost always mean a milling machine connected to a computer.
Technically, it can be used to describe any machine controlled by a computer.
NARSIMHA REDDY ENGINEERING COLLEGE Department of Mechanical Engineering

1
CHAPTER 2
1.LITERATURE REVIEW
Feng Cang-Xue et.al [1] studied the impact of turning parameters on surface roughness. He studied the
impact of Feed, Speed and Depth of Cut, Nose radius of tool and work material on the surface roughness of
work material. He found that the feed have most significant impact on the observed surface roughness and
also observed that there were strong interactions among different turning parameters.
Jafar Zare et.al [2] the performance characteristics in turning operations of Df2 (1.2510) steel bars using
Tin coated tools. Three cutting parameters namely, cutting speed, feed rate, and depth of cut, will be
optimized with considerations of surface roughness. The study shows that the Taguchi method is suitable
to solve the stated within minimum number of trials as compared with a full factorial design. The
main objective of this study was to demonstrate a systematic procedure of using Taguchi design method in
process control of turning process and to find a combination of turning parameters to achieve low material
removal rate.
Prasad et al.[3] reported the development of an optimization model for determining the machining
parameters for turning operations as a part of personal computer based generative CAPP system.
The work piece material considered in their study includes steel, cast iron, aluminum, copper and
brass. High speed steel and uncoated carbide insert tool materials are considered in this study. The
Minimization of production time is taken as the basis for formulating the objective function. The
constraint considered in this study include power, surface finish, tolerance, work piece rigidity, range of
cutting speeds, maximum or minimum depth of cut and total depth of cut. Improved mathematical models
are formulated by modifying the tolerance and work piece rigidity constraints for multi-pass turning
operations. The formulated models are solved by the combination of geometric and linear
programming techniques.
Feng et al.[4] investigated for the prediction of surface roughness in finish turning operation by
developing an empirical model through considering working parameters such as workpiece
hardness, feed, cutting tool point angle, depth of cut, spindle speed and cutting time. Data mining
techniques, non-linear regression analysis with logarithmic data transformation were employed for
developing the empirical model to predict the surface roughness.
Kirby et al.[5] developed the prediction model for surface roughness in turning operation. The
regression model was developed by a single cutting parameter and vibrations along three axes were
chosen for in-process surface roughness prediction system. By using multiple regression and analysis
of

2
variance a strong linear relationship among the parameters feed rate and vibration measured in three
axes and the response surface roughness was found. The authors demonstrated that spindle speed and
depth of cut might not necessarily have to be fixed for an effective surface roughness prediction model.
Pal et al.[6] studied on development of a back propagation neural network model for prediction of surface
roughness in turning operation and used mild steel work-pieces with high speed steel as the cutting tool for
performing a large number of experiments. The authors used speed, feed, depth of cut and the cutting forces
as inputs to the neural network model for prediction of the surface roughness. The work resulted that
predicted surface roughness was very close to the experimental value.
Singh et al. [7] studied on optimization of feed force through setting of optimal value of machining
parameters namely speed, feed and depth of cut in turning of EN24 steel with TiC coated tungsten uncoated
carbide inserts. The design approach and concluded that
the effect of depth of cut and feed in variation of feed force were affected more as compared to
speed.
Ahmed [8] developed the methodology required for obtaining optimal machining parameters for
prediction of surface roughness in Al turning. For development of empirical model nonlinear
regression analysis with logarithmic data transformation was applied. The developed model showed
small errors and satisfactory results. The study concluded that low feed rate was good to produce
reduced surface roughness and also the high speed could produce high surface quality within the
experimental domain.
M Y Noordin et al. [9] investigated the effect of feed rate, SCEA and cutting speed on the surface
roughness and tangential force when turning AISI1045 steel. The ANOVA revealed that feed was
the most significant factor influencing the response variable investigated. The SCEA and feed and
SCEA interaction factor provided secondary contribution to the responses investigated. The cutting
speed also provided secondary contribution to the tangential force. The reduced quadratic models
developed using RSM were reasonably accurate.
Marinkovic Velibor et al. [10] studied the Taguchi method for optimization of surface roughness
in dry single point turning of an alloy steel. They concluded that the surface roughness is
continuously improved with increase in cutting speed, but in increase in feed rate and depth of cut
causes significant deterioration of surface roughness. The results obtained using the Taguchi
optimization method revealed that cutting speed should be kept at the highest level, while both feed
rate and depth of cut should be kept at the lowest level.
Matthew A Kuttolamadom et al. [11] investigated the parameters affecting surface roughness of
machine roughness with an emphasis on the dominance of feed along with practical

3
Recommendations to improve surface quality. It was inferred that there is an increase in feed up
until a cut off surface roughness is reached and then increase the surface speed within the roughness
range, to maximize productivity.
Kumanan et al. [12] proposed the methodology for prediction of machining forces using multi-
layered perception trained by Genetic Algorithm. The data obtained from experimental results of a
turning process were explored to train the proposed Artificial Neural Networks with three inputs to
get machining forces as output. The optimal Artificial Neural Networks weights were obtained
using Genetic Algorithm search. This function replacing hybrid made of Genetic Algorithm and
Artificial Neural Networks was found computationally efficient as well as accurate to predict the
machining forces for the input machining conditions.
Thamizhmanii et al. [13] applied Taguchi method for finding out the optimal value of surface
roughness under optimum cutting condition in turning SCM 440 alloy steel. The experiment was
designed by using Taguchi method and experiments were conducted and results thereof were
analyzed with the help of Analysis of Variance method. The causes of poor surface finish as
detected were machine tool vibrations, tool chattering whose effects were ignored for analysis. The
authors concluded that the results obtained by this method would be useful to other researches for
similar type of study on tool vibrations, cutting forces etc. The work concluded that depth of cut
was the only significant factor which contributed to the surface roughness.
Shetty et al. [14] discussed the use of Taguchi and response surface methodologies for minimizing
The surface roughness in turning of Discontinuously Reinforced Aluminum Composites having
aluminum alloy 6061 as the matrix and containing 15% volume of silicon Uncoated Carbide Insert
particles of mean diameterm under pressured steam jet approach. The measured results were
then collected and analyzed with the help of the commercial software package MINITAB15. The
experiments were conducted using.
Conditions included cutting speeds of 45, 73 and 101 m/min, feed rates of 0.11, 0.18 and 0.25
mm/rev and steam pressure 4,7,10 bars while the depth of cut was kept constant of 0.5 mm. The
effect of cutting parameters on surface roughness was evaluated and the optimum cutting condition
for minimizing the surface roughness was also determined finally. A second-order model was
established between the cutting parameters and surface roughness using response surface
methodology. The experimental results revealed that the most significant machining parameter for
surface roughness was steam pressure followed by feed. The predicted values and measured values
were fairly close, which indicated that the developed model could be effectively used to predict the
surface roughness in the machining of Discontinuously Reinforced Aluminum composites.
Abburi et al. [15] developed a knowledge-based system for the prediction of surface roughness in

