DOCUMENTS

A Broad Systems Approach to the Design of an Improved Cast-Steel Car Wheel

The steel wheel for a freight car has three basic functions;

1. to act as a brake drum
2. to support the weight of the car and its cargo
3. to guide the freight car on the rails

Freight car wheel are produced by either casting or rotary forging. They are subjected to complex conditions of dynamic thermal and mechanical stresses. Safety is of great importance, since derailment can cause loss of life and property. Develop a broad systems approach to the design of an improved cast-steel car wheel.

INTRODUCTION

A wheel of various types has existed for centuries. King Solomon had 1400 war chariots equipped with metal (bronze) wheels, and in the centuries that followed, the various half – civilized nation of the earth had carts and other types of vehicle equipped with crude wheels, mostly fashioned of wood either crossed section of large tree trunks, or slabs of wood laid cross wise and joined together with the ends shaped in cylindrical form.

As wheel of other invention, there was little progress until the 19^th centuries, when huge strides where made. With the invention of the steam locomotive as a propelling force, it instantly became necessary to have new type of wheels that woods withstand the stresses of much greater speed and heavier loads.

The great success of the steam locomotive was made possible only by the ultimate invention of a flanged wheel to run on smooth tracks. Engineer and inventers, after several years of test and experiments, finally evolved the present type of car wheel made solid of cast metal as flanged. As it is used one of smooth track, it meets requirements very satisfactorily.

PROBLEM

A complex condition happened of dynamic thermal and mechanical stresses.

OVERCOME

Safety is important, since derailment can cause loss of life and property.

PURPOSE

Extended service life of freight car and improved dynamic performance of freight cars.

IMPORTANCE OF THE TECHNOLOGY

Replacing the standard friction assemblies with new, more durable once and introducing new devices into the construction to improve dynamic freight car performance. 

IMPROVEMENTS

 1. The uniform casting design system capable of containing details information of in the design process for product, devolve from its ability to realize casting know how as a valuable asset.

2.   Change the material from steel to alloy or cast-iron.

-  Weight - lighter so the lighter wheel

-   Better performance   – more agile

                                   - Better handling

                                    -More fuel efficiency

-  Strength – improved because it coated with magnesium
   -Magnesium has strong chemical and ionic bonding that   can stand any resistance

-   Heat dissipation for alloy is better than steel.

      - Its slight braking improvement (less heat near break)

      - Tough 

3.   Improve air pneumatic system  improvements in all areas.
    - imperative of having rail grinding, lubrication arrangements, top of rail friction modifiers, hot box detectors, track side bogie to ease the maintenance repair.

4.  Add concurrent systems : A systems approach requires concurrent monitoring systems and other safe guards.

ADVANTAGES

1.      Freight car is possible both for car in services and for new cars.

DISADVANTAGES

1.      The higher cost of the material compared to steel.