Industry Applications
Application
Case Details
Train wheel machining
Railway axles must meet the highest quality standards to ensure the utmost operational reliability. However, operating over thousands of miles on the most diverse track conditions while carrying heavy loads places immense stress on the wheels, resulting in equally extreme wear rates. The service life of the wheels depends largely on high-quality manufacturing and regular maintenance.
Arrowstone is a trusted partner to customers in the railway and rolling-stock industries. Close collaboration with manufacturers of axle-processed components and machine tools enables Arrowstone to enhance its expertise and develop high-performance cutting-tool solutions that deliver optimal performance. As a result, Arrowstone’s high-quality cutting-material solutions and tools for turning, drilling, and milling are synonymous with superior quality and machining reliability. Arrowstone offers numerous efficient solutions for railway running gear, heavy-pipe machining, and the energy sector. The following outlines Arrowstone’s solutions for railway axles:
Requirements for Axle Machining
In locomotives, the axle rigidly connects the two wheels. During daily operation, it is subjected to substantial stresses—bending and torsional—and significant loads—namely, the vehicle’s weight. Consequently, axle manufacturing is subject to extremely stringent requirements to ensure high quality and superior safety. Corresponding standards govern the axle’s structure, design, manufacturing processes, and quality control.
Machining of forged steel materials requires high-quality cutting tools and cutting inserts. These tools and inserts must deliver maximum machining reliability while maintaining excellent cost-effectiveness. Choose the ArrowStone tooling system—your experienced, trusted partner for axle machining.
In axle machining, ArrowStone offers a wide range of standard inserts, along with a variety of chip-breaker geometries and cutting grades.
Materials for axle machining
Axles are typically made from special tempered steel, with steel grades ranging from A1 to A5. The following table lists the detailed chemical composition and mechanical properties:
| Material Naming | C |
Yes |
Mn | P | S | Chemical composition [%] Cr |
Cu | Me | We |
V |
(Cr+Mo +Ni) |
Heat treatment method | Mechanical Tensile strength R [N/mm²] |
Performance Brinell hardness [HB] |
||
| A1 EA1T A2 |
0.42 0.22 |
0.40 0.40 |
70 | 45 | 45 | 40 | One | 10 | 40 | 63 | T N |
550 550-700 |
163-208 | |||
| 120 | 25 | 30 | 45 | 25 | 15 | 15 | 10 | One | N | 510-620 | 152-184 | |||||
| A3 | 50 | 40 | 70 | 0.045 | 45 | 40 | 10 | 10 | 40 | 63 | T N |
620-770 600-750 |
184-228 | |||
| A4/ EA4T |
25 | 25 | 80 | 20 | 15 | 12 | One | 20 | 30 | One | T | 650-800 | 193-238 | |||
| A5 | 25 | 25 | 70 | 20 | 15 | 100 | One | 20 | 30 | One | T | 730-880 | 216-261 |
N=Tempering
T=Heat Treatment
DIN Material Naming
| Material Naming | Standard designation (DIN |
| A1/EA1T | C35 |
| A2 | 22MnCrV5 |
| A3 | C45 |
| A4/EA4T | 25CrMo4 |
| A5 | 42CrMo4 |
Axle Machining – Machining Steps
Axle machining involves multiple processing steps. First, the two ends of the forged bar stock must be milled flat; both ends of the axle are machined, and a hole is drilled in the front end face. Next, the outer diameter is roughly machined on the lathe to meet specified dimensional requirements.
Axle Machining Case
Arrowstone Indexable Insert 1
Example of rough turning application:
Component: Train Axle
Material: 25CrMo4
Machine tool: lathe
Cutting parameters ：
Cutting speed: 160 m/min
f: 1.1 mm/rev
AP: 3–6 mm
Cooling: Emulsification
Arrowstone Indexable Insert 2
Example of finish turning application:
Component: Train Axle
Material: 25CrMo4
Machine tool: lathe
Cutting parameters:
VC: 220 m/min
f: 0.5 mm/rev
ap: 1 mm
Cooling: Emulsification
| Cutting parameters | Competitor | Belemnite |
| vc (m/mi (minimum) | 160 | 160 |
| f (mm/rev) | 0.8 | 0.8 |
| AP (millimeters) | 6 | 6 |
| Tool life | 35 | 48 |
Arrow Through Stone specializes in delivering high-efficiency machining solutions for heavy industry, with particular strengths in railway bogie components, heavy-duty pipeline fabrication, and the energy sector. By seamlessly integrating technological innovation with practical application, Arrow Through Stone has developed efficient transportation solutions across multiple industries. For industry case studies or technical solutions, please contact Arrow Through Stone.
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