SIST EN 13260:2009
Railway applications - Wheelsets and bogies - Wheelsets - Products requirements
Railway applications - Wheelsets and bogies - Wheelsets - Products requirements
This European Standard specifies the characteristics of new wheelsets for use on European networks:
This standard is applicable to wheelsets comprising elements that conform to the following European Standards:
- EN 13262 for wheels;
- EN 13261 for axles;
- EN 12080 for axlebox rolling bearings.
This standard is not applicable to repaired wheelsets.Some characteristics are given as a function of a category 1 or of a category 2. These categories can sometimes be divided according to the characteristics defined. Category 1 is generally chosen when the operating speed exceeds 200 km/h. The wheelset then comprises wheels and axle of category 1 as specified in prEN 13262 for the wheels and prEN 13261 for the axles.
Bahnanwendungen - Radsätze und Drehgestelle - Radsätze - Produktanforderungen
Die vorliegende Europäische Norm legt die Eigenschaften für neue Radsätze, die im europäischen Schienennetz eingesetzt werden, fest.
Diese Norm gilt für Radsätze, die aus Teilen bestehen, die mit folgenden Europäischen Normen übereinstimmen:
- EN 13262 für Räder;
- EN 13261 für Radsatzwellen;
- EN 12080 für Radsatzrollenlager.
Diese Norm gilt nicht für instandgesetzte Radsätze.
Einige Kenndaten werden nach Kategorie 1 und Kategorie 2 festgelegt. Diese Kategorien können in einigen Fällen Unterteilungen aufweisen, die von den Merkmalen abhängig sind. Die Kategorie 1 ist allgemein dann zu wählen, wenn die Zuggeschwindigkeit über 200 km/h liegt. In diesem Fall setzt sich der Radsatz aus Rädern und Radsatzwelle der Kategorie 1, nach EN 13262 für die Räder und EN 13261 für die Radsatzwellen, zusammen.
Applications ferroviaires - Essieux montés et bogies - Essieux-axes - Prescriptions pour le produit
La présente Norme Européenne spécifie les caractéristiques des essieux montés neufs utilisés sur les réseaux européens.
Cette norme s'applique aux essieux montés composés d'éléments définis par les Normes Européennes suivantes:
EN 13262 pour les roues;
EN 13261 pour les essieux-axes.
Cette norme ne s'applique pas en totalité aux essieux en maintenance.
Quelques caractéristiques sont données en fonction d'une catégorie 1 ou d'une catégorie 2. La catégorie 2 est divisée en sous-catégories (2a et 2b) afin de préciser certaines caractéristiques. La catégorie 1 est généralement choisie quand la vitesse de circulation est supérieure à 200 km/h. L'essieu monté est alors composé de roues et d'un essieu-axe de catégorie 1, selon l’EN 13262 pour les roues et l’EN 13261 pour les essieux-axes.
Železniške naprave - Kolesne dvojice in podstavni vozički - Kolesne dvojice - Zahtevane lastnosti proizvoda
General Information
Relations
Standards Content (Sample)
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Bahnanwendungen - Radsätze und Drehgestelle - Radsätze - ProduktanforderungenApplications ferroviaires - Essieux montés et bogies - Essieux-axes - Prescriptions pour le produitRailway applications - Wheelsets and bogies - Wheelsets - Products requirements45.040Materiali in deli za železniško tehnikoMaterials and components for railway engineeringICS:Ta slovenski standard je istoveten z:EN 13260:2009SIST EN 13260:2009en,fr01-junij-2009SIST EN 13260:2009SLOVENSKI
STANDARDSIST EN 13260:20041DGRPHãþD
SIST EN 13260:2009
EUROPEAN STANDARDNORME EUROPÉENNEEUROPÄISCHE NORMEN 13260March 2009ICS 45.040Supersedes EN 13260:2003
English VersionRailway applications - Wheelsets and bogies - Wheelsets -Product requirementsApplications ferroviaires - Essieux montés et bogies -Essieux montés - Prescriptions pour le produitBahnanwendungen - Radsätze und Drehgestelle -Radsätze - ProduktanforderungenThis European Standard was approved by CEN on 26 December 2008.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:
Avenue Marnix 17,
B-1000 Brussels© 2009 CENAll rights of exploitation in any form and by any means reservedworldwide for CEN national Members.Ref. No. EN 13260:2009: ESIST EN 13260:2009
prEN 13260:2009 (E) 2 Contents Page Foreword.4 Introduction.5 1 Scope.6 2 Normative references.6 3 Product definition.6 3.1 Assembly of components.6 3.1.1 General.6 3.1.2 Interference between axle wheel seat and wheel hub bore.7 3.1.3 Press-fitting diagram.7 3.2 Wheelset characteristics.8 3.2.1 Mechanical resistance of the assemblies.8 3.2.2 Fatigue characteristics.8 3.2.3 Electrical resistance.9 3.2.4 Imbalance.9 3.2.5 Dimensions and tolerances.10 3.2.6 Residual stresses.14 3.2.7 Protection against corrosion and impacts.14 3.2.8 Marking.14 Annex A (normative)
Characteristics of the press-fitting curve.16 Annex B (normative)
Fatigue characteristics for a wheelset with an axle of steel grade EA1T or EA4T.18 Annex C (informative)
Information on the test pieces for fatigue tests.19 Annex D (informative)
Documents for the identification of wheelset components.21 Annex E (informative)
