ISCAR'S MACHINING SOLUTIONS FOR THE

RAILWAY INDUSTRYw w w.isc a r.c om

Railway Industry

ISCAR'S Solutions for
the Railway Industry
The railway industry has played an importantrole in the past two decades becoming one of
the leading means of transportation for freightand passengers. Ongoing investments in modern
railway track infrastructure has opened a newedge to high-speed transportation mobility.
In addition, the environmental advantages offeredin railway transportation is expanding railway
traffic awareness. To keep up with the growing
demands in this heavy metalworking industry,
ISCAR has developed special machining expertisefor railway components with innovative cutting
tools and robust carbide grades.

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ISCAR

Reduced Highway Congestion

Fuel Efficiency

Fewer Emissions

Diesel Locomotive (~200 Km/Hr.)

High Speed Train (~380 Km/Hr. )Electric Train

Heavy Cargo Freight Train

Underground Train

Inner City Light Rail

3

Railway Infrastucture
Typical Rail Profiles
For inner city, long range cargo and passenger infrastructures

AS22

AS22

AS31

AS31

AS60

AS60

AS68

AS68

AS41

AS41

ZU - 160

ZU - 160

For switchers and crossing asymmetric rails

UIC33

UIC33

UIC54

UIC54

ISCAR

AS47

91LB

91LB

AS53

AS50

AS53

AS50

NZ50

NZ50

Tram rails

UIC60

UIC60

European Standard
Size: 60E1(UIC60), 55E1, 54E1(UIC54), 50E1, 49E1(S49), 50E2,
46E2(UC33), 54E2(UIC54E), 50E4, 50E6(U50), 56E1
American Standard
Size: 100RE, 115RE, 136RE, 90RA
Australian Standard
Size: 50kg, 53kg, 60kg, 66kg, 68kg, 73kg, 86kg, 89kg
British Standard
Size: 113A, 100A, 90A, 80A, 75A, 70A, 60A
Indian Standard
Size: 50, 60, 70, 80, 100, 120
Japanese Standard
Size: 22kg, 30kg, 37A, 50n, CR73

4

AS47

T62

Types of Railway Switchers and Separators

CrossoverSwitch DiamondThree-Way Switch

5

Switchers - Connecting Links UIC54

Shoulder Milling

ISCAR offers a standard line of cutters with different

1approach angels ranging from 22º up to 75º.

The connecting link blades are the running rails
placed alongside the switch rails when in theclosed position. They are designed with different
profiles and moles to fit rail configurations. The
connection link is usually manufactured frommanganese steel and the production operation
includes various types of profile milling.
Shoulder Milling

Range: Ø20 - 125 mm
T490 extended flute cutters withrigidly clamped tangential four cutting
edged inserts for machining side track
profiles, switchers and separators.

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4
3

1

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3

4

XFCW 13...

XFCW 13...

Shoulder Milling

Shoulder Milling

Shoulder Milling

Special T472 tapered extended flute
cutters with rigidly clamped tangential
four cutting edged inserts formachining top tapered track profiles,
switchers and separators.
ISCAR offers a standard line of
cutters with different approachangels ranging from 22º up to 75º.

Special concave profile extended
flute cutters with rigidly
clamped tangential inserts formachining top radius profiles,
switchers and separators.

Special concave profile extended
flute cutters with rigidly
clamped tangential inserts formachining top radius profiles,
switchers and separators.

7

Connecting Links

1

SNHT 16...

Rough Milling

SNHX 16...

Special face mount web slotting
cutters for machining steel
crossings and transition rails
made of alloy manganese. The
cutter’s positive rake cutting
action dramatically reduces
forces and improves toolconsistency in difficult-to-clamp
rail shapes while providing asmooth cut and eliminating
hard finishing applications.

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Connecting Links UIC33

1

Drilling

Range: Ø12 - 80 mm
Drills with spiral coolant channels
and a strong cutter body withexcellent resistance to torsion andvery efficient chip evacuation.

