SIST EN 13261:2004
(Main)Railway applications - Wheelsets and bogies - Axles - Product requirements
Railway applications - Wheelsets and bogies - Axles - Product requirements
This European Standard specifies the characteristics of axles for use on European networks.
It defines characteristics of forged or rolled solid and hollow axles, made from vacuum-degassed steel grade EA1N ) that is the most commonly used grade on European networks. For hollow axles, this standard applies only to those that are manufactured by machining of a hole in a forged or rolled hollow axle
In addition, the particular characteristics for axles in grade EA1T1) and EA4T1) are given in annex A (normative).
Two categories of axle are defined, category 1 and category 2. Generally, category 1 is chosen when operational speed in higher than 200 km/h.
This standard is applicable to axles that are designed in accordance with the requirements of EN 13103 and EN 13104
NOTE Different values for some characteristics may be agreed, if a particular process of fabrication (e.g cold rolling, shot peening) have an influence on them
Bahnanwendungen - Radsätze und Drehgestelle - Radsatzwellen - Produktanforderungen
Diese Europäische Norm legt die Eigenschaften von Radsatzwellen für den Einsatz auf europäischen Netzen fest.
Sie beschreibt die Eigenschaften für geschmiedete oder gewalzte Radsatzwellen aus vakuumentgastem Stahl der Sorte EA1N ), die bei den europäischen Bahnen am meisten verwendete Stahlsorte. Bei Hohlradsatz-wellen gilt diese Norm nur für diejenigen, die durch das Bohren eines Loches in eine geschmiedete oder gewalzte Radsatzvollwelle gefertigt werden.
Zusätzlich sind die für die Radsätze der Stahlgüten EA1T1) und EA4T1) besonders zu berücksichtigenden Werte und Eigenschaften im Anhang A (normativ) gegeben.
Es werden zwei Radsatzwellenkategorien unterschieden: Kategorie 1 und Kategorie 2. Im allgemeinen wird die Kategorie 1 gewählt, wenn die Betriebsgeschwindigkeit über 200 km/h liegt.
Diese Europäische Norm gilt für Radsatzwellen, die nach den Anforderungen von EN 13103 und EN 13104 konstruiert sind.
ANMERKUNG Andere Werte können für einige Eigenschaften vereinbart werden, wenn sie durch ein besonderes Herstellungsverfahren (z.B. Kaltschmieden, Kugelstrahlen) beeinflusst werden.
Applications ferroviaires - Essieux montés et bogies - Essieux-axes - Prescriptions pour le produit
Cette norme s'applique aux essieux-axes dont la conception est conforme aux regles définies dans l'EN****** ou l'EN******. Elle spécifie les caractéristiques des essieux-axes pleins et creux fabriqués par forgeage ou par laminage, en acier dégazé sous vide, de nuance EA1N 1) qui est la nuance la plus utilisée sur les réseaux de chemins de fer européens. Toutefois, les valeurs particulieres des caractéristiques a prendre en compte pour les essieux de nuance EA1T1) et EA4T1) sont données en annexe A (normative).
Železniške naprave - Kolesne dvojice in podstavni vozički – Osi – Zahtevane lastnosti proizvoda
General Information
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Standards Content (Sample)
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Railway applications - Wheelsets and bogies - Axles - Product requirementsApplications ferroviaires - Essieux montés et bogies - Essieux-axes - Prescriptions pour le produitBahnanwendungen - Radsätze und Drehgestelle - Radsatzwellen - Produktanforderungen45.040Materiali in deli za železniško tehnikoMaterials and components for railway engineeringICS:SIST EN 13261:2004enTa slovenski standard je istoveten z:EN 13261:200301-junij-2004SIST EN 13261:2004SLOVENSKI
STANDARD
EUROPEAN STANDARDNORME EUROPÉENNEEUROPÄISCHE NORMEN 13261September 2003ICS 45.040English versionRailway applications - Wheelsets and bogies - Axles - ProductrequirementsApplications ferroviaires - Essieux montés et bogies -Essieux-axes - Prescriptions pour le produitBahnanwendungen - Radsätze und Drehgestelle -Radsätze - ProduktanforderungenThis European Standard was approved by CEN on 14 February 2003.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 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 Management Centre has the same status as the officialversions.CEN members are the national standards bodies of Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece,Hungary, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Slovakia, Spain, Sweden, Switzerland and UnitedKingdom.EUROPEAN COMMITTEE FOR STANDARDIZATIONCOMITÉ EUROPÉEN DE NORMALISATIONEUROPÄISCHES KOMITEE FÜR NORMUNGManagement Centre: rue de Stassart, 36
