The railway industry is one of the sectors in which the quality of a single component is important for the reliability of the entire vehicle, device or infrastructure system.
Components used in the railway industry must be manufactured in accordance with technical documentation, customer requirements, and the principles assigned to a specific application. This applies to both simple mechanically processed parts and more complex subassemblies and welded structures.
Production for the railway industry is not just about producing a component with a specific shape. Equally important are process repeatability, quality control, material traceability, and proper documentation of completion.
Jakie elementy metalowe są wykorzystywane w branży kolejowej?
The railway sector utilizes a wide range of metal components. Their exact application depends on the type of vehicle, infrastructure, technical system, and specific manufacturer requirements.
Production may include, but is not limited to:
- handles and brackets,
- frames and supporting structures,
- housings and covers,
- mounting elements,
- vehicle equipment components,
- parts of mechanical systems,
- CNC machined components,
- welded components,
- prototypes and trial series,
- spare parts made on the basis of technical documentation.
Not every railway component is safety-critical. However, each must meet the requirements specified for its function, operating environment, and location of use.
CNC machining of components for the railway industry
CNC machining allows for the production of components with specific geometry, dimensions, and tolerances. Depending on the project, the process may include turning, milling, drilling, threading, and other machining operations.
In the production of components for the railway industry, the following are of particular importance:
- compliance with technical documentation,
- stability of processing parameters,
- correct selection of material,
- repeatability between subsequent batches,
- dimensional control,
- proper marking and identification of elements,
- ability to recreate implementation history.
In mass production, simply making the first piece correctly isn’t enough. The process must ensure that the established parameters are maintained for subsequent pieces.
Therefore, before starting a larger series, it is worth analyzing the technological feasibility of the project, making a prototype or the first production series, and determining the method of controlling the most important features.
Welding of railway structures and components
Welding is a process commonly used in the production of rail vehicles, components and structures used in the railway industry.
The EN 15085 series of standards applies to the welding of railway vehicles and their components. Requirements may include, among other things, process organization, personnel qualifications, welding supervision, process documentation, inspection, and quality requirements. [1]
However, the scope of requirements is not identical for every project. It depends on, among other things:
- purpose of the structure,
- joint classification,
- risk level,
- material,
- welding methods,
- customer documentation,
- contractual provisions,
- required level of manufacturer certification.
The manufacturer should not independently assume which standards and certification levels apply to a given order. These must be determined by documentation, the order, or agreements with the customer.
Why is repetition so important?
In railway production, components are often assembled into larger assemblies. Even small dimensional differences can affect the fit, assembly time, or performance of other parts.
Repeatability means the ability to regularly produce components that meet the same requirements.
In practice, it is influenced by, among others:
- appropriately prepared technology,
- stable machine settings,
- the correct way of attaching the detail,
- tool wear control,
- order of operations,
- qualifications of operators and welders,
- inter-operational control,
- properly defined acceptance criteria.
Repeatability isn’t achieved solely by purchasing modern machinery. It’s the result of a combination of technology, team competence, and a properly managed process.
Traceability of material and production process
Demanding industrial customers expect not only a finished component, but also the ability to confirm what it was made of and how it was made.
Depending on the project, traceability may include:
- type and batch of material,
- material documents,
- order or production batch number,
- the technology used,
- personnel performing specific operations,
- control and measurement results,
- possible deviations and corrective actions,
- method of marking the finished product.
The scope of documentation should be agreed upon before implementation begins. Attempting to recreate all data only after the elements have been completed may be difficult or impossible.
Quality control of railway components
Quality control should be tailored to the component’s function and customer requirements.
It may include, but is not limited to:
- It may include, but is not limited to:
- dimensional measurements,
- inter-operational control,
- visual inspection of welded joints,
- checking the geometry of the structure,
- assessment of surface quality,
- verification of marking,
- documentation control,
- final acceptance.
For certain components, additional non-destructive testing may be required, performed by appropriately qualified personnel.
The most important principle is simple: the scope of the inspection should not be arbitrary. It must be based on documentation, standards, quality plans, or contractual arrangements.
From prototype to serial production
Before starting regular production, it is worth verifying the design with a physical component.
A prototype or trial run can help you check:
- fitting parts,
- possibility of making the required geometry,
- correctness of tolerance,
- availability of tools,
- time of individual operations,
- risk of deformation during welding,
- the ability to conduct measurements,
- process repeatability,
- real cost of serial production.
Once the first piece is made, adjustments can be made to the documentation, technology, or inspection method before the problem is replicated throughout the entire batch.
How to choose a supplier of metal components for the railway industry?
Price is important, but it should not be the only criterion for choosing a supplier.
Before starting cooperation, it is worth checking:
- Does the company have experience in manufacturing for demanding industrial sectors?
- Can he or she work from technical drawings and 3D models?
- Does it have the appropriate machinery?
- Can it perform both machining and welding?
- What does quality control look like?
- Does it ensure traceability of materials and batches?
- How do you manage non-compliance?
- Can it go from prototype to series production?
- What certificates and qualifications does he/she have in relation to the specific scope of work?
- Does he or she understand the requirements for timely and continuous delivery?
The railway sector also operates the IRIS Certification system, based on the requirements of ISO 22163, which aims to standardise and develop quality management in the railway industry supply chain. [2]
This doesn’t mean, however, that every subcontractor must have exactly the same set of certificates. The requirements depend on the scope of work, the company’s position in the supply chain, and the terms and conditions set by the client.
Production for the railway industry at FEMET
FEMET developed its business, beginning with CNC machining and implementation for the railway sector. Over time, its services expanded to include comprehensive welding, prototype production, 3D modeling, and the fabrication of more advanced metal structures.
We implement projects based on the client’s technical documentation, taking into account the required materials, tolerances, order size and the agreed scope of inspections.
Each request is analyzed individually. Feasibility depends on technical requirements, applicable standards, necessary qualifications, and the expected level of documentation.
Do you have a project for the railway industry?
Send us:
- technical drawing or 3D model,
- information about the material,
- number of pieces,
- required tolerances,
- welding and inspection requirements,
- expected completion date,
- list of standards and acceptance documents.
The FEMET team will analyze the documentation and check the possibility of creating a prototype, trial series or mass production.
Contact us and discuss your project requirements.
Frequently asked questions
Does FEMET produce prototypes of components for the railway industry?
FEMET produces single prototypes and series of metal components based on customer documentation. Completion depends on the material, dimensions, tolerances, and requirements of a given project.
What documents should be submitted for valuation?
It is best to send a technical drawing, 3D model, material specification, number of elements, required tolerances and information regarding inspection, certification and acceptance documentation.
Does every railway component have to be manufactured according to EN 15085?
No. The EN 15085 series covers the welding of railway vehicles and components. Its application depends on the type of component, the scope of welding, the classification, and the customer’s requirements.
Is serial production possible after prototype approval?
Yes, provided the project is within FEMET’s technological capabilities and the prototype and process are accepted in accordance with the established requirements.
