Railway car coupler knuckle having improved bearing surface

Abstract

Knuckle coupler castings and methods for casting the knuckle coupler castings, where the knuckle coupler castings having enhanced bearing surfaces which may include a vertically flat surface.

1 . A coupler knuckle casting having an enhanced bearing surface area, said coupler knuckle casting utilized in a railway freight car coupler, said coupler knuckle casting having said enhanced bearing surface area comprising: 
 (a) a tail section;    (b) a hub section, said hub section having a pivot pinhole formed therein, said pivot pinhole having generally straight cylindrical sidewalls;    (c) a front face section connected to said hub section, said front face section including a nose section and a pulling face portion formed inwardly from said nose section, at least a portion of said front face portion and said nose section includes an enhanced bearing surface area which includes a substantially flat portion disposed substantially in a vertical direction and which is substantially arcuate in a horizontal direction, said substantially flat portion extending for a predetermined distance in said vertical direction and for a predetermined length along said horizontal direction; and    (d) a transition section joining said tail section to said hub section, said transition section including a top metal section and a bottom metal section extending toward each other.    
   
   
       2 . A coupler knuckle casting having an enhanced bearing surface area, according to  claim 1 , wherein said predetermined distance said substantially flat portion extends in said vertical direction is generally in a range of between about 3.5 inches and about 7.0 inches.  
   
   
       3 . A coupler knuckle casting having an enhanced bearing surface area, according to  claim 2 , wherein said predetermined distance said substantially flat portion extends in said vertical direction is generally in a range of between about 4.0 inches and about 5.5 inches.  
   
   
       4 . A coupler knuckle casting having an enhanced bearing surface area, according to  claim 3 , wherein said predetermined distance said substantially flat portion extends in said vertical direction is generally in a range of between about 4.0 inches and about 4.5 inches.  
   
   
       5 . A coupler knuckle casting having an enhanced bearing surface area, according to  claim 1 , wherein said coupler knuckle is cast steel.  
   
   
       6 . A coupler knuckle casting having an enhanced bearing surface area, according to  claim 4 , wherein said coupler knuckle is cast steel.  
   
   
       7 . A coupler knuckle casting having an enhanced bearing surface area, according to  claim 1 , wherein said predetermined length along said horizontal direction which is substantially arcuate extends over at least a portion of said hub section, said front face section and at least a portion of said nose section.  
   
   
       8 . A coupler knuckle casting having an enhanced bearing surface area, according to  claim 4 , wherein said predetermined length along said horizontal direction which is substantially arcuate extends over at least a portion of said hub section, said front face section and at least a portion of said nose section.  
   
   
       9 . A coupler knuckle casting having an enhanced bearing surface area, according to  claim 6 , wherein said predetermined length along said horizontal direction which is substantially arcuate extends over at least a portion of said hub section, said front face section and at least a portion of said nose section.  
   
   
       10 . A coupler knuckle casting having an enhanced bearing surface area, according to  claim 1 , wherein said enhanced bearing surface area is hardened to a predetermined hardness.  
   
   
       11 . A coupler knuckle casting having an enhanced bearing surface area, according to  claim 10 , wherein said predetermined hardness is at least about 40 Rockwell C.  
   
   
       12 . A coupler knuckle casting having an enhanced bearing surface area, according to  claim 1 , wherein said nose section includes a generally cylindrical opening formed in an end portion thereof.  
   
   
       13 . In combination with a railway freight car coupler, the improvement comprising a coupler knuckle casting having an enhanced bearing surface area, said coupler knuckle casting having: 
 (a) a tail section;    (b) a hub section, said hub section having a pivot pinhole formed therein, said pivot pinhole having generally straight cylindrical sidewalls;    (c) a front face section connected to said hub section, said front face section including a nose section and a pulling face portion formed inwardly from said nose section, at least a portion of said front face portion and said nose section includes an enhanced bearing surface area which includes a substantially flat portion disposed substantially in a vertical direction and which is substantially arcuate in a horizontal direction, said substantially flat portion extending for a predetermined distance in said vertical direction and for a predetermined length along said horizontal direction; and    (d) a transition section joining said tail section to said hub section, said transition section including a top metal section and a bottom metal section extending toward each other.    
   
   
       14 . The combination, according to  claim 13 , wherein said nose section includes a generally cylindrical opening formed in an end portion thereof.  
   
   
       15 . In combination with an existing railway freight car coupler, the improvement comprising retrofitting a coupler knuckle casting having an enhanced bearing surface area into said existing railway freight car coupler, said coupler knuckle casting having: 
 (a) a tail section;    (b) a hub section, said hub section having a pivot pinhole formed therein, said pivot pinhole having generally straight cylindrical sidewalls;    (c) a front face section connected to said hub section, said front face section including a nose section and a pulling face portion formed inwardly from said nose section, at least a portion of said front face portion and said nose section includes an enhanced bearing surface area which includes a substantially flat portion disposed substantially in a vertical direction and which is substantially arcuate in a horizontal direction, said substantially flat portion extending for a predetermined distance in said vertical direction and for a predetermined length along said horizontal direction; and    (d) a transition section joining said tail section to said hub section, said transition section including a top metal section and a bottom metal section extending toward each other.    
   
