1、BRITISH STANDARD BS 5892-2: 1992 Railway rolling stock materials Part 2: Specification for forged and rolled wheel centresBS5892-2:1992 This British Standard, having been prepared under the direction of the Iron and SteelStandards Policy Committee, was published underthe authority of the Standards B
2、oard and comesintoeffect on 15 November 1992 BSI 10-1999 First published August 1987 Second edition November 1992 The following BSI references relate to the work on this standard: Committee reference ISM/69 Draft for comment 91 37391 DC ISBN 0 580 20531 2 Committees responsible for this British Stan
3、dard The preparation of this British Standard was entrusted by the Iron and Steel Standards Policy Committee (ISM/-) to Technical Committee ISM/69, upon which the following bodies were represented: British Railways Board British Steel Industry London Underground Ltd. Ministry of Defence Railway Indu
4、stry Association of Great Britain Amendments issued since publication Amd. No. Date CommentsBS5892-2:1992 BSI 10-1999 i Contents Page Committees responsible Inside front cover Foreword ii 1 Scope 1 2 Definitions 1 3 Information to be supplied by the purchaser 1 4 Classification and heat treatment 1
5、5 Manufacture 1 6 Manufacturers brand marks 3 7 Inspection 3 8 Type and number of tests 4 9 Test methods 7 10 Test results 7 11 Conclusion of inspection 8 12 Certification 8 13 Protection in transport 8 Figure 1 Key to the symbols used in Table 2 4 Figure 2 Oil injection hole 5 Figure 3 Position of
6、brand marks on wheel centres 6 Figure 4 Position and direction within wheel centre rim of tensile test piece 7 Table 1 Chemical composition 2 Table 2 Machining allowances and dimensional tolerances 2 Table 3 Ready for assembly surface finishes and dimensions 3 Table 4 Type and number of tests 6 Tabl
7、e 5 Heat treatment condition and mechanical properties 7 Publication(s) referred to Inside back coverBS5892-2:1992 ii BSI 10-1999 Foreword This Part of BS5892 was prepared under the direction of the Iron and Steel Standards Policy Committee and supersedes BS5892-2:1987, which is withdrawn. BS5892, w
8、hich covers railway rolling stock material, is published in the following six Parts. Part 1: Specification for axles for traction and trailing stock; Part 2: Specification for forged and rolled wheel centres; Part 3: Specification for monobloc wheels for traction and trailing stock; Part 4: Specific
9、ation for forged and rolled tyres; Part 5: Specification for steel bars for retaining rings for tyred wheels; Part 6: Specification for wheelsets for traction and trailing stock. The format of this Part of BS5892 has been revised to incorporate the requirements for dimensional tolerancing for wheel
10、centres which were previously included in BS5892-6. This Part of BS5892 is related to ISO1005-4; however, it has not been possible to obtain equivalence. It is also related to UIC812-1. BS5892-1, BS5892-3, BS5892-4 and BS5892-6 have also been revised to ensure consistency with the requirements of th
11、is Part. Product certification. Users of this British Standard are advised to consider the desirability of third party certification of product conformity with this British Standard based on testing and continuing surveillance, which may be coupled with assessment of a suppliers quality systems agai
12、nst the appropriate Part of BS5750. Enquiries as to the availability of third party certification schemes will be forwarded to BSI to the Association of Certification Bodies. If a third party certification scheme does not already exist, users should consider approaching an appropriate body from the
13、list of Association members. A British Standard does not purport to include all the necessary provisions of a contract. Users of British Standards are responsible for their correct application. Compliance with a British Standard does not of itself confer immunity from legal obligations. Summary of p
14、ages This document comprises a front cover, an inside front cover, pagesi andii, pages1 to8, an inside back cover and a back cover. This standard has been updated (see copyright date) and may have had amendments incorporated. This will be indicated in the amendment table on the inside front cover.BS
15、 5892-2:1992 BSI 10-1999 1 1 Scope This Part of BS5892 specifies requirements for the manufacture, inspection and testing of forged and/or rolled wheel centres in the unmachined, part machined or ready for assembly condition for traction and trailing stock. This Part of BS5892 includes requirements
16、for the dimensions, tolerances, and surface finish that are to be adopted unless otherwise specified in the design drawing. NOTEThe titles of the publications referred to in this Part of BS5892 are listed on the inside back cover. 2 Definitions For the purposes of this Part of BS 5892 the following
17、definitions apply. 2.1 unmachined condition of a wheel centre that is forged and/or rolled having undergone no machining operation but is in the heat treatment condition specified (see4.2) 2.2 part machined condition of a wheel centre that is finish machined with the exception of the bore and the ri
