Railway applications - Track - Forged rail transitions

This European Standard specifies the requirements for the approval of a process wherein a rail of one profile has part of its length forged to a different profile, together with the requirements for subsequent forging production and product acceptance.
This European Standard applies to new railway rails according to EN 13674 1, and to switch and crossing rails used in conjunction with railway rails 46 kg/m and above according to EN 13674 2, to be welded or fish plated to make up switch rails or transition rails intended for use on railway infrastructures.

Bahnanwendungen - Oberbau - Geschmiedete Schienenübergänge

Diese Europäische Norm legt die Anforderungen an die Zulassung eines Verfahrens, bei dem eine Schiene mit einem Profil längs an eine Schiene mit anderem Profil geschmiedet wird, zusammen mit den Anforderungen an die spätere Schmiedeproduktion und Produktakzeptanz fest.
Die Norm gilt für neue Eisenbahnschienen entsprechend EN 13674-1, ebenso für Weichen und Kreuzungen und in Verbindung mit Eisenbahnschienen größer 46 kg/m entsprechend EN 13674-2, die für die Herstellung von Zungen- oder Übergangsschienen verschweißt oder gelascht werden und für den Einsatz in der Eisenbahninfrastruktur vorgesehen sind.

Applications ferroviaires - Voie - Rails forgés

Le présent document spécifie les exigences relatives à l'homologation d'un processus de forgeage qui consiste à forger une partie d'un rail à un profil de rail différent, ainsi que les exigences relatives à la production ultérieure par forgeage et les critères de réception du produit.
Le présent document s'applique aux rails de chemin de fer neufs conformes à l'EN 13674 1, et aux rails pour appareils de voie utilisés conjointement avec des rails de chemin de fer ayant une masse minimale de 46 kg/m et conformes à l'EN 13674 2, devant être soudés ou éclissés pour former des aiguilles ou des rails mixtes destinés aux infrastructures ferroviaires.

Železniške naprave - Zgornji ustroj - Prekovane prehodne tirnice

Ta evropski standard določa zahteve za odobritev postopka, pri katerem ima tirnica z določenim profilom del svoje dolžine prekovan v drug profil, skupaj z zahtevami za nadaljnja prekovanja in sprejemljivost izdelka.
Ta evropski standard velja za nove železniške tirnice v skladu s standardom EN 13674 1 in za kretnice ter križišča, ki se uporabljajo skupaj s tirnicami mase 46 kg/m in več v skladu s standardom EN 13674 2, ki jih je treba zvariti ali združiti s ploščami za izdelavo kretnic ali križišč, namenjenih uporabi na železniški infrastrukturi.

General Information

Status
Published
Public Enquiry End Date
10-Aug-2014
Publication Date
17-Feb-2015
Technical Committee
Current Stage
6060 - National Implementation/Publication (Adopted Project)
Start Date
28-Jan-2015
Due Date
04-Apr-2015
Completion Date
18-Feb-2015

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2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Železniške naprave - Zgornji ustroj - Prekovane prehodne tirniceBahnanwendungen - Oberbau - Geschmiedete SchienenübergängeApplications ferroviaires - Voie - Rails forgésRailway applications - Track - Forged rail transitions45.080Rails and railway componentsICS:Ta slovenski standard je istoveten z:EN 16273:2014SIST EN 16273:2015en,fr,de01-marec-2015SIST EN 16273:2015SLOVENSKI

STANDARD
SIST EN 16273:2015
EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM
EN 16273
December 2014 ICS 93.100 English Version
Railway applications - Track - Forged rail transitions
Applications ferroviaires - Voie - Rails forgés

Bahnanwendungen - Oberbau - Geschmiedete Schienenübergänge This European Standard was approved by CEN on 25 October 2014.

CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the CEN-CENELEC Management Centre or to any CEN member.

This European Standard exists in three official versions (English, French, German). A version in any other language made by translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC Management Centre has the same status as the official versions.

CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and United Kingdom.

EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION EUROPÄISCHES KOMITEE FÜR NORMUNG
CEN-CENELEC Management Centre:
Avenue Marnix 17,

B-1000 Brussels © 2014 CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Members. Ref. No. EN 16273:2014 ESIST EN 16273:2015

EN 16273:2014 (E) 2 Contents Page Foreword ..............................................................................................................................................................4 Introduction .........................................................................................................................................................5 1 Scope ......................................................................................................................................................6 2 Normative references ............................................................................................................................6 3 Terms and definitions ...........................................................................................................................6 4 Information to be supplied for approval ..............................................................................................8 4.1 By the purchaser....................................................................................................................................8 4.2 By the manufacturer ..............................................................................................................................8 5 Approval of the manufacturer ..............................................................................................................8 6 Requirements for the forging process ................................................................................................9 6.1 General ....................................................................................................................................................9 6.2 Forging parameters ...............................................................................................................................9 6.3 Post heat treatment ...............................................................................................................................9 6.4 Profile finishing ......................................................................................................................................9 6.5 Cutting to length ....................................................................................................................................9 6.6 Identification ...........................................................................................................................................9 7 Procedure approval ...............................................................................................................................9 7.1 General ....................................................................................................................................................9 7.2 Test specimen preparation ................................................................................................................ 10 7.3 Number of specimens ........................................................................................................................ 10 7.4 Non-destructive approval tests ......................................................................................................... 10 7.4.1 Geometry and dimensions ................................................................................................................. 10 7.4.2 Visual inspection ................................................................................................................................ 13 7.4.3 Surface finish ...................................................................................................................................... 13 7.4.4 Dye penetrant (DPI) or magnetic particle inspection (MPI) ............................................................ 13 7.4.5 Ultrasonic testing (UT) ....................................................................................................................... 13 7.5 Destructive approval tests ................................................................................................................. 14 7.5.1 Hardness distribution ......................................................................................................................... 14 7.5.2 Switch rails: hardness distribution in the rail head ........................................................................ 16 7.6 Test report ........................................................................................................................................... 18 7.7 Validity of approval ............................................................................................................................. 18 8 Production tests.................................................................................................................................. 18 8.1 Switches .............................................................................................................................................. 18 8.1.1 General ................................................................................................................................................. 18 8.1.2 Geometry and dimensions ................................................................................................................. 19 8.1.3 Hardness testing ................................................................................................................................. 19 8.2 Transition rails .................................................................................................................................... 20 8.2.1 General ................................................................................................................................................. 20 8.2.2 Hardness .............................................................................................................................................. 20 Annex A (informative)

Ultrasonic testing ..................................................................................................... 22 A.1 Reference line (DAC) generation – reference block ........................................................................ 22 A.2 Reference line (DAC) generation and acceptance criteria ............................................................. 23 Annex B (informative)

Documentation of approval tests ........................................................................... 24 SIST EN 16273:2015

EN 16273:2014 (E) 3 B.1 Forged switch rails .............................................................................................................................. 24 B.1.1 General information ............................................................................................................................ 24 B.1.2 Geometry and dimensions ................................................................................................................. 24 B.1.3 Dye penetrant (DPI) or magnetic particle inspection (MPI) ............................................................. 27 B.1.4 Ultrasonic testing (UT) ........................................................................................................................ 27 B.1.5 Hardness distribution on the surface ................................................................................................ 28 B.1.6 Test results of hardness distribution on the rail head .................................................................... 28 B.1.7 Test results of hardness distribution on the rail foot ...................................................................... 30 B.2 Forged transition rails ......................................................................................................................... 32 B.2.1 General information ............................................................................................................................ 32 B.2.2 Geometry and dimensions ................................................................................................................. 33 B.2.3 Dye penetrant (DPI) or magnetic particle inspection (MPI) ............................................................. 34 B.2.4 Ultrasonic testing (UT) ........................................................................................................................ 34 B.2.5 Hardness distribution on the surface ................................................................................................ 35 B.2.6 Test results of hardness distribution on the rail head .................................................................... 36 B.2.7 Test results of hardness distribution on the rail foot ...................................................................... 36 Bibliography ...................................................................................................................................................... 38

SIST EN 16273:2015

EN 16273:2014 (E) 4 Foreword This document (EN 16273:2014) 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 June 2015 and conflicting national standards shall be withdrawn at the latest by June 2015. 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 has been prepared under a mandate given to CEN by the European Commission and the European Free Trade Association. 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, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United Kingdom. SIST EN 16273:2015

