SIST CEN/TS 13979-2:2011
(Main)Railway applications - Wheelsets and bogies - Monobloc wheels - Technical approval procedure - Part 2: Cast wheels
Railway applications - Wheelsets and bogies - Monobloc wheels - Technical approval procedure - Part 2: Cast wheels
This European Standard defines the requirements for a cast monobloc wheel of a freight railway vehicle nonpowered
axle for use on a European network.
It only applies to wheels of new design or new European application.
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 does not address the quality requirements for cast wheels. These quality
requirements are defined in FprEN 15718.
Bahnanwendungen - Radsätze und Drehestelle - Vollräder - Technische Zulassungsverfahren - Teil 2: Gussräder
Diese Technische Spezifikation legt die Anforderungen an ein gegossenes Vollrad für einen nicht angetriebenen Radsatz eines Eisenbahngüterwagens für den Gebrauch in einem europäischen Netz fest.
Diese Technische Spezifikation gilt nur für neue Radkonstruktionen oder neue europäische Anwendungen.
Der Zweck der Anforderungen besteht darin, die Wahl der Konstruktion für den betrachteten Anwendungs-bereich nachzuweisen.
Die Bewertung hinsichtlich dieser Anforderungen ist das technische Zulassungsverfahren.
Diese Technische Spezifikation beschreibt nicht die Qualitätsanforderungen für Gussräder. Diese Qualitätsan-forderungen werden in CEN/TS 15718 definiert.
Applications ferroviaires - Essieux montés et bogies - Roues monobloc - Procédure d'homologation technique - Partie 2 : Roues en acier moulé
La présente norme européenne définit les exigences relatives aux roues monobloc moulées des essieux-axes porteurs des véhicules ferroviaires de fret utilisés sur les réseaux européens.
Elle s'applique uniquement aux roues de conception nouvelle ou conçues pour une nouvelle application européenne.
Ces exigences sont destinées à évaluer la validité du choix de conception pour l’application proposée.
L'évaluation de ces exigences constitue la procédure d'homologation technique.
La présente norme européenne ne traite pas des exigences de qualité s'appliquant aux roues en acier moulé. Ces exigences de qualité sont définies dans la norme européenne FprEN 15718.
Železniške naprave - Kolesne dvojice in podstavni vozički - Monoblok kolesa - Postopek za tehnično odobritev - 2. del: Lita kolesa
Ta evropski standard opredeljuje zahteve za lita kolesa monoblok na negnani osi tovornega železniškega vozila za uporabo v evropskem omrežju.
Velja samo za kolesa po novih načrtih ali nove evropske aplikacije.
Te zahteve so namenjene ocenitvi veljavnosti izbire načrta za predlagano uporabo.
Ocenitev teh zahtev je tehnični postopek odobritve.
Ta evropski standard ne obravnava zahtev glede kakovosti litih koles. Te zahteve glede kakovosti so opredeljene v FprEN 15718.
General Information
Standards Content (Sample)
SLOVENSKI STANDARD
SIST CEN/TS 13979-2:2011
01-november-2011
äHOH]QLãNHQDSUDYH.ROHVQHGYRMLFHLQSRGVWDYQLYR]LþNL0RQREORNNROHVD
3RVWRSHN]DWHKQLþQRRGREULWHYGHO /LWDNROHVD
Railway applications - Wheelsets and bogies - Monobloc wheels - Technical approval
procedure - Part 2: Cast wheels
Bahnanwendungen - Radsätze und Drehestelle - Vollräder - Technische
Zulassungsverfahren - Teil 2: Gussräder
Applications ferroviaires - Essieux montés et bogies - Roues monobloc - Procédure
d'homologation technique - Partie 2 : Roues en acier moulé
Ta slovenski standard je istoveten z: CEN/TS 13979-2:2011
ICS:
45.040 Materiali in deli za železniško Materials and components
tehniko for railway engineering
SIST CEN/TS 13979-2:2011 en,fr,de
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
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SIST CEN/TS 13979-2:2011
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SIST CEN/TS 13979-2:2011
TECHNICAL SPECIFICATION
CEN/TS 13979-2
SPÉCIFICATION TECHNIQUE
TECHNISCHE SPEZIFIKATION
September 2011
ICS 45.040
English Version
Railway applications - Wheelsets and bogies - Monobloc wheels
- Technical approval procedure - Part 2: Cast wheels
Applications ferroviaires - Essieux montés et bogies - Bahnanwendungen - Radsätze und Drehgestelle - Vollräder
Roues monobloc - Procédure d'homologation technique - - Technische Zulassungsverfahren - Teil 2: Gussräder
Partie 2: Roues en acier moulé
This Technical Specification (CEN/TS) was approved by CEN on 3 January 2011 for provisional application.
The period of validity of this CEN/TS is limited initially to three years. After two years the members of CEN will be requested to submit their
comments, particularly on the question whether the CEN/TS can be converted into a European Standard.
