CNC Milling for Railway Manufacturing
Frigate delivers Ra < 0.4 µm on critical railway components using carbide tooling and optimized chip loads. Surface integrity is validated through profilometry and stress scanning for dynamic load reliability.
Our Clients
- Process Capability for Precision Die Milling
Closed-Loop Machining for Rail Systems
CNC milling maintains <15 µm accuracy on extended rail components using thermal compensation and vibration control. Force-regulated cutting and CMM-verified GD&T ensure material integrity and compliance with EN 15085 and UIC.
Extended-Length Precision Milling
Frigate maintains <15 µm positional accuracy over 1000+ mm rail parts using hydrostatic guides, thermal compensation, and vibration-resistant fixturing to ensure dimensional consistency during continuous machining cycles.
Alloy-Specific Chip Load Control
Machining parameters are dynamically adjusted using real-time force sensors and alloy-specific data, preventing subsurface distortion in tempered steels and maintaining uniform microhardness for fatigue-critical railway components.
Dimensional Compliance Verification
All milled components meet EN 15085 and UIC tolerances, with CMM-validated GD&T features and complete traceability, enabling audit-ready documentation and first-article approval for OEM and Tier-1 programs.
- Machining Workflows
Our CNC Milling Process
Tight component tolerances and fine feature depths are achieved through high-speed, thermally stable CNC milling in cleanroom-compatible workflows.
Engineers design the part using CAD (Computer-Aided Design) software. The design includes all dimensions and specifications.
The CAD design is converted into CNC code, often using CAM (Computer-Aided Manufacturing) software. This code tells the milling machine how to move and cut the material.
Operators prepare the CNC milling machine by securing the material (workpiece) and installing the appropriate cutting tools.
The CNC machine reads the code and starts milling. The cutting tool rotates and moves along multiple axes to remove material from the workpiece and shape it into the desired part.
The machine monitors the cutting operations throughout the process. Operators may make adjustments to ensure precision and quality.
After milling, the part may undergo additional processes like deburring or polishing to achieve the final specifications.
The finished part is thoroughly inspected to meet all design requirements and tolerances.
- Real Impact
Words from Clients
See how global OEMs and sourcing heads describe their experience with our scalable execution.
“Quick turnaround and solid quality.”
“The instant quote tool saved us time, and the parts were spot-on. Highly recommend Frigate!”
“Great service, fair price, and the parts worked perfectly in our assembly.”
“Top-notch machining and fast shipping. Very satisfied with the results.”
“Frigate delivered high-quality parts at a competitive price. The instant quote tool is a huge plus for us!”
“We appreciate the precision and quality of the machined components in the recent delivery—they meet our specifications perfectly and demonstrate Frigate’s capability for excellent workmanship.”
“Flawless execution from quote to delivery.”
“The precision on these parts is impressive, and they arrived ahead of schedule. Frigate’s process really stands out!”
“Parts were exactly as spec’d, and the instant quote made budgeting a breeze.”
“Good value for the money.”
“The finish was perfect, and the team was easy to work with.”
- Surface Finish
Flawless Finishes for CNC Milling Parts
Surface roughness is optimized using specialized cutters and constant tool engagement techniques. This ensures compatibility with sealing systems, wear surfaces, and corrosion-resistant coatings.
Anodizing
Give your aluminum parts a tough, corrosion-resistant shield with anodizing, reaching surface hardness up to HV 500, while enhancing electrical insulation and durability.
Mechanical Finishing
Smooth out imperfections and refine surfaces to Ra 0.2 µm or better with mechanical finishing techniques like grinding, polishing, and bead blasting.
Heat Treatment
Boost material strength and hardness by heat treating parts at temperatures up to 1100°C, ensuring they meet the mechanical demands of your application.
Electroplating
Add protective or functional metal coatings with electroplating, delivering consistent layers as precise as ±2 µm for improved corrosion resistance and conductivity.
Our Machined Products
We support your production needs with CNC-machined parts, subassemblies, and performance-critical components.
