1、g49g50g3g38g50g51g60g44g49g42g3g58g44g55g43g50g56g55g3g37g54g44g3g51g40g53g48g44g54g54g44g50g49g3g40g59g38g40g51g55g3g36g54g3g51g40g53g48g44g55g55g40g39g3g37g60g3g38g50g51g60g53g44g42g43g55g3g47g36g58BRITISH STANDARDRailway rolling stock materials Part 3: Specification for monobloc wheels for tracti
2、on and trailing stockICS 45.040BS 5892-3:1992+A2:2009Licensed Copy: Wang Bin, ISO/EXCHANGE CHINA STANDARDS, 13/05/2009 01:21, Uncontrolled Copy, (c) BSIThis British Standard, having been prepared under the direction of the Iron and Steel Standards Policy Committee, was published under the authority
3、of the Standards Board and comes into effect on 15 November 1992First published February 1982Second edition November 1992The following BSI references relate to the work on this standard:Committee reference ISM/69Draft for Comment 91 37392 DCCommittees responsible for this British StandardThe prepara
4、tion 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 BoardBritish Steel IndustryLondon Underground Ltd.Ministry of DefenceRailway Industry Association of G
5、reat BritainBS 5892-3:1992+A2:2009ISBN 978 0 580 63229 7Amendments issued since publicationAmd. No. Date Comments16282 31 March 2006 See ForewordAmendment No. 2 See Foreword BSI 200831 December 2008Licensed Copy: Wang Bin, ISO/EXCHANGE CHINA STANDARDS, 13/05/2009 01:21, Uncontrolled Copy, (c) BSIiCo
6、ntentsPageCommittees responsible Inside front coverForeword ii1Scope 12 Definitions 13 Information to be supplied by the purchaser 14 Classification and heat treatment 15 Manufacture 36 Manufacturers brand marks 137Inspection 178 Type and number of tests 179 Test methods 2110 Test results 2111 Concl
7、usion of inspection 2212 Certification 2213 Protection in transport 22Figure 1 Key to symbols used in Table 4 (non-disc braked wheels) 8Figure 2 Key to symbols used in Table 5 (disc brake wheels) 12Figure 3 Oil injection hole 14Figure 4 Position of wear groove 15Figure 5 Correction of imbalance and
8、position of residual stress 16Figure 6 Position of brand marks on wheels 17Figure 7 Position of tensile and impact test samples and test pieces 20Figure 8 Position of the Brinell hardness tests 23Table 1 Chemical composition 2Table 2 Permitted variations of product analysis from the specified range
9、for significant elements 2Table 3 Heat treatment condition and mechanical properties 3Table 4 Machining allowances and dimensional tolerances for solid wheels (non-disc braked) 5Table 5 Machining allowances and dimensional tolerances for solid wheels (disc braked) 9Table 6 Ready for assembly toleran
10、ces 13Table 7 Maximum residual imbalance 13Table 8 Type and number of tests 19Publications referred to Inside back coverBS 5892-3:1992+A2:2009 BSI 2008 Licensed Copy: Wang Bin, ISO/EXCHANGE CHINA STANDARDS, 13/05/2009 01:21, Uncontrolled Copy, (c) BSIiiForewordThis Part of BS 5892 was prepared under
11、 the direction of the Iron and Steel Standards Policy Committee and supersedes BS 5892-3:1982, which is withdrawn. BS 5892, which 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
12、 forged and rolled wheel centres; Part 3: Specification for monobloc wheels for traction and trailing stock; Part 4: Specification 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 sto
13、ck.The format of this Part has been revised to incorporate the requirements for dimensional tolerances and surface finish for monobloc wheels which were previously included in BS 5892-6. This Part of BS 5892 is related to ISO 1005-6; however, it has not been possible to obtain equivalence. It is als
14、o related to UIC 812-3.BS 5892-1, BS 5892-2, BS 5892-4 and BS 5892-6 have also been revised to ensure consistency with the requirements of this Part.Product certification. Users of this British Standard are advised to consider the desirability of third party certification of product of conformity wi
15、th this British Standard based on testing and continuing surveillance, which may be coupled with asessment of a suppliers quality systems against the appropriate Part of BS 5750.Enquiries as to the availability of third party certification schemes will be forwarded by BSI to the Association of Certi
16、fication Bodies. If a third party certification scheme does not already exist, users should consider approaching an appropriate body from the list of Association members.Summary of pagesThis document comprises a front cover, an inside front cover, pages i and ii, pages 1 to 24, an inside back cover
17、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 5892-3:1992+A2:2009indicated in the text by tags # $. Minor editorial changes are not tagged.This publication does
18、 not purport to include all the necessary provisions of a contract. Users are responsible for its correct application.Compliance with a British Standard cannot confer immunity from legal obligations. BSI 2008The start and finish of text introduced or altered by Amendment No. 2:2009 is Licensed Copy:
19、 Wang Bin, ISO/EXCHANGE CHINA STANDARDS, 13/05/2009 01:21, Uncontrolled Copy, (c) BSI11 ScopeThis Part of BS 5892 specifies requirements for the manufacture, inspection and testing of rolled or forged monobloc wheels in the unmachined, finish machined or ready for assembly condition for traction and
20、 trailing stock. This Part of BS 5892 includes requirements for the dimensions, tolerances and surface finish that are to be adopted unless otherwise specified in the design drawing.NOTE The titles of the publications referred to in this Part of BS 5892 are listed on the inside back cover.BS 5892-3