B-1050 Brussels© 2003 CENAll rights of exploitation in any form and by any means reservedworldwide for CEN national Members.Ref. No. EN 13261:2003 E
EN 13261:2003 (E) 2 Contents Page Foreword.4 Introduction.5 1 Scope.5 2 Normative references.6 3 Product definition.6 3.1 Chemical composition.6 3.2 Mechanical characteristics.7 3.3 Microstructure characteristics.12 3.4 Material cleanliness.13 3.5 Permeability to ultrasound.14 3.6 Residual stresses.15 3.7 Surface characteristics.17 3.8 Geometrical and dimensional tolerances.20 3.9 Protection against corrosion and against mechanical aggression.25 3.10 Marking.29 Annex A (normative)
Particular characteristics for axles of steel grade EA1T and EA4T.30 A.1 Chemical composition.30 A.2 Mechanical characteristics.30 A.3
Microstructure characteristics.31 Annex B (normative)
Standard wedge for measurement of permeability to ultrasound.32 B.1 Test piece.32 B.2 Tolerances of the wedge.32 B.3 Steel grade.32 Annex C (normative)
Method to assess resistance to impact of the coating.33 C.1 Principle.33 C.2 Test piece.33 C.3 Apparatus.33 C.4 Procedure.33 C.5 Expression of results.33 Annex D (normative)
Method to assess resistance to gritting of the coating.34 D.1 Principle.34 D.2 Test piece.34 D.3 Apparatus.34 D.4 Procedure.34 D.5 Expression of results.34 Annex E (normative)
Method to assess the resistance of the coating to specific
corrosive products.35 E.1 Principle.35 E.2 Test piece.35 E.3 Apparatus.35 E.4 Corrosive products.35 E.5 Procedure.35 E.6 Expression of results.36 Annex F (normative)
Method to assess the resistance of the coating to cyclic mechanical stresses.37 F.1 Purpose.37
EN 13261:2003 (E) 3 F.2 Principle.37 F.3 Test piece.37 F.4 Apparatus.37 F.5 Procedure.37 F.6 Expression of results.38 Annex G (normative)
Measurement of the hydrogen content in the steel for axles at the melting stage.39 G.1 Sampling.39 G.2 Analysis methods.39 G.3 Precautions.39 Annex H (informative)
Drawings of test pieces.40 Annex I (informative)
Product qualification.42 I.1 General.42 I.2 Requirements.42 I.3 Qualification procedure.43 I.4 Qualification certificate.44 I.5 Qualification file.45 Annex J (informative)
Product delivery.46 J.1 General.46 J.2 Delivery condition.47 J.3 Controls on each axle.47 J.4 Batch control.48 J.5 Quality plan.49 J.6 Allowable rectification.50 Bibliography.51
EN 13261:2003 (E) 4 Foreword This document EN 13261:2003 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 March 2004, and conflicting national standards shall be withdrawn at the latest by March 2004. According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Slovakia, Spain, Sweden, Switzerland and the United Kingdom. This document has been prepared under a mandate given the CEN by the European Commission and the European Free Trade Association, and supports essential requirements of EU Directive(s). Annexes A, B, C, D, E, F and G are normative.
Annexes H, I and J are informative. This document contains a bibliography. According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Slovakia, Spain, Sweden, Switzerland and the United Kingdom.
EN 13261:2003 (E) 5 Introduction Normative documents which have been used until now in Europe for axle delivery (UIC leaflets, national standards) had, for the main purpose, a complete definition of delivery procedures and axle characteristics that were to be measured.
Product qualification was sometimes mentioned but the procedures and the characteristics that had to be verified for the qualification were not given.
This standard addresses these issues by:
a) definition of all axle characteristics. These are verified either during qualification or delivery of the product (see clause 3); b) definition of qualification procedures (see informative annex I);
c) definition of delivery conditions (see informative annex J). Here, a choice is given to the supplier of either: a traditional delivery procedure with a control by batch sampling as in existing documents (see J.4), or a delivery procedure using quality assurance concepts (see J.5).
1 Scope
This European Standard specifies the characteristics of axles for use on European networks.
It defines characteristics of forged or rolled solid and hollow axles, made from vacuum-degassed steel grade EA1N1) that is the most commonly used grade on European networks. For hollow axles, this standard applies only to those that are manufactured by machining of a hole in a forged or rolled solid axle
In addition, the particular characteristics for axles in grade EA1T1) and EA4T1) are given in annex A (normative).