4
Turning process. Fuzzy set theory and neural networks were utilized for this purpose. The
authors developed rule for predicting the surface roughness for given process variables as well
as for the prediction of process variables for a given surface roughness.
Wang et al. [16] used Orthogonal Array of Taguchi method coupled with grey relational analysis
considering four parameters viz. Speed, cutting depth, feed rate, tool nose run off etc. For
optimizing three responses: surface roughness, tool wear and material removal rate in precision
turning on an ECCOCA-3807 CNC LT16 XI lathe. The MINITAB software was explored to
analyze the mean effect of Signal-to-noise (S/N) ratio to achieve the multi-objective features. This
study not only proposed an optimization approaches using Orthogonal Array and grey relational
analysis but also contributed a satisfactory technique for improving the multiple machining
performances in precision CNC turning with profound insight.
E. Daniel Kirby et al. [17] conducted an effective Taguchi Parameter Design study requires of
literature regarding turning parameters and similar studies. Of course, the most readily controlled
factors in a turning operation are feed rate, cutting speed, and depth of cut: each of which may
have an effect on surface finish. Several studies exist which explore the effect of federate, spindle
speed, and depth of cut on surface finish. These studies all supported the idea that feed rate has a
strong influence on surface finish. Spindle speed and depth of cut were found to have differing
levels of effect in each study, often playing a stronger role as part of an interaction. This would
seem to indicate that these controlled parameters would play an important role in optimizing
surface roughness. Vibration as an uncontrolled noise factor can also affect surface finish.
Lin and chang [18] studied the effect of radial vibrations on surface finish, and found that the
amplitude and frequency due to spindle speed both had strong effects on the surface topography.
Spindle vibrations due to damaged or unbalanced jaws, for example, would therefore have an effect
of surface finish depending on the degree of out-of-balance condition and the speed of the spindle.
PROBLEM STATE MENT:
After studying above journals still we can improve mechanical properties. of
“CNC pit wheel lathe machine” And we can check all dimensions of the train wheel. We can learn all the G-
codes and M – codes of CNC pit wheel lathe machine foe to make the train wheel.

5
2. HISTORY
To understand where CNC Machining first appeared, it is important to note thatthe said machine's
advent can be traced back to the invention of the NC (numerical controlled) machine made by John T.
Parsons during the 1940s1950s. The NC was a break through invention that led the way towards
modem automated machines. Together with Frank L. Stulen Parsons first utilized computer methods
to crack machining setbacks, especially the accurate interpolation of the curves that is found in
helicopter blades. Stulen got an idea from his brother to employ stress calculations on the rotors.
Parsons observed what Stulen was experimenting on with punched card machines generating an
outline with 17 points and then inquired if it was possible for Stulen to generate an outline with
200points.
+fig(i) CNC Machines used to be as big as size of a room
John T. Parsons Frank L. Stulen
In 1940's to 1950's, two American inventors developed a CNC machine to reducethe human effort.
In the process of developing smoother rotors, they managed to generate an earlyversion of the NC,
6
where generating numbers for complex and précised outputs was possible. Attached point, Parsons
considered a fully automated tool that can surpass the performance of the current NC. In 1949, he
turned to Gordon S. Brown's Servomechanisms Laboratory at MIT to develop a feedback system that
can gauge how far the controls had turned. With enough resources to back the project, the system was
displayed in September 1952.The MIT's system was a triumph, so that it was now possible to come up
with any complex cut that cannot be copied manually. Yet due to its complexity, its reliability in a
production setting is reduced, not to mention its cost that is worth more than 196,940,794.8165Rsin
an Indian currency.
The Air Force halted its funding in 1953, but Giddings and Lewis Machine Tool Co-resumed the
project by producing NC that can reduce the expenses and improve quality and efficiency. With their
direction of the project, the Numerical controller was created, replacing punch type readers with
magnetic tape readers.

7
CNC Lathe Machine
Lathes used in turning centers operate by rotating the material rapidly on a spindle. While the material
is turning, a cutting tool is used to shape the piece into its desired form. CNC lathes are ideal for
manufacturing symmetrical objects that have conical, spherical or cylindrical shapes. A lathe machine
is generally used in metalworking, metal spinning, woodturning, and glass working. The various
operations that it can perform include the following: sanding cutting, knurling, drilling, and deforming
of tools that are employed in creating objects which have symmetry about the axis of rotation. Some
of the most common products of the lathe machine are crankshafts, camshafts, table Leg, bowls, and
candlestick holders.

8
Fig(ii)Part of a CNC Lathe Machine
CNC Lathes are normally used for machining parts, where the material/ part is clamped and rotated
whereas the cutting tool is stationery mounted for OD (Outer Diameter) and ID (Inner Diameter)
operations, c.g. shafts and pipes. They are ideal for parts that have same symmetry around an axis that
could be chucked up (i.e. radially clamped) in the spindle.
A simple CNC Lathe operates on 2-axis and the tool is located in a fixed position at 8 to 24 station
turret. The rotating action of the part is called "turning", hence certain types of CNC Lathes are called
CNC Turning Machines.
Milling (cutting tool moves around stationery work piece), boring and tapping (a tool that cuts threads
inside hole) tools are normally driven by a separate drive system inside the turret. Depending on the
application, the life tools (i.c. active tool) are mounted for axial or radial operational directions. These
could be found in 3-axis CNC Lathes or CNC Turning Machines
Lathe machines with additional options such as Y-axis, sub-spindles, or specific selected options for
automation are commonly called Turning Centers. These sophisticated machine tools are capable of
machining complex parts - these go beyond standard OD & ID turning operations and may incorporate
milling, drilling and tapping operations to complete the part in one setting. Taking a pic from raw part
to finished product, such all-in-one machine tools significantly improves productivity.
TYPES OF CNCLATHE MACHINES
Surface CNC Wheel Lathe (YSL-08)
CNC Surface Wheel lathe is an automatic machine for simultaneous re-profiling new or worn-out
wheels when dis-assembled from railway vehicles like locomotives, electrical & diesel multiple units,
coaches, wagons, metro & tram coaches, etc. This extremely rigid machine is capable of taking 8-
10mm depth of cut simultaneously on both the wheels of a wheel set.

9
fig(iii) CNC Surface Wheel Lathe (YSL-08)
CNC Under Floor Wheel Lathe (YUL-08)
CNC under Floor Wheel lathe is an automatic machine for simultaneous profiling of new or worn out
wheels of railways vehicles in situ. Wheel sets of railways rolling stock i.e. locomotive, coaches,
wagons etc. are turned on this machine when in assembled condition. It is equipped with dual CNC
tool post for turning any wheel profile along with pre and post measurement system.
CNC under Floor Wheel Lathe (YUL-08)
CNC under Floor Wheel lathe is a automatic machine for simultaneous profiling of new or worn out
wheels of railways vehicles in situ. Wheel sets of railways rolling stock i.e. locomotive, coaches, he
(YPL-01)
CNC Portal Wheel lathe is an automatic machine in portal construction with roll through movement
of wheel sets. It is suitable for simultaneous reprofiling of new or worn- out wheels when
disassembled from railways vehicles like locomotives, electrical & diesel multiple units, coaches,
wagons, metro &

10
Tram coaches, etc... This extremely rigid machine is capable of taking min. 0.5mm to max. 15mm
depth of cut simultaneously on both the wheels of a wheel set.
Fig(v)CNC Portal Wheel Lathe(YPL-01)
CNC TANDAM UNDERFLOOR WHEEL LATHE(YUL-12T)

A tandem under floor wheel lathe is a specialized machine used for the maintenance and repair of

11
Treads while the train is positioned on the tracks, without the need to remove the wheels from
the train.
Here's how it typically works:
1. Positioning: The tandem under floor wheel lathe is installed in a pit or recessed area below the
tracks. The train is brought over the machine, and the wheels to be re-profiled are positioned on the
lathe.
2. Clamping: The machine features clamping mechanisms that securely hold the train wheels in
place during the lathe operation. This ensures stability and accurate machining.
3. Machining: The lathe has cutting tools that are precisely aligned with the wheel treads. The
cutting tools remove a thin layer of material from the wheel tread, restoring the proper profile. The
lathe may have multiple cutting tools to simultaneously work on both wheels of an axle.
4. Control and Measurement: The tandem under floor wheel lathe is equipped with sensors and
control systems that monitor the machining process and ensure the correct dimensions are achieved.
This helps maintain the wheel’s proper profile and prevents excessive material removal.
5. Finishing: After the machining is complete, the wheels may undergo additional processes such
as polishing or grinding to achieve a smooth surface finish.
6. Testing: Once the re-profiling is finished, the train wheels are thoroughly inspected to ensure
they meet the required specifications and safety standards.