Product qualification.25 E.1 General.25 E.2 Requirements.25 E.2.1 Requirements to be met by the supplier.25 E.2.2 Qualification of personnel.25 E.2.3 Requirements to be met by the product.26 E.3 Qualification procedure.26 E.3.1 General.26 E.3.2 Documentation required.26 E.3.3 Evaluation of the manufacturing plant and processes.26 E.3.4 Laboratory tests.27 E.3.5 Testing of finished products.27 E.4 Qualification certificate.27 E.4.1 Condition of validity.27 E.4.2 Modification and extension.27 E.4.3 Transference.28 E.4.4 Lapsed certification.28 E.4.5 Cancellation.28 E.5 Qualification file.28 Annex F (informative)
Product delivery.29 F.1 General.29 F.2 Specific verifications.29 F.3 Optional checks.30 F.3.1 Dimensional check.30 SIST EN 13260:2009
EN 13260:2009 (E) 3 F.3.2 Ultrasonic examination.30 F.4 Allowable rectification.30 F.5 Documents.31 F.5.1 Shrink-fitting.31 F.5.2 Press-fitting.31 F.5.3 Components.31 F.6 Quality plan.32 F.6.1 General.32 F.6.2 Objectives.32 F.6.3 Validity.32 Annex ZA (informative)
Relationship between this European Standard and the Essential Requirements of Council Directive 96/48/EC of 23 July 1996 on the interoperability of the trans-European high-speed rail system amended by Directive 2004/50/EC of 29 April 2004.33 Annex ZB (informative)
Relationship between this
European Standard and the Essential Requirements of 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 amended by Directive 2004/50/EC of 29 April 2004.34 Bibliography.36
SIST EN 13260:2009
prEN 13260:2009 (E) 4 Foreword This document (EN 13260:2009) 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 September 2009, and conflicting national standards shall be withdrawn at the latest by September 2009. Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. CEN and/or CENELEC shall not be held responsible for identifying any or all such patent rights. This document is intended to supersede EN 13260:2003. This European Standard has been prepared under a mandate given to CEN/CENELEC/ETSI by the European Commission and the European Free Trade Association, and supports essential requirements of Directives 96/48/EC and 2001/16/EC, amended by Directive 2004/50/EC.
For relationship with EU Directives 96/48/EC and 2001/16/EC, see informative Annexes ZA and ZB, which are integral parts 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 the United Kingdom. SIST EN 13260:2009
EN 13260:2009 (E) 5
Introduction The main purpose of normative documents used until now for the delivery of wheelsets (UIC leaflets, national standards) was a complete definition of the acceptance procedures and of the wheelset characteristics which were to be verified. Product qualification was sometimes mentioned but the procedures used and the product characteristics to be verified during qualification were not given. This standard addresses these points by: a) definition of all the wheelset characteristics that are assembly characteristics and finished product characteristics and do not arise from a choice of design parameters such as diameters, interferences, materials etc. They are verified during either qualification or delivery of the product (see clause 3); b) definition of qualification procedures (see Annex E); c) definition of delivery conditions (see Annex F).
They are based on quality assurance concepts. SIST EN 13260:2009
prEN 13260:2009 (E) 6
1 Scope This European Standard specifies the characteristics of new wheelsets for use on European networks: This standard is applicable to wheelsets comprising elements that conform to the following European Standards:
EN 13262 for wheels; ¾ EN 13261 for axles; This standard is not fully applicable to wheelsets undergoing maintenance. Some characteristics are given as a function of a category 1 or of a category 2.
Category 2 can be divided into sub-categories (2a and 2b) to specify certain characteristics.
Category 1 is generally chosen when the operating speed exceeds 200 km/h.
The wheelset then comprises wheels and axle of category 1 as specified in EN 13262 for the wheels and EN 13261 for the axles. 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 13103, Railway applications – Wheelsets and bogies – Non-powered axles – Design method EN 13104, Railway applications – Wheelsets and bogies – Powered axles – Design method EN 13261 Railway applications – Wheelsets and bogies – Axles – Product requirements EN 13262 Railway applications – Wheelsets and bogies – Wheels – Product requirements 3 Product definition 3.1 Assembly of components 3.1.1 General Before being assembled, all elements which comprise the wheelset shall meet the geometric requirements of the documents which define them.
In particular, the wheels and the axle shall be in the "ready for assembly" state defined in EN 13262 for the wheels and EN 13261 for the axles. The elements comprising the wheelset may be shrink-fitted or press-fitted.
The interferences to be used for fitting shall be defined by the designer of the element to be fitted and are a function of the characteristics of the element material and the forces and torque to be transmitted by the fitting.
This interference shall be defined according to the geometric tolerances of the axle seats specified in
EN 13261. For the wheel fittings, unless otherwise specified by the wheel designer, the interference values to be used are given in 3.1.2.
