Best technology
Our enterprises concentrate the most advanced technologies, well proven in Russia and abroad.
High quality of castings at RM Rail VKM-Steel plant is provided by HWS-Sinto automatic vacuum-film molding line. The technology runs on dry sand without adding any binders, which reduces the amount of mixture waste and lowers the cost of castings. Additionally, this process gives lower product surface roughness (≈100 μm) and prevents hot cracking. The line is fully automatic, and its maximum productivity is 10 molds per hour.
Through the use of LAEMPE core shooters, we are able to produce complex-shaped cold-box-amine cores of 120 kg max. weight. They have the required strength, minimal friability and excellent surface quality. The castings are free from any gas- or sand-related defects.
Optimal heat treatment conditions are provided by a special-purpose gas-fired industrial continuous furnace of ThermoGas LO series designed for continuous normalizing and annealing of railway castings. Through strict adherence to operating practices, we obtain castings with the best mechanical properties that meet GOST requirements. This is another secret of our large rail car castings’ quality.
There are modern AC electric arc steelmaking furnace of 16 tons capacity manufactured by Thermomelt (Italy) and a shot blasting machine by Stem (Slovenia). The steelmaking furnace is equipped with an automatic ferroalloy dosing system, which eliminates manual interventions by the furnace operators and improves the accuracy of the molten metal chemical composition in alloying elements content. The furnace uses low-maintenance water-cooled roof helping to reduce refractory materials consumption. Through higher transformer power and oxygen/carbon injection system, duration of heat is shortened by 30-40%. A new generation shot blasting machine significantly improves shot blasting quality.
At Ruzkhimmash, metal cutting, including that of thin sheet and non-ferrous metal, is made on a TRUMPF 3040 laser cutting machine. It is capable of processing metal sheets of up to 4000x2000 mm size and 18 mm maximum thickness.
The plant operates KOIKE gantry CNC plasma cutting machine for the processing and cutting of sheet metal, including non-ferrous metal, such as aluminum and high-carbon (stainless) steel. The advantage of the machine is that it gives the perfect cut quality on bevels and full compliance with the required dimensions.
ALIKO hydraulic press brake gives precise bending regardless of product position and length. The plant is equipped with two presses of this type, which ensure uninterrupted round-the-clock manufacture of various parts from flat rolled sheet and strip by cold bending.
Double action hydraulic sheet stamping press (P4644) is a unique piece of equipment with maximal single action force of 4000 tf. It is intended for drawing of hot and cold formed parts in making ellipsoidal heads and is also used for sizing and bending of sheet metal blanks.
Our VABS welding and assembly portal is a one-of-a-kind advanced machine, exclusively represented in Ruzkhimmash machinery pool. Due to its versatility, it can be used for production of both 40ft and 80ft flat cars. Through the use of air clamps, the required parameters are available in a wide range. The technology is capable of working with variable section parts up to 26 m long, which provides enhanced quality and reliability of equipment during operation.
Technological complex Pilot for figural cutting of rolled metal from low-carbon, high-carbon steels and their alloys, non-ferrous metals and aluminum. The modern development of today’s machine tool builders is equipped with 10 cutters at once, which increase manufacturing accuracy and cutting speed.
Termostal roller hearth furnace (NB 1431; NV 5222) is intended for heat treatment (heating for quenching, annealing) of large products, including tank car barrels. Roller hearth reduces the time for product loading/unloading and makes the heat treatment process automatic. Having dimensions of 20000x5000 mm, the furnace processes vessels with a maximum diameter of 3400 mm at a maximum heating temperature of 900°С. Five-sided heating provides very good temperature uniformity in the furnace chamber.
Products are pre-finished for painting in a mechanical/pneumatic shot blasting chamber. Here, before cladding, bonding, electroplating and metal spraying, rail cars are cleaned from paint, rust, scale to obtain perfect surface finish.
Spray/cure paint booth has five painting and curing modes. This helps to achieve a better quality coating and shorter curing time: natural drying of a rail car takes 4-6 hours, whereas it takes only one hour at a temperature of 60°C in the cure booth.
