CEN/TR 17469:2020

Railway applications - Axle design method

This document presents the stage of knowledge resulting from the Euraxles project about the design of the axle, and further steps to be taken.
It is the support:
- to define the loads to be taken into account;
- to describe the stress calculation method using finite elements and the validation processes associated;
- to specify the maximum permissible stresses to be assumed in calculations and the safety factors to be used.
This technical report is applicable for:
- wheelset Axles defined in EN 13261 as "pure wheelset";
- other axle designs such as those encountered in particular rolling stocks e.g. with independent wheels, variable gauges, urban rail...
This document has not for aim to replace EN 13103-1 and CEN/TS 13103-2 but to present a complementary method to the existing ones.

Bahnanwendungen - Konstruktionsverfahren von Radsatzwellen

Applications ferroviaires - Méthode de conception des essieux-axes

Le présent document décrit l'état des connaissances acquises dans le cadre du projet EURAXLES en ce qui concerne la conception des essieux-axes, ainsi que les autres éléments à prendre en compte.
Il a pour objet de :
- définir les charges à prendre en compte ;
- décrire la méthode de calcul des contraintes selon la méthode des éléments finis, ainsi que les processus de validation associés ;
- spécifier les contraintes maximales admissibles à utiliser pour les calculs, ainsi que les coefficients de sécurité à appliquer.
Le présent Rapport technique est applicable aux :
- essieux montés définis dans l'EN 13261 ;
- autres conceptions d'essieux-axes rencontrées sur les matériels roulants particuliers, par exemple les essieux-axes équipés de roues indépendantes, à écartement variable ou empruntant le réseau ferroviaire urbain, etc.
Le présent document n'a pas pour objet de remplacer l'EN 13103 1 et la CEN/TS 13103-2, mais de décrire une méthode complémentaire aux méthodes actuelles.

Železniške naprave - Metoda načrtovanja osi

General Information

• Status: Published
• Publication Date: 24-Mar-2020
• ICS: 45.040 - Materials and components for railway engineering
• Technical Committee: CEN/TC 256 - Railway applications
• Drafting Committee: CEN/TC 256/SC 2/WG 11 - Wheels - Wheelsets
• Current Stage: 6060 - Definitive text made available (DAV) - Publishing
• Start Date: 25-Mar-2020
• Due Date: 22-Feb-2020
• Completion Date: 25-Mar-2020
• Directive: 2008/57/EC - Directive 2008/57/EC of the European Parliament and of the Council of 17 June 2008 on the interoperability of the rail system within the Community (Recast)
• Mandate: M/483 - Mandate for programming and standardisation addressed to the European standardisation bodies under directive 2008/57/EC in the field of the interoperability of the rail system within the European Union
• Ref Project: SIST-TP CEN/TR 17469:2020 - Railway applications - Axle design method

Standards Content (Sample)

SLOVENSKI STANDARD
01-junij-2020
Železniške naprave - Metoda načrtovanja osi
Railway applications - Axle design method
Bahnanwendungen - Konstruktionsverfahren von Radsatzwellen
Applications ferroviaires - Méthode de conception des essieux
Ta slovenski standard je istoveten z: CEN/TR 17469:2020
ICS:
45.040 Materiali in deli za železniško Materials and components
tehniko for railway engineering
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

CEN/TR 17469
TECHNICAL REPORT
RAPPORT TECHNIQUE
March 2020
TECHNISCHER BERICHT
ICS 45.040
English Version
Railway applications - Axle design method
Applications ferroviaires - Méthode de conception des Bahnanwendungen - Konstruktionsverfahren von
essieux Radsatzwellen
This Technical Report was approved by CEN on 24 February 2020. It has been drawn up by the Technical Committee CEN/TC
256.
CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,
Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway,
Poland, Portugal, Republic of North Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and
United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION

EUROPÄISCHES KOMITEE FÜR NORMUNG

CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels
© 2020 CEN All rights of exploitation in any form and by any means reserved Ref. No. CEN/TR 17469:2020 E
worldwide for CEN national Members.