Two categories of axle are defined, category 1 and category 2.
Generally, category 1 is chosen when the operational speed is higher than 200 km/h.
This standard is applicable to axles that are designed in accordance with the requirements of EN 13103 and EN 13104
NOTE Different values for some characteristics may be agreed if a particular process of fabrication (e.g
cold rolling, shot peening) has an influence on them.
1) N for the normalized metallurgical condition T for the quenched and tempered metallurgical condition
EN 13261:2003 (E) 6 2 Normative references This European Standard incorporates by dated or undated reference, provisions from other publications. These normative references are cited at the appropriate places in the text and the publications are listed hereafter. For dated references, subsequent amendments to or revisions of any of these publications apply to this European Standard only when incorporated in it by amendment or revision. For undated references the latest edition of the publication referred to applies (including amendments). EN 10002-1, Metallic materials – Tensile testing – Part 1: Method of test at ambient temperature.
EN 10045-1, Metallic materials –
Charpy impact test – Part 1: Test method.
EN 13103, Railway applications – Wheelsets and bogies – Non-powered axles – Design method. EN 13104, Railway applications – Wheelsets and bogies – Powered axles – Design method. EN 13260, Railway applications – Wheelsets and bogies – Wheelsets – Product requirements.
EN 20898-2, Mechanical properties of fasteners – Part 2: Nuts with specified proof load values – Coarse thread (ISO 898-2:1992).
EN 22768-1, General tolerances – Part 1: Tolerances for linear and angular dimensions without individual tolerance indications (ISO 2768-1:1989).
EN 22768-2, General tolerances – Part 2: Geometrical tolerances for features without individual tolerance indications (ISO 2768-2:1989).
ISO 643, Steels – Micrographic determination of the apparent grain size.
ISO 2409, Paints and varnishes – Cross-cut test.
ISO 2808, Paints and varnishes – Determination of film thickness.
ISO 4967, Steel – Determination of content of non-metallic inclusions – Micrographic method using standard diagrams.
ISO 5948, Railway rolling stock material – Ultrasonic acceptance testing.
ISO 6933:1986, Railway rolling stock material – Magnetic particle acceptance testing.
ISO 9227, Corrosion tests in artificial atmospheres – Salt spray tests.
ISO/TR 97692), Steel and iron – Review of available methods of analysis.
ISO 14284:1996, Steel and iron – Sampling and preparation of samples for the determination of chemical composition.
3 Product definition 3.1 Chemical composition
3.1.1 Values to be achieved
The maximum percentage contents of the various elements are given in Table 1.
2) See also CR10261
EN 13261:2003 (E) 7
Table 1 C Si Mn Pa
Sab
Cr Cu Mo Ni V 0,40 0,50 1,20 0,020 0,020 0,30 0,30 0,08 0,30 0,06 a A maximum content of 0,025 % may be agreed at the time of enquiry and the order.
b
A minimum sulfur content may be agreed at the time of enquiry and the order according to the steelmaking process, in order to safeguard against oxygen cracking.
3.1.2 Location of sample
The test sample shall be taken at mid-radius of solid axles or at mid-distance between external and internal surfaces of hollow axles.
3.1.3 Chemical analysis
The chemical composition analysis shall be performed according to the methods and definitions described in ISO/TR 9769.
3.2 Mechanical characteristics
3.2.1 Characteristics from tensile test
3.2.1.1 Values to be achieved
The values to be achieved at mid-radius of solid axles or at mid-distance between external and internal surfaces of hollow axles are given in Table 2.
The values to be achieved near the external surface shall be greater than or equal to 0,95 times the values measured at mid-radius of solid axles or at the mid-distance between external and internal surfaces of hollow axles.
The values to be achieved in the centre of solid axles or near the internal surface of hollow axles shall be greater than or equal to 0,8 times the values measured at mid-radius or at mid-distance between external and internal surfaces.
Table 2
ReH (N/mm2)a
Rm (N/mm2)
As %
≥ 320
550-650
≥ 22
a If no distinctive yield strength is present, the proof stress R0,2 shall be determined
3.2.1.2 Location of test pieces
The test pieces shall be taken from three levels in the largest axle section:
as near as possible to the external surface for all the axles; at mid-radius and in the centre of solid axles;
EN 13261:2003 (E) 8 at mid-distance between external and internal surfaces, and near the internal surface of hollow axles;
as shown in Figure 1 a) and b). Dimensions in millimetres.