   
       16 . The combination, according to  claim 15 , wherein said nose section includes a generally cylindrical opening formed in an end portion thereof.  
   
   
       17 . A coupler knuckle casting having an enhanced bearing surface area, said coupler knuckle casting utilized in a railway freight car coupler, said coupler knuckle casting having said enhanced bearing surface area comprising: 
 (a) a tail section;    (b) a hub section, said hub section having a pivot pinhole formed therein, said pivot pinhole having generally straight cylindrical sidewalls;    (c) a front face section connected to said hub section, said front face section including a nose section and a pulling face portion formed inwardly from said nose section, at least a portion of said front face portion and said nose section includes an enhanced bearing surface area which includes a substantially flat portion disposed substantially in a vertical direction and which is substantially arcuate in a horizontal direction, said substantially flat portion extending for a predetermined distance in said vertical direction and for a predetermined length along said horizontal direction, said predetermined length extends over at least a portion of said hub section and said front face section and at least a portion of said nose section; and    (d) a transition section joining said tail section to said hub section, said transition section including a top metal section and a bottom metal section extending toward each other.    
   
   
       18 . In combination with a railway freight car coupler, the improvement comprising a coupler knuckle casting having an enhanced bearing surface area, said coupler knuckle casting having: 
 (a) a tail section;    (b) a hub section, said hub section having a pivot pinhole formed therein, said pivot pinhole having generally straight cylindrical sidewalls;    (c) a front face section connected to said hub section, said front face section including a nose section and a pulling face portion formed inwardly from said nose section, at least a portion of said front face portion and said nose section includes an enhanced bearing surface area which includes a substantially flat portion disposed substantially in a vertical direction and which is substantially arcuate in a horizontal direction, said substantially flat portion extending for a predetermined distance in said vertical direction and for a predetermined length along said horizontal direction, said predetermined length extends over at least a portion of said hub section and said front face section and at least a portion of said nose section; and    (d) a transition section joining said tail section to said hub section, said transition section including a top metal section and a bottom metal section extending toward each other.    
   
   
       19 . In combination with an existing railway freight car coupler, the improvement comprising retrofitting a coupler knuckle casting having an enhanced bearing surface area into said existing railway freight car coupler, said coupler knuckle casting having: 
 (a) a tail section;    (b) a hub section, said hub section having a pivot pinhole formed therein, said pivot pinhole having generally straight cylindrical sidewalls;    (c) a front face section connected to said hub section, said front face section including a nose section and a pulling face portion formed inwardly from said nose section, at least a portion of said front face portion and said nose section includes an enhanced bearing surface area which includes a substantially flat portion disposed substantially in a vertical direction and which is substantially arcuate in a horizontal direction, said substantially flat portion extending for a predetermined distance in said vertical direction and for a predetermined length along said horizontal direction, said predetermined length extends over at least a portion of said hub section and said front face section and at least a portion of said nose section; and    (d) a transition section joining said tail section to said hub section, said transition section including a top metal section and a bottom metal section extending toward each other.    
   
   
       20 . A method of casting a coupler knuckle casting for a railway car coupler, the coupler knuckle casting having an enhanced bearing surface with a substantially flat portion in one direction, the method comprising: 
 providing a cope mold portion and a drag mold portion, the cope and drag mold portions having internal walls defining at least in part the perimeter boundaries of a mold cavity;    positioning one or more cores in the mold cavity of either the cope or drag mold portion, at least one of the cores having one or more surfaces substantially flat in one direction forming a portion of the perimeter boundaries of the mold cavity for forming at least a portion of the enhanced bearing surface;    closing the cope and drag mold portions with the one or more cores therebetween; and    at least partially filling the cavity with a molten alloy, the molten alloy solidifying after filling to form the coupler knuckle casting.    
   
   
       21 . A method of casting a coupler knuckle casting in accordance with  claim 20 , wherein the step of closing the cope and drag mold portions with the one or more cores therebetween includes the step of arranging the surface of the core that is substantially flat in one direction both adjacent to and between portions of the walls of the cope and drag mold portions and combining the surface of the core that is substantially flat in one direction and the portions of the adjacent walls of the cope and drag mold portions to form an enhanced bearing surface sidewall portion of the perimeter boundary of the mold cavity that forms the enhanced bearing surface of the coupler knuckle casting when the cavity is at least partially filled with the molten alloy.  
   
   
       22 . A method of casting a coupler knuckle casting in accordance with  claim 21 , wherein the step of providing the cope mold portion and the drag mold portion includes the step of providing the portions of the walls of the cope and drag mold portions at tapered angles, the tapered angles of the portions of the walls being tapered at an angle relative to the one or more surfaces substantially flat in one direction of the core, the angles being inclined inwardly relative to the cavity and away from the one or more surfaces substantially flat in one direction of the core.  
   
   
       23 . A method of casting a coupler knuckle casting in accordance with  claim 22 , wherein the ratio between one of the portions of the walls of the cope and drag mold portions having tapered angles and the one or more surfaces substantially flat in one direction of the core is between about 3:10 and 7:10.  
   
