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Machining
The machining capabilities of Bochumer Verein encompass a multitude of advanced facilities so as to provide the high dimensional accuracy required for railway wheels and wheelsets. The range of machining activities is extensive and includes fabricating rough-forged monobloc wheels to precise dimensions. Despite the complicated wheel geometries as well as wheel dimensions that include a diameter of 1,400 mm, tolerances within a hundredth of a millimetre are required.
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Machining centres
On the CNC machining centres, monobloc wheels can be turned, drilled and milled in a work-fixture, for which purpose two supports, each fitted with 12 tools, are available. The centres are equipped with two face plates to accommodate wheels with a maximum diameter of 1,400 mm, enabling one monobloc wheel to be machined while another is being prepared for machining.
Vertical turning machines
Vertical turning machines are used for the machining of large series. These units enable the simultaneous utilisation of two tools, thereby achieving a high metal removal rate.
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Hub precision-boring machine
Once the monobloc wheel has been given its geometry on a machining centre, the hub is precision-bored in a follow-on production step. The machines used for this purpose achieves a hub bore with a tolerance of two-hundredths of a millimetre.
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Ultrasonic testing system
To ensure that the machined monobloc wheel does not have any material flaws, it is tested ultrasonically in a fully automatic system. The monobloc wheel is then coated in the requisite colour and can be installed in a wheelset or shipped as an individual monobloc wheel.
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Wheel mounting press
The finish-machined components – axle, brake disks, gears and wheels – are mounted, using a press, to form a complete wheelset.
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