Manufacturing of Railway Wheels Ring Roller Closes the Gap

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Schuler AG

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Andritz Schuler presented an innovative ring roller for the first time in mid-September at the Erfurt site (Germany). The system is intended for a railway wheel manufacturer in Kazakhstan, enabling the production of rings with a diameter of up to 79 inches and a height of up to 16 inches.

It all began with the project "Close the Gap." For the production of seamless rings, the press manufacturer Andritz Schuler back then offered all facilities except one, which, however, plays a central role: the ring roller. Encouraged by the success story of the self-developed wheel roller for the production of railway wheels, the decision was finally made in 2017 to close the gap in the manufacturing process.

Jens Aspacher from sales at Andritz Schuler still remembers well: "In the past, we had already built numerous presses for the production of ring blanks, including various tooling concepts. Customers repeatedly asked us to deliver a completely turnkey line. However, we were missing the ring roller for that."

100 Participants at the Live Demonstration

And it was precisely this that visitors to the "Ring Roller Technology Days" could now observe in mid-September at Andritz Schuler's site in Erfurt (Germany), where the company presented the new development to the public in action for the first time. Around one hundred participants from all over the world witnessed over two days how a glowing ring blank was rolled into a wheel tire.

The presented system will also be used in the railway industry, which, unlike the automotive industry, is growing worldwide, as Schuler notes from recent orders from countries such as India. However, it can equally be used to roll rings for large engines or bearings in wind turbines, for example.

Up to 6.6 Feet in Diameter

Typical of the ring rolling process is that the diameter of the preform, weighing half a ton, gradually increases. In this case, the well-known railway wheel profile, including the flange on the outer surface, is created in about one minute. The demonstrated roller also enables the production of rings with a diameter of up to 6.6 feet and a height of 16 inches.

A special feature of the ring roller, according to project planner Matthias Brenzinger, is the patented height-adjustable vertical unit, which allows the upper bearing of the mandrel roller to be locked at different heights. This enables the use of mandrels of various lengths. Thus, the optimal mandrel can be chosen for rings of different heights.

Cassettes for Rollers Ensure Short Changeover Times

The extremely rigidly built system with a radial force of 220 US tons and an axial force of 176 US tons also features modular cassettes for the axial and radial rollers, allowing for quick changes or short setup times and thus minimizing downtime. The actual assembly and disassembly of the rollers from the cassettes take place outside the machine, minimizing downtime and facilitating maintenance.

The control system of the ring roller offers functions such as automatic adjustment of rolling parameters, real-time data access, and the capability for simulation using Digital Twin and FEM software, thereby increasing quality and process reliability. The high rigidity of the system and the improved cooling of the tools also contribute to this. The user interface is modeled on the press control system and allows for intuitive operation.

Axes Adjustable in Real-Time

Thanks to the control architecture ("M-Rolling" by Muraro), all hydraulic and electric axes can be controlled in real-time, as expert Angelo Sartori explained. Using FEM simulations, which operate with the same dataset as the machine control system, parameters can be realistically optimized—before material and tools are actually used. Users can adjust the target specifications for the rolling process, enabling them to achieve good results more quickly. All process data is also accessible in real-time, ensuring seamless monitoring, analysis, and documentation of the forming process.

All relevant production data is seamlessly documented with the automation and digitalization solution Metris "Track and Trace" and is available for evaluation and production optimization, while the "Shopfloor Operations Management" application ensures transparency regarding production processes, quality, and availability. Robert Vollmer from Andritz Schuler and Mario Sinkovic from the "Digital Factory" of Andritz in Zagreb presented an impressive demonstration of the installed "Copilot," which—just like its namesake on the desktop PC—comes from Microsoft and can answer questions about the system.

Production, Delivery, And Assembly from A Single Source

The commissioning of the ring roller at the customer's production site in Kazakhstan is already planned for the spring of next year. Immediately after the live demonstration, preparations began for dismantling the ring roller, which will form the heart of the production line. Just a few hours earlier, Uwe Konnerth from sales at Andritz Schuler had explained what distinguishes turnkey projects like this one: full responsibility from development and design to manufacturing and delivery, as well as assembly, commissioning, and operator training.

In addition to strong project management, transparent communication at every project phase is key—whether in process development, layout design, manufacturing, quality control, logistics, assembly, or operation. Close collaboration among all parties minimizes sources of error and builds trust. As production, delivery, and assembly come from a single source, efficiency and quality of the project are increased.

Rotary Hearth Furnace And Heat Treatment

In addition to the ring roller, the entire production line includes a rotary hearth furnace for heating the blanks, forging robots for automation, a 11,000 US tons hydraulic press for producing the ring preform, a marking press, two laser measuring units, a 1,100 US tons hydraulic open-die forging press for manufacturing railway axles, and heat treatment for the various products.

The rotary hearth furnace and heat treatment also come from an Andritz sister company: Andritz Metals Germany, based in Krefeld. The two companies had been collaborating on other railway projects for years, even before Schuler also received the name addition of its parent company.

Modern Burners Increase Energy Efficiency

Heinz-Willi Maassen from sales at Andritz Metals Germany explained the various types of furnaces, which are tailored to process requirements such as temperature range, throughput, and flexibility. Modern burners enable a significant increase in energy efficiency and a reduction in emissions, while hybrid heating systems allow the use of both gas and electric energy. The "H2 Ready" concepts provide the flexibility to switch to green hydrogen, thereby supporting the decarbonization of the industry.

Through simulations and digital twins, temperature profiles, energy flows, and material properties can be precisely predicted and optimized. The integration of real-time data and AI-supported models for continuous process monitoring and optimization leads to improved product quality, lower rejection rates, and more efficient resource utilization.

*Media Relations, Andritz Schuler

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