2

Shoulder Milling

Range: Ø20 - 125 mm
T490 extended flute cutters withrigidly clamped tangential inserts formachining switchers and separators.

The UIC33 rail is a common part which
is produced to keep the wheel in correctalignment when approaching a switch.

2

1

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Switchers - Connecting Links

Tangential Cutters

Switcher/Separator Milling

Special concave profile extended flute cutters with rigidly
clamped tangential inserts positioned on an angular spindle
axis for smooth machining of switchers and separators.

Special spherical extended flute cutters withrigidly clamped tangential inserts for machining
switchers and separator shoulders. Their uniquedesign, with a combination of left and right flutes,
assures minimum vibrations and smooth cutting.

XFCW 1307...R130

SNHT 1205...R10.0*2 cutting edges.

SNHT 1205...R13.0
SNHT 1205...R15.0
SNHT 1205...R20.0*4 cutting edges.

SNHT 1608...R13
SNHT 1608...R16*4 cutting edges.

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ISCAR

XFCW...13

XFCW...13

Shoulder Milling

Tapered Switcher Blade Machining

Special concave profile extended flute cutterswith tangential inserts for switcher profiling.

Specially tapered extended flute cutters withhelical flutes for high metal chip removal andrigidly clamped tangential inserts for machining top
tapered track profiles, switchers and separators.

SNHX 1608...

LNAT 1306...R15.0*4R.H.+4L.H. cutting edges.

*2 cutting edges.

SNHX 160812...

SNHX 1608...R100

SNHX 160820...

SNHX 1608...R140*2R.H.+2L.H. cutting edges.

SNHX 1608...R200*2 cutting edges.

SNHX 1608...R05
SNHX 1608...R07
SNHX 1608...R10*2R.H.+2L.H. cutting edges.

11Connecting Links

Slitting

Range: Ø100 - 160 mm
Indexable slotting cutters with tangentially mounted
inserts and a unique clamping design for durable parting.

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ISCAR

Drilling

Range: Ø12 - 80 mm
Drills with spiral coolant channels and a strong
cutter body with excellent resistance to torsion
and very efficient chip evacuation.

1

2

Shoulder Milling

Shoulder Milling

Special profile extended flute cutters with rigidly clamped
tangential inserts for machining switchers and separators.

Special profile extended flute cutters with rigidly clamped
tangential inserts for machining switchers and separators.

2

1

13

Connecting Link Type E61

The connecting link blades are the running rails placed alongside
the switch rails when in the closed position. They are designed withdifferent profiles and moles to fit rail configurations. The connection
link is usually manufactured from manganese steel and the
production operation includes various types of profile milling.

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2

3

4

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ISCAR

1

OPTION 1

2

OPTION 2

Face Milling Rail
Base Section

2

Milling Rail Head Section

3

Milling Rail Head Section

4

Milling Web Section

Milling Base Section

15

Switchers

1

2

Shoulder Milling

Shoulder Milling

Special T490 extended milling cutters with rigidly
clamped tangential four cutting edged inserts formachining switchers and separator shoulders.

Special or concave profile extended flute cutters with
tangentially clamped inserts for machining top andbottom filter track profiles, switchers and separators.

The switcher, also known as the frog, refers to the crossing
point of two rails. This can be assembled by several
appropriately cut and bent pieces of rail or can be a single
casting of alloy manganese steel. ISCAR offers a wide rangeof standard and specially designed mills and drills for the
production of switchers.

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4

Shoulder Milling

Shoulder Milling

Special T479 tapered extended flute cutters with
tangentially clamped inserts for machining switchersand separators and semi-finishing operations.

Special T414 tapered cutters with tangentiallyclamped inserts for machining top and bottom
track profiles, switchers and separators.