12
Tandem under floor wheel lathes offer several advantages over traditional methods of wheel re-
profiling, such as improved efficiency, reduced down time, and increased accuracy. By performing
the maintenance without removing the wheels, it eliminates the need for time-consuming wheel
removal and reinstallation processes.
These machines are commonly used in rail maintenance facilities or depots to keep train wheels in
optimal condition, ensuring safe and efficient train operations.
Chapter 2
CNC NEW GENERATION UNDER FLOOR WHEEL
LATHE
CNC under Floor Wheel lathe is an automatic machine for simultaneous profiling of new or worn out
wheels of railways vehicles in situ. Wheel sets of railways rolling stock i.e. locomotive, coaches,
wagons etc. are turned on this machine when in assembled condition. It is equipped with dual CNC
tool post for turning any wheel profile along with pre and post measurement system.
fig(vi) CNC Under Floor Wheel Lathe Machine

13
The machine is arranged in a pit. The wheel sets to be re-profiled are brought into the machine via the
supply rails (if still attached to the vehicle) or by crane (if removed from the vehicle). For re-profiling,
the wheel sets are driven by friction rollers pushing on the running surfaces. The high dynamic
stiffness of clamped wheel sets required to produce the highest possible machining precision
guaranteed by the radial centering of the axle bearing box. Lateral positioning of the wheel set is
executed by the use of axial guide rollers. The machine is operated from a central control panel,
which enables the operator to have constant access to all machine functions. During machining, the
operator is protected from flying chips. The automated machining takes most of the work from the
operator's hands, making the machine easy to operate.
2.1 Technical Information
1 The machine is designed as a two-column construction. Both machine columnar erected on a

common foundation frame.
2 The machine stands in a pit below the feed rails. A section of these rails is hydraulically pushed out
of the range of the machine before a wheel-set is processed.
3 A wheel-set is profiled without its being removed from the vehicle.
4 The axle loads of vehicles with low axle loads can be increased by means of the hold- down device.
High axle loads permit large, and therefore economical, cross-sectional areas of cut.
5 The slide-ways are hardened and precision ground. The counter Slide-ways are applied with SKC-
3 material.
6 Tools with reversible carbide tips are used for wheel-set processing
7 If the wheel-set to be processed on the machine are coupled with one or morewheels of the coupled
wheel-sets must be lifted off the rails by means of jacks.
Sl.No. Description UNITS
1 LEADING PAREMETERS
1.1 Track guage 1676mm
1.2 Cutting speed 15 to 60 meters/rev

(Infinitely variable)

14
1.3 Feed 0.5 to 2.0 mm/rev
(Infinitely variable)
1.4 Axle load 8 to 25 tones
1.5 Tread diameter 700 to 1250 mm
2 JOB parameters
2.1 Max. width of 3660mm

roller stock
2.2 Wheel guage (distance 1595 to 1602mm

between inner faces of
flange)
2.3 Width of tyre 125mm to 140mm
2.5 Distance between axlesof 1600 mm

the vehicles
3 Axles length(range) 1889mm to 2750mm
3 OTHER PARAMETERS
3.1 Power supply 415+/-10%,50Hz+/-3%

15
Chapter 3
MACHINE DESIGNE AND FUNDAMENTAL
The most important and component groups of the machine and where necessary, explanations of their
functions and special characteristics as well as information designed to contribute towards the
prevention and correction of malfunctions.
In many cases the additional consultation of our assembly drawings hydraulic circuit diagram
and other documents will contribute towards a better understanding of the units concerned.
Fig(vii)CNC Under floor wheel lathe assembly

16
COMPONENTS OF CNC UNDER FLOOR WHEEL LATHE MACHINE
Column
The machine is equipped with two rigid columns, one on the either side. This columns are subjected
to static and dynamic loading of the wheel set rotation as well as dynamic load of cutting forces
during the wheel set machining.
fig(viii) Column
Considering this and to impart very high static and dynamic rigidity and to absorb the dynamic cutting
forces, columns are manufactured out of close grained "C.I' casting to grade FG 260 to IS 210. These
column are box structured to get highest rigidity. These columns are anchored to the foundation. It is
having suitable number of holes for foundation bolts. Each foundation bold is accompanied by the
leveling bolt. This will enable fast and precision leveling in both the directions.
On the column hold down device and axle box jack is mounted. For mounting and guiding these
devices precisely bored and honed holes are provided on the column. This gives firm guide and rigid
support to the hold down device and axle box jack. On this column, drive roller arms are supported
with suitable guide mechanism. Heavy-duty hydraulic cylinders are incorporated for movement on
these roller arms. Cross rail carrying the CNC tool posts is mounted on these columns. Similarly
support roller assemblies are mounted on this column.

17
Drive Roller Assembly

Drive to the wheels is from a set of two drive rollers on either side. Drive rollers are of
suitable heat treated alloy steel. Distance between the drive rollers is designed to accommodate
standard gauge wheel sets. Each drive roller is individually connected to its motor. The drive rollers
are mounted on the rigid shaft. These drive rollers are connected to drive motor using timer belt and
the reduction gearbox to get the required torque and the speed. Drive rollers are subjected to very
high forces, which includes supporting force and cutting force. Also these rollers are subjected to
uneven contact of worn out tread of wheel set. Special lead in chamfer is incorporated on the drive
rollers to allow smooth passage of cut. This lead in chamfer when working in co-ordination with
special accumulator charged hydraulic circuit gives continuous support to wheel set during profiling
operation from chamfer to the outer radius of flange.
fig(ix) Drive Roller
Consider very high carbon and chromium contents, and to avoid cracking, hardening of these rollers
in hardened condition to 58-62 HRC, have extreme wear resistance. Each drive roller is mounted on a
rigid shaft. This shaft is supported on suitable bearing assembly.
The drive rollers are mounted on the driving roller arms. Two number roller arms are provided on
coach columns these roller arms will be rigid steel casting as perIS 1030. These arms are connected to
the machine columns using highly wear resistant linear motion bearings. The drawing vertical motion
of the arms is done using heavy duty hydraulic cylinder
All the drive roller arms are connected to the position transducer to monitor the vertical movement.
During the initial lifting of wheel set form the rails, all four arms moves in synchronized manner
allowing equal lifting and controlling the

18
Center line of wheel set to the center line of the machine. This ensures machining of the wheels with
respect to centerline.
HOLD DOWN EQUIPMENT

A suitable hydraulically operated hold down device for machining of independent wheel set with
respect to the center line of the outboard axle box is provided one on each column. It basically consist
of two nos. guide bars which are rigidly held on the support bracket are guided in the precision bores
provided in the column as explained earlier. These guide bars are supporting the lead screws which
are engaged with the nut are interconnected by the timer belt. Common hydraulic motor is provided to
drive these lead screws. Hydraulic motor applies the torque which is converted to vertical force to
create additional load on the axle box.
Fig(x) HOLD DOWN EQUIPMENT
Pressure reducing valve is provided in the supply line of this motor, which is easilyset to the required
load suitable for axle box bearings. Rigid housing is mountedon vertical guide bar support bracket. It
is suitably located and rigidly bolted.