EN 16273:2014 (E) 5 Introduction This European Standard has three main topics: — requirements of a forged part; — procedure approval; — forged rail production following approval. This European Standard satisfies the needs of the railway authority and the manufacturer should achieve the specified requirements of this standard. SIST EN 16273:2015

EN 16273:2014 (E) 6 1 Scope This European Standard specifies the requirements for the approval of a process wherein a rail of one profile has part of its length forged to a different profile, together with the requirements for subsequent forging production and product acceptance. This European Standard applies to new railway rails according to EN 13674-1, and to switch and crossing rails used in conjunction with railway rails 46 kg/m and above according to EN 13674-2, to be welded or fish plated to make up switch rails or transition rails intended for use on railway infrastructures. 2 Normative references The following documents, in whole or in part, are normatively referenced in this document and are indispensable for its application. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN 13232–5:2005+A1:2011, Railway applications – Track – Switches and crossings – Part 5: Switches EN 13674-1:2011, Railway applications – Track – Rail – Part 1: Vignole railway rails 46 kg/m and above EN 13674-2, Railway applications – Track – Rail – Part 2: Switch and crossing rails used in conjunction with Vignole railway rails 46 kg/m and above EN ISO 3452-1, Non-destructive testing – Penetrant testing – Part 1: General principles (ISO 3452-1) EN ISO 9934 (all parts), Non-destructive testing – Magnetic particle testing (ISO 9934) 3 Terms and definitions For the purposes of this document, the following terms and definitions apply. 3.1 manufacturer company that produces forged switch and transition rails 3.2 purchaser buyer of the forged switch or transition rails 3.3 railway infrastructure permanent way of national or private railways 3.4 specimen portion detached from a forged rail transition and prepared as required for testing 3.5 profile finishing operation by which the rail or relevant part of the component is returned to required profile Note 1 to entry : This operation can be by grinding, milling, planing or any other suitable means. SIST EN 16273:2015

EN 16273:2014 (E) 7 3.6 finished condition finished component 3.7 railway authority (RA) either the railway regulator or the owner of the railway infrastructure or the custodian with a delegated responsibility for a railway infrastructure 3.8 forged switch rail – flexible switch rail the switch rail in the movable area of the switch is made of one profile only. This can be either a standard rail profile or a special profile

Figure 1 — Forged switch rail – flexible switch rail 3.9 forged switch rail – spring rail switch – rail the switch rail in the movable area of the switch is made of two different profiles. The transition and the weld between one to the other profile takes place in the movable part of the switch rail and can be either a standard rail profile or a special profile

key

Flash butt weld Figure 2 — Forged switch rail – spring rail switch – rail 3.10 forged switch rail – forged part the forged part is the end section of a switch rail with the transition. It is made of one profile only

Figure 3 — Forged switch rail – forged part SIST EN 16273:2015

EN 16273:2014 (E) 8 3.11 forged transition rail part of a symmetrical vignole rail profile 1 forged to another symmetrical vignole rail profile 2

Figure 4 — Forged transition rail 3.12 forged rail transition a rail of one profile having part of its length forged to a different profile. A rail with an asymmetrical profile forged to a symmetrical profile is a forged switch rail (see 3.8, 3.9 and 3.10). A rail with a symmetrical profile forged to another symmetrical profile is termed a forged transition rail (see 3.11) 3.13 heat affected zone (HAZ) part of the rail heated to a temperature affecting the hardness 4 Information to be supplied for approval 4.1 By the purchaser The following information shall be supplied by the purchaser, agreed with the manufacturer and shall be fully documented: — the initial and final rail profiles, length of the switch rail or transition rail and geometrical requirements of the rail transition; — the rail grade; — the profile class of the rail leg-end extension as specified in EN 13674-1 and EN 13674-2. 4.2 By the manufacturer The following information shall be supplied by the manufacturer, agreed with the purchaser and shall be fully documented: — a drawing of the switch or transition rail. 5 Approval of the manufacturer The manufacturer shall operate an independently approved quality assurance system or an other quality assurance system accepted by the purchaser. SIST EN 16273:2015

