Precision for the railway: 218 rail acceptance gauges successfully inspected

The year 2015 was particularly difficult for the DB turnout manufacturing plant in Witten. A major fire destroyed large parts of the production facilities during the summer. The damage also affected the entire stock of rail acceptance gauges needed for quality control of the rail profiles produced.

More than 200 gauges in just five months

By combining waterjet cutting and wire electrical discharge machining, we were able to manufacture replacements for the unusable gauges within a short time. W.S. Werkstoff Service first checked the dimensional accuracy of the new gauges using a measuring microscope. Final acceptance then took place at the DB testing facility in Chemnitz. This preliminary check ensured that no dimensional deviations arose during the official final inspection and that acceptance could proceed quickly.

A total of 218 rail acceptance gauges were newly manufactured and measured. These comprised two complete sets for each of the three rail families of 49 kg, 54 kg and 60 kg. Manufacture and measurement of the gauges were completed within just five months.

Annual inspection in the accredited testing laboratory

The following year, the gauges were due for their regular annual inspection. W.S. Werkstoff Service was again able to save time through a flexible approach. Instead of sending the gauges back to Chemnitz for inspection, they could be checked using the measuring microscope in our accredited testing laboratory. This considerably accelerated the entire inspection process.

All 218 gauges were inspected within three months and then returned to the DB turnout manufacturing plant in Witten. The inspection ran smoothly, with every gauge passing the dimensional check without any issues.

An additional advantage was that, had a deviation been found in a gauge, a replacement could have been manufactured and inspected within approximately one week. Our proximity to Witten and our collection and delivery service also helped ensure a quick turnaround.

Manufacture of gauges and reference blocks

In addition to inspection, we also manufactured gauges and reference blocks for various applications in materials testing and quality assurance. These include gauges for profile and contour measurement, reference blocks for non-destructive inspection methods, as well as check and comparison blocks and templates for checking complex geometries.

W.S. Werkstoff Service – expertise in manufacturing

Are you looking for reference blocks for non-destructive testing? Do you need check blocks, comparison blocks or templates for checking a complex geometry? The workshop specialists at the W.S. MaterialtestCenter have modern manufacturing and measuring equipment and carry out these tasks with the precision of an accredited testing laboratory.

Further information is available under manufacture of gauges and reference blocks