How Is E Type Rail Elastic Clip Produced?
The production of an E-type rail elastic clip is a sophisticated process that integrates precision engineering, stringent quality control, and materials science to ensure the final product possesses exceptional mechanical properties and long-term durability. The manufacturing begins with the selection of high-quality spring steel, most commonly 60Si2MnA or similar grades of high-carbon silicon-manganese steel, renowned for their high yield strength, excellent elasticity, and fatigue resistance.
| railway E clips Specifications | ||||
| Type | E clip (e1809, e2006,e2007,e2009,etc) | |||
| Skl clip (skl1,skl3,skl12,skl14) | ||||
| Or the type by customers' drawings | ||||
| Material | 60Si2MnA | 60Si2CrA | 55Si2Mn | 38Si7 |
| Chemical composition(%) | C:0.56-0.64, Mn:0.60-0.90, Si:1.60-2.00, Cr:≤0.35, P:≤0.03, S:≤0.03 | C:0.56-0.64, Mn:0.40-0.70, Si:1.40-1.80,Cr:0.70-1.00 P:≤0.03, S:≤0.03 | C:0.52-0.60, Mn:0.60-0.90, Si:1.50-2.00,Cr:≤0.35 P:≤0.03, S:≤0.03 | C:0.35-0.42, Mn:0.50-0.80, Si:1.50-1.80, P:≤0.03, S:≤0.03 |
| Hardness | For e clip: 44-48HRCFor skl clip: 42-47HRC | |||
| Fatigue life | for Dia.18 is 3 millions cycles without breaking for Dia.20 is 5 millions cycles without breaking | |||
| Surface | plain (oiled), Oxide black, color painting | |||
| Standard refers | DIN17221, BS970, GB/T1222 | |||
The first step in the production process is shearing, where coiled spring steel is cut into precise lengths. These steel bars are then fed into a medium-frequency induction heating furnace, where they are heated to a specific temperature suitable for forming (approximately 950-1050°C). The heated billet is quickly transferred to precision dies and undergoes hot forging in a high-tonnage press, which stamps the distinctive "E" shape in a single operation. This forming step is critical, as it defines the clip's fundamental geometry and internal grain flow structure.
Following forming, the clips must immediately undergo rigorous heat treatment to achieve the required elasticity and hardness. This involves two core stages: first, quenching in oil to rapidly cool the clip, resulting in a hard martensitic microstructure; subsequently, tempering at a specific temperature (e.g., around 450°C) for a set duration to relieve internal stresses, adjust hardness, and significantly enhance toughness and elasticity. After heat treatment, the clip's hardness must be consistently within the international standard range of 44-48 HRC.
Finally, depending on customer requirements or the application environment, the clips receive various surface treatments, such as anti-rust oiling, oxide blackening, zinc plating, or epoxy painting, to enhance their corrosion resistance. Every batch of E-type clips is subjected to multiple stringent quality inspections, including hardness testing, fatigue testing (simulating millions of load cycles), dimensional checks, and surface quality assessment, ensuring their performance fully complies with technical specifications.
GNEE RAIL possesses advanced automated production lines and a comprehensive quality management system, focusing on manufacturing high-performance, high-consistency E-type rail elastic clips. We ensure that every clip delivered to our customers features reliable quality, capable of meeting the demanding requirements of various applications, from high-speed railways to heavy-haul lines.