SIST EN 13260:2009
EN 13260:2009 (E) 7 In the case of shrink-fitting, the whole wheel should be heated and its temperature shall not exceed 250 °C.
If a different heating method is used, proof shall be provided that there has been no effect on the wheel characteristics as defined in EN 13262. If a different fitting method is used, this shall be the subject of an agreement between the customer and the supplier.
In this agreement, the supplier shall demonstrate at least that the axle and wheel characteristics as defined in EN 13261 and EN 13262 are not modified by the fitting.
Then, the mechanical resistance of the assembly (see 3.2.1) shall be demonstrated and the traceability documents for each fitting shall be defined so as to give the same type of information as specified in F.5.
The static imbalance of the two wheels of each wheelset shall be within the same diametric plane and on the same side of the axle.
The static imbalance of the gearwheels and brake discs shall be in the same plane as those of the wheels, but on the opposite side of the axle. 3.1.2 Interference between axle wheel seat and wheel hub bore Unless otherwise specified by the wheel designer, the interference values "j" to be adhered to are, in mm: ¾ for shrink-fitting:
0,0009 dm £ j £ 0,0015 dm ¾ for press-fitting:
0,0010 dm £ j £ 0,0015 dm + 0,06 where dm is the mean diameter in mm. 3.1.3 Press-fitting diagram 3.1.3.1 Results to be achieved For press fitting, the force-displacement curve gives confidence that the fitting has not damaged the contact surfaces and that the specified interference has been effective. The shape of the curve to be obtained is defined in Annex A. The final fitting force, in MN, is a function of the force F defined in 3.2.1 and shall be within the range: 0,85 F < final fitting force < 1,45 F 3.1.3.2 Measurement method The press used for the assemblies shall have a calibrated system to plot the diagram of the force value at each position of the element to be fitted, obtained during the displacement of the latter on the axle. The abscissa scale of displacement shall be at least equal to 0,5 times the actual displacement of the element to be fitted. The ordinate scale of force shall allow the force to be read at each point of the curve with an accuracy of 0,025 MN.
The accuracy of the force sensor shall be 0,01 MN.
The abscissae and ordinates may be reversed. In the case of point recording, at least one point shall be plotted per millimetre of relative displacement of the elements to be fitted and per 0,025 MN variation in force. SIST EN 13260:2009
prEN 13260:2009 (E) 8 3.2 Wheelset characteristics 3.2.1
Mechanical resistance of the assemblies 3.2.1.1 Results to be achieved In order to be able to transmit forces and torques between the fitted elements, the assemblies shall be capable of withstanding an axial force F for 30 s without there being any displacement between one element and another. This force F shall be defined by the designer of the element to be fitted. For wheels, unless otherwise specified by the designer, the value of the force F in MN is: F = 4 .10-3 dm when
0,8 dm < L< 1,1 dm where dm is the mean diameter of the seat in mm and L is the length of the fitting in mm. 3.2.1.2 Test method The test shall be carried out on a press equipped with a device to record forces. The force is applied gradually up to F between one of the faces of the fitted component hub and the axle.
For press-fitted wheels, the test shall be carried out at least 48 h after fitting. For shrink-fitted wheels, the test shall be carried out when the wheels and axle have returned to the same temperature after the fitting. 3.2.2 Fatigue characteristics 3.2.2.1 General The rotational bending fatigue limit values for 107 cycles are defined here.
These values are used to calculate the maximum permissible axle seat stresses and are required for application of EN 13103 and EN 13104.
These fatigue characteristics are not the same for a solid axle as for a hollow axle.
This is the result of the axle bore effect on stress distribution.
For a solid axle, only one fatigue limit (F3) shall be determined under the fitting areas. For a hollow axle, given that the fitting effect is greater on the journals than on the other fitted areas because of the different metal thicknesses, two fatigue limits shall be considered: ¾ under the fitted parts , except for journals, limit F4, ¾ under the fitted parts of the journal, limit F5
NOTE 1 The fatigue limit F4 is verified by testing during qualification. The fatigue limit F5 can be calculated using the ratios F4 /F5 = 1,17 and F3 /F5 = 1,276 NOTE 2 The fatigue characteristic F1 and F2 of the axle are defined in EN 13261. SIST EN 13260:2009
EN 13260:2009 (E) 9 3.2.2.2 Values defined for EA1N The minimum values for wheelsets using an axle of EA1N grade steel are given in Table 1. Table 1 — Minimum values for wheelsets with an axle made of EA1N steel Fatigue limit F3 F4 F5 N/mm2 120 110 94
For other steel grades, the values are given in Annex B. 3.2.2.3 Fatigue test pieces The area of the test piece where the crack initiates shall have geometry, environment and surface condition representative of the axle under consideration. For the fatigue testing of the wheelsets, one wheel or test piece with similar dimensions (particularly the hub) shall be press-fitted or shrink-fitted on the wheel seat.
The interference shall meet the requirements of 3.1.2.
It is not mandatory to use a wheelset as the test piece.