CEN members are required to announce the existence of this CEN/TS in the same way as for an EN and to make the CEN/TS available
promptly at national level in an appropriate form. It is permissible to keep conflicting national standards in force (in parallel to the CEN/TS)
until the final decision about the possible conversion of the CEN/TS into an EN is reached.
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.
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. CEN/TS 13979-2:2011: E
worldwide for CEN national Members.
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Contents Page
Forew ord .4
Introduction .5
1 Scope .6
2 Normative references .6
3 Parameters for the definition of the application covered .6
3.1 Parameters for geometric interchangeability .6
3.1.1 Functional requirements .6
3.1.2 Assembly requirements .7
3.1.3 Maintenance requirements .7
3.2 Parameters for thermomechanical assessment .7
3.3 Parameters for mechanical assessment .7
3.4 Parameters for acoustic assessment .8
4 Description of the wheel to be approved .8
5 Assessment of the geometric interchangeability .8
6 Assessment of the thermomechanical behaviour .8
6.1 General procedure .8
6.2 First stage – Braking bench test .9
6.2.1 Test procedure .9
6.2.2 Decision criteria .9
6.3 Second stage – Wheel fracture bench test .10
6.3.1 General .10
6.3.2 Test procedure .10
6.3.3 Decision criterion .10
6.4 Third stage – Field braking test .10
6.4.1 General .10
6.4.2 Test procedure .10
6.4.3 Decision criteria .10
7 Assessment of the mechanical behaviour .11
7.1 General procedure .11
7.2 First stage - Calculation .11
7.2.1 Applied forces .11
7.2.2 Calculation procedure .12
7.2.3 Preliminary assessment criterion .13
7.3 Second stage – Bench test .13
7.3.1 General .13
7.3.2 Definition of bench loading and of the test procedure .13
7.3.3 Decision criteria .13
8 Assessment of the acoustic behaviour .13
8.1 General procedure .13
8.2 Calculation procedure .14
8.3 Field measurements .14
8.4 Decision criteria .14
9 Technical approval documents .15
Annex A (normative) Assessment of the thermomechanical behaviour .16
A.1 Assessment flow chart .16
A.2 Braking bench test procedure .17
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A.2.1 Principle of the test . 17
A.2.2 Definition of braking . 17
A.2.3 Method of measuring the decision criteria . 17
A.2.4 Tests and measurements . 18
A.2.5 Anomalies . 19
A.3 Wheel fracture bench test procedure . 19
A.3.1 Principle of the test . 19
A.3.2 Definition of drag braking . 19
A.3.3 Pre-cracking of the rim . 20
A.3.4 Tests and measurements . 20
A.3.5 Anomalies . 21
A.4 Field braking test procedure . 21
A.4.1 Principle of the test . 21
A.4.2 Definition of braking . 21
A.4.3 Method of measurement of the decision criteria . 21
A.4.4 Tests and measurements . 22
A.4.5 Anomalies . 23
Annex B (normative) Flow chart of the mechanical behaviour assessment . 24
Annex C (informative) Mechanical behaviour – Finite element code assessment. 25
Annex D (informative) Mechanical behaviour – Bench loading and test procedure. 26
D.1 Principle of bench loading and test procedure . 26
D.2 Definition of loading . 27
D.2.1 General . 27
D.2.2 Measurement of the stresses during field tests . 27
D.3 Fatigue bench test . 27
D.3.1 Method 1 – Random fatigue test . 27
D.3.2 Method 2 – Single-stage fatigue test . 29
Annex E (informative) Assessment of the acoustic behaviour . 31
E.1 Assessment flow chart . 31
E.2 Calculation procedure . 32
E.2.1 Preliminary comment . 32
E.2.2 Calculation of the wheel modal basis . 32
E.2.3 Selection of the reference track model . 32
E.2.4 Definition of the calculation parameters . 32
E.2.5 Power calculation . 32
E.2.6 Insertion . 33
E.2.7 Calculations of the decision criteria for acoustic technical approval of the wheel . 34
E.2.8 Optional calculations . 34
E.3 Field measurement procedure . 34
E.3.1 Objective and preliminary remark . 34
E.3.2 Recommendations for the operating conditions . 35
E.3.3 Measurement procedure . 38
E.3.4 Analysis of results . 40
Annex F (informative) Drag braking values for interoperability . 44
Bibliography . 45
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Foreword
This document (CEN/TS 13979-2:2011) has been prepared by Technical Committee CEN/TC 256 “Railway
applications”, the secretariat of which is held by DIN.
Your attention is drawn to the fact that certain elements in this document may be subject to intellectual
property or similar rights. The CEN and/or CENELEC cannot be held responsible for not identifying such
property rights and providing a warning of their existence.
