Design Services - Progress Rail Services

Vehicle & General Engineering Castings
Permanent Way Track Materials
Permanent Way Trackwork
Cast Manganese Products
Design Services
Design, Manufacture,
Project Management and
Global Supply Capability
Switches & Crossings
Permanent Way Switch Systems
Design Services
Permanent Way Catenary Structures

Switches, Crossings and Turnout Design
We have a dedicated team of graduate and Chartered Engineers from
mechanical, metallurgical and electrical backgrounds. We support our
engineers in their membership of the IMechE and industry specific
professional bodies
Mechanical Analysis
We assess product life cycle and expected performance, operation and
maintenance requirements using a combination of classical mechanical
analysis, Finite Element Analysis (FEA), practical testing and empirical
data from over 100 years of manufacturing experience
We undertake work for our own process and product development, but
also deliver commissioned work for various clients in the UK and overseas
We consider risk management a fundamental aspect of good design and
follow ‘yellow book’ engineering safety management principles at the
appropriate level for all product developments
We design products using state-of-the-art 3D CAD software, considering
mechanical integrity, potential failure modes and human interaction
aspects before progressing to prototyping and testing
Switch Performance Optimisation
Our in house analysis tools allow us to fine tune the flexural behaviour of
switches, minimising the thrust requirements and optimising the location
and quantity of drive points. This process minimises the work done by the
points operating equipment whilst ensuring closed switch fit and free wheel
clearance are satisfactory under all operating conditions
We also model customer’s current problems and derive mathematical
models demonstrating the root causes and the potential remedies
All of our products are supplied with operation and maintenance
guidelines, developed with the end user in mind
New Product Development
The demands on the rail infrastructure continue to increase with faster trains and increased occupancy. To support this we are constantly driving ourselves
to develop new products and allow our customers to meet these demands

Design Services
Visit us online at:
www.progressrail.com
Cast Manganese Products Modelling,
Methods and Metallurgy
3D modelling and FEA allow us to engineer all of our products more
efficiently. From CNC controlled pattern making for cast manganese
crossings (frogs) to Failure Mode and Effect Analysis (FMEA) to determine
weaknesses in design
Our current engineering processes revolve around 3D modelling to
generate LEAN products with highly analysed performance characteristics
3D modelling interfaces directly with our Computer Numerical Controlled
(CNC) machines to offer a superior and repeatable quality product
The casting process itself is a well established and highly controlled
process. This control stems, in part, from 3D modelling the molten shape
and the molten metal flow to ensure cooling rates and other parameters
are within known tolerances to produce a high quality product
Within our South Queensferry and Midland foundries we have qualified
metallurgical engineers and are members of the Cast Metal Federation
Complex Cast Manganese Solutions
Our design engineers are qualified to high standards and are able to
solve complex geometrical alignment problems facing many of the
world’s railways
We undertake work regularly for London Underground and have also
worked for various subterranean rail systems around the world where
alignment is paramount. We have been involved in tunnel wall studies
and modelling train paths to ensure clearance is within permitted levels
Geometrical data is used to develop 3D models of cast manganese
products and these models are used to create the wooden patterns used
in the production of sand moulds for the casting process
Molten Metal Modelling using Magma 5 Software
Using Magma 5 software we simulate mould filling, solidification and
cooling rates for different shape and complexity patterns
This state-of-the-art analysis tool ensures that the molten metal witnesses
directional solidification in order to eliminate the formation of shrinkage
cavities within the casting
We are also able to simulate metal entering the mould cavity using
particle tracers, which move just like metal flow, allowing the identification
and elimination of high and low velocities during mould filling which can
lead to the formation of casting defects , oxide films and inclusions
References
Our Design Services team have undertaken work for customers in:
• Commissioned Design and Standards work in the UK, USA and Australia
• Trackwork and Cast Manganese Crossings (Frogs) designed and supplied to worldwide customers

Visit us online at:
www.progressrail.com
DET NORSKE VERITAS AUDITED
• ISO 9001-2008
• ISO14001-2004
• ISO18001-2007
Progress Rail Services UK Ltd Sites
South Queensferry
Headrig Road, South
Queensferry, Scotland
Closest Airport : Edinburgh (EDI)
- 7 Miles from site
Darlington
Dumfries Street,
Darlington, England
Closest Airport : Durham Tees (MME)
- 6 Miles from site
Sheffield
Shepcote Lane,
Sheffield, England
Closest Airport: Robin Hood
Doncaster Sheffield (DSA)
- 20 Miles from site
Sandiacre and Beeston
Osmaston Street, Sandiacre,
Nottingham, England
Closest Airport : East Midlands (EMA)
- 10 Miles from site
Regions supplied:
Please contact us for further information:
David Evans
Head of Sales & Marketing
Progress Rail Services UK Ltd
Osmaston Street, Sandiacre, Nottingham, NG10 5AN, UK
devans@progressrail.com
Tel: +44 (0) 115 921 8218 | Mob: +44 (0) 752 738 8803 | Fax: +44 (0) 115 921 8219
Copyright © 2013 Progress Rail Services UK Ltd. All Rights Reserved. No part of this publication may be reproduced without the permission of Progress Rail Services UK Ltd.
Brochure: PRSUK_Design Services_revision1_April 2013