Examples of test pieces are given in Annex C. 3.2.2.4 Test method The tests shall be carried out on machines capable of creating rotating bending stresses in the area where it is required to initiate a crack. For each limit F3, and F4, it shall be verified on three test pieces that no crack has appeared after 107 cycles of a load creating a surface stress equal to F3 or F4. These stress levels shall be calculated on the seat, in accordance with the beam theory, disregarding the interference stresses. 3.2.3 Electrical resistance The electrical resistance of each wheelset measured between the treads of the two wheels shall not exceed 0,01 W. The means and method used for this measurement shall be defined in agreement between the customer and the supplier. The test voltage shall be in the range 1,8 – 2,0 V DC. 3.2.4 Imbalance
3.2.4.1 Values to be achieved For a non-powered wheelset capable of running at a speed of greater than 120 km/h, a maximum dynamic imbalance shall be specified. The maximum values are given in Table 2. They are measured in the plane of the wheels. SIST EN 13260:2009
prEN 13260:2009 (E) 10 Table 2 — Maximum imbalance values Speed (km/h) Maximum imbalance x measuring plane (g.m) 120 < V £ 200 V > 200 75 50
3.2.4.2 Test piece The imbalance is measured on a fully assembled and machined wheelset. 3.2.4.3 Test method The customer and the supplier shall agree the means of measurement. 3.2.5 Dimensions and tolerances 3.2.5.1 General The dimensions of the wheelset shall be in accordance with the design drawings and the dimensional and geometric tolerances to be applied when assembling the different parts of the wheelset are given in the following subclauses.
They are dependent on the category of the wheelset. The values are given for measurements taken with no load on the wheelset. 3.2.5.2 Wheels The tolerances of the parameters defined in Figure 1 shall be those given in Table 3.
Figure 1 — Wheel parameters SIST EN 13260:2009
EN 13260:2009 (E) 11 Table 3 — Tolerances on wheel parameters Dimensions in mm Description Symbol Category 2
Category 1
a b
Distance between the internal wheel facesa a1 + 2 b 0 + 2 b 0 Difference in distances between the internal face of each wheel and the plane on the journal side defining the corresponding collar bearing surface c – c1 or c1 - c £ 1 £ 1 Difference in tread circle diameter d – d1 or d1 – d
£ 0,5
£ 0,3 £ 0,3 Radial run-out in tread circle
h
£ 0,5
£ 0,3
£ 0,3 Axial run-out of the internal wheel face a
g
£ 0,8
£ 0,5
£ 0,3 a Measurement at 60 mm beneath the top of the flange b The tolerances may be changed for special designs of wheelsets
3.2.5.3 Brake discs 3.2.5.3.1 General The tolerances on the parameters defined in Figures 2 and 3 shall be those required in Tables 4, 5 and 6. Table 4 — Axial run-out of the internal face Dimensions in mm Description Symbol Category 2 a
Category 2 b
Category 1
Axial run-out of the internal face a g1 £ 0,75 £ 0,5 £ 0,5 a See Figures 2 and 3.
Measurements at 30 mm from the external diameter
SIST EN 13260:2009
prEN 13260:2009 (E) 12 3.2.5.3.2 Single-seat axle for one or two brake discs
Figure 2 — Single-seat axle for one or two brake discs Table 5 — Tolerances for single-seat axles for one or two brake discs Dimensions in mm Description Symbol Category 1 and 2
Distance between the internal face of the disc crown and the plane on the journal side defining the corresponding collar bearing surface f ± 0,5
3.2.5.3.3 Double-seat axles for two or four brake discs
Figure 3 — Double-seat axles for two or four brake discs
SIST EN 13260:2009
EN 13260:2009 (E) 13 Table 6 — Tolerances for double-seat axles for two or four brake discs
Dimensions in mm
Description Symbol Category 1 and 2
Distance between the internal faces of the disc crowns
a3
± 0,5 Difference in distances between the internal face of each disc and the plane on the journal side defining the corresponding collar bearing surface f – f1 or f1 - f
£ 1
3.2.5.3.4 More than two seats If there are more than two seats for the brake discs, the tolerances on the dimensions such as a3 or f – f1 (see Figure 3) are the same as in 3.2.5.3.3. 3.2.5.4 Cylindrical gear wheels for motor axle, reducing gears etc. The tolerances of the parameters defined in Figure 4 shall be those required by Table 7. Table 7 — Tolerances for cylindrical gear wheels for motor axle, reducing gears etc. Dimensions in mm Description Symbol Category 2
Category 1
Radial run-out a
h1
b
b
Axial run-out a
g2
b
b Distance between the lateral reference surface of the gear wheel and the plane on the journal side defining the corresponding collar bearing surface a
c2
± 0,5
± 0,2 a See Figure 4. b In accordance with the specifications of the designer.
SIST EN 13260:2009
prEN 13260:2009 (E) 14
Figure 4 – Cylindrical gear wheels for motor axle, reducing gears etc. 3.2.6 Residual stresses 3.2.6.1 General The different manufacturing operations leading to a "ready to assemble" state for the axle shall not create residual stresses likely to facilitate fatigue crack initiation. 3.2.6.2 Values to be achieved On the axle seats at a depth of 0,1 mm below the surface, the residual stresses shall be £ 100 N/mm2 in tension. 3.2.6.3 Test piece and position of the measuring points The test piece is the axle in the "ready to assemble" state.