- Material Behavior
Optimized Material Strategies for Rail CNC Milling
Railway components require materials that deliver structural integrity and fatigue resistance under prolonged stress. Milling parameters are configured to manage thermal load, material response, and geometric consistency.
- Thermal input is controlled to reduce distortion during extended cuts.
- Chip load and toolpath are optimized to prevent surface hardening.
- Fixturing minimizes stress release and dimensional shift.
- Cutting strategy ensures required surface finish for functional fits.
A2 Tool Steel is a high-carbon, high-chromium steel known for its toughness and wear resistance. It’s ideal for producing durable, high-strength parts that can withstand heavy use.
Aluminum is a lightweight, corrosion-resistant metal with good machinability. Because of its strength-to-weight ratio, it’s commonly used in aerospace, automotive, and various industrial applications.
Brass is a copper-zinc alloy known for its machinability and corrosion resistance. It’s used for components requiring precise detailing and good mechanical properties.
Bronze is a copper-tin alloy with excellent wear resistance and strength. It’s often used for bushings, bearings, and other friction-prone components.
Cast Iron is known for its high wear resistance and machinability. It’s used in heavy-duty applications such as machinery parts and engine components.
Copper offers excellent thermal and electrical conductivity. It’s used in applications requiring heat dissipation or electrical conductivity, such as electronic components.
Steel is a versatile material known for its strength and durability. It’s used in various applications, from construction to automotive parts.
Titanium is a lightweight, high-strength metal with excellent corrosion resistance. It’s used in aerospace, medical implants, and high-performance engineering applications.
Stainless Steel offers high corrosion resistance and strength. It’s widely used in applications ranging from kitchen equipment to industrial machinery.
Zinc is a ductile and corrosion-resistant metal known for its excellent machinability, especially in its alloy forms. It's often used for components requiring intricate details, good surface finish, and precise dimensions, commonly found in automotive, hardware, and electrical applications.
- Load Integration
Precision Milling for Structural Assembly Interfaces
Railway components within primary load paths must align with both machined and welded structures without introducing localized stress concentrations. Milling strategies are developed to maintain tolerance stack integrity and structural coherence under mechanical load transfer conditions.
- Locating features are machined to sub-20 µm positional tolerance for accurate assembly fit.
- Stress-relief geometries are incorporated to reduce crack initiation points in high-strain zones.
- Chamfer radii and edge transitions are defined per FEA-driven load models.
- Grain direction is preserved during roughing to support axial and lateral force distribution.
- Regulatory Alignment
Machining Compliance for Critical Rail Applications
CNC-milled railway components must conform to stringent dimensional, structural, and documentation standards governing rail safety and manufacturing repeatability. Compliance is achieved through controlled processes, closed-loop validation, and traceable quality data at every stage of production.
- Dimensional tolerances are verified using calibrated metrology systems with multi-axis CMM inspection.
- Process capability is maintained through statistical controls and monitored tool wear thresholds.
- Manufacturing records include complete traceability from raw material to final geometry verification.
- Machining sequences are validated against project-specific criteria for fatigue zones and assembly-critical features.
We meticulously follow this international quality management system, ensuring consistent precision and repeatability across all CNC milling operations for railway parts.
Our milling processes conform to this railway-specific standard, demonstrating robust quality control for critical railway components.
Our milling supports precise preparation of components for welding, adhering to the requirements for high-integrity railway welded structures.
We mill components that align with the design methodology and dimensional requirements for railway axle systems.
We mill materials to relevant ASTM standards, guaranteeing precise chemical composition, high strength, and fatigue resistance crucial for railway component longevity.
We apply GD&T principles rigorously during milling, ensuring exact dimensional accuracy, critical for proper assembly and safe operation of railway systems.
- We achieve specified surface finishes during milling, crucial for minimizing friction, enhancing wear resistance, and optimizing performance in railway bogies and frames.
- We export to 12+ countries
Frigate’s Global Presence
Frigate takes pride in facilitating “Make in India for the globe“. As our global network of Frigaters provides virtually limitless capacity, and through our IoT enabled platform your parts go directly into production. By digitally and technologically enabling “the silent pillars of the economy” MSME and SME manufacturing industries, we are able to tap the huge potential for manufacturing to bring the best results for our clients.