19
Axle Box Support Jack

Rigid jack is provided on the column to support the axle box from bottom. This consist of a rigid
base guide in the machine column using tow guide bars. One of the guide bars have hydraulics motor
connected to lead screw and nut arrangement, which provides the self locking properly. This provide
vertical movement to the axle support jack.
fig(xi) Axle box Support Jack
Hydraulic motor applies the torque which is converted to vertical force to support the axle box.
Pressure reducing valve is provided in the supply line of this motor. Which easily set to the required
load suitable for axle box. The axle box supports are commanded by the CNC and is integrated in the
operation cycle of the machine. These are in locked position due to lead screw and nut mechanism
during the machining processes to keep the axle boxes steady. evenin case of power failure.
CNC Profile Machining System

CNC tool slide assemblies are mounted on the cross rail which is supported on the columns of the
machine. As explained earlier, drive rollers withroller arm floats due to in- accuracies of the wheel
set, but slide assemble remains rigidly guided on the cross rail. Longitudinal slide is guided on the
crossrail. Hardened and ground guide ways made from alloy steel and are fixed to thecross rail. SKC 3
lining is provided on the longitudinal slide sideways mating withthese hardened and ground guide.

20
remains rigidly guided on the cross rail. Longitudinal slide is guided on the crossrail. Hardened and
ground guide ways made from alloy steel and are fixed to thecross rail. SKC 3 lining is provided on the
longitudinal slide sideways mating withthese hardened and ground guide.
fig(xii) CNC Profile Machining System
This gives extremely durable and wear resistant guide way configuration with very high dynamic
rigidity. Suitable taper wedge is also incorporated for taking up the wear in service. Servo motor and
preloading, ball screw is provides the controlled feed motion as well as rapid motion to the
longitudinal slide. On the longitudinal slide is box structured. Suitable guide ways are incorporated on
thevertical slide. Guide way combination is such that one of the guide ways in the pair is hardened
and ground and the other mating guide way is having wear resistant SKC 3 linear. Suitable taper
wedge is also incorporated for taking up thewear in service. Servo motor ensures controlled feed
motion as well as rapid motion to the longitudinal slide. Wheel measurement system is also provided
onthis vertical slide with suitable protecting cover.

21
Fig(xiii)Servo motor
Servo motor is driven by its drive, which is controlled by the CNC system. Both the 'X' and "Z' axis
are having feedback from servo motor encoders which will give position and speed feed back to the
CPU of the CNC system. Once a particular profile selected by the measurement system, this data is
transferred to the CNC system. In this way by the composite motion of two axis required wheel
profile is generated automatically. The system is capable for continuous path control. This drawing
gives the details of methods adopted for the movement of both the slides. Schematic details of the
CNC control are given, CNC controller is control the entire operation. Based on the selected profile
andmachining parameters this controller set out the movement signals to the individual axis.Feed back
is available from individual axis for real position and velocity which is compared with the adopted
values. In case any variations are observed for positioning or velocity same are corrected
instantaneously. This is continuous path control.
Railway wheel turning is extremely difficult operation. Hence special and rigid tools are incorporated
for wheel turning to withstand very high cutting force andto make the profiling automatic. Cutting
tools is located between the two drivingrollers. Throw away type carbide inserts with built in chip
breaker are used. These insert and tool holders are manufactured by Sandvik/Widia- Kenametal and
are available easily.
MEASURING SYSTEM
The machine is equipped with CNC based system to determine minimum metal removal necessary to
achieve the required profile for the wheel sets in normal worn out condition. The system performs the
measurement at various locationsfor both the wheels of wheel set for deciding the precise diameter
along with minimal material removal required for turning. The display system indicates thediameter
before and after turning along with depth of cut. Based on these

22
corrective actions taken by operator CNC system calculates the distribution of cuts in order to process
the profiling in single/multiple cuts.
Fig(xiv) MEASURING UNIT fig(xv) MEASURING PROBE OF THICKNESS
The two measuring heads are incorporated on each vertical slide. One measuringhead is for the profile
measurement and the other is for the diameter measurement. Both these heads are mounted within the
protective enclosure which is closed and opened by the pneumatic cylinder. During the measuring
cycle only this cover gets opened automatically and remains close otherwise, giving protection to the
measuring heads.it basically consists of a measuring probe, which is mounted on the extension shaft.
This shaft is made from alloy steel and is hard chrome plated and ground. It is guided in the housing
using lincar motion bearing bushes. Housing is also made from alloy steel in hardenedand tempered
condition. This extension shaft is connected to the pneumatic cylinder using a coupler. Extension
shaft is having a through hole in the center for passage of cable for the probe.
The measuring probe touches various measuring points of the wheel profile. CNCaxis position are
recorded by the measuring system. Entire sequence is automatic. Recorded data is compared with the
standard profile data.

23
fig(xvi) MEASURING PROBE OF DIAMETER
Wheel diameter measuring head, it basically consists of a disc measuring head connected to rotary
encoder which is mounted on the extension shaft. Circular measurement disc is in contact with the
wheel to be measured. Optical sensor is provided to count the number of revolution of the wheel to be
measured. Basically circumferential measurement is carried out to measure the diameter ofthe wheel.
Extension shaft is made from alloy steel and is hard chrome plated and ground. It is guided in the
house using linear motion bearing bushes. Housing is also made from alloy steel in hardened and
tempered condition.
RAIL SYSTEM
Rail system is meant for bridging the machine work area on the entryand exit sides and is supplied
with the machine. Rail system allows rolling in the Locomotive or vehicle or wheel set on the
machine and rolling out the same from the machine. The two beams are shown onthe operator side.
These beams are rigid fabricated 'C shaped fabricated structure I made from MS plates as per IS 2062.
These beams are thermally stress relieved after fabrication and accurately machined. These beams for
the guidance of sliding mill, and supportedon the machine pit at one end on the machine column at the
wheel set of vehicle in lateral direction. Once the sliding rails are extended out by bydraulic cylinder,
locked by pneumatic cylinders and sensed bylimit switches signal is given to controls to roller wheel
set on to the machine. Once the wheel set is received in loading condition it is liftedby drive rollers
supported by the jack and clamped by hold down device. After these activities sliding rails are
retracted to clear the space for the machining

24
fig(xvii) RAIL SYSTEM
Standard rails are provided between the pit edge and the column of the machine on the other side of
the machine. In this is connecting thesliding rails from the operator side of the machine. In this way
rails are connecting the machine from both ends of the pit. Rail system is sufficiently rigid to bear the
axle load as specified in the technical specification.
HYDRAULICS
Hydraulic system of the machine is explained, it basically consists of atank with its accessories like,
oil level gauge temperature gauge, thermostat, float switch, oil filler breather etc. Drain plug also
incorporated at lowest portion of the tank for draining out the oil. Pumps and filters are also mounted
on this tank. Various valves like direction control valves, flow control valves, pressure reducing
valves, check valves, pilot operated check valves etc., are incorporated basedon the functional
requirement of the actuator.
fig(xviii) Hydraulic portal fig(xix) Oil level indicator fig(xx) Oil level gauge
Hydraulic system is procured from reputed manufacturer. Machine elements likehydraulic cylinder,
hydraulic motor etc. are connected byrigid seamless pipes which are amply supported on the brackets.
Hydraulic hoses of reputed make are used are required.