Contents Page
European foreword . 4
Introduction . 5
1 Scope . 9
2 Normative references . 9
3 Terms, definitions, symbols and abbreviations . 9
3.1 Terms and definitions . 9
3.2 Symbols and abbreviations . 9
4 Loads . 11
4.1 Reliability analysis based on the Stress Strength Interference Analysis method . 11
4.2 Fatigue load analysis method . 13
4.2.1 General . 13
4.2.2 Load signals processing and Fatigue-Equivalent-Load . 13
4.2.3 Method to generate the distribution of in-service load severities . 19
4.3 Fatigue reliability assessment of a railway passenger coach axle . 23
4.3.1 Load measurements . 23
4.3.2 Load spectra classification and generation and distribution of load severity. 27
4.3.3 Estimation of the probability of a crack initiation . 31
5 Modelling . 33
5.1 General . 33
5.2 Stress concentration factors . 33
5.3 Length of the transition . 36
5.4 Numerical modelling of axles . 38
5.4.1 Development of numerical models and validation . 38
5.4.2 Analysis of mounted components . 42
5.4.3 Modelling recommendations . 43
5.5 Axle calculation method . 44
6 Fatigue limits . 45
6.1 Testing method principals . 45
6.1.1 F1 tests . 45
6.1.2 F4 tests . 46
6.1.3 Fatigue limit estimation . 46
6.2 Test plan . 47
6.3 Axle body fatigue limit results . 51
6.3.1 F1 standard surface – transitions and groves (EA4T axles) . 51
6.3.2 F1 Blasted surface – transitions (EA4T axles) . 52
6.3.3 F1 Standard surface – transitions (EA1N axles) . 53
6.3.4 F1 Corroded surfaces – transitions of unpainted axles . 54
6.4 Axle press-fit seat fatigue limits (F4) . 55
6.4.1 Diameter ratio = 1,12 (EA4T axles) . 55
6.4.2 Diameter ratio = 1,08 (EA4T) . 56
7 Safety factors. 57
7.1 Aims and problem statement. 57
7.2 Probabilistic fatigue assessment . 60
7.2.1 Failure probability under constant amplitude stress . 60
7.2.2 Fatigue damage under VA loading . 60
7.2.3 Bignonnet method . 61
7.3 Input data for probabilistic fatigue assessment of railway axles . 62
7.3.1 Definitions of reference S-N diagrams . 62
7.3.2 Miner Index at failure. 63
7.3.3 Target reliability and failure rate for railway axles . 66
7.4 Probabilistic fatigue damage calculations for railway axles . 66
7.4.1 Format for the calculations . 66
7.4.2 Montecarlo simulations . 67
7.4.3 Stress spectra . 67
7.5 Results . 68
7.5.1 General . 68
7.5.2 Safety factor and reliability under constant amplitude stress . 69
7.5.3 Safety factor for damage calculations . 70
8 Conclusions of Euraxles Project . 71
9 Recommendations of CEN TC256/SC2/WG11 . 75
Annex A (informative) Application example of the axle calculation method . 76
A.1 General . 76
A.2 General descriptions . 76
A.3 Load distribution . 77
A.4 Results according to EN 13103-1 . 78
A.5 Design of EURAXLES method . 80
A.6 Comparison of results . 82
Bibliography . 83

European foreword
This document (CEN/TR 17469:2020) has been prepared by Technical Committee CEN/TC 256 “Railway
applications”, the secretariat of which is held by DIN.
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. CEN shall not be held responsible for identifying any or all such patent rights.
Introduction
The first railway accident due to the fatigue failure of an axle occurred on 1842, May 8th, in France, near
Meudon, on the Versailles-Paris line.
In those days, the fatigue phenomenon was unknown. This failure initiated numerous studies including
German Engineer August WOHLER works on wheelset failures at the end of XIX century.
In the middle of XX century, M. KAMMERER, an engineer working for French railways, established the
bases for the calculation of wheelset axles.
At international level, the report ORE B136 RP11 « Calculation of fret wagon and passenger coaches’
wheelset axles » was edited in April 1979, using in particular the French approach.
This document allowed editing on 1994, July 1st of UIC leaflet 515-3 «Railway rolling stock – Bogie –
Running gears – Axle calculation method».
The first edition of the European Standards about design of axles occurs on April 2001 (EN 13103 for
non-powered axles for powered axles).
The ongoing European standardization has allowed the merging of EN 13103 in only one standard
(EN 13103-1 Railway applications – Wheelsets and bogies – Part 1: Design method for axles with external
journals) and the creation of a new Technical Specification about internal journal (CEN/TS 13103-2
Railway applications – Wheelsets and bogies – Part 2: Design method for axles with internal journals).
All these documents, including M. KAMMERER’s work up to EN 13103-1 and CEN/TS 13103-2, use the
beam theory calculation method. The stresses taken into account are then the nominal stresses. The
fatigue limit is determined from full scale tests in which nominal stresses are taken into account.
Concentration factors are defined from tests to consider the local geometry and to increase the nominal
stress locally. The method is quite simple, with no need of sophisticated calculations or dedicated
software.
On another hand, in the middle of XX century, the need in mechanic
...