oSIST prEN 16273:2011
(Main)Railway applications - Track - Forged rail transitions
Railway applications - Track - Forged rail transitions
Standardization in the field of sleepers and bearers. The standard shall provide particular design guidance in the following areas:
- geometry requirements;
- material and processing requirements;
- requirements for fastening points and insulating;
- test procedures.
Bahnanwendungen - Oberbau - Geschmiedete Schienenübergänge
Diese Europäische Norm legt die Anforderungen für die Zulassung eines Verfahrens, worin eine Schiene eines Profils längs mit einem andersartigen Profil zu einem Teil geschmiedet ist, und nach der Zulassung die Anforderungen an das Schmieden und die Annahme für die laufende Fertigung fest. Die Norm gilt für neue Vignolschienen nach EN 13674-1 und EN 13674-2, die für die Herstellung von Zungen- oder Übergangsschienen verschweißt oder verlascht werden und für den Einsatz in der Eisenbahninfrastruktur vorgesehen sind.
Applications ferroviaires - Voie - Rails forgés
La présente Norme européenne spécifie les exigences relatives à l'homologation d'un processus de forgeage qui consiste à forger une partie d’un rail à un profil de rail différent, ainsi que les exigences relatives à la production ultérieure par forgeage et les critères de réception du produit. La présente norme s'applique aux rails Vignole neufs conformes à l'EN 13674 1 et à l'EN 13674 2, soudés ou éclissés pour former des aiguilles ou des rails mixtes destinés aux infrastructures ferroviaires.
Železniške naprave - Zgornji ustroj - Prekovane prehodne tirnice
General Information
Standards Content (Sample)
SLOVENSKI STANDARD
oSIST prEN 16273:2011
01-julij-2011
Železniške naprave - Zgornji ustroj - Prekovane prehodne tirnice
Railway applications - Track - Forged rail transitions
Bahnanwendungen - Oberbau - Geschmiedete Schienenübergänge
Applications ferroviaires - Voie - Rails forgés
Ta slovenski standard je istoveten z: prEN 16273
ICS:
45.080 7UDþQLFHLQåHOH]QLãNLGHOL Rails and railway
components
oSIST prEN 16273:2011 en,fr,de
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
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oSIST prEN 16273:2011
EUROPEAN STANDARD
DRAFT
prEN 16273
NORME EUROPÉENNE
EUROPÄISCHE NORM
April 2011
ICS 93.100
English Version
Railway applications - Track - Forged rail transitions
Applications ferroviaires - Voie - Rails forgés Bahnanwendungen - Oberbau - Geschmiedete
Schienenübergänge
This draft European Standard is submitted to CEN members for enquiry. It has been drawn up by the Technical Committee CEN/TC 256.
If this draft becomes a European Standard, 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.
This draft European Standard was established by CEN 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-CENELEC Management
Centre has the same status as the official versions.
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, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.
Recipients of this draft are invited to submit, with their comments, notification of any relevant patent rights of which they are aware and to
provide supporting documentation.
Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without notice and
shall not be referred to as a European Standard.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
Management Centre: Avenue Marnix 17, B-1000 Brussels
© 2011 CEN All rights of exploitation in any form and by any means reserved Ref. No. prEN 16273:2011: E
worldwide for CEN national Members.