EN 16273:2014 (E) 9 6 Requirements for the forging process 6.1 General All heating, forging, cooling and dressing shall be carried out in a controlled process. 6.2 Forging parameters The forging process and any post heat treatment, including the working ranges, shall be determined during procedural trials. Once approval has been granted they shall not be changed without prior purchaser approval. The parameters shall be monitored and checked against approval limits. These records shall be referenced to the relevant products. 6.3 Post heat treatment Post heating or controlled post cooling may be required and shall in such case be monitored. 6.4 Profile finishing The finishing shall be carried out in the longitudinal direction using machining and optionally additional grinding. The roughness limit shall be maximum 6,3 Ra. The profile finishing shall not cause any thermal or mechanical damage. The rail profile in the wheel contact area shall be maintained during profile finishing. The profile finishing shall not end in the zone S (see Figure 8). 6.5 Cutting to length The switch rails shall be cut square, in accordance with Table 9 in EN 13674-1:2011, to the requested length. Burrs shall be removed from all edgings. Flame cutting is not allowed for the final cut. 6.6 Identification The identification shall permit traceability to production records. Every forged rail blank shall be encoded by: — the sign of the manufacturer; — the year of manufacturing; — the identification number for the forged part. The identification shall permit the traceability of the product for at least the guarantee period. 7 Procedure approval 7.1 General Procedure approval tests shall be done for the production of switch and transition rails by the manufacturer as described in chapter 7 of this standard. For grade R260 rails, approval is granted by grade (not per profile). For grade R350HT rails, approval is granted by grade (not per profile) and by rail manufacturer. SIST EN 16273:2015

EN 16273:2014 (E) 10 Procedure approval shall be carried out by testing samples produced in accordance with this standard; the samples shall be representative of those carried out in production. One failure during the approval tests described in 7.4 and 7.5 involves the rejection of the approval. Refer to 7.7 for re-qualification requirements. 7.2 Test specimen preparation The test specimens shall be produced and inspected by the same method used for production pieces. 7.3 Number of specimens Four test specimens in the finished condition (see 3.6) shall be manufactured. 7.4 Non-destructive approval tests 7.4.1 Geometry and dimensions 7.4.1.1 Switch rails The dimension of the forged rail head and the profile of the vignole rail at the heel of the switch rail shall comply with the tolerances in Table 1. Figure 5 indicates the parts of the forged rail that shall be checked according to Table 1.

Key SR switch rail VR vignole rail NOTE For further terms shown in this Figure, see Table 1. Figure 5 — Dimensions of forged switch rail SIST EN 16273:2015

EN 16273:2014 (E) 11 Table 1 — Length and tolerances for the forged switch rail Dimension Length [mm] Measurement equipment Length of the forged rail transition LT Minimum 3 x HD Measuring stick, tape or gauge Dimension Admissible tolerance [mm] Measurement equipment Length that ends where the switch rail profile begins LG ±20 Measuring stick, tape or gauge Length of the vignole part measured on the foot LF ±20 Measuring stick, tape or gauge Vertical alignment across the running surface along the longitudinal centre line starting at the forged rail end until 1500 mm, measured by moving a 1 m straight edge and a thickness gauge. - 0,1 / + 0,2 1 m straight edge and a thickness gauge Horizontal alignment on the running edge at 14 mm below the running surface, starting at the forged rail end until 1500 mm measured by moving a 1 m straight edge and a thickness gauge. ±0,4 1 m straight edge and a thickness gauge Head profile concavity (EN 13232–5:2005+A1:2011, Figure 18) HC An area of concavity may exist only on the opposite of the running edge. This shall not exceed 2 mm 1 m straight edge and a thickness gauge Vertical twist (twist base length 1 m) ±0,5 Method agreed between the manufacturer and the purchaser Head profile C eM,6 / −M,3 Gauge E.4 according to EN 13674–1:2011 dependent on the rail profile Height difference from one rail foot to the other rail

...

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Železniške naprave - Zgornji ustroj - Prekovane prehodne tirniceBahnanwendungen - Oberbau - Geschmiedete SchienenübergängeApplications ferroviaires - Voie - Rails forgésRailway applications - Track - Forged rail transitions45.080Rails and railway componentsICS:Ta slovenski standard je istoveten z:FprEN 16273kSIST FprEN 16273:2014en,fr,de01-julij-2014kSIST FprEN 16273:2014SLOVENSKI

STANDARD
kSIST FprEN 16273:2014
EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM
FINAL DRAFT
FprEN 16273
April 2014 ICS 93.100 English Version
Railway applications - Track - Forged rail transitions

This draft European Standard is submitted to CEN members for unique acceptance procedure. It has been drawn up by the Technical Committee CEN/TC 256.

