SIST EN 13979-1:2004+A1:2009
(Main)Railway applications - Wheelsets and bogies - Monobloc wheels - Technical approval procedure - Part 1: Forged and rolled wheels
Railway applications - Wheelsets and bogies - Monobloc wheels - Technical approval procedure - Part 1: Forged and rolled wheels
The aim of this European Standard is to define the requirements that a monobloc wheel of a freight of passenger railway vehicle non-powered axle shall meet in order to be able to be used on a European network.
For wheels of powered axles or wheels with noise dampers, the requirements may be amended or supplemented.
For light vehicles and tramways, other standards or documents accepted by the customer and supplier may be used.
This European Standard only applies to wheels of new design.
These requirements are intended to assess the validity of the design choice for the proposed use.
The assessment of these requirements is the technical approval procedure.
This European Standard is applicable to forged and rolled wheels for which the quality requirements are defined in EN 13262.
Bahnanwendungen - Radsätze und Drehgestelle - Vollräder - Technische Zulassungsverfahren - Teil 1: Geschmiedete und gewalzte Räder
Diese Europäische Norm legt Anforderungen fest, denen ein Vollrad für Eisenbahnfahrzeuge genügen muss, bevor es auf dem europäischen Eisenbahnnetz eingesetzt werden kann.
Für Räder von Treibradsätzen oder für Räder mit Schallabsorbern können die Anforderungen geändert werden.
Für Nahverkehrsfahrzeuge und Straßenbahnen können andere Normen oder Dokumente angewendet werden. Diese sind zwischen Kunden und Lieferanten zu vereinbaren.
Diese Norm gilt nur für neue Radkonstruktionen.
Der Zweck der Anforderungen besteht darin, die Wahl der Konstruktion für den betrachteten Anwendungs-bereich zu genehmigen.
Die Bewertung dieser Anforderungen wird technisches Zulassungsverfahren genannt.
Dieser Teil der Norm bezieht sich auf geschmiedete und gewalzte Räder, deren Qualitätsanforderungen in
EN 13262 festgelegt sind.
Applications ferroviaires - Essieux montés et bogies - Roues monobloc - Procédure d'homologation technique - Partie 1: Roues forgées et laminées
Železniške naprave - Kolesne dvojice in podstavni vozički - Monoblok kolesa - Postopek za tehnično odobritev - 1. del: Kovana in valjana kolesa
General Information
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Standards Content (Sample)
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Bahnanwendungen - Radsätze und Drehgestelle - Vollräder - Technische Zulassungsverfahren - Teil 1: Geschmiedete und gewalzte RäderApplications ferroviaires - Essieux montés et bogies - Roues monobloc - Procédure d'homologation technique - Partie 1: Roues forgées et laminéesRailway applications - Wheelsets and bogies - Monobloc wheels - Technical approval procedure - Part 1: Forged and rolled wheels45.040Materiali in deli za železniško tehnikoMaterials and components for railway engineeringICS:Ta slovenski standard je istoveten z:EN 13979-1:2003+A1:2009SIST EN 13979-1:2004+A1:2009en,fr01-maj-2009SIST EN 13979-1:2004+A1:2009SLOVENSKI
STANDARDSIST EN 13979-1:2004/kprA1:2009SIST EN 13979-1:20041DGRPHãþD
SIST EN 13979-1:2004+A1:2009
EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM
EN 13979-1:2003+A1
April 2009 ICS 45.040; 45.060.01 Supersedes EN 13979-1:2003English Version
Railway applications - Wheelsets and bogies - Monobloc wheels - Technical approval procedure - Part 1: Forged and rolled wheels
Applications ferroviaires - Essieux montés et bogies - Roues monobloc - Procédure d'homologation technique - Partie 1: Roues forgées et laminées
Bahnanwendungen - Radsätze und Drehgestelle - Vollräder - Technische Zulassungsverfahren - Teil 1: Geschmiedete und gewalzte Räder This European Standard was approved by CEN on 3 November 2003 and includes Amendment 1 approved by CEN on 24 February 2009.
CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national standards 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 translation under the responsibility of a CEN member into its own language and notified to the CEN Management Centre has the same status as the official 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 STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION EUROPÄISCHES KOMITEE FÜR NORMUNG
Management Centre:
Avenue Marnix 17,
B-1000 Brussels © 2009 CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Members. Ref. No. EN 13979-1:2003+A1:2009: ESIST EN 13979-1:2004+A1:2009
EN 13979-1:2003+A1:2009 (E) 2 Contents Page Foreword .4Introduction .51Scope .62Normative references .63Parameters for the definition of the application covered .63.1Parameters for geometrical interchangeability .63.1.1Functional requirements .63.1.2Assembly requirements .73.1.3Maintenance requirements .73.2Parameters for thermomechanical assessment .73.3Parameters for mechanical assessment .73.4Parameters for acoustic assessment .84Description of the wheel to be approved .85Assessment of the geometrical interchangeability .86Assessment of the thermomechanical behaviour .86.1General procedure .86.2First stage – Braking bench test .96.2.1Test procedure .96.2.2Decision criteria .96.3Second stage – Wheel fracture bench test . 106.3.1General . 106.3.2Test procedure . 106.3.3Decision criterion. 106.4Third stage – Field braking test . 106.4.1General . 106.4.2Test procedure . 106.4.3Decision criteria . 107Assessment of the mechanical behaviour . 117.1General procedure . 117.2First stage - Calculation . 117.2.1Applied forces . 117.2.2Calculation procedure . 127.2.3Decision criteria . 137.3Second stage – Bench test . 137.3.1General . 137.3.2Definition of bench loading and of the test procedure . 137.3.3Decision criteria . 138Assessment of the acoustical behaviour . 138.1General procedure . 138.2Calculation procedure . 148.3Field measurements . 148.4Decision criteria . 149Technical approval documents . 15Annex A (normative)
Assessment of the thermomechanical behaviour . 17A.1Assessment organigram . 17A.2Braking bench test procedure . 18SIST EN 13979-1:2004+A1:2009
EN 13979-1:2003+A1:2009 (E) 3 A.2.1Principle of the test . 18A.2.2Definition of braking . 18A.2.3Method of measuring the decision criteria . 18A.2.4Tests and measurements . 20A.2.5Anomalies. 21A.3Wheel fracture bench test procedure . 21A.3.1Principle of the test . 21A.3.2Definition of drag braking . 21A.3.3Pre-cracking of the rim . 22A.3.4Special measurement methods required for this test . 22A.3.5Tests and measurements . 22A.3.6Anomalies. 23A.4Field braking test procedure . 23A.4.1Principle of the test . 23A.4.2Definition of braking . 23A.4.3Method of measurement of the decision criteria . 24A.4.4Standard test run . 24A.4.5Tests and measurements . 25A.4.6Anomalies. 26Annex B (normative)
Organigram of the mechanical behaviour assessment . 27Annex C (informative)
Mechanical behaviour – Finite element code assessment . 28Annex D (informative)
Mechanical behaviour – Bench loading and test procedure . 29D.1Principle of bench loading and test procedure . 29D.2Definition of loading . 29D.2.1General . 29D.2.2Measurement of the stresses during field tests . 30D.3Fatigue bench test . 30D.3.1Method 1 – Random fatigue test . 30D.3.2Method 2 – Single-stage fatigue test . 31Annex E (informative)
Assessment of the acoustical behaviour . 34E.1Assessment organigram. 34E.2Calculation procedure . 35E.2.1Preliminary comment . 35E.2.2Calculation of the wheel modal basis . 35E.2.3Selection of the reference track model . 35E.2.4Definition of the calculation parameters . 35E.2.5Power calculation . 35E.2.6Insertion. 36E.2.7Calculations of the decision criteria for acoustical technical approval of the wheel . 37E.2.8Optional calculations . 37E.3Field measurement procedure . 37E.3.1Objective and preliminary remark . 37E.3.2Recommendations for the operating conditions . 38E.3.3Measurement procedure . 41E.3.4Analysis of results . 43Annex F (informative)
!!!!Drag braking values for interoperability"""" . 46Annex ZA (informative)
!!!!Relationship between this European Standard and the Essential Requirements of EU 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"""" . 47Bibliography . 49 SIST EN 13979-1:2004+A1:2009
EN 13979-1:2003+A1:2009 (E) 4 Foreword This document (EN 13979-1:2003+A1:2009) 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 October 2009, and conflicting national standards shall be withdrawn at the latest by October 2009. This document includes Amendment 1, approved by CEN on 2009-02-24. This document supersedes EN 13979-1:2003. The start and finish of text introduced or altered by amendment is indicated in the text by tags ! ". Annexes A and B are normative. !Annexes C, D, E and F are informative." This document contains a bibliography. This European Standard is part of a series of two EN 13979 standards, Part 2 of which is:
!Part 2: Cast wheels." !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. SIST EN 13979-1:2004+A1:2009
EN 13979-1:2003+A1:2009 (E) 5 Introduction To date, UIC regulations specified that for a wheel to be used in Europe: its design had to be standardized; it had to conform to the quality requirements of UIC leaflet 812-3. In order to be able to adapt to new railway working conditions, on the one hand, and to facilitate the introduction of new technical solutions, on the other, it has been necessary to replace the concept of standardization with the definition of specifications that a wheel design shall meet to be accepted on a European network. The standard covers these specifications and describes precisely how to assess the wheel design. To be able to apply these specifications, it is essential to define the use of the wheel; this standard also states how to define this use. At least four aspects are described with different purposes: a geometrical aspect: to allow interchangeability of different solutions for the same application; a thermomechanical aspect: to manage wheel deformations and to ensure that braking will not cause wheels to break; a mechanical aspect: to ensure that no fatigue cracks occur in the web; an acoustical aspect: to ensure that the solution chosen is as good as the reference wheel, for the use in question. For each of these three latter aspects, the rules proposed tend to limit the procedure, the easier the objectives are to attain by the wheel under study. This standard does not cover assessment of the hub nor of the static mechanical dimensioning of the wheel. SIST EN 13979-1:2004+A1:2009