   
       24 . A method of casting a coupler knuckle casting in accordance with  claim 23 , wherein the ratio between one of the portions of the walls of the cope and drag mold portions having tapered angles and the one or more surfaces substantially flat in one direction of the core is about 1:2.  
   
   
       25 . A method of casting a coupler knuckle casting in accordance with  claim 20 , wherein the enhanced bearing surface is positioned on at least a portion of the pulling face portion of the coupler knuckle casting.  
   
   
       26 . A method of casting a coupler knuckle casting in accordance with  claim 25 , wherein the enhanced bearing surface is positioned on at least a portion of a nose section of the coupler knuckle casting.  
   
   
       27 . A method of casting a coupler knuckle casting in accordance with  claim 25 , wherein the enhanced bearing surface is positioned on at least a portion of a throat of the coupler knuckle casting.  
   
   
       28 . A method of casting a coupler knuckle casting in accordance with  claim 25 , wherein the enhanced bearing surface is positioned on at least a portion of the pulling face portion and the throat of the coupler knuckle casting, the portion of the enhanced bearing surface extending from the enhanced bearing surface to a tangent surface between two radii of the throat.  
   
   
       29 . A method of casting a coupler knuckle casting in accordance with  claim 20 , wherein the enhanced bearing surface is positioned on at least a portion of the inner side region of the locking face of the coupler knuckle casting.  
   
   
       30 . A method of casting a coupler knuckle casting in accordance with  claim 29 , wherein the enhanced bearing surface is positioned on at least a portion of the pulling face portion of the coupler knuckle casting.  
   
   
       31 . A method of casting a coupler knuckle casting in accordance with  claim 30 , including the step of using the core to form the enhanced bearing surfaces on the pulling face portion and inner side region of the locking face of the coupler knuckle casting.  
   
   
       32 . A method of casting a coupler knuckle casting for a railway car coupler, the coupler knuckle casting having an enhanced bearing surface with a substantially flat portion in one direction, the method comprising: 
 means for providing a mold cavity having perimeter boundaries;    means for providing a portion of the perimeter boundaries with one or more surfaces substantially flat in one direction for forming at least a portion of the enhanced bearing surface; and    means for casting the coupler knuckle casting in the mold cavity.    
   
   
       33 . A method of casting a coupler knuckle casting in accordance with  claim 32 , including means for providing a portion of the perimeter boundaries adjacent the one or more surfaces substantially flat in one direction and on both sides of the one or more surfaces with a taper inward relative to the cavity.  
   
   
       34 . A coupler knuckle casting for a railway car coupler, the coupler knuckle casting comprising: 
 tail, hub and front face sections, the front face section having a nose section and the hub section having a pivot pin hole with a vertical axis; and    a pulling face portion forward inwardly of the front face section and having an enhanced bearing surface having a portion substantially flat in a vertical direction generally parallel to the vertical axis of the pivot pin hole.    
   
   
       35 . A coupler knuckle casting in accordance with  claim 34 , wherein the portion of the enhanced bearing surface that is substantially flat in the vertical direction is substantially arcuate in a horizontal direction generally normal to the vertical axis of the pivot pin hole.  
   
   
       36 . A coupler knuckle casting in accordance with  claim 35 , wherein portions of the enhanced bearing surface on either side of the substantially flat portion are tapered inwardly relative to the flat portion.  
   
   
       37 . A coupler knuckle casting in accordance with  claim 36 , wherein the ratio between the flat portion and either of the inwardly tapered portions is between about  3 : 10  and  7 : 10 .  
   
   
       38 . A coupler knuckle casting in accordance with  claim 37 , wherein the ratio between the flat portion and either of the inwardly tapered portions is about 1:2.  
   
   
       38 . A coupler knuckle casting in accordance with  claim 34 , wherein the enhanced bearing surface is positioned on at least a portion of the nose section of the coupler knuckle casting.  
   
   
       39 . A coupler knuckle casting in accordance with  claim 34 , wherein the enhanced bearing surface is positioned on at least a portion of a throat of the coupler knuckle casting.  
   
   
       40 . A coupler knuckle casting in accordance with  claim 34 , wherein the enhanced bearing surface is positioned on at least a portion of the inner side region of the locking face of the coupler knuckle casting.  
   
   
       41 . A method of casting a coupler knuckle casting for a railway car coupler comprising: 
 providing a cope mold portion and a drag mold portion, the cope and drag mold portions having internal walls defining at least in part the perimeter boundaries of a mold cavity;    positioning one or more cores in the mold cavity of either the cope or drag mold portion, one of the cores having surfaces for forming both a portion of a lock wall and a bearing surface of a pulling face portion of the knuckle;    closing the cope and drag mold portions with the one or more cores therebetween; and    at least partially filling the cavity with a molten alloy, the molten alloy solidifying after filling to form the coupler knuckle casting.    
   
   
       42 . A method of casting a coupler knuckle casting for a railway car coupler in accordance with  claim 41 , wherein the surface for forming the bearing surface of the one of the cores is substantially flat in a vertical direction.