This document has been prepared as part of a mandate given to CEN by the European Commission and the
European Free Trade Association and provides support for the main requirements of EU Directive
2008/57/CE.
This European Standard is part of a series Railway applications — Wheelsets and bogies — Monobloc wheels
— Technical approval procedure which consists of the following parts:
⎯ Part 1: Forged and rolled wheels;
⎯ Part 2: Cast wheels.
According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following
countries are bound to announce this Technical Specification: Austria, Belgium, Bulgaria, Cyprus, Croatia, the
Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Ireland, Iceland, Italy,
Latvia, Lithuania, Luxembourg, Malta, Norway, the Netherlands, Poland, Portugal, Romania, Slovakia,
Slovenia, Spain, Sweden, Switzerland and the United Kingdom.
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Introduction
Part 1 of this series applies to monobloc wheels manufactured by forging and rolling. This process was the
only authorized process accepted in the UIC regulations that were applicable in the recent past in most of the
European countries.
Cast wheels are commonly used by AAR networks and have been introduced into Europe on some
applications for freight wagons. This standard defines the specified requirements linked to the casting process
for the technical approval of a monobloc wheel. It follows the same methodology as Part 1.
As this standard applies only to freight wagons and supports European interoperability, this standard defines
in the informative Annex F the specific parameters for the thermomechanical assessment of a freight wagon
wheel designed for European interoperability.
The standard describes how to assess the wheel design. To be able to apply the 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 geometric 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 acoustic 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; thus, the easier the
objectives are to attain by the wheel under study.
This Technical Specification does not cover assessment of the hub nor of the static mechanical dimensioning
of the wheel.
The main content of this standard is derived from Part 1. The only technical differences are linked to the
needs of the cast process for the product.
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1 Scope
This Technical Specification defines the requirements for a cast monobloc wheel of a freight railway vehicle
non-powered axle for use on a European network.
It only applies to wheels of new design or new European application.
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 Technical Specification does not address the quality requirements for cast wheels. These quality
requirements are defined in Technical Specification CEN/TS 15718.
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 reference document
(including any amendments) applies.
EN 13103, Railway applications — Wheelsets and bogies — Non-powered axles — Design method
CEN/TS 15718, Railway applications — Wheelsets and bogies — Product requirements for cast wheels
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 geometric interchangeability
The application shall be defined by geometric interchangeability 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;
⎯ 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.
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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 (where required);
⎯ 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 tread surface. This energy
may be defined by a power P , a time t and a train speed V during drag braking. If it is defined by other
a a a
parameters (for braking to a stop, for example), these parameters are defined by agreement between the
customer and the supplier. Required values of P for European interoperability are given in informative
a
Annex F;
NOTE For interoperable freight rolling stock, the thermomechanical behaviour does not need to be verified when
braking to a stop, but only when drag braking, because of the lower energy in braking to a stop.
⎯ the type of brake shoes applied to the wheel (nature, dimensions and number).
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.
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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 (casting, shot peening, heat treatment, machining condition);
⎯ the definition of the wheel geometry (drawing);
⎯ the following fabrication parameters:
⎯ geometric 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 product qualification as defined in Technical Specification CEN/TS 15718.
5 Assessment of the geometric 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 flowchart for this assessment is shown in normative Annexe A. It shall be noted that stages 1 and 2 can
occur in any order as they are both mandatory for cast wheels. The following text maintains the same order as
EN 13979-1; however, it shall be noted that the sequence shown in Annex A may be preferable in practice.
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).
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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 geometric tolerance ranges. The wheel designer shall prove by
numeric simulation that the tested wheels give the worst results. If that is not the case, the numeric simulation
shall allow correction of the results to correspond with those that would be obtained on wheels in the most
unfavourable geometric conditions.
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 P (P is defined in 3.2). The duration of each
a
a
drag braking period and the train speed are those defined in 3.2 (t and V ).
a a
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:
2
⎯ σ ≤ + Σ N/mm as the average of three measurements;
r n r
2
⎯ σ ≤ + (Σ + 50) N/mm for each measurement;
i n r
⎯ 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:
2
⎯ σ ≤ +(Σ + 75) N/mm as the average of three measurements;
r w r
2
⎯ σ ≤ +(Σ + 100) N/mm for each measurement;
i w r
⎯ maximum lateral displacement of the rim after cooling: + 1,5 / - 0,5mm.
2
For steel grade CER7, a value of Σr = 200 N/mm is adopted. For CER8, the value of Σr shall be determined.
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.
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6.3 Second stage – Wheel fracture bench test
6.3.1 General
This second stage is mandatory for cast wheels due to the currently limited European experience on those
products.
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 P (P is defined in 3.2). The duration of each drag
a a
braking and the running speed of the train are those defined in 3.2 (t and V ).
a a
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:
2
⎯ σ ≤ + (Σ - 50) N/mm as the average of t
...
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