25
LUBRICATION
Lubrication system is incorporated for the slide lubrication. All the guide ways and ball screw are
lubrication. Intermittent, pressurized, metered quantity of lubrication oil is supplied to all lubrication
point.
fig(xxi) Lubrication point
Float switch and pressure switches is incorporated to ensureprotection against lubrication failure.
Signals from float switch and pressure switch is connected to controls. In case of low lubrication oil
level or low lubrication oil pressure machine stops working on completion of running cycle.
CONTROLS
Machine is provided with centralized ergonomically designed control console. Operator friendly
screens are developed for ease of operation. Please note that due to continuous improvements,
formatting of screen can be changed for improved ease of operation.

26
fig(xxii) CNC CONTROLED MONITOR
This enables machine operation with the soft key on the CNC operatorpanel. CNC control panel is air
conditioned to ensure satisfactory working in the local ambient conditions.
AUTOMATIC CONVEYOR CHIP DISPOSAL SYSTEM
The chip conveyor is installed in a pit below the machine for effectivecollection of chips. Chips
discharge end is at a suitable height above normal ground level. Chips are collected in a chip bin
/trolley parked on the ground level.

27
fig(xxiii) CHIP CONVEYOR SYSTEM
Conveyor get switched on automatically once the cycle start commandis given through CNC.
Similarly, 'ON' and 'OFF' push buttons are incorporated on control desk for its operation in manual
mode. Hinged belt conveyor keeps on moving continuously.
Chapter 4
COMPONENTS USED IN
OPERATION
CUTTING TOOL
A cutting tool in metal working can be defined as "any tool that is usedto remove metal from the work
piece by means of shear deformation".
28
Frequently, it also refers as a tool bit. In order to perform effective cutting operation, the cutting tool
must be made of a material harderthan the work material to be cut. Also, the tool must be able to
withstand the heat generated during machining process. The tool musthave a specific geometry (known as
tool geometry) for effective cutting and smooth surface finish. According to the tool geometry, the cutting
tools can be classified into solid cutting tools and carbide tipped tools.
fig(xxiv) DIMENTIONS OF CUTTING TOOL
fig(xxv) CUTTING OPERATION fig(xxvi)BEFORE AND AFTER OPERATION
Nose radius is one which connects the side and end cutting edge. Now,we will discuss the functions
and effects of cutting tool angles on cutting process. The face and the flank are pain surfaces, the
cutting edge can be assumed to be a line. These surfaces and the edges are inclined with respect to
some reference plan or line. The inclinations are called tool angles.
WHEEL PROFILES
A profile gauge or contour gauge is a tool for recording the cross sectional shape of a surface.
Contour gauges consist of a set of steel or plastic pins that are set tightly against one another in a
framewhich keeps them in the same plane and parallel while allowing themto move independently,
perpendicularly to the frame. When pressed

29
against an object, the pins conform to the object. The gauge can thenbe used to draw the profile or to
copy it on to another surface.
• Rail interaction with IRS wheel profile results in rapid wear ofthe flange and root of the
flange during initial stages till a wearadapted/worn wheel profile is obtained.
• Since the wear after the worn wheel profile is obtained in service is considerably less,
wheels are now provided with worn wheel/wear adapted profile.
fig(xxvii) DIFFERENT TYPES OF PROFILE
TYRE DEFECTGAUGE
A gauge, in science and engineering, is a device used to make measurements or in order to display
certain dimensional information.A wide variety of tools exist which serve such functions, ranging
from simple pieces of material against which sizes can be measured to
complex pieces of machinery. Depending on usage, a gauge can be described as a device for
measuring a physical quantity for example todetermine thickness, gap in space, diameter of materials,
or pressure of flow or a device that displays the measurement of a monitored system by the use of a
needle or pointer that moves along a calibratedscale.

30
complex pieces of machinery. Depending on usage, a gauge can be described as a device for
measuring a physical quantity for example todetermine thickness, gap in space, diameter of materials,
or pressure of flow or a device that displays the measurement of a monitored system by the use of a
needle or pointer that moves along a calibratedscale.
fig(xxviii) TYRE DEFECT GAUGEChecking

for sharp flange

31
Checking the root of flange
Checking thin flange

32
Checking Deep flange
Checking Hollow Type

33
Checking flat type
Checking thin type

34
Chapter 5
WHEEL SET
Railway wheel is assembly of two wheels fixed to the axle by interference fit and
they rota along with the axle, without any independent relative movement as inthe case of oth
automobile wheels. These wheels are provided with flange towards the inner side, whic guide the
wheels to travel on the rails and does notallow it to fall down from the rails.
The wheel and axle consists of two wheels attached to a small axle, so that thesetwo par rotate
together, in which a force is transferred from one to the other. Ahinge or bearin supports the axle,
allowing rotation. It can amplify force; a smallforce applied to the periphery of the large wheel can
move a larger load attachedto the axle. The wheel and axl can be viewed as a version of the lever,
with a drive force applied tangentially to the perimeter of the wheel and a load force applied to the
axle, respectively, that are balance around the hinge which is thefulcrum. The mechanical advantage
of the wheel and axle is the ratio of the distances from the fulcrum to the applied loads, or what is the
same thing the ratio of the diameter of the wheel and axle. A major application is in wheeled vehicles,
in which the wheel and axle are used to reduce friction of the moving vehicle with the ground.
fig(xxix) ICF Coach Wheel fig(xxx) LHB Coach Wheel

35
Fig(xxxi)BOXN Wheel
Railway Wheels
The wheel is better understood by dividing it into the following parts.
• Hub
• Disc
• Tyre
fig(xxxii) WHEEL PARTS
HUB
Hub is the center portion of the wheel, where the wheel is fixed tothe axle by means of interference
fit. Thickness of the wheel is
maximum at the hub portion.

36
DISC
Disc is the portion of the wheel between the hub and the tyre. This portion is the thinnest portion of
the wheel as it does not come in contact with rail nor itis coming in contact with the axle.
Tyre
Tyre is the portion in contact with the rail, which wears out in service. The profile of the tyre is
significant for safe running of the trains. Taper is given onthe tread to have higher diameter near the
flange and lower diameter at the outer edge, to facilitate curve negotiation.
fig(xxxiii) TYRE
Details Of Wheel Set
Wheel Gauge:
There should be no variation in the values of wheel gauge -measured at four points 90 degrees apart
on a wheel set. However, the actual value of the wheelgauge can vary as per tolerances given
Measurement of Wheel Gauge and recorded duly indicating the following:
(i) Tightness or slackness of gauge.
(ii) Whether any indication exists about shifting of wheel on the axle.
Note: It must be ensured that the back surfaces of wheels are cleaned thoroughlybefore measuring the
wheel gauge in order to avoid erroneous readings.
(iii)If the wheel gauge is more than permissible limit, there exists a possibility ofa relatively
newer wheel hitting the nose of crossing.