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Contents Page
Foreword .3
Introduction .4
1 Scope .5
2 Normative references .5
3 Terms and definitions .5
4 Information to be supplied for approval .7
4.1 By the purchaser.7
4.2 By the manufacturer .7
5 Approval of the manufacturer .7
6 Requirements for the forging process .7
6.1 General .7
6.2 Forging parameters .7
6.3 Post heat treatment .7
6.4 Profile finishing .7
6.5 Cutting to length .8
6.6 Identification .8
7 Procedure approval .8
7.1 General .8
7.2 Test specimen preparation .8
7.3 Number of specimens .8
7.4 Non-destructive approval tests .8
7.4.1 Geometry and dimensions .8
7.4.2 Visual inspection . 12
7.4.3 Surface finish . 12
7.4.4 Dye penetrant (DPI) or magnetic particle inspection (MPI) . 12
7.4.5 Ultrasonic testing (US) . 13
7.5 Destructive approval tests . 13
7.5.1 Hardness distribution . 13
7.5.2 Switch rails: hardness distribution in the rail head . 16
7.6 Test report . 18
7.7 Validity of approval . 18
8 Production tests. 18
8.1 Switches . 18
8.1.1 Geometry and dimensions . 18
8.1.2 Hardness testing . 19
8.2 Transition rails . 19
8.2.1 Hardness . 20
Annex A (informative) Ultrasonic testing . 21
A.1 Reference line (DAC) generation – reference block . 21
A.2 Reference line (DAC) generation and acceptance criteria . 22
Annex B (informative) Documentation of approval tests . 24
B.1 Forged switch rails . 24
B.2 Forged transition rails . 31
Bibliography . 36
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Foreword
This document (prEN 16273:2011) has been prepared by Technical Committee CEN/TC 256 “Railway
applications”, the secretariat of which is held by DIN.
This document is currently submitted to the CEN Enquiry.
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Introduction
This standard has 3 main topics:
requirements of a forged part;
procedure approval;
forged rail production following approval.
This standard satisfies the needs of the railway authority and the manufacturer shall achieve the specified
requirements of this standard.
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1 Scope
This European Standard specifies the requirements for the approval of a process wherein a rail of one profile
has part of its length forged to a different profile, together with the requirements for subsequent forging
production and product acceptance. The standard applies to new Vignole rails according to EN 13674-1 and
EN 13674-2, to be welded or fish plated to make up switch rails or transition rails intended for use on railway
infrastructures.
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 571-1, Non destructive testing – Penetrant testing – Part 1: General principles
EN 13232-5, Railway applications – Track – Switches and crossings – Part 5: Switches
EN 13674-1, Railway applications – Track – Rail – Part 1: Vignole railway rails 46 kg/m and above
EN 13674-2, Railway applications – Track – Rail – Part 2: Switch and crossing rails used in conjunction with
Vignole railway rails 46 kg/m and above
EN ISO 6507-1, Metallic materials – Vickers hardness test – Part 1: Test method (ISO 6507-1)
EN ISO 9934 series, Non-destructive testing – Magnetic particle testing (ISO 9934 series)
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
3.1
manufacturer
company that produces forged switch and transition rails
3.2
purchaser
buyer of the forged switch or transition rails in accordance with the requirements of the railway authority
3.3
railway infrastructure
permanent way of national or private railways
3.4
specimen
portion detached from a forged rail transition and prepared as required for testing
3.5
profile finishing
operation by which the rail or relevant part of the component is returned to required profile
NOTE This operation can be by grinding, milling, planing or any other suitable means.
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3.6
finished condition
finished component
3.7
railway authority (RA)
either the railway regulator or the owner of the railway infrastructure or the custodian with a delegated
responsibility for a railway infrastructure
3.8
flexible switch
the switch rail in the movable area of the switch is made of one profile only. This can be either a standard rail
profile or a special profile
3.9
spring rail switch
the switch rail in the movable area of the switch is made of two different profiles. The transition and the weld
between one to the other profile takes place in the movable part of the switch rail and can be either a standard
rail profile or a special profile
Flash butt weld
3.10
forged part for switches
the forged part is the end section of a switch rail with the transition. It is made of one profile only
3.11
transition rail
part of a symmetrical vignole rail profile 1 forged to another symmetrical vignole rail profile 2
3.12
heat affected zone (HAZ)
part of the rail heated to a temperature affecting the hardness
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4 Information to be supplied for approval
4.1 By the purchaser
The following information shall be supplied by the purchaser, agreed with the manufacturer and shall be fully
documented:
a) the initial and final rail profiles, length of the switch rail or transition rail and geometrical requirements of
the rail transition;
b) the rail grade;
c) the profile class of the rail leg-end extension as specified in EN 13674-1 and EN 13674-2.
4.2 By the manufacturer
The following information shall be supplied by the manufacturer, agreed with the purchaser and shall be fully
documented:
a) a drawing of the switch or transition rail.
5 Approval of the manufacturer
The manufacturer shall operate an independently approved and audited quality assurance system, e.g.
conforming to the requirements of EN ISO 9001 or other approval accepted by the purchaser.
