SIST EN 12080:2008
(Main)Railway applications - Axleboxes - Rolling bearings
Railway applications - Axleboxes - Rolling bearings
This European Standard specifies the quality parameters of axlebox rolling bearings, required for reliable operation of trains on European networks. It covers metallurgical and material properties as well as geometric and dimensional characteristics. It also defines methods for quality assurance and conditions for approval of the products.
Bahnanwendungen - Radsatzlager - Wälzlager
Diese Europäische Norm legt die Qualitätsanforderungen für Wälzlager von Radsatzlagern fest, die für einen zuverlässigen Zugbetrieb auf den europäischen Schienennetzen erforderlich sind. Sie beschreibt metallurgische Eigenschaften und Werkstoffeigenschaften und legt die Maß- und Formgenauigkeit fest. Darüber hinaus legt sie Verfahren der Qualitätssicherung und Freigabebedingungen fest.
Applications ferroviaires - Boîtes d'essieux - Roulements
La présente Norme européenne définit pour les roulements de boîtes d’essieux les paramètres de qualité requis pour assurer la fiabilité de la circulation des trains sur les réseaux européens. Elle comprend les caractéristiques métallurgiques et les propriétés des matériaux ainsi que les caractéristiques géométriques et dimensionnelles. Elle définit les métho¬des d’assurance qualité et les conditions pour l’homologation des produits.
Železniške naprave - Ohišja ležajev kolesnih dvojic - Kotalni ležaji
General Information
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Standards Content (Sample)
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Railway applications - Axleboxes - Rolling bearingsŽelezniške naprave - Ohišja ležajev kolesnih dvojic - Kotalni ležajiApplications ferroviaires - Boîtes d'essieux - RoulementsBahnanwendungen - Radsatzlager - WälzlagerTa slovenski standard je istoveten z:EN 12080:2007SIST EN 12080:2008en,fr,de45.04021.100.20ICS:SIST EN 12080:20011DGRPHãþDSLOVENSKI
STANDARDSIST EN 12080:200801-marec-2008
EUROPEAN STANDARDNORME EUROPÉENNEEUROPÄISCHE NORMEN 12080December 2007ICS 21.100.20; 45.040Supersedes EN 12080:1998
English VersionRailway applications - Axleboxes - Rolling bearingsApplications ferroviaires - Boîtes d'essieux - RoulementsBahnanwendungen - Radsatzlager - WälzlagerThis European Standard was approved by CEN on 8 November 2007.CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this EuropeanStandard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such nationalstandards may be obtained on application to the CEN Management Centre or to any CEN member.This European Standard exists in three official versions (English, French, German). A version in any other language made by translationunder the responsibility of a CEN member into its own language and notified to the CEN Management Centre has the same status as theofficial versions.CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland,France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal,Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.EUROPEAN COMMITTEE FOR STANDARDIZATIONCOMITÉ EUROPÉEN DE NORMALISATIONEUROPÄISCHES KOMITEE FÜR NORMUNGManagement Centre: rue de Stassart, 36
B-1050 Brussels© 2007 CENAll rights of exploitation in any form and by any means reservedworldwide for CEN national Members.Ref. No. EN 12080:2007: E