The measuring points are located at the centre and at one end of the seats.
On each circumference, two points are measured at 120°. 3.2.6.4 Measurement method The measurements can be made either with conventional strain gauges or by X-ray diffraction. 3.2.7 Protection against corrosion and impacts The wheelset components shall be protected according to the requirements of their relevant standards. Cavities arising from the overhang of the wheel hub on the wheel seats shall be protected or filled with an anticorrosion product. 3.2.8 Marking The constituent parts of the wheelsets shall be marked according to the relevant standards. The wheelset shall be identified as a minimum by the following marks (in accordance with the purchase order): 1) type of wheelset; 2) serial number; SIST EN 13260:2009
EN 13260:2009 (E) 15 3) assembler's marks; 4) date of assembly; 5) owner's marks. These marks shall be located at the end of the journal which already bears the axle marks defined in
EN 13261 and be below the latter marks. At the other end of the journal, one half the surface shall be free of any marks.
It is reserved for maintenance identification.
The other half of this surface is free for any other marking. The marks shall be stamped.
Any protruding burrs resulting from the stamping shall be levelled to allow ultrasonic examination to be carried out in service. SIST EN 13260:2009
prEN 13260:2009 (E) 16 Annex A (normative)
Characteristics of the press-fitting curve The characteristics of the press-fitting curve are described in Figure A.1.
The fitting force shall start to increase before the wheel seat displacement on to the wheel hub reaches 30 mm.
The force shall then increase continuously without falling outside the limit curve values given by the curves stated by the designer of the component to be fitted. Nevertheless, the following cases are permitted: 1) a reduction in the fitting force at the groove for removal by oil injection is permitted.
The maximum force reached before the groove shall be reached again within a further displacement of 25 mm.
During this decrease, the fitting force value may be lower than that defined by the lower curve; 2) a maximum decrease of 0,05 MN over the last 25 mm of displacement; 3) curves showing local deviation, if previously agreed between the customer and supplier, or on qualification of the product.
SIST EN 13260:2009
EN 13260:2009 (E) 17
NOTE
- AB, BC, HE and ED are portions of a straight line, AG is equal to the length of the seat; - for the wheels, the positions of the different
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01-december-2006
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Railway applications - Wheelsets and bogies - Wheelsets - Products requirements
Bahnanwendungen - Radsätze und Drehgestelle - Radsätze - Produktanforderungen
Applications ferroviaires - Essieux montés et bogies - Essieux-axes - Prescriptions pour
le produit
Ta slovenski standard je istoveten z: prEN 13260
ICS:
45.040 Materiali in deli za železniško Materials and components
tehniko for railway engineering
oSIST prEN 13260:2006 en
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
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EUROPEAN STANDARD
DRAFT
prEN 13260
NORME EUROPÉENNE
EUROPÄISCHE NORM
August 2006
ICS 45.040 Will supersede EN 13260:2003
English Version
Railway applications - Wheelsets and bogies - Wheelsets -
Products requirements
Applications ferroviaires - Essieux montés et bogies - Bahnanwendungen - Radsätze und Drehgestelle - Achsen -
Essieux-axes - Prescriptions pour le produit Produkltanforderungen
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 Management Centre has the same
status as the official versions.
CEN members are the national standards bodies of Austria, Belgium, 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: rue de Stassart, 36 B-1050 Brussels
© 2006 CEN All rights of exploitation in any form and by any means reserved Ref. No. prEN 13260:2006: E
worldwide for CEN national Members.
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prEN 13260:2006 (E)
Contents Page
Foreword.4
Introduction .5
1 Scope .5
2 Normative references .6
3 Product definition .6
3.1 Assembly of components .6
3.1.1 General.6
3.1.2 Interference between axle wheelseat and wheel hub bore .7
3.1.3 Press-fitting diagram.7
3.2 Wheelset characteristics.7
3.2.1 Mechanical resistance of the assemblies .7
3.2.2 Fatigue characteristics.8
3.2.3 Electrical resistance .9
3.2.4 Imbalance .9
3.2.5 Dimensions and tolerances .9
3.2.6 Residual stresses .14
3.2.7 Protection against corrosion and impacts.14
3.2.8 Marking .14
Annex A (normative) Characteristics of the press-fitting curve .15
Annex B (normative) Fatigue characteristics for a wheelset with an axle of steel grade EA1T or
EA4T.17
Annex C (informative) Drawing of the test piece for fatigue tests .18
Annex D (informative) Documents for the identification of wheelset components .19
Annex E (informative) Product qualification.23
E.1 General.23
E.2 Requirements.23
E.2.1 Requirements to be met by the supplier .23
E.2.2 Qualification of personnel .23
E.2.3 Requirements to be met by the product.23
E.3 Qualification procedure .24
E.3.1 General.24
E.3.2 Documentation required .24
E.3.3 Evaluation of the manufacturing installations and processes .24
E.3.4 Laboratory tests.25
E.3.5 Testing of finished products .25
E.4 Qualification certificate .25
E.4.1 Condition of validity .25
E.4.2 Modification and extension .25
E.4.3 Transference .26
E.4.4 Lapsed certification.26
E.4.5 Cancellation.26
E.5 Qualification file.26
Annex F (informative) Product delivery.27
F.1 General.27
F.2 Specific verifications.27
F.3 Optional checks .28
F.3.1 Dimensional check .28
2
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prprEN 13260:2006 (E)
F.3.2 Ultrasonic examination.28
F.4 Allowable rectifications .28
F.5 Documents .29
F.5.1 Shrink-fitting .29
F.5.2 Press-fitting.29
F.5.3 Components.30
F.6 Quality plan .30
F.6.1 General .30
F.6.2 Objectives .30
F.6.3 Validity.30
Annex ZA (informative) Relationship between this European Standard and the Essential
Requirements of EU Directive 96/48/EC.31
Annex ZB (informative) Relationship between this European Standard and the Essential
Requirements of EU Directive 2001/16/EC.32
Bibliography.33
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Foreword
This document (prEN 13260:2006) 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.