If this draft becomes a European Standard, CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration.

This draft European Standard was established by CEN in three official versions (English, French, German). A version in any other language made by translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC Management Centre has the same status as the official versions.

CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey 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
CEN-CENELEC Management Centre:
Avenue Marnix 17,

B-1000 Brussels © 2014 CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Members. Ref. No. FprEN 16273:2014 EkSIST FprEN 16273:2014

FprEN 16273:2014 (E) 2 Contents Page Foreword ..............................................................................................................................................................4 Introduction .........................................................................................................................................................5 1 Scope ......................................................................................................................................................6 2 Normative references ............................................................................................................................6 3 Terms and definitions ...........................................................................................................................6 4 Information to be supplied for approval ..............................................................................................8 4.1 By the purchaser....................................................................................................................................8 4.2 By the manufacturer ..............................................................................................................................8 5 Approval of the manufacturer ..............................................................................................................8 6 Requirements for the forging process ................................................................................................8 6.1 General ....................................................................................................................................................8 6.2 Forging parameters ...............................................................................................................................9 6.3 Post heat treatment ...............................................................................................................................9 6.4 Profile finishing ......................................................................................................................................9 6.5 Cutting to length ....................................................................................................................................9 6.6 Identification ...........................................................................................................................................9 7 Procedure approval ...............................................................................................................................9 7.1 General ....................................................................................................................................................9 7.2 Test specimen preparation ................................................................................................................ 10 7.3 Number of specimens ........................................................................................................................ 10 7.4 Non-destructive approval tests ......................................................................................................... 10 7.4.1 Geometry and dimensions ................................................................................................................. 10 7.4.2 Visual inspection ................................................................................................................................ 12 7.4.3 Surface finish ...................................................................................................................................... 13 7.4.4 Dye penetrant (DPI) or magnetic particle inspection (MPI) ............................................................ 13 7.4.5 Ultrasonic testing (UT) ....................................................................................................................... 13 7.5 Destructive approval tests ................................................................................................................. 13 7.5.1 Hardness distribution ......................................................................................................................... 13 7.5.2 Switch rails: hardness distribution in the rail head ........................................................................ 16 7.6 Test report ........................................................................................................................................... 17 7.7 Validity of approval ............................................................................................................................. 18 8 Production tests.................................................................................................................................. 18 8.1 Switches .............................................................................................................................................. 18 8.1.1 General ................................................................................................................................................. 18 8.1.2 Geometry and dimensions ................................................................................................................. 18 8.1.3 Hardness testing ................................................................................................................................. 19 8.2 Transition rails .................................................................................................................................... 19 8.2.1 General ................................................................................................................................................. 19 8.2.2 Hardness .............................................................................................................................................. 20 Annex A (informative)

Ultrasonic testing ..................................................................................................... 22 A.1 Reference line (DAC) generation – reference block ........................................................................ 22 A.2 Reference line (DAC) generation and acceptance criteria ............................................................. 23 Annex B (informative)

Documentation of approval tests ........................................................................... 24 kSIST FprEN 16273:2014

FprEN 16273:2014 (E) 3 B.1 Forged switch rails .............................................................................................................................. 24 B.1.1 General information ............................................................................................................................ 24 B.1.2 Geometry and dimensions ................................................................................................................. 25 B.1.3 Dye penetrant (DPI) or magnetic particle inspection (MPI) ............................................................. 27 B.1.4 Ultrasonic testing (UT) ........................................................................................................................ 27 B.1.5 Hardness distribution on the surface ................................................................................................ 28 B.1.6 Test results of hardness distribution on the rail head .................................................................... 29 B.1.7 Test results of hardness distribution on the rail foot ...................................................................... 31 B.2 Forged transition rails ......................................................................................................................... 32 B.2.1 General information ............................................................................................................................ 32 B.2.2 Geometry and dimensions ................................................................................................................. 33 B.2.3 Dye penetrant (DPI) or magnetic particle inspection (MPI) ............................................................. 34 B.2.4 Ultrasonic testing (UT) ........................................................................................................................ 34 B.2.5 Hardness distribution on the surface ................................................................................................ 35 B.2.6 Test results of hardness distribution on the rail head .................................................................... 36 B.2.7 Test results of hardness distribution on the rail foot ...................................................................... 36 Bibliography ...................................................................................................................................................... 38

kSIST FprEN 16273:2014

FprEN 16273:2014 (E) 4 Foreword This document (FprEN 16273:2014) 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 Unique Acceptance Procedure. This document has been prepared under a mandate given to CEN by the European Commission and the European Free Trade Association. kSIST FprEN 16273:2014

