BEGINI TAHAPAN PROSES PEMBUATAN RODA KERETA API DI PABRIK MODERN

Summary

The video explores the fascinating process of manufacturing railway wheels. It starts with the melting of recycled steel in an electric furnace at 1600°C, followed by casting into large cylindrical molds. The wheels undergo several stages: cleaning, pressing into rough shapes, expanding in diameter, and adding a hub for the axle. After heat treatment and cooling, the wheels are finished and inspected. They are then paired with axles, lubricated, and assembled, ready for installation on train carriages. The entire process highlights the precision and durability required to produce railway wheels that withstand significant wear.

Takeaways

• 😀 The train wheels are made of steel and have an oval shape, not a perfect round form, which helps them navigate curves smoothly.
• 😀 Unlike rubber wheels, steel train wheels cannot go flat, but they do wear out over time due to usage, requiring regular production.
• 😀 The process of making steel train wheels starts at a melting furnace, where recycled steel is heated to around 1600°C.
• 😀 Large molten steel is transferred into cylindrical molds, which can be up to 6 meters long and later split to make wheels.
• 😀 Each wheel mold weighs approximately 450 kg, and the next step involves heating it to about 1300°C in a rotary furnace.
• 😀 High-pressure water is used to clean the outer layer of the steel, removing impurities before further processing.
• 😀 A press machine then shapes the steel wheel, applying 9,000 tons of pressure to form a rough wheel shape with a 76 cm diameter.
• 😀 The wheel is further processed to increase its diameter to 91 cm and its width by 20% using specialized machinery.
• 😀 After heat treatment, the wheel undergoes cooling through water spraying to harden the steel.
• 😀 The final wheel is inspected, labeled, and ready for assembly, with a worker attaching the wheel to the axle using lubrication, bearings, and fasteners.

Q & A

What is the importance of the steel wheels in trains?

Steel wheels are crucial for trains as they provide the necessary durability and strength to handle the high demands of movement on railways. They are designed to be slightly elliptical in shape, which helps the train navigate curves smoothly.

Why do train wheels have an elliptical shape instead of a perfect circle?

The elliptical shape of train wheels allows them to turn more easily on curved tracks. This design helps in maintaining smoother transitions when the train moves through bends on the rail.

Can train wheels deflate like rubber tires?

No, train wheels do not deflate like rubber tires. Instead, they undergo wear over time due to constant use. However, unlike rubber tires, they maintain their structural integrity for much longer.

How are train wheels produced?

Train wheels are produced through a multi-step process, starting with melting recycled steel in an electric furnace at temperatures around 1600°C. The liquid steel is poured into cylindrical molds and then undergoes several stages of shaping, pressing, and heat treatment to form the final wheel.

What is the role of the high-pressure water in the manufacturing process?

The high-pressure water is used to clean the surface of the steel, removing any outer metal layer and ensuring a smooth and clean surface for further processing.

How does the press machine shape the steel into a rough wheel?

The press machine applies a pressure of 9,000 tons to the molten steel, shaping it into a rough wheel. This process significantly alters the material's structure and begins the formation of the final wheel shape.

What happens after the rough wheel is shaped?

After the wheel is shaped, it undergoes further refinement. The diameter of the wheel is expanded to 91 cm, and additional shaping processes are performed to ensure it meets the necessary specifications.

Why is heat treatment used during the manufacturing of train wheels?

Heat treatment is applied to harden the steel, increasing its durability. The wheels are sprayed with water to cool them down, which enhances their strength and prepares them for installation on trains.

How are train wheels assembled onto the axles?

Once the wheels are completed, they are mounted onto the axles. A worker lubricates the axles and attaches bearings before securing the wheel onto each axle using bolts. The assembly is then tightened using a torque wrench.

What happens after the wheels are assembled on the axles?

After the wheels are securely assembled onto the axles, the completed units are moved from the assembly line and are ready to be installed under train carriages for use in actual operations.