Figure 1 a) — Solid axle
Figure 1 b) — Hollow axle
EN 13261:2003 (E) 9
3.2.1.3 Test method The test shall be carried out in accordance with EN 10002-1. The test piece diameter shall be at least 10 mm in the machined-down portion. The gauge length shall be five times the diameter.
3.2.2 Impact test characteristics
3.2.2.1 Values to be achieved
Impact test characteristics shall be determined at 20°C in the longitudinal and the transverse directions. Values to be achieved at mid-radius of solid axles, or at mid-distance between external and internal surfaces of hollow axles, are given in Table 3.
Near the surface, they shall be greater than or equal to 0,95 times the values measured at mid-radius, or at mid-distance between external and internal surfaces of hollow axles.
In the centre of solid axles, or near the internal surface of hollow axles, they shall be greater than 0,8 times the values measured at mid-radius or at mid-distance between external and internal surfaces.
For each level (surface, mid-radius, centre), the average value of the 3 test pieces (see 3.2.2.2) is defined in Table 3.
No individual value shall be less than 70 % of the values in Table 3.
Table 3
KU longitudinal (J)
KU transverse (J)
≥ 30 ≥ 25
3.2.2.2 Location of test pieces
The test pieces shall be taken from three levels in the largest axle section:
as near as possible to the external surface for all the axles; at mid-radius and in the centre of solid axles; at mid-distance between external and internal surfaces, and near the internal surface of hollow axles, as shown in Figure 2 a) and b).
3.2.2.3 Test method
The test shall be carried out in accordance with EN 10045-1.
EN 13261:2003 (E) 10 Dimensions in millimetres
Figure 2 a) — Solid axle
Figure 2 b — Hollow axle
Key
1 Longitudinal test piece 2 Transverse test piece
EN 13261:2003 (E) 11 3.2.3 Fatigue characteristics
3.2.3.1 General
Verification of the fatigue characteristics is essential in order to have a correctly dimensioned axle. The satisfactory performance of an axle in service depends upon these characteristics. The values defined in this subclause are used for the calculation of the maximum permissible stresses that are referred to in the design rules in EN 13103 and EN 13104.
It is necessary to estimate the fatigue limits in the following two areas, in order to predict the behaviour of the axle under in-service stresses:
for the material, tests are made on reduced test pieces, for which the shapes do not depend upon the product geometry, for the product, tests are made on full size test pieces, for which the dimensions and manufacture are similar to the final product and its associated permissible fabrication defects.
3.2.3.1.1
Fatigue limits on reduced test pieces
The fatigue limits defined with reduced test pieces are used to verify that the notch effect of the material used for the fabrication of the axle is in accordance with the security coefficient "S", defined in design standards
EN 13103 and EN 13104. They are determined from:
smooth surface test pieces (fatigue limit RfL ) and notched test pieces (fatigue limit RfE )
3.2.3.1.2
Fatigue limits on full size test pieces
The limits determined on full size test pieces are used to verify that the axle fatigue characteristics are in accordance with those that are used to calculate the maximum permissible stresses referred to in design standards EN 13103 and EN 13104.
These fatigue limits apply to different axle areas. Only the fatigue limits applying to the axle body are taken into account in this standard. The limits applying to the wheelset depend mostly on the assembly and are referred to in EN 13260.
It is necessary to define two fatigue limits:
on the body surface, limit F1, on the bore surface in the case of a hollow axle, limit F2.
3.2.3.2 Values to be achieved
The values to be achieved are given in Table 4.
Table 4
Limit F1 F2 RfL RfE q = RfL/RfE Value ≥ 200 N/mm2 ≥ 80 N/mm2 ≥ 250 N/mm2 ≥ 170 N/mm2 ≤ 1,47
EN 13261:2003 (E) 12
3.2.3.3 Fatigue test pieces
For F1 and F2 determination, the test piece areas where the cracks initiate shall have a similar geometry and surface roughness to those of the axle areas that have to be analysed. For F2 determination, the test piece surface shall have a 1 mm deep notch as shown in Figure 3a. All of these test pieces shall come from the same fabrication process as that for the axle.
For RfL and RfE determination, the test piece diameter is nominally 10 mm in the area where the crack initiates. The roughness (Ra) of the test piece for RfL determination is less than or equal to 0,4 µm. The notch for RfE determination is shown in Figure 3b. These test pieces are located as near as possible to the surface of the axle body.
Dimensions in millimetres
Figure 3 a — Solid axle
Figure 3b — Hollow axle
Examples of full size and reduced test piece drawings are given in annex H (informative).