6 Requirements for the forging process
6.1 General
All heating, forging and cooling shall be carried out in a controlled process.
6.2 Forging parameters
The forging process and any post heat treatment, including the working ranges, shall be determined during
procedural trials and once approval has been granted. They shall not be changed without prior purchaser
approval.
The parameters shall be monitored and checked against approval limits. These records shall be referenced to
the relevant products.
6.3 Post heat treatment
Post heating or controlled post cooling may be required.
6.4 Profile finishing
The finishing shall be carried out in the longitudinal direction using machining and optionally additional
grinding. The roughness limit shall be 6,3 Ra.
The profile finishing shall not cause any thermal or mechanical damage. The rail profile in the wheel contact
area shall be maintained during profile finishing.
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6.5 Cutting to length
The switch rails shall be cut square, in accordance with Table 10 in EN 13674-1, to the requested length.
Burrs shall be removed from all edgings. Flame cutting is not allowed for the final cut.
6.6 Identification
The identification shall permit traceability to production records. Every forged rail blank shall be encoded by:
the sign of the manufacturer;
the year of manufacturing;
the identification number for the forged part.
The identification shall permit the traceability of the product for at least the guarantee period.
7 Procedure approval
7.1 General
Procedure approval tests shall be done for the production of switch and transition rails by the manufacturer as
described in chapter 7 of this standard. For grade R260 rails, approval is granted by grade (not per profile).
For grade R350HT rails, approval is granted by grade (not per profile) and by rail manufacturer.
Procedure approval shall be carried out by testing samples produced in accordance with this standard; the
samples shall be representative of those carried out in production. One failure during the approval tests
described in 7.4 and 7.5 involves the rejection of the approval.
Refer to 7.7 for re-qualification requirements.
7.2 Test specimen preparation
The test specimens shall be produced and inspected by the same method used for production pieces.
7.3 Number of specimens
Four test specimens in the finished condition (see 3.6) shall be manufactured.
7.4 Non-destructive approval tests
7.4.1 Geometry and dimensions
7.4.1.1 Switch rails
The dimension of the forged rail head and the profile of the vignole rail at the heel of the switch rail shall
comply with the tolerances in Table 1.
Figure 1 indicates the parts of the forged rail that shall be checked according to Table 1.
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Key
SR switch rail
VR vignole rail
Figure 1 — Dimensions of forged switch rail
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Table 1 — Length and tolerances for the forged switch rail
Dimension Length [mm] Measurement equipment
length of the forged rail transition LT Minimum 3 x HD measuring stick, tape or gauge
Admissible tolerance
Dimension Measurement equipment
[mm]
Length of the forged vignole part, when ± 20 measuring stick, tape or gauge
delivered without weld, measured on the foot
LF
LG ± 20 measuring stick, tape or gauge
Length of the vignole part measured in the web ± 20 measuring stick, tape or gauge
LV
Vertical alignment across the running surface - 0,1 / + 0,2 1 m straight edge and a
along the longitudinal centre line starting at the thickness gauge
forged rail end until 1500 mm, measured by
moving a 1 m straight edge and a thickness
gauge.
Horizontal alignment on the running edge at ± 0,4 1 m straight edge and a
14 mm below the running surface, starting at thickness gauge
the forged rail end until 1500 mm measured by
moving a 1 m straight edge and a thickness
gauge.
Head profile concavity (EN 13232-5, Figure 18) An area of concavity may exist 1 m straight edge and a
only on the opposite of the
thickness gauge
HC
running edge. This shall not
exceed 2 mm
Vertical twist (twist base length 1 m) method agreed between the
± 0,5
manufacturer and the purchaser
Head profile C
+0,6 / -0,3 gauge E.4 according to
EN 13674-1 dependent of the
rail profile
Height difference from one rail foot to the other ± 1,1 method agreed between the
rail foot (Figure 1) manufacturer and the purchaser
HD
NOTE Other measuring methods can be used but in case of dispute, the equipment described above shall be used.
Other tolerances for the vignole profile shall be in accordance with EN 13674-1, Table 8 profile class X.