37
(iv)If the wheel gauge is less than minimum value, there is a possibility of wheelhitting at the back of
a tongue rail while passing through the switch and thusdamaging the tongue rail.
(v) Wheel gauge to be checked in no load condition.
fig(xxxiv) WHEEL SET
Bent Axle:
A bent axle starts wobbling during motion causing severe vibrations. In order toconfirm whether an
axle is bent or not, it must be checked carefully on a sensitivemachine or measuring table.
Wheel Diameter on Tread :
Wheel diameter is measured on the tread at a distance of 63.5 mm from the inside face of the wheel.
Two measurements 180 degrees apart should be takenfor each wheel. Variation in tread diameter on
the same axle as specified is at the time of tyre turning. Effect on safety of any variation beyond this
limit shouldbe analysed on case to case basis.

38
fig(xxxv) WHEEL DIMENSIONS
Two brake disks (4), diameter 640 mm and width 110 mm.Two wheel discs
of diameter 915 (New), 845 (worn).
Wheel defect
• Shelled tread
• Shattered rim
• Spread rim
• Thermal crack
• Heat checks
• Disc crack
• Loose axle
Shelled Tread
Shelling can be identified by pieces of metal breaking out of the tread surface inseveral places more or
less continuously around the rim. Shelling takes place when small pieces of metal break out between
the fine thermal checks. These are generally associated with small skid marks or "chain sliding" Such
wheels should be withdrawn from service and sent to workshops for re-profiling.
fig(xxxvi) Shelled Tread

39
Shattered Rim
A wheel with a fracture on the tread or flange must be withdrawn from service.Shattered Rim is a
rejectable defect. (This does not include wheels with localizedpitting or flaking without presence of
any rejectable condition).
fig(xxxvii) Shattered Rim
Spread Rim
If the rim widens out for a short distance on the front face, an internal defect may be present.
Spreading of the rim is usually accompanied by a flattening ofthe tread, which may or may not have
cracks or shelling on the tread. Such
wheels must be withdrawn from service.

40
fig(xxxviii) Spread rim
Thermal Crack
Thermal cracks appear on a wheel tread due to intense heating of the wheel arising out of severe brake
binding. Such cracks occur on the tread and generallyprogress across the tread in a transverse & radial
direction. Whenever such a crack becomes visible on the outer face of the rim or tread crack has
reached theouter edge (non-gauge face) of the rim, the wheel should be withdrawn from service. If a
crack becomes visible on the outer flange face, the wheel should bewithdrawn from service. Such
wheels should be sent to workshop for examination and subsequent rejection. Wheels involved in
brake binding duringservice, should be examined carefully during the maintenance to rule out the
possibility of rejectable thermal cracks. Such wheels may be identified by presence of flats (even
within acceptable limits) and severe discoloration or blue/ black heating marks on the tread.
fig(xxxix) Thermal Crack
Heat Checks
Fine superficial cracks visible on the tread on or adjacent to the braking surfaceare called heat checks,
which are usually denser than the thermal cracks. Heat checks are caused on the tread due to heating
and cooling cycles undergone bythe wheel during normal braking. Such wheels need not be
withdrawn but should be carefully distinguished from the rejectable thermal cracks.

41
Disc Crack
A crack on the disc due to material failure is called disc crack. The wheel shouldbe with drawn from
service.
fig(XL) Heat Checks

42
fig(XLI) Disc Crack
Loose Axle
While assembling wheel with axle proper interference should be maintained between wheel and axle.
Due to improper selection of interference the wheel may shift outwards or it may come out
completely. Loose axle is a rejectable defect. Axles involved in Accidents should be magnaflux tested
in addition to Ultrasonic test. Axle having notch should be withdrawn from service. All wheel sets
withdrawn from service for any of the conditions mentioned above must besent to the associated
workshops for detailed investigations and further disposal.The date and station code of the
maintenance depot where the wheels are changed should be stencilled on the end panels. An entry
should also be made in the maintenance card of the coach. No repairs, except wheel profiling of
wheelsets is permitted to be done in the maintenance depot.
Wheel Gauge
• To be checked at Quarter points
• COACHING/GOOD STOCK1600 MM (1602-1599)
• No variation among values of quarter points of same axle is permitted

43
Fig(XLII)WHEELGAUGE
Description Std Max Min
Coach MG 930 932 929
ICF coach BG 1600 1602 1599
LHB coach 1600 1601 1599
Wagons 1600 1602 1599
Wheel Tread Diameter
• Measured on the tread at 63.5 mm from the back of the wheel.Two measurements, across
the quarter points to be taken for each wheel • Difference of Diameter on the same axle:
persistent angularity • Excessive difference of diameter ondifferent axles of the same
vehicle-> adverse effect on buffer heights
DIAMETERS OF WHEEL USED ON BG SOCK WITH CONDEMNINGLIMITS
S.NO Axle Type Diameteron Condemning tread Wear

Load tread when diameter(mm) allowance(mm)
new(mm)
1 16.3 Solid 1090 990 50

&19.33
2 16.3 Tyred 1090 1015 37.5
&19.33
3 22.9 Solid 915 813 51
4 22.9 Tyred 915 813 51
5 20.3 Solid 1000 860 70
6 22.9 Solid 1000 906 37.5

44
DIAMETER TURNING SERVICE TOLERANCE

MEASURED ON TOLERANCE
SAME WHEEL 0.5MM 2.5MM
SAME AXLE 2.0MM 8.0MM
SAME BOGIE 15MM 25MM
Step Size of Worn Wheel Profile

Further to reduce the metal removal during tyre turning, intermediateworn wheel profile based
on the thickness is introduced.
Flange thicknesss(X) (Y) (Z)
28mm 42.23mm 13.5mm

27mm 41.29mm 13.0mm
26mm 40.34mm 12.5mm
25mm 38.41mm 11.5mm
24mm 37.44mm 11.0mm
23mm 36.47mm 10.5mm
22mm 35.49mm 10.0mm
21mm 34.5mm 9.5mm
20mm 33.5mm 9.0mm

45
Standard & condemning limits

Defect Std Cond
Thin flange 28.5 22(coaches)

16(wagons)
Deep flange 28.5 35
Sharp flange(radius) 14.5 5
Less radius at 14(wwp) 13
rootof flange
(radius)
hollow type 5
Thin tyre Based on wheel dia
Flat tyre 50(coaches)

60(wagons)
Wheel Diameter
Description Std Cond
Coach MG
ICF coach BG 915 825
LHB coach 915 845
BOXN 1000 906
UIC 1000 860
BLC 840 780
Wheel Changing
Wheels to be paired within the diameters variation as below while changing thewheels. While tyre
turning, it should be ensured that variation on the same axleis within 0.5 mm For in service wheels the
variation on the same axle shall be guided by the tyre defect gauge

46
Type On the same bogie On the same coach
Coach MG 5 10
Coach BG 5 13
Wagons 13 25
Chapter 6
SEQUENCE OF
OPERATION
FLOW CHART OF SEQUENCE OPERATION

47
STEP BY STEP PROCESS
TABLE OF SEQUENCE OPERATION

SR.NO. Operation Remark
1 Switch on MAIN Electrical supply will reach up to

Isolator of machine voltage stabilizer
supply point.
2 Switch ON key Voltage stabilizer will switch on.

of voltage
stabilizer.
3 Switch ON main Main control panel of machine will get
MCCB of control onVFD ready indication will get on.
panel
4 Release Machine preparaton interlock will become

EMERGENCY push inready state.
button on
MOP,LH&RH
CONTROL
PANEL.
5 Press NC ON CNC and main display screen will turn on

green push button. andgreen indication lamp will glow.
6 Press and hold Hydraulic will turn ON and green indicationlamp

Machine will glow.
preparation green
push button on
MOP for 3
seconds
7 Press – at same time Any alarm present on display will get

and then pressalarm resetupon this.
reset key on MOP.

