How Is rail elastic clip Produced?
The production process of a rail elastic clip is a systematic engineering project that integrates materials science with precision manufacturing technology, beginning with the high-standard selection of raw materials. The core of manufacturing a high-quality clip lies in using spring steel with a specific composition, such as 60Si2MnA or 55CrMo, chosen specifically for their high elastic limit and fatigue resistance.
| 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 |
| Model | Diameter | Weight |
| Type III | Ø18 | 0.80kg/pc |
| E1609 | Ø16 | 0.43 kg/pc |
| E1809 | Ø20 | 0.61kg/pc |
| E1813 | Ø18 | 0.62kg/pc |
| E2001 | Ø20 | 0.80kg/pc |
| E2007 | Ø20 | 0.80kg/pc |
| E2009 | Ø20 | 0.80kg/pc |
| E2039 | Ø20 | 0.80kg/pc |
| E2055 | Ø20 | 0.80kg/pc |
| E2056 | Ø20 | 0.80kg/pc |
| E2063 | Ø20 | 0.80kg/pc |
| PR85 Rail Clip | Ø13 | 0.25kg/pc |
| PR309A | Ø19 | 0.85kg/pc |
| PR401 | Ø20 | 0.97kg/pc |
| PR415 | Ø20 | 0.95kg/pc |
| PR601A | Ø20 | 1.03kg/pc |
| SKL 1 | Ø13 | 0.48kg/pc |
| SKL 3 | Ø13 | 0.48kg/pc |
| SKL 12 | Ø13 | 0.53kg/pc |
| SKL 14 | Ø13 | 0.53kg/pc |
| Special Rail Clip | Ø13 | 0.48kg/pc |
| Russia Rail Clip | Ø18 | 0.58kg/pc |
| Deenik Clip | Ø25 | 0.49-0.68kg/pc |
| Single Anti- | Ø20 | 0.25kg/pc |
| Theft |
The steel is first hot-rolled into rods of a specific diameter, which is the initial step in giving the product its basic form. Subsequently, the rod is further processed through cold drawing to achieve a precise diameter, simultaneously enhancing the steel's mechanical properties.
The next stage is crucial for determining the clip's elasticity and durability-forming and heat treatment.
The cold-drawn wire is fed into precision automatic bending machines, where it is cold-formed through a series of dies into the exact geometric shape specified by the design. The formed clips then undergo rigorous heat treatment, typically involving quenching at a specific temperature followed immediately by high-temperature tempering. This quenching and tempering process aims to achieve a desirable microstructure known as tempered troostite, which grants the clip both high strength and sufficient toughness. The heat treatment process must be precisely controlled, as any deviation directly impacts the final performance and service life of the product.
After acquiring the required mechanical properties, the clips undergo surface treatment to enhance their corrosion resistance. The most common method is hot-dip galvanizing, where the clips are immersed in a bath of molten zinc, forming a thick and adherent zinc alloy coating on the surface that effectively protects against environmental factors like moisture and salt.
The final step in production is strict quality inspection, which includes dimensional checks, hardness testing, and, most critically, fatigue performance testing to ensure every batch of clips leaving the factory meets design standards and customer requirements.
GNEE RAIL implements stringent quality control throughout the entire production chain, ensuring every elastic clip we supply possesses exceptional performance and a long service life.
