How are railway axleboxes manufactured? A case study of PGO S.A. Odlewnia Żeliwa in Śrem

What is a railway axlebox?

A railway axlebox is an element of the axlebox assembly used in rail vehicles. In practice, it serves as a rolling bearing housing that connects the wheelset with the bogie of a wagon or another rail vehicle. A complete axlebox assembly consists of an axlebox housing, axlebox cover, retaining ring, axlebox cover gasket and screws securing the cover.

It is a safety-critical component. It operates in a demanding environment, which means that its production requires proper material selection and precise control at each stage of the manufacturing process.

Why are railway axleboxes a good example of the capabilities of Odlewnia Żeliwa Śrem?

An axlebox requires a combination of technological and quality-related expertise. In the case of the axlebox housing and cover, the casting geometry, cast iron quality, dimensional repeatability, compliance with documentation and the ability to deliver the component after machining are all highly important.

PGO S.A. Odlewnia Żeliwa, Śrem Plant, specialises in the production of iron castings made of white, grey, ductile and alloy cast iron. The plant has the facilities required to manufacture raw castings, pre-machined castings and fully machined castings. In railway projects, expertise in testing, acceptance documentation and process supervision is also particularly important.

What does the production process of an axlebox housing and cover look like?

Development of casting technology

The technology for manufacturing axlebox housings and covers is prepared using Siemens NX software and MAGMASoft casting process simulations. The simulations include, among others, the pouring and solidification of molten metal, supporting the selection of appropriate technological solutions before production begins.

Pattern tooling / Moulding sands / Cores

Pattern tooling is produced using traditional machining equipment. Depending on the project requirements, metal patterns or patterns made from polyurethane boards may be used. Casting moulds are produced in bentonite sand, while cores can be made using cold-box technology or manual core boxes.

Melting, composition control and pouring

Molten cast iron is prepared to achieve a chemical composition compliant with the requirements of the PN-EN 1563 standard. Once the required parameters have been achieved, the metal is transferred to a ladle, subjected to spheroidisation and then directed to the mould pouring process.

Knockout / Cleaning / Finishing of castings

After a defined period of time, the castings are knocked out of the moulds, initially cleaned by shot blasting and then stripped of gating systems and feeders. The next stages include grinding, removal of sharp edges and surface preparation in accordance with the documentation requirements.

Machining and dimensional inspection

The parts are machined while maintaining the required dimensions, tolerances, surface roughness and shape. In Śrem, both rough and finish machining of castings are performed, enabling the delivery of components in a condition compliant with the order requirements.

Structural welding and quality acceptance

For components requiring welding, the process is carried out in accordance with the requirements of the PN-EN 15085 series of standards. Quality acceptance includes testing, measurements and documents confirming the product’s compliance with the order requirements.

Painting of axleboxes

After welding and quality acceptance, axleboxes go through the stage of surface preparation and paint coating application. Surfaces intended for painting are cleaned and degreased, and then verified in terms of the required substrate preparation, including preparation grade St2 according to PN-EN ISO 12944-4. Before application, areas that must not be coated with paint according to the documentation are protected, while the process itself is carried out under controlled temperature and humidity conditions.

What technological facilities support the production of iron castings in Śrem?

PGO S.A. Odlewnia Żeliwa in Śrem has facilities covering a pattern shop, moulding lines, machining and a testing laboratory. The plant has, among others, an automatic moulding line, a semi-automatic moulding line and hand moulding stations for larger and more complex castings.

The production process is also supported by inspection and measurement tools, including a 3D scanner and a Wenzel CMM coordinate measuring machine. The laboratory in Śrem holds Polish Centre for Accreditation certificate No. AB 040 and conducts tests including chemical analysis, metallography, mechanical testing and non-destructive testing.

How does IRIS support projects for the railway industry?

The railway industry requires particular process discipline and consistent quality management throughout the entire production cycle.

PGO S.A. Odlewnia Żeliwa, Śrem Plant, holds IRIS / ISO 22163 certification. This is an important signal for partners from the rail sector, as it confirms the operation of a quality management system adapted to the requirements of the railway industry. This is complemented by ISO 9001, ISO 14001, PKP Cargo approval and welding-related certifications according to PN-EN 15085 and PN-EN ISO 3834.

What does the customer gain by choosing PGO S.A. Odlewnia Żeliwa Śrem?

The customer receives support from a partner that combines foundry experience, technological facilities and quality control.

Thanks to this, PGO S.A. Odlewnia Żeliwa, Śrem Plant, can support manufacturers and suppliers from the railway industry in projects requiring high-strength iron castings.

Iron castings for the railway industry? Let’s talk about your project.

A railway axlebox shows how many stages are involved in the production of a finished component. Each of them affects the final result.

If you are looking for a partner in the production of iron castings for the railway industry, contact our sales department.