EN 12080:2007 (E) 2 Contents Page Foreword.4 Introduction.5 1 Scope.6 2 Normative references.6 3 Terms and definitions.6 4 Information and requirements to be agreed and documented.7 4.1 General.7 4.2 Information to be supplied by customer.7 4.3 Optional requirements.8 4.4 Requirements for agreement.8 5 Quality systems.8 6 Manufacture.9 6.1 Steel manufacturing.9 6.2 Heat treatment.9 6.3 Traceability.9 7 Material properties.9 7.1 General.9 7.2 Steel for rings and rolling elements.9 7.3 Materials of other components (cages, spacers, seals etc.).10 8 Geometry and dimensions.10 8.1 Dimensions and tolerances.10 8.2 Rolling bearing internal clearance before mounting.10 9 Mechanical properties — inner ring expanding ability.10 10 Physical properties.10 10.1 Visual aspect.10 10.2 Soundness of rings and rolling elements.11 10.3 Case depth.11 10.4 Surface hardness.12 11 Marking.12 12 Inspection.12 12.1 Inspection plan.12 12.2 Sampling.13 13 Quality records.13 14 Approval.14 15 Delivery and packing.14 15.1 Greasing of rolling bearings.14 15.2 Rust protection.14 15.3 Packaging.14 Annex A (normative)
Ultrasonic inspection of rolling bearing rings.15 A.1 Purpose.15 A.2 Principle.15 A.3 Equipment.15 A.4 Operating procedure.15
EN 12080:2007 (E) 3 Annex B (normative)
Magnetic particle inspection of ring surfaces.20 B.1 Purpose.20 B.2 Principle.20 B.3 Equipment.20 B.4 Operation procedure.20 Annex C (normative)
Eddy current inspection of the raceways of the rollers.22 C.1 Purpose.22 C.2 Principle.22 C.3 Equipment.22 C.4 Operating procedure.22 Annex D (informative)
Cages of polymeric material.25 D.1 Purpose.25 D.2 References.25 D.3 Material.25 D.4 Cage requirement.26 D.5 Mechanical tests.27 D.5 Compatibility with lubricating greases.29 Annex E (normative)
Approval procedures.30 E.1 General.30 E.2 Complete procedure, type C.30 E.3 Reduced procedure, type R.31 Annex F (informative)
Criteria to determine the extent of approval procedures.32 Annex ZA (informative)
Relationship between this European standard and the Essential Requirements of EU Directive 2001/16/EC of the European Parliament and of the Council of 19 March 2001 on the interoperability of the trans-European conventional rail system, as modified by EU Directive 2004/50/EC of 29 April 2004.34 Bibliography.35
EN 12080:2007 (E) 4 Foreword This document (EN 12080:2007) has been prepared by Technical Committee CEN/TC 256 “Railway applications”, the secretariat of which is held by DIN. This European Standard shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by June 2008, and conflicting national standards shall be withdrawn at the latest by June 2008. This document supersedes EN 12080:1998. This European Standard has been prepared under a mandate given to CEN/CENELEC/ETSI by the European Commission and the European Free Trade Association to support Essential Requirements of EU Directive 2001/161), as modified by EU Directive 2004/502) of 29 April 2004. For relationship with EU Directives, see informative Annex ZA, which is an integral part of this document. According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.
1) Official Journal of the European Communities No. L 110 of 20.4.01. 2) Official Journal of the European Communities No. L 220 of 21.6.04.
EN 12080:2007 (E) 5 Introduction This European Standard has been drawn up with the purpose of aiming at optimum performance in rail transportation. Performance implies a certain quality level of the vehicle running gear, which every railway undertaking may require, notably by imposing procedures in approval and requesting the existence of a quality assurance system for the supply of rolling bearings intended for rolling stock operating on its network or other networks in Europe.