FprEN 16273:2014 (E) 5 Introduction This European Standard has 3 main topics: — requirements of a forged part; — procedure approval; — forged rail production following approval. This European Standard satisfies the needs of the railway authority and the manufacturer should achieve the specified requirements of this standard. kSIST FprEN 16273:2014

FprEN 16273:2014 (E) 6 1 Scope This European Standard specifies the requirements for the approval of a process wherein a rail of one profile has part of its length forged to a different profile, together with the requirements for subsequent forging production and product acceptance. This European Standard applies to new railway rails according to EN 13674-1, and to switch and crossing rails used in conjunction with railway rails 46 kg/m and above according to EN 13674-2, to be welded or fish plated to make up switch rails or transition rails intended for use on railway infrastructures. 2 Normative references The following documents, in whole or in part, are normatively referenced in this document and are indispensable for its application. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN 13232–5:2005+A1:2011, Railway applications – Track – Switches and crossings – Part 5: Switches EN 13674-1, Railway applications - Track - Rail - Part 1: Vignole railway rails 46 kg/m and above EN 13674-2, Railway applications – Track – Rail – Part 2: Switch and crossing rails used in conjunction with Vignole railway rails 46 kg/m and above EN ISO 3452-1, Non-destructive testing - Penetrant testing - Part 1: General principles (ISO 3452-1) EN ISO 9934 (all parts), Non-destructive testing – Magnetic particle testing (ISO 9934) 3 Terms and definitions For the purposes of this document, the following terms and definitions apply. 3.1 manufacturer company that produces forged switch and transition rails 3.2 purchaser buyer of the forged switch or transition rails 3.3 railway infrastructure permanent way of national or private railways 3.4 specimen portion detached from a forged rail transition and prepared as required for testing 3.5 profile finishing operation by which the rail or relevant part of the component is returned to required profile Note 1 to entry : This operation can be by grinding, milling, planing or any other suitable means. kSIST FprEN 16273:2014

FprEN 16273:2014 (E) 7 3.6 finished condition finished component 3.7 railway authority (RA) either the railway regulator or the owner of the railway infrastructure or the custodian with a delegated responsibility for a railway infrastructure 3.8 forged switch rail – flexible switch rail the switch rail in the movable area of the switch is made of one profile only. This can be either a standard rail profile or a special profile

Figure 1 3.9 forged switch rail – spring rail switch – rail the switch rail in the movable area of the switch is made of two different profiles. The transition and the weld between one to the other profile takes place in the movable part of the switch rail and can be either a standard rail profile or a special profile

key

Flash butt weld Figure 2 3.10 forged switch rail – forged part the forged part is the end section of a switch rail with the transition. It is made of one profile only

Figure 3 3.11 forged transition rail part of a symmetrical vignole rail profile 1 forged to another symmetrical vignole rail profile 2 kSIST FprEN 16273:2014

FprEN 16273:2014 (E) 8

Figure 4 3.12 forged rail transition a rail of one profile having part of its length forged to a different profile. A rail with an asymmetrical profile forged to a symmetrical profile is a forged switch rail (see 3.8, 3.9 and 3.10). A rail with a symmetrical profile forged to another symmetrical profile is termed a forged transition rail (see 3.11) 3.13 heat affected zone (HAZ) part of the rail heated to a temperature affecting the hardness 4 Information to be supplied for approval 4.1 By the purchaser The following information shall be supplied by the purchaser, agreed with the manufacturer and shall be fully documented: — the initial and final rail profiles, length of the switch rail or transition rail and geometrical requirements of the rail transition; — the rail grade; — the profile class of the rail leg-end extension as specified in EN 13674-1 and EN 13674-2. 4.2 By the manufacturer The following information shall be supplied by the manufacturer, agreed with the purchaser and shall be fully documented: — a drawing of the switch or transition rail. 5 Approval of the manufacturer The manufacturer shall operate an independently approved quality assurance system or an other quality assurance system accepted by the purchaser. 6 Requirements for the forging process 6.1 General All heating, forging, cooling and dressing shall be carried out in a controlled process. kSIST FprEN 16273:2014