Figure 2 shows the definitions of the algebraic sign in the alignment measurement.
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Figure 2 — Definitions of the algebraic sign
7.4.1.2 Transition rails
The dimension of the transition rail shall comply with the tolerances in Table 2.
Figure 3 indicates the parts of the transition rail that shall be checked according to Table 2.
Figure 3 — Dimensions of forged rail transition
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Table 2 — Tolerances for the transition rail, before welding
Dimension Length [mm] measurement equipment
Length of the forged rail transition LT Minimum 3 x HD measuring stick, tape or gauge
Admissible tolerance
Dimension measurement equipment
[mm]
Length of the forged vignole part, measured ± 20 measuring stick, tape or gauge
on the foot
LF
Total length of the transition rail ± 20 measuring stick, tape or gauge
LG
Vertical alignment across the running surface - 0,1 / + 0,2 1 m straight edge and a
along the longitudinal centre line measured thickness gauge
by moving a 1 m straight edge and a
thickness gauge.
Dimension Admissible tolerance
measurement equipment
[mm]
Horizontal alignment on the running edge at 1 m straight edge and a
14 mm below the running surface measured thickness gauge
± 0,4
by moving a 1 m straight edge and a
thickness gauge.
NOTE Other measuring methods can be used but in case of dispute, the equipment described above shall be used.
7.4.2 Visual inspection
For all the specimens in the finished condition, the forged part shall be inspected for cavities, cracks, damage
and geometrical non-conformities. No cracks are allowed.
The depth of hot marks and seams shall not exceed:
0,35 mm for the running surface and the underside of the foot;
0,5 mm for the rest of the profile.
In the case of longitudinal marks, there shall be a maximum of two, to the-depth limits specified, at any point
along the length of the rail but no more than one of these shall be on the rail running surface.
The maximum width of the marks shall be 4 mm. The width to depth ratio of allowable marks shall be a
minimum 3:1.
7.4.3 Surface finish
The roughness of all the specimens shall be checked against and conform to 6.4 of this standard.
7.4.4 Dye penetrant (DPI) or magnetic particle inspection (MPI)
On completion of visual inspection the forged part shall be tested by non-destructive testing method:
dye penetrant inspection according to EN 571-1
• or
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magnetic particle inspection according to series EN ISO 9934.
No linear indications are accepted; no round indications with size bigger than 3mm are accepted.
7.4.5 Ultrasonic testing (US)
For switch rails all specimens shall be tested by an ultrasonic method at the forged part, agreed with the
customer. In case of dispute the method described in Annex A shall be used.
The acceptance criteria are the following:
registration limit: ≥ 50% reference line
7.5 Destructive approval tests
7.5.1 Hardness distribution
A Brinell hardness HBW 5/750 or HBW 2,5/187,5 distribution is performed on the four specimens with a
stationary machine. To prepare the hardness tests on the running surface the rail head shall be milled off
0,5 mm up to maximum 1 mm.
The testing of hardness shall be performed along the longitudinal centre line following Figure 5 for switch rails
and Figure 6 for transition rails until the hardness of the parent rail is reached.
The indicated hardness values of the switch rail shall be in the range of the specifications in Table 3 and
Figure 4. The indicated hardness values of the transition rail shall be in the range of the specifications in
Table 3.
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Key
Hn: nominal hardness of the parent rail grade
Hm: minimum hardness in zone S according to Table 3
s: width between the two nominal hardness points on the hardness distribution curve
1: HAZ
2: parent rail
Figure 4 — Hardness distribution of a switch rail
An isolated hardness value falling outside of the minima and maxima stated in Table 3 shall be permitted
when such a hardness value falls between the two adjacent values that conform to the requirements.