EN 13979-1:2003+A1:2009 (E) 6
1 Scope The aim of this European Standard is to define the requirements that a monobloc wheel of a freight of passenger railway vehicle non-powered axle shall meet in order to be able to be used on a European network. For wheels of powered axles or wheels with noise dampers, the requirements may be amended or supplemented. For light vehicles and tramways, other standards or documents accepted by the customer and supplier may be used. This European Standard only applies to wheels of new design. These requirements are intended to assess the validity of the design choice for the proposed use. The assessment of these requirements is the technical approval procedure. This European Standard is applicable to forged and rolled wheels for which the quality requirements are defined in !EN 13262". 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 12668-3, Non-destructive testing – Characterization and verification of ultrasonic examination equipment – Part 3: Combined equipment EN 13103, Railway applications – Wheelsets and bogies – Non-powered axles – Design !guide" !EN 13262", Railway applications – Wheelsets and bogies – Wheels –
Product requirements 3 Parameters for the definition of the application covered The application for which the wheel is to be approved shall be defined by the following parameters. If the application parameters are changed for an approved wheel, the customer and supplier shall review the assessments. 3.1 Parameters for geometrical interchangeability The application shall be defined by geometrical interchangeabliity parameters divided into three categories according to whether they are linked to functional, assembly or maintenance requirements. 3.1.1 Functional requirements the nominal tread diameter that influences the buffer height and the loading gauge; the maximum rim width
linked to the points and crossing and the track brakes; the tread profile outside the conical part of the tread; SIST EN 13979-1:2004+A1:2009
EN 13979-1:2003+A1:2009 (E) 7 the position of the rim internal surface relative to the corresponding surface of the hub;
the conicity of the hub bore; the space required for disc brakes mounted on the wheel; the space needed on the bogie frame, braking equipment and suspension equipment. 3.1.2 Assembly requirements the bore diameter; the hub length to ensure overhanging of the hub on the wheelseat. 3.1.3 Maintenance requirements the wear limit diameter or the last reprofiling diameter; the wear groove shape; the geometry of the area for wheel clamping on reprofiling machines; the position and shape of the hole and groove for displacement under oil pressure; the general rim shape to allow ultrasonic measurement of residual stresses in wheels braked by shoes. 3.2 Parameters for thermomechanical assessment The application shall be defined by: the maximum braking energy created by the friction of the brake shoes on the rail surface. This energy may be defined by a power Pa, a time ta and a train speed Va during drag braking. If it is defined by other parameters (for braking to a stop, for example), these parameters are defined by agreement between the customer and the supplier; the type of brake shoes applied to the wheel (nature, dimensions and number). !NOTE For interoperable freight rolling stock, the thermomechanical behavior does not need to be verified when braking to a stop, but only drag braking, because of the lower energy in stop braking." 3.3 Parameters for mechanical assessment The application shall be defined by: the maximum vertical static force
per wheelset; the type of service to be provided by the vehicles that will be fitted with the wheels to be approved: description of the lines: geometric quality of the tracks, curve parameters, maximum speeds . ; running times on these lines; the calculated service life of the wheel, in kilometres. SIST EN 13979-1:2004+A1:2009
EN 13979-1:2003+A1:2009 (E) 8 3.4 Parameters for acoustic assessment The application shall be defined by all the parameters influencing the noise emitted by the wheel and not directly involved in the design of the wheel to be approved, such as: the reference track on which the wheel is to run; the reference wheel to which the design will be compared; the reference rolling stock and one or more reference speeds; one or two surface roughness spectra representative of the range of operational values of the wheel under test. 4 Description of the wheel to be approved The designer of the wheel to be approved shall supply documentation comprising: the description of the fabrication process (forging, rolling, heat treatment,…); the definition of the wheel geometry (drawing); the following fabrication parameters, if they differ from those defined in !EN 13262": geometrical tolerances; surface finishes; steel grade; the parameters for defining the application for which the approval is requested. At the end of this technical approval procedure and before being put into service, a wheel shall be subjected to the product qualification procedure defined in !EN 13262".