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2
3

4

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Switchers

12

Face Milling

Range: Ø50 - 315 mm
45° face milling cutters carrying
square or octagonal double-sided
inserts with 8 and 16 cuttingedges for roughing operationsat an 8 mm depth of cut.

Deep Shouldering (Contour)
Special T479 full profile cuttersfor machining switchers andsemi-finishing operations.

1

2

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ISCAR

Slide Plate

1

2

Slot Milling

Range: Ø25 - 100 mm
H490 is an extended flute cutter
characterized by radially clamped
double-sided rectangular insertswith 4 helical cutting edges
available in 09 /12 /17 mm sizes.

1

3

Profile Slot Milling

Profile Slot Milling

Special tangential slot milling
cutters for machining profile
slots and grooves on rail
track connecting links.

Special tangential slot milling
cutters for machining profile
slots and grooves on sideplates and connecting links.

2
3

A slide plate, base plate, or sole plate is
typically manufactured from cast steel or steel.
The slide plate increases the bearing area and holds
the rail to a correct gauge. They are fastened towooden or concrete ties by means of spikes or bolts
through holes in the plate. The slide plate is used onrail tracks between the flanged T-rail and crossties.

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New Wheel Production

Special CAMFIX holders
with a screw and top lever
for roughing and finishingboring operations.

Round inserts and special
CAMFIX holders with ascrew and top lever forrobust clamping.

SNMM19125-R4P

SNMM19125-NR

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2

5

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ISCAR

1

Roughing
Application

2

3

Finishing Application

4

Finishing Application

5

Rough Rim Turning

Roughing and Finshing Combi-Bore

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New Wheels Turning

Round Inserts

For Roughing and Finishing Operations and Machining Rim and Web Areas

RCMT 1204MO-M3P-R
Screw clamped Insert

RCMT 16-14 (MO)Screw clamped Insert

RCMT 20-14 (MO)Screw clamped Insert

RCMT 20-M3P-R (00)Lever clamped Insert

RCMT 25-SR (MO)Screw clamped Insert

RCMX 25-NR (00)Lever clamped Insert

RCMX 32-NR (MO)Screw Clamped Insert

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ISCAR

RCMX 32-M3P-R (00)Lever clamped Insert

RCMT 16-M3P-R (MO)Screw clamped Insert

RCMX 25-M3P-R (00)Lever clamped Insert

RCMX 32-R3P-R (00)Lever clamped Insert

RCMT 16-SR (MO)Screw clamped Insert

Area

Vc

f

A

70 - 200 m/min

0.5 - 2.0 mm/rev

B

50 - 100 m/min

0.5 - 1.5 mm/rev

ap
12
10

14 / SR /M3P-R (16)0.3 - 3.5 mm

14 / M3P-R (20)

1.5 - 7.0 mm

8NR / M3P-R (25)

2.5 - 7.0 mm

6NR / M3P-R/R3P-R (32)

3.0 - 12 mm

4

NR/M3P-R (25)Depth of cut according to M3P-R(12) chipbreaker geometry:

M3P-R (12)14/SR/M3P-R (16)14/M3P-R (20)mm

NR/M3P-R/R3P-R (32)Cutting data by area:

Material: Alloy steel
Cutting speed: Vc=50-200 m/min

2

In case of worn wheels with skid flats, built-up
shelled tread or thermal cracks, reduce the cutting
speed to ISCAR’s recommended minimum machining speed.
High carbon wheels should be machined at ISCAR’s
recommended low range cutting speed. Feeds
should be optimized within the recommended range
per chipformer and actual chip formation.

Wheels steel requirements according to
UIC812-3 and EN 13262

0
0

0.5

1.0

1.5

f mm/rev

2.0

B

A

Wheels material

The majority of wheel types (95%) are made of rolled
steel, while other types are made of cast steel material
standards in hardnesses which range from ER1 to ER9.
Five steel categories, ER6, ER7, ER8, ERS8 and ER9 aredefined as common types. This standard can also apply
to light rail and tramway applications.