3.2.3.4 Test method
The tests shall be performed with machines that induce rotating bending stresses in the area where it is required to initiate a fatigue crack.
For each limit, F1 and F2, it shall be verified that for three test pieces there is no crack after 107 cycles of load that generates a surface stress level equal to F1 and F2. The values of the stresses are calculated by classical beam theory where it may be applied. If not, the stresses shall be measured by strain gauges in the areas where the fatigue cracks initiate.
RfL and RfE shall be determined for 107 cycles for a non-fracture probability of 50 %, which requires the use of at least 15 test pieces for each limit and a statistical method for the interpretation of the results.
3.3 Microstructure characteristics
3.3.1 Values to be achieved
The microstructure shall be one of ferrite and perlite.
The grain size shall not be greater than that defined by the reference diagram V of ISO 643.
3.3.2 Location of the test piece
The test pieces shall be taken from the largest axle section in a 200 mm2 plane, perpendicular to arrow F, at mid-radius of solid axles, or at mid-distance between external and internal surface of hollow axles, as shown in Figure 4.
EN 13261:2003 (E) 13
3.3.3 Test method
Tests shall be performed in accordance with ISO 643.
3.4 Material cleanliness
3.4.1 Micrographic cleanliness
3.4.1.1 Cleanliness level to be achieved
The level of cleanliness shall be measured by micrographic examination as defined in 3.4.1.2 and 3.4.1.3. The maximum values of thick series inclusions to be obtained are given in Table 5. Thin series inclusions are not taken into account.
Table 5
Category 1 Category 2 Type of inclusions Thick series (maximum) Thin series (maximum) Thick series (maximum) Thin series (maximum) A (Sulfur) 1,5 1,5 1,5 2 B (Aluminate) 1 1,5 1,5 2 C (Silicate) 1 1,5 1,5 2 D (Globular oxide) 1 1,5 1,5 2 B + C + D 2 3 3 4
3.4.1.2 Location of the micrographic sample
The examination field is given in Figure 4.
The examination shall be made in a 200 mm² plane, perpendicular to arrow F, at mid-radius of the solid axles, or at mid-distance between external and internal surface of hollow axles. The test pieces shall be taken from the largest axle section.
EN 13261:2003 (E) 14
Figure 4
3.4.1.3 Test method
Cleanliness level determination shall be carried out in accordance with ISO 4967, method A.
3.4.2 Internal integrity
3.4.2.1 General Internal integrity shall be determined by ultrasonic examination. Standard defects shall be flat bottom holes at different depths.
3.4.2.2 Level to be achieved
The axles shall have no internal defects that give echo magnitudes equal to or greater than those obtained for a standard defect situated at the same depth. The diameter of this standard defect shall be 3 mm. No attenuation of the back echo higher than 4 dB due to non-homogenates or internal defects shall be accepted.
3.4.2.3 Test piece
The examination shall be made on the axle itself after heat treatment and in the delivery condition before the final protection is applied.
3.4.2.4 Method of examination
The axle internal integrity is verified by ultrasonic diametral examination according to method Da of ISO 5948. The whole axle shall be examined, except certain parts (fillets, grooves, etc.) after agreement between the customer and the supplier.
3.5 Permeability to ultrasound
3.5.1 General The permeability shall ensure the feasibility of ultrasonic testing during service and is verified by producing a record for the axle after a preliminary calibration of the testing apparatus.
EN 13261:2003 (E) 15 3.5.2 Level to be achieved
The echo obtained on the axles being checked shall have an amplitude equal to or greater than 50 % of full screen height, after preliminary calibration of the apparatus on the standard wedge described in annex B. The height of the background noise shall be less than 10 % of the screen height.
3.5.3 Test piece
The test piece to be examined shall be the axle, after full heat treatment.
The condition of the journal ends, at the moment of inspection, shall be the same as that required for delivery, without protection.
3.5.3. Test method
The ultrasonic permeability examination shall be performed by longitudinal checking of the axle according to method T of ISO 5948.
If the tests are not performed by an automated process, the measurement shall be performed a minimum of 6 points, equally distributed around the axle journal section.
The probes used are the piezoelectric type, transmitter and receiver, in quartz or barium titrate BaTi with round or rectangular sections (between 80 mm2 and 450 mm2). Their frequency and the height of the echo obtained in front of the flat bottom ∅ 1 mm are described in Table 6 for each category of axle. The noise during the calibration shall not exceed 5 % of the full screen height.
For this test, the instrument shall operate with narrow fre
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