18、m section 2.3 ready for assembly condition of a wheel centre that has received all machining operations required for assembly 2.4 normal speed operational speed up to and including 200 km/h 2.5 high speed operational speed greater than 200 km/h 3 Information to be supplied by the purchaser The follo
19、wing information to be supplied by the purchaser in the enquiry and order shall be fully documented: a) the number of this British Standard, i.e.BS5892-2; b) a fully dimensioned drawing of the wheel centre; c) the type of heat treatment required (see 4.2); d) the degree of finish (see 4.3); e) the t
20、ype of inspection quality assurance system required (see clause 7); f) whether a statement giving the cast analysis and/or results of mechanical or other tests is required (see clause 12); g) whether any special marking is required (seeclause 6); h) the method of protection against corrosion and mec
21、hanical damage (seeclause13). 4 Classification and heat treatment 4.1 Grade of steel The steel used in the manufacture of wheel centres shall have the composition given in Table 1. 4.2 Heat treatment condition The wheel centres shall be supplied in one of the following conditions see item c) of clau
22、se 3: a) untreated, which shall be designated by the letter U; b) normalized or normalized and tempered, which shall be designated by the letter N. 4.3 Degree of finish Wheel centres shall be supplied in one of the following degrees of finish seeclause2 and item d) of clause 3: a) unmachined; b) par
23、t machined; c) ready for assembly. 5 Manufacture 5.1 Steelmaking The wheel centres shall be made from steel produced by the electric process or the basic oxygen process. The steel shall be killed in the furnace or in the ladle and treated to ensure that the finished wheel centres have a grain size o
24、f5 to8 as determined by the method in Appendix F of BS4490:1989. Ingots shall be bottom poured. 5.2 Manufacture of wheel centres The wheel centres shall be hot forged and/or rolled from one of the following: a) ingots; or b) rolled or forged bars; or c) continuously cast bars. All feedstock material
25、s shall be inspected to ensure that visible defects are removed prior to the manufacture of wheel centres. The ingot or bar sections shall be rough shaped and punched using a forging hammer or press and finally shaped by forging or rolling.BS5892-2:1992 2 BSI 10-1999 Precautions shall be taken durin
26、g hot working to ensure that material is not damaged by overheating or by grain growth due to high finish working temperatures. NOTEGenerally, forging should not be done at temperatures above1260 C and should terminate between850 C and1000 C. The manufacturer shall carry out a post-rolling treatment
27、 on wheel centres to ensure freedom from the formation of hydrogen cracks (flakes). 5.3 Appearance The wheel centres shall be free from forging or rolling defects. The surface shall not show any mark other than those specified in clause 6 (see also 5.7). 5.4 Identification of the wheel centres durin
28、g manufacture All ingots, rolled bars, concast bars and forged wheel centres shall be marked at each stage of manufacture so that before delivery each wheel centre can be identified as specified in clause 6. Where the identification marks are stamped, and differ from the final identification marks s
29、pecified in clause 6, they shall not be visible on the finished wheel centre after machining. Table 1 Chemical composition Table 2 Machining allowances and dimensional tolerances Cast composition C max. Si max. Mn max. P max. S max. Cr max. Cu max. Mo max. Ni max. V max. % % % % % % % % % % 0.33 0.4
30、0 0.90 0.05 0.05 0.30 0.30 0.15 0.40 0.05 Part Designation Symbol for machining allowance Symbol for dimension Unmachined Part machined Ready for assembly Machining allowance Tolerance Machining allowance Tolerance Tolerance mm mm mm mm mm Rim External diameter A a 5 3 Width B b 5 3 Internal diamete
31、r C c 1 , c 2 3 Hub External diameter D d 1 , d 2 8 Length E e 10 3 Internal diameter F f 12 5 a , b Web Thickness at the connection with the rim G g 5 Centre position H h 5 Thickness at the connection with the hub I i 6 a The tolerance on diameter and the interference value to ensure the required f
32、it on the axle should be sufficient to comply with BS5892-6. b See also Table 3. +12 0 +2 0 +0.2 0 +8 0 +2 0 +0 0.5 +0 10 +3 3 + 0 6 +20 0 +5 5 +5 5 +10 0 +2 0 +3 0 +0 20 +0 3 +10 0 +5 0 +5 0 +10 0 +5 0 +5 0 +10 0 +5 0 +5 0BS 5892-2:1992 BSI 10-1999 3 5.5 Heat treatment When heat treatment is specif
33、ied see item c) of clause 3, the heat treatment operations shall be carried out at a uniform temperature so as to ensure uniformity of structure of comparable parts of the same wheel centre and of wheel centres from the same batch (see 8.2). Details of temperatures and times shall be recorded and sh