EN 12080:2007 (E) 6 1 Scope This European Standard specifies the quality parameters of axlebox rolling bearings, required for reliable operation of trains on European networks. It covers metallurgical and material properties as well as geometric and dimensional characteristics. It also defines methods for quality assurance and conditions for approval of the products. 2 Normative references The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN 12081, Railway applications — Axleboxes — Lubricating greases EN 12082, Railway applications — Axleboxes — Performance testing EN ISO 683-17, Heat treated steels, alloy steels and free-cutting steels — Part 17: Ball and roller bearing steels (ISO 683-17:1999) EN ISO 2639, Steels — Determination and verification of the depth of carburized and hardened cases
(ISO 2639:2002) EN ISO 6507-1, Metallic materials — Vickers hardness test — Part 1: Test method (ISO 6507-1:2005) EN ISO 6508-1, Metallic materials — Rockwell hardness test — Part 1: Test method (scales A, B, C, D, E, F, G, H, K, N, T) (ISO 6508-1:2005) EN ISO 6508-2, Metallic materials — Rockwell hardness test — Part 2: Verification and calibration of testing machines (scales A, B, C, D, E, F, G, H, K, N, T) (ISO 6508-2:2005) EN ISO 6508-3, Metallic materials — Rockwell hardness test — Part 3: Calibration of reference blocks (scales A, B, C, D, E, F, G, H, K, N, T) (ISO 6508-3:2005) ISO 281, Rolling bearings — Dynamic load ratings and rating life ISO 492, Rolling bearings — Radial bearings — Tolerances 3 Terms and definitions For the purposes of this document, the following terms and definitions apply. 3.1 customer railway undertaking, manufacturer or buyer of railway rolling stock or subassemblies, or their representative 3.2 railway undertaking organisation or its representative, whatever status it has, which is responsible for the registration of rolling stock 3.3 supplier supplier of axlebox rolling bearings manufactured under his responsibility
EN 12080:2007 (E) 7 3.4 network infrastructure, on which any railway undertaking can operate rolling stock 3.5 axlebox assembly of box housing, rolling bearings, sealing and grease 3.6 rolling bearing bearing, operating with rolling motion between the parts supporting load and moving in relation to each other 3.7 cartridge bearing rolling bearing with two or more rows of rolling elements within a single outer ring, greased and equipped with integral seals 3.8 ring annular part of a rolling bearing incorporating one or more raceways 3.9 rolling elements cylindrical, tapered or convex rollers or balls 3.10 cage component, which partly surrounds the rolling elements and moves with them 3.11 grease semi-solid lubricant, which consists of a thickener and additives dispersed in a lubricating oil 3.12 sealing component that protects the bearings against ingress of water and dust and retains the grease in the rolling bearings 3.13 box housing structural component which contains rolling bearings, sealing and grease 4 Information and requirements to be agreed and documented 4.1 General The following information shall be fully documented by the supplier. Both the requirements specified throughout this European Standard and the following documented requirements shall be satisfied before a claim of compliance with this European Standard can be made and verified. 4.2 Information to be supplied by customer The following information is to be supplied by customer and shall be fully documented: interface drawing showing mounting conditions; all dimensions of the space available for the rolling bearings; dimensions, tolerances and materials of shaft and box housing;
EN 12080:2007 (E) 8 load spectra; ambient temperatures in operation; if required special steel composition, cleanliness and soundness class (see 7.1 and 10.2); approval procedure type and conditions to be applied (see Clause 14 and Annex E); special conditions for quality records and traceability (see 6.3 and Clause 13). 4.3 Optional requirements If the customer wishes to take up any of the optional requirements given in 8.2, 10.2.1, 10.3, 10.4, Clause 11, Clause 12 and 15.2, such requirements shall be specified and documented. 4.4 Requirements for agreement The following requirements to be agreed between the contracting parties, which are specified in the clauses referred to, shall be fully documented: boundary dimensions and interface tolerances of the rolling bearing (see Clause 8); internal clearance values before and after mounting (see Clause 8); references to standards and special requirements (see Clause 7 and 10.2); use of steel of special composition, manufacture or metallurgical quality (see 7.1); soundness Class, 1 or 2, and the test methods to be used (see 10.2); type of heat treatment to be applied and methods of testing (see 6.2, 10.3, 10.4 and 12.2); marking (see Clause 11); inspection plan (see 12.1); for cartridge bearings grease designation, quantity and distribution (see 15.1); for non-sealed bearings, grease designation and compatibility with preservatives (see 15.2); selection of mechanical testing method for cages of polymeric material (see D.5.1). 5 Quality systems The supplier shall operate a quality management system3). The personnel responsible for non destructive testing shall be qualified and certified4).
3) The system used should offer equivalence with EN ISO 9001. 4) The system used should offer equivalence with EN 473.