Very High

Precision
Level

High Speed Train (~380 Km/Hr. )Electric Train

Wheel Dimensions

Different types of trains have different wheels.
The wheel diameters range between 400 – 1200 mm:• Metro: 400 – 650 mm• Heavy Cargo / Freight: 800 to 900 mm• High speed: 900 to 1200 mm

High

Inner City Light Rail
Heavy Cargo Freight Train

ER6

ER7

ER8

Soft

Steel Category
UIC 812-3

EN 13262

ER9

Steel
Category

Hard

CarbonContent (%)

Yield
Strength(N/mm2)TensileStrength(N/mm2)Elongation(%)

UIC/ENEN 13262

UIC/ENUIC/EN

Notch Impact Energy
UIC 812-3
U-notch (RT)EN 13262
V-notch (-20˚C)

R6 T, E

ER6

≤0.48

≥500

780...900

≥15

≥15

≥12

R7 T, E

ER7

≤0.52

≥520

820...940

≥14

≥15

≥10

R8 T, E

ER8

≤0.56

≥540

860...980

≥13

≥15

≥10

R9 T, E

ER9

≤0.60

≥580

900...1050

≥12

≥10

≥8

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Re-Turning Rail Wheel

1

2

Rough Turning

Rough Turning

Tools with two cartridges and tangentially mounted
inserts for re-turning railroad wheels are able tomachine the entire outer wheel profile in a single cut.

Longitudinal turning is performed with a 30 mm longand 4 mm corner radius tangentially clamped insert,
positioned with its long side against the machining
direction. This insert can handle large cutting
depths for roughing or semi-finishing applications,depending on the outer wheel condition.

Portal CAM or CNC counter-wheel machines
are used for re-turning wheelsets. Capable ofsimultaneously re-turning both left and rightwheels while providing high profile accuracy andpreserving the dimensions and profile of thewheels. The majority of wheel raw material ismade of rolled steel and cast iron. The wheel’s
diameter varies from 400mm to 1200mm.
ISCAR offers standard tools with interchangeable
cartridges and tangential inserts, sizes 19 & 30mm,with a wide range of geometries and carbide
grades for the wide spectrum of wheelset forms
and sizes for re-turning.

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ISCAR

3

4

Rough Turning

Rough Turning

Machining depth can range from 0.3 mm to 12 mm
depending on the outer wheel condition prior to
re-conditioning. Large depths of cut are usually
performed by several machining paths in orderto prevent heavy loads and poor insert life.

A 19 mm long and 4 mm radius tangentially clamped
insert positioned perpendicularly to the larger insert
is used to machine the massively eroded rim zone.

4

1
2
3

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Re-Turning Rail Wheel

Inserts and
Tools

1

Toolholders andCartridges for Under
Floor Re-turning Lathes(Model 106 Thread
Profile Machine)

32

Assembly and Spare Parts

1

2

PRWR/L 177-CA-19

Designation
LNMX 191940
LNMX 301940
CNMX 191140

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ISCAR

3

PRWR/L 175-CA-19

Screw

Lever

Key

SR LCS 5

LR 5

HW 3.0PRWR/L 175-CA-30

Conventional Wheel Lathe

1

CNC Portal Wheel Lathe

4

PRWR/L 177-CA-19

4

5

5

PRWR/L 177-CA-1911
CNMX 191140...

1

PRWR/L 175-CA-1911
CNMX 191140...

527

Chipformers and Grades

LNMX 191940-F3P
For finish operation

LNMX 301940-WM
For medium/semi-finishing operations

LNMX 191940-WF
For semi-finish operation

LNMX 301940-WR
For roughing operations

LNMX 191940-WM
For medium/semi-finishing operations

LNMX 1919-WKR
For roughing operations- Unstable conditions

LNMX 301940-WKR
For roughing operations- Unstable conditions

CNMX 1911-M3PFor Medium operations

Chip Formation at the Rim Curve
Competitor

ISCAR

✘
One of the common problems in wheel re-turning is chip
formation during the back turning operation at the rim zone.