48
MACHINING OF COACH/WAGON WHEELSET WITH WHEEL

MEASUREMENT SYSTEM
SR. Operation Remark
NO
2 Press function key To open operator login

page
3 Choose name and press select function key To open ID PASSWORD
authentication page.
4 Enter appropriate ID and PASSWORD thenpress To open “MAIN” screen
login function
5 Press function key on main screen. To open wheel
measurement system
screen to operate the
function of wheel
measurement system for
LOCO and COACH.
6 Type wheel type number and press To select type of wheelset

INPUT. WHEEL TYPE NO: 3 and Drive roller pressure
TYPE OF WHEEL SET: INDU. for different
WHEELPRESSURE SET: 35 Bar wheel set automatically.
WHEEL TYPE NO
SELECTION:
1. CALIBRATION
2. COACH/WAGON
3. INDU. WHEEL
4. LOCO
7 Press function key on main WMS screen To navigate

COACH/WAGOAN
loading screen for
coach loading
operation.
8 Press function key on main To select coach loadingcycle
machine operation screen. program.

49
9 Press “AUTO”key on MOP Please conform for auto

mode selection on MOP
10 Press”CYCLE START”on MOP Automatically roller arm
bracket goes up a cycle will
stop and pendent
enable for ho
down function.
11 Press manually "HOLD DOWN UP FWD AND Check proper

pressurefor hold down.
DOWN" button on LH and pendent, then HOLD
DOWN RH hand O function key
12 Press cycle start on MOP Automatically jack
up,rail reverse and
lateral roller
forward activity
complete.
13 Press key onpendent.
14 Press function key. To navigate back to
COACH/WAGOAN PRE-
INSPECTION screen.
15 Press “start insp” function key. To select coach

pre inspection cycle
16 Press ”AUTO” key on MOP Please confirm for AUTO
mode selection cycle
17 Fix the magnet on wheel inside face. To sense the sensor in
wheel dia-measuring
system
18 Press "CYCLE START" On MOP. Cycle will start
for measurement.
19 Gradually rise speed 50% and FEED 70% Speed and feed reach
by selector knob on MOP. to program value
.machining operation will
get complete automatically
and tool slide withdraw to
home
position.

50
20 Enter coach/wagon/loco no. And wheel To enter coach/wagon/loco

set identification no in the entry window. no and wheel set
no.
21 Press calc function key on screen. Displayed data will

calculate for profile
depth of cut and
additional depth of cut
advice diameter
Calculation. Displayed data
will save to CF card
after pressing calculate.
22 Press function key on screen Report page will open. Here

operator can read saved data
from CF card.To read data
enter date,loco number and
wheel
number.
23 Press key on pendent.

24 Press ”CYCLE START”ON MOP. Advised profile
turning cycle will start.
26 Press function key. To navigate Next
to
COACH/WAGON
TURNING.
27 Press function key. To navigate next to
COACH/WAGON POST
INSPECTION.
28 Fix the magnet on wheel inside face. To sense sensor pulse

during wheel dia
measuring cycle.
29 Press function key. To select post inspection
cycle.
30 Press "AUTO" key on MOP. Please confirm for AUTO
mode selection on MOP.

51
31 Press "CYCLE START" On MOP. Diameter and profile

will indicate after
measurement.
33 Press soft key on screen. Measurement data

willsend to database
system, Display data
will send to CF card

35 Press key on pendent. To navigate next to
"COACH/WAGON
UNLOADING"
36 Press soft key on screen To select unloading
cycle.
37 Press "AUTO" key on MOP. Please confirm for AUTO
mode selection on MOP.
38 Press "CYCLE START” on MOP. Automatically lateral
reverse, rail forward,
activity complete then
cycle stopdue to
optional stop hold
down applicationon
axle bearing box.
39 Press ”HOLD DOWN OFF” function key Hold Down continuous

down command
will turned off.
40 Press manually "HOLD DOWN UP FWD AND Please use hanging
DOWN" button on LH and RH hand pendent pendent for hold
down
function at LH and
RH side.
41 Press "CYCLE START" On MOP. Automatically jack down
roller arm down active
42 Press key on pendent
43 Press WMS MAIN soft key on screen. To open WMS main
screen.

52
44 Repeat the sequence no.3,4,5 for the nextjob. To continue the next
wheel set.
Chapter 7
COMPARISION BETWEEN COVENTIONAL MACHINE AND CNCMACHINE
Convetional machine
1. Single operation
2. Secondary and tertiary machining operations
3. Different types of cutting and finishing tool
4. CAD model not required
5. Very high risk factor
6. Intricate features within the pattern cannot be built
7. Single pattern at a time 8. Generally solid pattern
CNC machine
1. Simultaneous operations
2. Secondary machining operation
3. Different types of cutting and finishing tools
4. CAD data required
5. High risk factor
6. Forming intricate features are limited
7. Single pattern at a time
8. Solid & hollow pattern
9. Forming intricate features are limited
10. Single pattern at a time
11. Solid & hollow pattern

53
Chapter 8
ADVANTAGES AND DIS-
Advantages ADVANTAGES
• Continuous Use: Unlike manual labor, CNC machinery (barring any malfunction or
maintenance issue) can work continuously over any periodof time without a break. This
greatly increases productivity and efficiency.
• Consistency, Precision and Redundancy: With computer software, the design of any given
product only needs to be programmed once. The CNCmachine can then perfectly replicate that
design, for any order quantity.
• Low Skill Requirement: CNC machine operators require little training andskill when
compared to manual machine operators.
• Fewer Personnel: Because computer software controls the machinery, fewer technicians are
needed for operation and oversight, cutting overallexpenses.
• Flexibility: The software can be reprogrammed quickly and easily toproduce different parts,
allowing operations to keep up with shifting customer demands.
• Capability: This technology uses computer precision to go beyond the limitations of manual
capabilities. More complex and intricate operationsare possible with CNC machining.
Disadvantages
• Cost: CNC machines are more expensive and require a greater initial investment than
machines that can be operated manually. However, as this technology becomes the standard.
supply is increasing resulting in costs gradually decreasing.
• Skills Loss: As the demand for manual machine operators decreases, fewer and fewer new
students adopt those skills. This could eventually lead to the complete loss of long-preserved
skills.
• Unemployment: Automation decreases the need for manpower, andfewer laborers are hired.
That said, the need is now shifting to software engineers and mechanical engineers, and
education and training will haveto adjust to meet that need. For more information on the skills
gap in themanufacturing industry.

54
Overall, the advantages of CNC machining far outweigh the disadvantages. As with the advent of any
new technology, we must anticipate shifts and adjustments to meet new challenges. This has never
been more true in the manufacturing industry, as automation and 3D printing continue to advance.
Mainstay Manufacturing boasts a wide range of CNC machining capabilities, including punching,
forming, turning and milling. For more information about our specific equipment and software.
CONCLUSION
• CNC machines which are applicable any type of processing.
• Manufacturing anything is identical in shorter time
• CNC machines provide many advantages
• Many industries prefer using CNC machines
• In the study of computer numerical control machines the productionimprovement can be

done more effectively and efficiently.
• The CNC programming is a way to operate CNC machine.
• CNC Lathe machine usage gives many benefits of increased productivity and accuracy and
time management but the only drawback is its cost.
• This could not be employed for all small jobs and is preferable to use in large amount of
production and complicated shapes.
• CNC Lathe machines are economical only for industrial purposes in largescale production
and is not suitable for small scale industries because of its high initial cost.
• What we can conclude from this report is we able to study the meaning of CNC which stands
for Computer Numerical Control. The computer has a very unique software unlike the
software in the normal computer because this software is specially designed for CNC
machine. The use of CNC machine is to produce an object that has a very complex design
like cars, components, accessories and many more.