This document is intended to supersede EN 13260:2003.
This document has been prepared under a mandate given to CEN by the European Commission and the
European Free Trade Association, and supports essential requirements of EU Directive(s).
For relationship with EU Directive(s), see informative Annex ZA, which is an integral part of this document.
Council Directive 96/48/EC of 23 July 1996 on the interoperability of the trans-European high-speed rail
1)
system ;
Directive 2001/16/EC of the European Parliament and of the Council of 19 March 2001 on the
interoperability of the conventional rail system.
1) Official Journal of the European Communities, No. L 235/6 of 17 September 1996
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Introduction
The main purpose of normative documents used until now for the delivery of wheelsets (UIC leaflets, national
standards) was a complete definition of the acceptance procedures and of the wheelset characteristics which
were to be verified.
Product qualification was sometimes mentioned but the procedures used and the product characteristics to be
verified during qualification were not given.
This standard addresses these points by:
a) definition of all the wheelset characteristics that are assembly characteristics and finished product
characteristics and do not arise from a choice of design parameters such as diameters, interferences,
materials etc. They are verified during either qualification or delivery of the product (see clause 3);
b) definition of qualification procedures (see Annex E);
c) definition of delivery conditions (see Annex F). They are based on quality assurance concepts.
1 Scope
This European Standard specifies the characteristics of new wheelsets for use on European networks:
This standard is applicable to wheelsets comprising elements that conform to the following European
Standards:
EN 13262 for wheels;
EN 13261 for axles;
EN 12080 for axlebox rolling bearings.
This standard is not applicable to repaired wheelsets.
Some characteristics are given as a function of a category 1 or of a category 2. These categories can
sometimes be divided according to the characteristics defined. Category 1 is generally chosen when the
operating speed exceeds 200 km/h. The wheelset then comprises wheels and axle of category 1 as specified
in EN 13262 for the wheels and EN 13261 for the axles.
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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 13103, Railway applications – Wheelsets and bogies – Non-powered axles – Design method
EN 13104, Railway applications – Wheelsets and bogies – Powered axles – Design method
EN 13261 Railway applications – Wheelsets and bogies – Axles – Product requirements
EN 13262 Railway applications – Wheelsets and bogies – Wheels – Product requirements
3 Product definition
3.1 Assembly of components
3.1.1 General
Before being assembled, all elements which comprise the wheelset shall meet the geometric requirements of
the documents which define them. In particular, the wheels and the axle shall be in the "ready for assembly"
state defined in EN 13262 for the wheels and EN 13261 for the axles.
The elements comprising the wheelset may be shrink-fitted or press-fitted.
The interferences to be used for fitting shall be defined by the designer of the element to be fitted and are a
function of the characteristics of the element material and the forces and torque to be transmitted by the fitting.
This interference shall be defined according to the geometric tolerances of the axle seats specified in
EN 13261.
For the wheel fittings, unless otherwise specified by the wheel designer, the interference values to be used
are given in 3.1.2.
In the case of shrink-fitting, the whole wheel should be heated and its temperature shall not exceed 250 °C. If
a different heating method is used, proof shall be provided that there has been no effect on the wheel
characteristics as defined in EN 13262.
If a different fitting method is used, this shall be the subject of an agreement between the customer and the
supplier. In this agreement, the supplier shall demonstrate at least that the axle and wheel characteristics as
defined in EN 13261 and EN 13262 are not modified by the fitting. Then, the mechanical resistance of the
assembly (see 3.2.1) shall be demonstrated and the traceability documents for each fitting shall be defined so
as to give the same type of information as specified in F.5.
The static imbalance of the two wheels of each wheelset shall be within the same diametric plane and on the
same side of the axle. The static imbalance of the gearwheels and brake discs shall be in the same plane as
those of the wheels, but on the opposite side of the axle.
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3.1.2 Interference between axle wheelseat and wheel hub bore
Unless otherwise specified by the wheel designer, the interference values "j" to be adhered to are, in mm:
for shrink-fitting: 0,0009 dm ≤ j ≤ 0,0015 dm
for press-fitting: 0,0010 dm ≤ j ≤ 0,0015 dm + 0,06
where dm is the mean diameter in mm.