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ISCAR

✔
The WM chipformer (on the 30 mm insert) has been
specifically designed to prevent long chip formation
during rim turning.

Cutting Data
High

Grade Recommendation

IC8150A very hard substrate with a cobalt enriched layer, improved MTCVD TiCN and a thickalpha Al2O3 CVD coating. Features excellent thermal stability, resistance to chipping andplastic deformation.
Recommended for high speed machining of steel at stable or slightly unstable conditions.

IC8250A tough substrate with a cobalt enriched layer combined with improved
MTCVD TiCN and a thick alpha Al2O3 CVD coating. Recommended forgeneral use machining of steel in a wide range of conditions, featuringhigh toughness and resistance to chipping and plastic deformation.

Speed

P

Low

Cutting Data Recommendations

B

C

A

f

A

30 - 70 m/min

0.3 - 1.8 mm/rev

B

50 - 100 m/min

0.5 - 2.0 mm/rev

C

50 - 100 m/min

0.5 - 2.0 mm/rev

Depth of cut according to
chipbreaker geometry:
F3P

0.20-1.50

WF

1.00-3.50

WM/M3P (19)1.50-5.00

WKR (19)

3.00-6.00

WKR/WR (30)

3.00-12.00

In case of worn wheels with skid flats, built-up and shelled
tread or thermal cracks, reduce the cutting speed to ISCAR’s
recommended minimum speed.
High carbon wheels should be machined at ISCAR’s recommended
low range cutting speed. Feeds should be optimized within therecommended range per chipformer and actual chip formation.

ap mm
12
10
8
6
4
2

30-WM

Vc

19-F3P
19-WF
19-WM / M3P / WKRArea

LNMX 30-WR / WKR

Cutting Data by Area:

Material: Alloy steel
Cutting speed: Vc=30-100 m/min

0
0

0.5

1.0

1.5

2.0

f mm/rev29

Under Floor Wheel Milling

Locomotive Re-Profiling Wheels
Underfloor, counter-wheel machines areused for locomotive wheel reprofiling.
They are capable of simultaneously
reprofiling both left and right wheels
while providing high profile accuracy andpreserving the dimensions and profile of
the wheels. ISCAR offers specially designed
mills with interchangeable cartridges forlocomotive wheel reprofiling. The cutter iscurry’s round RPMW 16 mill insert witha quick chip breaker.

Capable of simultaneously re-profilingboth left and right wheels and provide
high profile accuracy, preserving thedimensions of the wheels undervarious conditions.

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ISCAR

Special-type extended flute
cutters carrying accurate roundinserts for re-profiling locomotive
wheels. Recommended for under
floor machining.

RPMW 1609-PP-TM

31

Turning Rail Car Wheel Axles

1

2

External Turning (Roughing)
A line of external and internal
tools and large-sized inserts
for heavy duty applications.

New Axles

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ISCAR

External Turning(Semi-Finishing)
Double-sided trigon wiper
inserts for high surface
finishing at high feed rates.

3

External Grooving
ISCAR groove-turn tools (GRIP) offer
a surface quality far superior whenturning with standard ISO tools ascompared to grinding operations.

Reconditioned Axles

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5

Semi-Finishing

Drilling

55º positive flank inserts formachining low carbon steel;recommended for semi-finish
and finishing operations.

Range: Ø6 - 32.9 mm
The SUMOCHAM drill family is themost productive and profitable
solution in the hole making industry.

The rail bogie axle shaft is part of a wheelset railroad car axle
wheel assembly. Rail axle shafts are made of forged and rolled
heat-treated high strength steel. ISCAR offers standard turning,
drills and mill threading tools for the productionof rail axle shafts.