5 Assessment of the geometrical interchangeability The wheel design shall conform to the requirements of 3.1. 6 Assessment of the thermomechanical behaviour 6.1 General procedure This assessment may comprise three stages. The transition from one stage to the next depends on the results obtained. The flowchart for this assessment is shown in normative annexe A. For each of the three stages, the test shall be carried out on a new rim (nominal tread diameter) and a worn rim (wear limit tread diameter). SIST EN 13979-1:2004+A1:2009
EN 13979-1:2003+A1:2009 (E) 9 In each case, new rim and worn rim, the web geometry of the tested wheels shall be the least favourable for thermomechanical behaviour within the geometrical tolerance ranges. The wheel designer shall prove, by numerical simulation, that the tested wheels give the worst results. If that is not the case, the numerical simulation shall allow the results that would be obtained on wheels not in the most unfavourable geometrical conditions to be corrected. !Required values of Pa for European interoperability are given in informative Annex F." In order to allow measurement of residual stress, the wheels to be tested shall not have either a wear limit groove or a bevel. NOTE For the moment, the calculation codes and thermomechanical parameters are too imprecise and not well known enough to be used as assessment parameters in a standard. In future, if this situation develops, a thermomechanical calculation should be made as the first stage of the assessment. 6.2 First stage – Braking bench test 6.2.1 Test procedure The test method and the measurements to be made are given in normative annex A. The power to be applied during this test shall be equal to 1,2 Pa (Pa is defined in 3.2). The duration of each drag braking period and the train speed are those defined in 3.2 (ta and Va). 6.2.2 Decision criteria Three criteria shall be met simultaneously for the wheel with the new rim and the wheel with the worn rim. Wheel with new rim: maximum lateral displacement of the rim during braking :+ 3 / -1 mm; level of residual stress in the rim after cooling: σrn ≤ + Σr N/mm2 as the average of three measurements; σin ≤ + (Σr + 50) N/mm2 for each measurement; maximum lateral displacement of the rim after cooling:+ 1,5 / - 0,5mm. Wheel with worn rim: maximum lateral displacement of the rim during braking :+ 3 / -1 mm; level of residual stress in the rim after cooling: σrw ≤ +(Σr + 75) N/mm2 as the average of three measurements; σiw ≤ +(Σr + 100) N/mm2 for each measurement; maximum lateral displacement of the rim after cooling:+ 1,5 / - 0,5mm. The value of Σr shall be defined according to the criteria of the wheel rim steel grade. For grades ER6 and ER7 of !EN 13262", Σr = 200 N/mm2. SIST EN 13979-1:2004+A1:2009
EN 13979-1:2003+A1:2009 (E) 10 The lateral displacement is positive if the distance between the two inner faces of the wheel of the wheelset increases. For domestic traffic, if the track tolerances differ from general tolerances used in Europe, other values of lateral displacement may be agreed between the parties concerned 6.3 Second stage – Wheel fracture bench test 6.3.1 General This second stage shall only be proceeded with if the residual stress levels measured during the first stage exceed the decision criteria. 6.3.2 Test procedure The test procedure is given in normative annex A. 6.3.3 Decision criterion The tested wheels shall not fracture. 6.4 Third stage – Field braking test 6.4.1 General This third stage shall be proceeded with if one of the results of the first stage does not meet the decision criteria and the wheel is not rejected after the second stage. 6.4.2 Test procedure The test method and the measurements to be taken are given in normative annex A. The power to be taken into account for this test is 1,2 Pa (Pa is defined in 3.2). The duration of each drag braking and the running speed of the train are those defined in 3.2 (ta et Va). 6.4.3 Decision criteria Three criteria shall be met simultaneously for the wheel with the new rim and the wheel with the worn rim. Wheel with new rim: maximum lateral displacement of the rim during braking :+ 3 / -1 mm; level of residual stress in the rim after the tests and after cooling: σrn ≤ + (Σr - 50) N/mm2 as the average of the three measurements σin ≤ + Σr N/mm2 for each of the measurements maximum lateral displacement of the rim after cooling: + 1,5 /- 0,5 mm. Wheel with worn rim: maximum lateral displacement of the rim during braking :+ 3 /-1 mm; SIST EN 13979-1:2004+A1:2009
EN 13979-1:2003+A1:2009 (E) 11 level of residual stress in the rim after the tests and after cooling: σrw ≤ + Σr
N/mm2 as the average of the three measurements; σiw ≤ + (Σr + 50) N/mm2 for each of the measurements; maximum lateral displacement of the r
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