Table 3 — Reference values for hardness on the rail
grade of the reference values [HBW 5/750 / HBW 2,5/187,5] for the rail
switch
head foot
HAZ, except zone S Zone S forged part
R 260 260 to 300 min. 220 max. 300
(max. 5 hardness points shall
fall below Hn = 260)
R 350 HT 350 to 390 min. 280 max. 390
(max. 5 hardness points shall
fall below Hn = 350)
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grade of the reference values [HBW 5/750 / HBW 2,5/187,5] for the rail
transition rail
head foot
R 260 measured hardness of parent rail - 40/+ 40
Key
place of inspection on the running surface
place of inspection on the foot
a end of forged heat affected zone
Figure 5 — Examination of hardness spreading in the heat affected zone for switch rail
Key
place of inspection on the running surface
place of inspection on the foot
a end of forged heat affected zone
Figure 6 — Examination of hardness spreading in the heat affected zone for transition rail
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7.5.2 Switch rails: hardness distribution in the rail head
For switches, from 1 specimen, 3 samples for hardness distribution in the head are prepared according to
Figure 7. The hardness distribution Vickers HV30 in the rail head should be investigated according to
EN ISO 6507-1. The positions and the places of inspection for the hardness indents are shown in Figure 8.
The series of tests start with the first hardness indent at a distance of 1 mm below the surface. The hardness
indents shall have a distance of 2 mm between them.
Key
a end of forged heat affected zone
b unaffected parent rail
Q1 – Q3 transverse specimens
Figure 7 — Position of the samples for hardness distribution on the switch rail
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Key
T1 – T4 location of the hardness distribution
Figure 8 — Testing of hardness distribution in the rail head
The hardness values (Vickers HV 30) of the rail head distribution shall be in the range as specified in Table 4.
The decrease of hardness between two adjacent indents shall not be more than 20HV.
Table 4 — Switch rail: reference values for hardness in the rail head
Forged rail Hardness [HV 30]
hardness indent at a hardness indent at a
distance of 1 mm to the distance of 15 mm to the
surface surface
grade
265 to 305 > 260
R 260
grade
360 to 400 > 300
R 350 HT
NOTE An isolated hardness value falling outside of the stated minima and maxima above
shall be permitted when such a hardness value falls between the two adjacent values that
conform to the requirements.
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7.6 Test report
A report which contains the results shall be produced.
The test report shall include as a minimum:
identification of the machine;
identification of the document describing the forging process including post treatment and the working
ranges;
rail grade;
the rail manufacturer for heat treated rails;
results of all approval tests. Annex B may be used for the documentation of the results of all approval
tests of forged switch rails and transition rails.
7.7 Validity of approval
Re-approval of procedures is required at least once every five years and when:
steel grades or steel production methods are changed;
changes are made to production parameters within an approved process. Adaptations within the working
ranges of the process are allowed.
8 Production tests
8.1 Switches
The manufacturer shall ensure the quality of the forged rail transition by testing according to Table 5.
Table 5 — Production tests for switches
Test Frequency Results
Visual inspection Each piece 7.4.2
Surface finish Each piece 7.4.3
Geometry Each piece 8.1.1
NDT (MPI or DPI) Each piece 7.4.4
NDT (US) Each piece 7.4.5
Hardness For each grade and profile: the first and 8.1.2
last produced piece of 1 day
8.1.1 Geometry and dimensions
The dimension of the forged rail head and the profile of the vignole rail at the heel of the switch rail shall
comply with the tolerances in 7.4.1.1. Additionally the dimensions in table 6 shall be checked during
production.
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Table 6 — Additional tolerances for the forged switch rail
Dimension Admissible tolerance [mm] Measurement equipment
total length of the switch rail LA ± 3 length ≤ 24 m tape measure
± 4 24 m < length ≤ 35 m
± 20 length > 35 m
NOTE Tolerances are valid for dimension measurements in temperature range 20°C ± 5°C. LA according to
EN 13232-5, Figure 14.
8.1.2 Hardness testing
The switch rail shall be investigated by a Brinell hardness testing device or a device allowing conversion to
HBW. To prepare the hardness tests, 0,5 mm shall be removed locally on the head outside the running
surface. The hardness of the rail head shall be measured 3 times at each position (Figure 9):
place of inspection 1 in the zone of extended vignole profile (50 mm);
place of inspection 2 in the transition zone;
place of inspection 3 in the parent rail, outside the heat affected zone.
Key
1, 2 and 3 are measurement points
a end of forged heat affected zone
b unaffected parent rail
Figure 9 — Hardness testing of the rail head
The average hardness value at each position shall be in the range
...
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