EN 12080:2007 (E) 9 6 Manufacture 6.1 Steel manufacturing The process of steel manufacture in mass production shall be such that the metallurgical characteristics are the same as those of the rolling bearings submitted for the approval procedure. NOTE The choice of manufacturing procedures is left to the discretion of the supplier. 6.2 Heat treatment The heat treatment processes for the rolling bearing components shall be such that the hardness values specified in 10.3 and/or 10.4 are respected. The heat treatment processes shall be such that all the rolling bearings produced in a production batch are treated uniformly. The bearings shall be heat-treated to retain dimensional stability for operating temperatures up to + 150 °C, (designated S0 stabilisation in bearing catalogues). 6.3 Traceability At the customer's request, the supplier shall set up and maintain a system of identification and traceability of finished products (see Clause 4), which allows the detection, based on an identification mark, of the following elements: material origin including the chemical analysis of every heat and steel manufacturing batch; heat treatments; inspection of boundary dimensions as well as inspection of soundness; batch number. 7 Material properties 7.1 General The grades and qualities of materials used shall conform to the requirements in 7.2 and 7.3. 7.2 Steel for rings and rolling elements 7.2.1 Grades Steels should be selected from the grades specified in EN ISO 683-17. Alternative steel grades selected by bearing suppliers may be used by agreement between customer and supplier. For particular applications (high rotational speed, reliability etc.) it may be requested that the rolling bearings are made from steel with special composition, metallurgical quality or manufacturing processes (see Clause 4). 7.2.2 Inclusion content The methods for determining the inclusion content shall be agreed between customer and supplier. The applicable acceptance limits shall meet the requirements of EN ISO 683-17. For steel with special composition, metallurgical quality or manufacturing processes, the inclusion content shall be documented in accordance with Clause 4.
EN 12080:2007 (E) 10 7.3 Materials of other components (cages, spacers, seals etc.) The materials of each one of these components shall be documented in accordance with Clause 4 and endorsed by the customer at the time of approval. For cages of polymeric material, if not otherwise specified, refer to Annex D. 8 Geometry and dimensions 8.1 Dimensions and tolerances The boundary dimensions shall be agreed and documented in accordance with 4.4. Applicable tolerances shall be those given in ISO 492, normal tolerance class, unless otherwise agreed and documented in 4.4. 8.2 Rolling bearing internal clearance before mounting Rolling bearing internal clearance, axial and/or radial, depending on the type of rolling bearing, shall conform to the values documented in accordance with 4.4. The methods for radial and/or axial clearance inspection can be agreed and documented in accordance with 4.3. 9 Mechanical properties — inner ring expanding ability With the exception of case-hardened rings and bainite hardened rings, an expansion test shall be performed to guarantee that the inner rings can withstand an increase of the bore diameter without causing fracture in service. This test shall be performed before the inspection for surface soundness. The value of this diameter increase shall not be less than 0,001 5 times the diameter. The rings shall neither rupture nor show any traces of cracks (see 10.2.3). This expansion test shall be made with an expandable mandrel that is inserted in the bore of the inner ring. The expansion shall be achieved progressively in a few seconds. 10 Physical properties 10.1 Visual aspect 10.1.1 Rings and rolling elements Rings and rolling elements shall be free of any defects, especially on working surfaces, which can be harmful to their function (such as burrs, scratches, rust stains, nicks and dents). 10.1.2 Cages Rolling bearing cages shall exhibit no defects that might affect their function (such as burrs, scratches, rust). To avoid crack initiation, the connection between the cage bars and the annular body shall be smooth and conform to the rounding-off shown on the detail drawing. If not otherwise documented in accordance with Clause 4, the requirements for cages of polymeric material shall be taken into account (see Annex D).