55
REFERENCE
1. HYT engineering company Pvt. Ltd. Formerly known as HYT Engineering Corporation,
started its operation in 1977 with manufacturing of small drilling machines and lathe HYT
proudly holds 90% of the market share in India for the supply of CNC Surface Wheel & CNC
Under floorWheel Lathe.
2. South central railway zone, COACH DEPARTMENT OFFICE

3. H.C.W. de Vet “When to use agreement versus reliability measures” (2006) J. Clin. Epidemiol.
4. M. Asplund “Evaluating the measurement capability of a wheel profile measurement system by
using GR&R” (2016) Meas. J. Int. Meas. Confed.
5. A. Cavuto “Train wheel diagnostics by laser ultrasonics” (2016) Meas. J. Int. Meas. Confed.
6. X.X. Yuan “A nonlinear mixed-effects model for degradation data obtained from in-service
inspections” (2009) Reliab. Eng. Syst. Saf.
7. P.K. Choudhary “Semiparametric regression for assessing agreement using tolerance bands”
(2007) Comput. Stat. Data Anal.
8. P.K. Choudhary “A tolerance interval approach for assessment of agreement in method comparison
studies with repeated measurements” (2008) J. Stat. Plan. Inference
9. M.R. Dann “Stochastic corrosion growth modeling for pipelines using mass inspection data”
(2018) Reliab. Eng. Syst. Saf.
10.G. Pulcini “A perturbed gamma process with statistically dependent measurement errors” (2016)
Reliab. Eng. Syst. Saf.
11.J. Lin “Reliability analysis for preventive maintenance based on classical and Bayesian semi-
parametric degradation approaches using locomotive wheel-sets as a case study” (2015) Reliab.
Eng. Syst. Saf.
12.P. Urda “Wheel-rail contact force measurement using strain gauges and distance lasers on a scaled
railway vehicle” (2020) Mech. Syst. Signal Process.
13.Y. Huang “Fault diagnosis on railway vehicle bearing based on fast extended singular value
decomposition packet” (2020) Meas. J. Int. Meas. Confed.
14. N. Boss “Wheel flat detection algorithm for onboard diagnostic” (2018) Meas. J. Int. Meas. Confed.

56
15. A.R. Andrade “Assessing the potential cost savings of introducing the maintenance option of
‘Economic Tyre Turning’ in Great Britain railway wheel sets” (2017) Reliab. Eng. Syst. Saf.
16. Z. Chi “Data-driven approach to study the polygonization of high-speed railway train wheel-sets
using field data of China’s HSR train” (2020) Meas. J. Int. Meas. Confed.
17.A. Alemi “Condition monitoring approaches for the detection of railway wheel defects” (2017)
Proc. Inst. Mech. Eng. Part F J. Rail Rapid Transit.
18. S. Madanat “Optimal Inspection and Repair Policies for Infrastructure Facilities”
(1994) Transp. Sci.
Website
1. Http://www.hytwheellathes.com
2. Http://www.wikipedia.org/wiki/CNCUWL
3. Http://www.autodesk.com/products/autocad/free-trail

57

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CNC PIT WHEEL LATHE MACHINE

A Project report submitted in partial

Under the esteemed guidance of

Project Guide Head of the Department

Submitted for the viva-voice examination held on:

We A.RAM CHARAN, 21X05A0302, D.JYOTHENDRA PAVAN,

A.RAM CHARAN (21X05A0302)

NARSIMHA REDDY ENGINEERING COLLAGE Department of Mechanical Engineering

NARSIMHA REDDY ENGINEERING COLLAGE Department of Mechanical Engineering

1.2 TYPES OF CNC MACHINE 4

1.2.3 CNC PORTAL WHEEL LATHE (YPL-01) 7

1.2.4 CNC TANDAM UNDERFLOOR WHEEL LATHE(YUL-12T) 8

2 CNC NEW GENERATION UNDER FLOOR WHEEL LATHE 9

2.1 TECHNICAL INFORMATION 10

3.1 COMPONENTS OF CNC UNDER FLOOR WHEEL LATHEMACHINE 12

3.1.3 HOLD DOWN EQUIPMENT 15

NARSIMHA REDDY ENGINEERING COLLAGE Department of Mechanical Engineering

AUTOMATIC CONVEYOR CHIP DISPOSAL SYSTEM 23

TYRE DEFECT GAUGE 26

DETAILS OF WHEEL SET 29

WHEEL DIAMETER ON TREAD 32

HEAT CHECKS 5.3.6 DISC CRACK 38

365.3.7 LOOSE AXLE 39

WHEEL TREAD DIAMETER 41

DIAMETER OF WHEEL USING ON BG STOCK WITH

STEP SIZE OF WORN WHEEL PROFILE 43

NARSIMHA REDDY ENGINEERING COLLAGE Department of Mechanical Engineering

FLOW CHART OF SEQUENCE OPERATION 48

TABLE OF SEQUENCE OPERATION 49

MACHINING OF COACH/WAGON WHEELSET WITH WHEEL SET 50

7 COMPARISION BETWEEN CONVENTIONAL MACHINE AND CNC MACHINE 51

8 ADVANTAGES AND DISADVANTAGES 52

NARSIMHA REDDY ENGINEERING COLLAGE Department of Mechanical Engineering

Fig (i) CNC MACHINES USED TO BE AS BIG SIZE OF ROOM 3

Fig (ii) PARTS OF A CNC LATHE MACHINE 3

Fig (iii) CNC SURFACE WHEEL LATHE 5

Fig (iv) CNC UNDER FLOOR WHEEL LATHE 5

Fig (v) CNC PORTAL WHEEL LATHE 6

Fig (vi) CNC UNDER FLOOR WHEEL LATHE MACHINE 7

Fig (vii) CNC UNDER FLOOR WHEEL LATHE ASSEMBLY 10

Fig (viii) COLUMN 11

Fig (ix) DRIVER ROLLER 12

Fig (x) HOLD DOWN EQUIPMENT 13

Fig (xi) AXLE BOX SUPPORT JACK

Fig (xii) CNC PROFILE MACHINING SYSTEM 14

Fig (xiii) SERVO MOTOR 15

Fig (xiv) MEASURING UINT 15

Fig (xv) MEASURING PROBE OF THICKNESS 16

Fig (xvi) MEASURING PROBE OF DIAMETER 17

Fig (xvii) RAIL SYSTEM 18

Fig (xviii) HYDRAULICS PORTAL 19

Fig (xix) OIL LEVEL INDICATOR 19

Fig (xx) OIL LEVEL GAUGE 19

NARSIMHA REDDY ENGINEERING COLLAGE Department of Mechanical Engineering

Fig (xxii) CNC CONTROLED MONITOR 20

Fig (xxiii) CHIP CONVEYOR SYSTEM 21

Fig (xxiv) DIMENTION OF CUTTING TOOL 22

Fig (xxv) CUTTING OPERATION 22

Fig (xxvi) BEFORE AND AFTER OPERATION 22