3.1.3 Press-fitting diagram
3.1.3.1 Results to be achieved
For press fitting, the force-displacement curve gives confidence that the fitting has not damaged the contact
surfaces and that the specified interference has been effective.
The shape of the curve to be obtained is defined in Annex A.
The final fitting force, in mN, is a function of the force F defined in 3.2.1 and shall be within the range:
0,85 F < final fitting force < 1,45 F
3.1.3.2 Measurement method
The press used for the assemblies shall have a calibrated system to plot the diagram of the force value at
each position of the element to be fitted, obtained during the displacement of the latter on the axle. The
abscissa scale of displacement shall be at least equal to 0,5 times the actual displacement of the element to
be fitted. The ordinate scale of force shall allow the force to be read at each point of the curve with an
accuracy of 0,025 mN. The accuracy of the force sensor shall be 0,01 mN. The abscissae and ordinates may
be reversed.
In the case of point recording, at least one point shall be plotted per millimetre of relative displacement of the
elements to be fitted and per 0,025 mN variation in force.
3.2 Wheelset characteristics
3.2.1 Mechanical resistance of the assemblies
3.2.1.1 Results to be achieved
In order to be able to transmit forces and torques between the fitted elements, the assemblies shall be
capable of withstanding an axial force F for 30 s without there being any displacement between one element
and another.
This force F shall be defined by the designer of the element to be fitted.
For wheels, unless otherwise specified by the designer, the value of the force F in mN is:
-3
F = 4 .10 dm
when 0,8 dm < L< 1,1 dm
where dm is the mean diameter of the seat in mm and L is the length of the fitting in mm.
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prEN 13260:2006 (E)
3.2.1.2 Test method
The test shall be carried out on a press equipped with a device to record forces.
The force is applied gradually up to F between one of the faces of the fitted component hub and the axle. The
test shall be carried out at least 48 h after fitting.
3.2.2 Fatigue characteristics
3.2.2.1 General
7
The rotational bending fatigue limit values for 10 cycles are defined here. These values are used to calculate
the maximum permissible axle seat stresses and are required for application of EN 13103 and EN 13104.
These fatigue characteristics are not the same for a solid axle as for a hollow axle. This is the result of the
axle bore effect on stress distribution.
For a solid axle, only one fatigue limit (F ) shall be determined under the fitting areas.
3
For a hollow axle, given that the fitting effect is greater on the journals than on the other fitted areas because
of the different metal thicknesses, two fatigue limits shall be determined:
under the fitted parts , except for journals, limit F ,
4
under the fitted parts of the journal, limit F
5
NOTE The fatigue characteristics F and F of the axle are defined in EN 13261.
1 2
3.2.2.2 Values to be achieved
The minimum values for wheelsets using an axle of EA1N grade steel are given in Table 1.
Table 1 — Minimum values for wheelsets with an axle made of EA1N steel
Fatigue limit
F F F
3 4 5
2
N/mm 120 110 94
For other steel grades, the values are given in Annex B.
3.2.2.3 Fatigue test pieces
The area of the test piece where the crack initiates shall have the same geometry, environment and surface
condition as the axle under consideration.
For the fatigue testing of the wheelsets, one wheel or test piece with similar dimensions (particularly the hub)
shall be press-fitted or shrink-fitted on the wheel seat. The interference shall meet the requirements of 3.1.2.
For testing in the journal area, the corresponding inner ring of a bearing shall be mounted.
It is not mandatory to use a wheelset as the test piece. Examples of test pieces are given in Annex C.
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3.2.2.4 Test method
The tests shall be carried out on machines capable of creating rotating bending stresses in the area where it is
required to initiate a crack.
7
For each limit, F , F and F , it shall be verified on three test pieces that no crack has appeared after 10
3 4 5
cycles of a load creating a surface stress equal to F , F or F .
3 4 5
These stress levels shall be calculated on the seat, in accordance with the beam theory, disregarding the
interference stresses.
3.2.3 Electrical resistance
The electrical resistance of each wheelset measured between the treads of the two wheels shall not exceed
0,01 Ω.
The means and method used for this measurement shall be defined in agreement between the customer and
the supplier.
3.2.4 Imbalance
3.2.4.1 Values to be achieved
For a non-powered wheelset capable of running at a speed of greater than 120 km/h, a maximum dynamic
imbalance shall be specified.
The maximum values are given in Table 2. They are measured in the plane of the wheels.
Table 2 — Maximum imbalance values
Speed (km/h) Maximum imbalance x measuring plane
(g.m)
75
120 < V ≤ 200
V > 200 50
3.2.4.2 Test piece
The imbalance is measured on a fully assembled and machined wheelset.
3.2.4.3 Test method
The customer and the supplier shall agree the means of measurement.
3.2.5 Dimensions and tolerances
3.2.5.1 General
The dimensions of the wheelset shall be in accordance with the design drawings and the dimensional and
geometric tolerances to be applied when assembling the different parts of the wheelset are given in the
following subclauses.
They are dependent on the category of the wheelset.
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The values are given for measurements taken with no load on the wheelset.
3.2.5.2 Wheels
The tolerances of the parameters defined in Figure 1 shall be those given in Table 3.