EN 12080:2007 (E) 11 10.2 Soundness of rings and rolling elements 10.2.1 General rules Rings and rolling elements shall have no internal defects, nor any form of surface defect that may be harmful to their function. The soundness shall be inspected by the manufacturer. The methods are described in Annexes A, B and C. Any alternative methods to be used, which give equivalent results, shall be agreed and documented in accordance with 4.4. Two soundness classes are defined: Class 1, with the highest demands; Class 2. The classification only concerns the ring internal soundness (see Annex A). NOTE For vehicle speeds ≥ 200 km/h Class 1 is recommended. 10.2.2 Internal soundness of rings The reference method for the inspection of internal soundness of rings is described in Annex A. When tested, no ring shall exhibit defect indications on the raceway, or in a section of 4 mm depth below the raceway, with the amplitude equal to or greater than that observed with the master defect corresponding to the soundness class in question in accordance with Annex A. Larger defects are tolerated deeper than this section, though the defect indications shall not be more than twice the amplitude of that observed with the master defect. 10.2.3 Soundness of ring surfaces The reference method for the inspection of surface soundness of rings is described in Annex B. When tested, no evidence of defects shall be observed on any of the ring surfaces. NOTE Surface soundness inspection of rings can also be carried out with an approved equivalent standardized inspection method, e.g. a calibration and test procedure analogous to the eddy current testing of rollers in Annex C. 10.2.4 Soundness of roller raceway surfaces The reference method for the inspection of the raceway surface soundness of rollers is described in Annex C. When tested, no roller shall exhibit defect indications on its raceway with amplitude equal to or greater than that observed with the master defect as defined in Annex C. 10.2.5 Grinding burns There shall be no grinding burns during the different grinding operations. 10.3 Case depth For rolling bearings manufactured of case-hardening steel, the effective depth of the hardened case shall be documented in accordance with Clause 4. The depth of the hardened case is determined as a function of the change in hardness of the transversal cross section of a test piece or a prepared sample. The hardness shall be measured in accordance with EN ISO 6507-1 and EN ISO 2639 or another process agreed and documented in accordance with 4.4. At this depth, the Vickers hardness shall be at least 550 HV1.
EN 12080:2007 (E) 12 10.4 Surface hardness Rings and rolling elements shall have a Rockwell hardness (HRC) between 57 HRC and 66 HRC. There shall be no more than 4 HRC difference between the values measured: on all the rings of one rolling bearing; on all the rolling elements in one rolling bearing. Surface hardness shall be inspected according to the Rockwell method, referred to in EN ISO 6508-1 to -3. For case-hardened steel rolling bearings, surface hardness may be measured by the Vickers HV 30 method, referred to in EN ISO 6507-1, or by another equivalent method agreed and documented in accordance with 4.4. 11 Marking The supplier shall mark rolling bearings visibly and indelibly outside of any surfaces in contact with spacers, thrust rings etc. Should this not be possible, the marking area shall be agreed and documented in accordance with 4.4. The supplier is responsible for selecting the marking process. Where marking punches are used, these shall not have any sharp edges. Marking by electric pencil (spark erosion) is prohibited. If no other indications are given, the following marking is compulsory: supplier’s trade mark and country of origin; production plant code, if there is more than one plant; rolling bearing designation, including a reference to this European Standard and the soundness class; date of manufacture in clear or coded form. When rolling bearing components or sub-assemblies are not allowed to be interchanged, they shall be marked with a unique identification number. 12
Inspection 12.1 Inspection plan If not otherwise documented in accordance with 4.4, the sampling plan and the number of inspections to be undertaken by the supplier shall be in accordance with Table 1. The results shall be documented.
EN 12080:2007 (E) 13 Table 1 — Inspection plan Nature of inspections Number of inspections to be performed for a batch of N components or bearings
N ≤10 10 < N ≤ 50 50 < N ≤ 100 100 < N ≤ 250 250 < N ≤ 500 N > 500 Visual aspect 100 % 100 % 100 % 100 % 100 % 100 % Functional dimensions a 100 % 100 % 100 % 100 % 100 % 100 % Surface soundness b
100 % 100 % 100 % 100 % 100 % 100 % Internal soundness c 100 % 100 % 100 % 100 % 100 % 100 % Case depth b 1 1 2 3 4 5 Hardness b 1 2 3 5 7 10 Internal clearance d 100 % 100 % 100 % 100 % 100 % 100 % Inner ring expansion ability e 100 % 100 % 100 % 100 % 100 % 100 % Marking 100 % 100 % 100 % 100 % 100 % 100 % If a component or a bearing is found to be faulty: — whole batch shall be rejected, if inspection by sampling; — faulty component or rolling bearing shall be rejected, in case of 100 % inspection. a In accordance with 4.4. b On outer and inner rings, on rolling elements and on loose ribs and thrust collars. c On outer and inner rings. d Radial clearance for cylindrical and spherical roller bearings; axial clearance for cartridge bearings and matched pa
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