FprEN 16273:2014 (E) 9 6.2 Forging parameters The forging process and any post heat treatment, including the working ranges, shall be determined during procedural trials. Once approval has been granted they shall not be changed without prior purchaser approval. The parameters shall be monitored and checked against approval limits. These records shall be referenced to the relevant products. 6.3 Post heat treatment Post heating or controlled post cooling may be required and shall in such case be monitored. 6.4 Profile finishing The finishing shall be carried out in the longitudinal direction using machining and optionally additional grinding. The roughness limit shall be maximum 6,3 Ra. The profile finishing shall not cause any thermal or mechanical damage. The rail profile in the wheel contact area shall be maintained during profile finishing. The profile finishing shall not end in the zone S (see Figure 8). 6.5 Cutting to length The switch rails shall be cut square, in accordance with Table 9 in EN 13674-1, to the requested length. Burrs shall be removed from all edgings. Flame cutting is not allowed for the final cut. 6.6 Identification The identification shall permit traceability to production records. Every forged rail blank shall be encoded by: — the sign of the manufacturer; — the year of manufacturing; — the identification number for the forged part. The identification shall permit the traceability of the product for at least the guarantee period. 7 Procedure approval 7.1 General Procedure approval tests shall be done for the production of switch and transition rails by the manufacturer as described in chapter 7 of this standard. For grade R260 rails, approval is granted by grade (not per profile). For grade R350HT rails, approval is granted by grade (not per profile) and by rail manufacturer. Procedure approval shall be carried out by testing samples produced in accordance with this standard; the samples shall be representative of those carried out in production. One failure during the approval tests described in 7.4 and 7.5 involves the rejection of the approval. Refer to 7.7 for re-qualification requirements. kSIST FprEN 16273:2014

FprEN 16273:2014 (E) 10 7.2 Test specimen preparation The test specimens shall be produced and inspected by the same method used for production pieces. 7.3 Number of specimens Four test specimens in the finished condition (see 3.6) shall be manufactured. 7.4 Non-destructive approval tests 7.4.1 Geometry and dimensions 7.4.1.1 Switch rails The dimension of the forged rail head and the profile of the vignole rail at the heel of the switch rail shall comply with the tolerances in Table 1. Figure 5 indicates the parts of the forged rail that shall be checked according to Table 1.

Key SR switch rail VR vignole rail Figure 5 — Dimensions of forged switch rail kSIST FprEN 16273:2014

FprEN 16273:2014 (E) 11 Table 1 — Length and tolerances for the forged switch rail Dimension Length [mm] Measurement equipment Length of the forged rail transition LT Minimum 3 x HD measuring stick, tape or gauge Dimension Admissible tolerance [mm] Measurement equipment Length that ends where the switch rail profile begins LG ±20 measuring stick, tape or gauge Length of the vignole part measured on the foot LF ±20 measuring stick, tape or gauge Vertical alignment across the running surface along the longitudinal centre line starting at the forged rail end until 1500 mm, measured by moving a 1 m straight edge and a thickness gauge. - 0,1 / + 0,2 1 m straight edge and a thickness gauge Horizontal alignment on the running edge at 14 mm below the running surface, starting at the forged rail end until 1500 mm measured by moving a 1 m straight edge and a thickness gauge. ±0,4 1 m straight edge and a thickness gauge Head profile concavity (EN 13232–5:2005+A1:2011, Figure 18) HC An area of concavity may exist only on the opposite of the running edge. This shall not exceed 2 mm 1 m straight edge and a thickness gauge Vertical twist (twist base length 1 m) ±0,5 method agreed between the manufacturer and the purchaser Head profile C eM,6 / −M,3 gauge E.4 according to EN 13674–1 dependent on the rail profile Height difference from one rail foot to the other rail foot (Figure 5) HD ±1,1 method agreed between the manufacturer and the purchaser Other measuring methods can be used but in case of dispute, the equipment described above shall be used. Other tolerances for the vignole profile shall be in accordance with EN 13674-1, Table 7, profile class X. Figure 6 shows the definitions of the algebraic sign in the alignment measureme

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