Figure 1 — Wheel parameters
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prprEN 13260:2006 (E)
Table 3 — Tolerances on wheel parameters
b a
Description Symbol Category Category
mm mm
a b
a b b
Distance between the internal wheel faces a + 2 + 2
1
0 0
Difference in distances between the internal face of each wheel and the plane on the c – c
1 ≤ 1 ≤ 1
journal side defining the corresponding bearing collar or
c - c
1
Difference in tread circle diameter d – d ≤ 0,3
1
or
≤ 0,5 ≤ 0,3
d – d
1
Radial deviation in tread circle
h
≤ 0,5 ≤ 0,3 ≤ 0,3
a
Axial deviation of the internal wheel face
g
≤ 0,8 ≤ 0,5 ≤ 0,3
a
Measurement at 60 mm beneath the top of the flange
b
The tolerances may be changed for special designs of wheelsets
3.2.5.3 Brake discs
3.2.5.3.1 General
The tolerances on the parameters defined in Figures 2 and 3 shall be those required in Tables 4, 5 and 6.
Table 4 — Axial deviation of the internal face
Description Symbol Category 2 a Category 2 b Category 1
mm mm mm
a
Axial deviation of the internal face g
1 ≤ 0,75 ≤ 0,5 ≤ 0,5
1)
See Figures 2 and 3. Measurements at 30 mm from the external diameter
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3.2.5.3.2 Single-seat axle for one or two brake discs
Figure 2 — Single-seat axle for one or two brake discs
Table 5 — Tolerances for single-seat axles for one or two brake discs
Description Symbol Category 1 and 2
mm
Distance between the internal face of the disc crown and the plane on
≤ 0,5
f
the journal side defining the corresponding bearing collar
3.2.5.3.3 Double-seat axles for two or four brake discs
Figure 3 — Double-seat axles for two or four brake discs
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prprEN 13260:2006 (E)
Table 6 — Tolerances for double-seat axles for two or four brake discs
Symbol Category 1 and 2
Description
mm
Distance between the internal faces of the disc crowns a ± 0,5
3
Difference in distances between the internal face of each disc and the f – f
1
plane on the journal side defining the corresponding bearing collar or
≤ 1
f - f
1
3.2.5.3.4 More than two seats
If there are more than two seats for the brake discs, the tolerances on the dimensions such as a or f – f (see
3 1
Figure 3) are the same as in 3.2.5.3.3.
3.2.5.4 Cylindrical gear wheels for motor axle, reducing gears etc.
The tolerances of the parameters defined in Figure 4 shall be those required by Table 7.
Table 7 — Tolerances for cylindrical gear wheels for motor axle, reducing gears etc.
Description Symbol Category 2 Category 1
mm mm
a b b
Radial deviation h
1
a b b
Axial deviation g
2
Distance between the lateral reference surface of the gear
wheel and the plane on the journal side defining the c
2 ± 0,5 ± 0,2
a
corresponding bearing collar
a
See Figure 4.
b
In accordance with the specifications of the designer.
Figure 4 – Cylindrical gear wheels for motor axle, reducing gears etc.
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3.2.6 Residual stresses
3.2.6.1 General
The different manufacturing operations leading to a "ready to assemble" state for the axle shall not create
residual stresses likely to facilitate fatigue crack initiation.
3.2.6.2 Values to be achieved
2
On the axle seats at a depth of 0,1 mm below the surface, the residual stresses shall be ≤ 100 N/mm in
tension.
3.2.6.3 Test piece and position of the measuring points
The test piece is the axle in the "ready to assemble" state. The measuring points are located at the centre
and at one end of the seats. On each circumference, two points are measured at 120°.
3.2.6.4 Measurement method
The measurements can be made either with conventional gauges or by X-ray diffraction.
3.2.7 Protection against corrosion and impacts
The wheelset components shall be protected according to the requirements of their relevant standards.
Cavities arising from the overhang of the wheel hub on the wheelseats shall be filled with an anticorrosion
product.
3.2.8 Marking
The constituent parts of the wheelsets shall be marked according to the relevant standards.
The wheelset shall be identified as a minimum by the following marks (in accordance with the purchase
order):
type of wheelset;
order number;
assembler's marks;
date of assembly;
owner's marks.
These marks shall be located at the end of the journal which already bears the axle marks defined in
EN 13261 and be below the latter marks.
At the other end of the journal, one half the surface shall be free of any marks. It is reserved for maintenance
identification. The other half of this surface is free for any other marking.
The marks shall be stamped. Any protruding burrs resulting from the stamping shall be levelled to allow
ultrasonic examination to be carried out in service.
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Annex A
(normative)
Characteristics of the press-fitting curve
The characteristics of the press-fitting curve are described in Figure A.1. The fitting force shall start to
increase before the wheelseat displacement on to the wheel hub reaches 30 mm. The force shall then
increase continuously without falling outside the limit curve values given by the curves stated by the designer
of the component to be fitted.
Nevertheless, the following cases are permitted:
a reduction in the fitting force at a location of the groove for removal of oil is permitted. The maximum
force reached prior to the groove shall be reached again within a further displacement of 25 mm. During
this decrease, the fitti
...
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