1
5

2

3

4

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Machining Bogie Frames, Side A+B

12

Face Milling

Range: Ø50 - 315 mm.
Cutter: SOF45 D...-R18
Insert: S845 SNMU 1806ANR-MM
Insert: ONMU 070610-TR-MM
Helido 45° face milling cutterscarry square or octagonal
double-sided inserts with 8 and
16 cutting edges; recommended
for roughing operations at
an 8 mm depth of cut up.

Shoulder Milling

Range: Ø50 - 160 mm.
Cutter: S890 FSN D...- R13
Insert: S890 SNMU 1305 PNTR
Helido S890 face mills with square
double-sided inserts; recommended
for general milling applications
at a 9 mm depth of cut.

The Bogie is a chassis or framework that carries
a wheelset, which can take various forms invarious modes of transport. It supports the rail
vehicle body and stability on both straight andcurved tracks. Usually, two bogies are fitted
to each carriage, wagon, or locomotive. Some
cars are designed for heavy loads have more
axles per bogie. The bogie frames are usuallyfabricated from carbon steel.

3

Drilling

Range: Ø6 - 32.9 mm
The SUMOCHAM drill family is themost productive and profitable
solution in the hole making industry

451Side A

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ISCAR

4

5

6

FW

Shoulder Milling

Range: Ø25 - 250 mm.
Cutter: T490 ELN/FLN D...-13
Insert: T490 LNMT 1306 PNTR
The HELITANG T490 Line isrecommended for shoulderingand slotting operations at
a 12 mm depth of cut.

Drilling

HL

Rough Shoulder Milling

Range: Ø12 - 80 mm
Drills designed with spiral coolant
channels and a strong cutter bodywith excellent resistance to torsion
and very efficient chip evacuation.

Range: Ø25 - 100 mm
P290 is a family of extended flute
cutters carrying inserts with 2
serrated cutting edges for roughand finishing operations and highoverhang machining. The HL straightedged inserts are recommended
for finishing operations.

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2Side B35

Locomotive Power Train Engine

1

2

Rough Shoulder Milling

Range: Ø125 - 315 mm
65º face milling cutters carrying
tangentially clamped inserts withfour 22 mm long cutting edges.

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ISCAR

Slot Milling

Range: Ø80 - 250 mm
Tangential slot milling cutterswith cartridges carrying
LNET12... tangential insertswith 4 cutting edges.

3

Deep Shoulder Milling

Range: Ø20 - 125 mm
Extended flute cutters carrying
T490 LNHT/MT 08/13... tangential
inserts with 4 cutting edges
for higher productivity.

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5

Deep Drilling

Range: Ø5 - 10xD
Solid carbide drills with coolant
holes and a drilling depth of 20xD.

1

6

Thread Milling

Range: Ø4 - 20 mm
Solid carbide 3 flute threading
endmills with a short 3-tooth cuttingzone and a released neck for the
production of small internal threads.

3

5

4

2

Drilling and Chamfering
Special request indexable headdrills with coolant holes.

637

Locomotive Power Train Engine

7

Face Milling (Finish)Special face milling cutters with adjustable cartridges
carrying 16 cutting edged inserts for finishing operations.

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ISCAR

8

Deep Drilling

Range: Ø25 - 65 mm
Deep drills for milling centers and lathe
machines with a drilling ratio of up to 7x D.

109High Feed and Speed Reaming

Range: Ø11.5 - 32 mm
Interchangeable solid carbide reaming heads witha quick change bayonet mechanism; recommended
for high productivity and accuracy.

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8

10

9

ThreadingRange: Ø12 - 40 mm
Internal thread milling and external precision thread millingon CNC machines by use of helical interpolation performed
with NC programming.
MILLTHREAD milling cutters, in addition to solid
carbide cutters, are available with indexable thread
milling inserts for any standard thread profile.

39

ISCAR'S MACHINING SOLUTIONS FOR THE

RAILWAY INDUSTRY

3459337 01/2024© ISCAR LTD
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