Application of Press Brakes in Railway Industry Fabrication Processes

Nature of railway operations

This industry is one of the oldest and most relied industries in transportation of cargo and people. The use of sheet metal in this sector spans many centuries when trains were powered by steam to the present day magnetic levitation trains.

Press brakes are used in this industry to manufacture a wide range of structures used in trains and other components. Most corporations have central and regional shops dedicated to continuous production of components used and in maintenance.

This industry depends on large heavy duty press brakes to form most of the bends. These machines are long, hydraulic or pneumatic operated and specially designed to handle both small and large gauge materials.

Critical quality and cost in railway fabrications

To achieve high quality train cabins and other structures, good press brake need to be used. The equipments have structure with high mechanical strength and rigidity in order to withstand heavy compressive forces.

The effective manufacturing and production of specially formed sheet requires the use of this machine. They perform bending operations fast, reliably and cost effectively. The devices used must allow for great variability when bending in order to make different shapes using one machine tool. This reduces the capital and operation costs.

CNC controlled types are also utilized to achieve precision and accuracy when positioning and bending to specified angles. Hydraulic operated ones are fitted with computerized control modules to run the whole system.

The back gauge is specially designed from cast iron and is long to ensure adequate positioning. The tool has advanced clamping and hydraulic system to increase the speed of cutting. They also have large throat and back gauge to hold and curve large pieces of up to 40mm thickness.

Manufacturing steel and aluminum to develop rail freight cars

When manufacturing train cabins; long and heavy gauge materials that require long dies and punches are used. The machines used are therefore large, long and with high strength parts.

These machines are used to make the outer casing for most train cabins. Rail freight cars that transport goods are fabricated with steel. These contain corrugated sheet which are curved using the press brakes.

For the passage freight cars, there is an increasing use of aluminum to manufacture the body since they are lighter, aesthetic, withstands corrosion and are more durable (+30 years). These are extruded, cut, folded and used to make the structure. They use less welding when compared to steel types. Currently, both steel and aluminum rail cabin use these folding devices to achieve a variety of shapes that are assembled to for the final cabin.

Containerization in the rail industry

With increasing need to pack products in enclosed spaces, there is a rise in special containers used to store electronics, perishable goods and other materials. Most rail containers are rectangular shaped or cylindrical (for liquid materials). The manufacturing and repair of these containers require the use of press brakes to fold and shape the metal plate before welding.