34、all be available for inspection by the purchaser. 5.6 Dimensions Unless otherwise specified by the purchaser, the machining allowances and dimensional tolerances shall be those given in Table 2 and Table 3 (seealsoFigure 1 and Figure 2). Table 3 Ready for assembly surface finishesand dimensions NOTE
35、In the ready for assembly condition, whilst every effort should be made to ensure size conformity, it is permissible, unless otherwise specified, for the internal hub bore dimension to be tailored to a specific axle. However, the maximum size deviation from the drawing should be no more than0.5 mm s
36、uch that in all instances the assembly requirements specified in BS5892-6 are achieved. The bore of the wheel centre shall be perpendicular to the plane of the wheel and concentric with the rim within the run-out requirements of the finished assembly as defined in BS5892-6. The bore shall not have a
37、 lead-in taper. Provision shall be made for wheel centre removal by means of the oil injection method. The oil groove and the injection hole parameters shall be in accordance with Figure 2. The edges of the oil groove and the oil injection holes shall be blended out to remove sharp corners. 5.7 Remo
38、val of surface defects Rectified surfaces shall have no heat cracking and be within specified tolerances and surface finishes and be smoothly blended into the surrounding area. Magnetic particle inspection shall be used to ensure that the defect is completely eliminated. Rectification by welding, ch
39、emical deposition of metal, metal spraying or by use of local heating shall not be carried out. 6 Manufacturers brand marks Unless the purchaser indicates that special marking is required see item g) of clause 3 each wheel centre shall be identified by the manufacturer with stamp marks in the positi
40、on shown in Figure 3. The markings shall include the following: a) the number of this British Standard, i.e.BS5892-2 1) ; b) the manufacturers mark; c) the cast number; d) the heat treatment condition, U or N; e) the date of manufacture (month and last two figures of the year of production); f) the
41、inspectors mark. 7 Inspection The inspection of wheel centres shall be undertaken in one of the following ways see item e) of clause 3: a) by the purchaser or his nominated representative, who shall inspect the wheel centres ordered and witness any of the tests; or b) by delegation of the responsibi
42、lity for the inspection by the purchaser to the manufacturer; or c) within the application of a quality assurance system (see BS5750 and the foreword). Designation Surface finish max. Dimension 4m mm Radius at axle bore entry end 3 Hub bore 3.2 a Hub end faces 12.5 Hub end face (bearing surface) 1.6
43、 Cylindricity of hub bore b 0.03 Cylindricity of rim b 0.4 Rim 3.2 a Minimum sampling length is8 mm. b Cylindricity is as defined in BS308-3. 1) Marking BS5892-2 on or in relation to a product represents a manufacturers declaration of conformity, i.e. a claim by or on behalf of the manufacturer that
44、 the product meets the requirements of the standard. The accuracy of the claim is therefore solely the responsibility of the person making the claim. Such a declaration is not to be confused with third party certification of conformity, which may also be desirable.BS5892-2:1992 4 BSI 10-1999 8 Type
45、and number of tests 8.1 Type of test The type and number of tests to be carried out shall be in accordance with Table 4. The tests shall be made on wheel centres in the specified degree of finish see item d) of clause 3. 8.2 Test unit, subdivision into batches and number of test pieces The test unit
46、 for the various types of test shall be in accordance with Table 4. For the purpose of testing, the wheel centres shall be grouped in batches. Each batch shall comprise wheel centres produced from the same cast and having undergone a similar heat treatment, if applicable. Figure 1 Key to the symbols
47、 used in Table 2BS 5892-2:1992 BSI 10-1999 5 Figure 2 Oil injection holeBS5892-2:1992 6 BSI 10-1999 Table 4 Type and number of tests NOTEIt is permissible to include wheel centres of different size and shape within a batch. The number of wheel centres per batch to be subjected to the tests, the numb
48、er of tests per wheel centre and the condition of the wheel centres when submitted for testing, shall be in accordance with Table 4. 8.3 Sampling and preparation of samples and test pieces 8.3.1 General The axle(s) intended for testing, selected at random from the batch, shall be identified by indel
49、ible stamping. This identification shall be maintained throughout testing (see 5.4). 8.3.2 Tensile test One test piece shall be selected from the sample wheel centre at the position shown in Figure 4. Figure 3 Position of brand marks on wheel centres Requirements Test unit Number of wheel centres per batch to be subjected to the checks and tests for batches of Up to 250 Over 250 Cast chemical analysis s Tensile test ch 1 2 Dimensions and appearance All 100%