100,000+
Parts Manufactured
250+
Frigaters
2000+
Machines
450+
Materials
25+
Manufacturing Process
- Verified Standards and Methods
Quality Testing Standards for CNC Milling Services
To measure the roundness of cylindrical features, ensuring they meet tolerance requirements.
To check internal surfaces for flatness, critical for sealing and assembly purposes.
To identify burrs or sharp edges that may affect assembly or safety.
To ensure that complex profiles (e.g., contours, curves) conform to design specifications.
To check the topography and texture of the surface, ensuring it meets the required specifications for function or aesthetics.
To verify that the surface hardness depth meets the required specifications for wear resistance.
To measure internal stresses that could lead to deformation or failure during or after machining.
To verify grain structure, inclusions, and material consistency, ensuring the part meets performance requirements.
- See Our CNC Machined Components
CNC Milling Parts
We maintain stringent dimensional consistency through high-resolution spindle encoders, thermal drift compensation, and ultra-fine servo motor tuning. Delivering components engineered to withstand extreme mechanical stresses and fluctuating thermal environments.
Other Industries We Serve
We deliver machining support across sectors that require consistency, material reliability, and tight dimensional control.
- Solid Progress
Our Manufacturing Metrics
Frigate brings stability, control, and predictable performance to your sourcing operations through a structured multi-vendor system.
2.8X
Sourcing Cycle Speed
Frigate’s pre-qualified network shortens decision time between RFQ and PO placement.
94%
On-Time Delivery Rate
Structured planning windows and logistics-linked schedules improve project-level delivery reliability.
4X
Multi-Part Consolidation
We enable part family batching across suppliers to reduce fragmentation.
22%
Quality Rejection Rate
Multi-level quality checks and fixed inspection plans lower non-conformities.
30%
Procurement Costs
Optimized supplier negotiations and bulk order strategies reduce your overall sourcing expenses.
20%
Manual Processing Time
Automation of sourcing and supplier management significantly reduces time spent on manual tasks.
Get Clarity with Our Manufacturing Insights
- FAQ
Having Doubts? Our FAQ
Check all our Frequently Asked Questions in CNC Milling
Frigate uses machines equipped with real-time thermal sensors and compensation algorithms integrated into the CNC control loop. This maintains sub-15 µm positional accuracy even during extended cycle times. Spindle growth, machine frame expansion, and ambient shifts are actively corrected during machining. This ensures reliable geometries in components over 1,200 mm length.
Frigate applies tolerance simulation at the CAM stage using GD&T-based constraints aligned with the customer’s 3D model. Key interface features such as holes, slots, and locating surfaces are machined with sub-20 µm repeatability. Final part validation includes CMM mapping and cross-referencing with the assembly tree. This eliminates field-fit errors and ensures proper subsystem integration.
Frigate generates full machining traceability, including material origin, toolpath validation, and in-process measurement logs. All features are digitally verified against the 3D model with annotated inspection reports. Process capability indices (Cp/CpK) are maintained per control plan. Documentation is formatted to align with supplier approval protocols from global railway OEMs.
Fatigue-critical surfaces are milled using low-radial engagement strategies to avoid tensile residual stress zones. Tool deflection is dynamically compensated using force-feedback sensors and tool wear tracking. Ra values below 0.4 µm are achieved on surfaces such as brake mounting pads and axle housing bores. Surface finish and microstructure are verified using profilometry and post-machining hardness scans.
Frigate segments the toolpath based on localized hardness zones identified via material certificates or in-house mapping. Cutting parameters are modified mid-process using adaptive feed control and variable depth strategies. This prevents tool chatter, premature wear, and geometric distortion. It ensures uniform material removal without compromising tolerance or surface quality.
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LOCATIONS
Registered Office
10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.
Operations Office
9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ
Other Locations
- Bhilai
- Chennai
- USA
- Germany