21、is not applicable to wheels to be fitted to axles designed to BS EN 13103 and BS EN 13104, the manufacture, inspection and testing of which are specified in BS EN 13261. 2 DefinitionsFor the purposes of this Part of BS 5892 the following definitions apply.2.1 unmachinedcondition of a monobloc wheel
22、in the forged and heat treated condition having undergone no machining operation other than proof machining by the manufacturer2.2 finish machinedcondition of a monobloc wheel where all the machining operations have been carried out apart from those required for assembly onto the axle2.3 ready for a
23、ssemblycondition of a monobloc wheel that has received all machining operations required for assembly2.4 normal speedoperational speed up to and including 200 km/h2.5 high speedoperational speed greater than 200 km/h3 Information to be supplied by the purchaserThe following information to be supplie
24、d by the purchaser in the enquiry and order shall be fully documented:a) the number of this British Standard, i.e. BS 5892-3;b) a fully dimensioned drawing of the monobloc wheel;c) whether high or normal speeds apply (see 2.4and 2.5);d) the grade of steel (see 4.1);e) the type of heat treatment requ
25、ired (see 4.2);f) the degree of finish (see 4.3);g) the maximum permissible amount of imbalance if not in accordance with Table 7(see 5.8);h) the conditions for machining and the elimination of imbalance if not in accordance with Table 7 (see 5.8);i) the type of inspection and quality assurance syst
26、em required (see clause 7);j) whether ultrasonic testing is required (see 9.7and 10.7);k) whether checks on uniformity of rim hardness are required (see 8.3.6.1);l) whether assessment of residual stress is required (see 9.6);m) whether a statement giving the cast analysis and/or results of mechanica
27、l or other tests is required (see clause 12);n) whether a product check analysis is required (see 8.3.2 and 10.1);o) whether any special marking is required (see clause 6);p) the method of protection against corrosion and mechanical damage (see clause 13);q) whether static balancing tests are requir
28、ed (see 5.8).4 Classification and heat treatment4.1 Grades of steelThe grade(s) of steel shall be selected from those listed in Table 1 and Table 3 (see item d) of clause 3). Grades R1, R2, R3, R6, R7, R8 and R9 shall have the composition and properties given in Table 1, Table 2and Table 3.BS 5892-3
29、:1992+A2:2009 BSI 2008 Licensed Copy: Wang Bin, ISO/EXCHANGE CHINA STANDARDS, 13/05/2009 01:21, Uncontrolled Copy, (c) BSI2Table 1 Chemical compositionTable 2 Permitted variations of product analysis from the specified range for significant elements4.2 Heat treatment conditionThe wheels shall be sup
30、plied in one of the following conditions (see item e) of clause 3):a) untreated, in the case of steels R1, R2 and R3, which shall be designated by the letter U;b) normalized or normalized and tempered, in the case of steels R1, R2 and R3, which shall be designated by the letter N;d) immersion quench
31、ed and tempered in the case of steels R6, R7, R8 and R9, which shall be Examples. R3N is steel grade R3 delivered in the normalized or normalized and tempered condition. R7E is steel grade R7 delivered in the immersion quenched and tempered condition.Grade of steelCast compositionC max. Si max. Mn m
32、ax.P max. S max. Crmax.Cumax.Mo max.Nimax.V max. Cr + Mo + Nimax.%R1 0.50 1.20 0.040 0.040 0.30 0.30 0.08 0.30 0.05 0.60R2 0.50 1.20 0.040 0.040 0.30 0.30 0.08 0.30 0.05 0.60R3 0.70 0.50 0.90 0.040 0.040 0.30 0.30 0.08 0.30 0.05 0.60R6 0.48 0.40 0.75 0.040 0.040 0.30 0.30 0.08 0.30 0.05 0.60R7 0.52
33、0.40 0.80 0.040 0.040 0.30 0.30 0.08 0.30 0.05 0.60R8 0.56 0.40 0.80 0.040 0.040 0.30 0.30 0.08 0.30 0.05 0.60R9 0.60 0.40 0.80 0.040 0.040 0.30 0.30 0.08 0.30 0.05 0.60Element Range in which maximum of specified element fallsVariation on specified range%Carbon Up to and including 0.50Over 0.50, up
34、to and including 0. 70Up to and including 0.50ManganeseOver 1.0, up to andincluding 1.20Sulfur0.040Phosphorus0.0400.03+00.04+00.03+00.04+00.08+00.006 +00.006 +0BS 5892-3:1992+A2:2009Silicon#0Over 0.50, up to andUp to and including 1.0including 0.70+ 0.040Over 0.70, up to andincluding 1.10+ 0.06#$Up
35、to and including# $Up to and including0.56 0.040 0.30 0.30 0.08 0.30 0.05 0.601.10 1.10 0.040# RS8 $c) rim chilled, in the case of steels R6, R7, R8, designated by the letter E.#by the letter T; , RS8$ and R9, which shall be designated BSI 2008Licensed Copy: Wang Bin, ISO/EXCHANGE CHINA STANDARDS, 1
36、3/05/2009 01:21, Uncontrolled Copy, (c) BSI3Table 3 Heat treatment condition and mechanical properties4.3 Degree of finishThe wheels shall be supplied in one of the following degrees of finish (see clause 2 and item f) of clause 3):a) unmachined;b) finish machined;c) ready for assembly.5 Manufacture
37、5.1 SteelmakingThe wheels 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 wheels have a grain size of 5 to 8 as determined by the method in poured.5.2 Manufacture of
38、 the wheelsWheels shall be manufactured by hot forging and rolling from one of the following:a) ingots; orb) rolled or forged bars; orc) continuously cast bars.The ingot or bar sections shall be rough shaped and punched using a forging hammer or press and finally shaped by forging or rolling.Precaut
39、ions shall be taken during hot working toensure that material is not damaged by overheatingor by grain growth due to high finish working temperatures.NOTE Generally, forging should not be done at temperatures above 1 260 C and should terminate between 850 Cand 1 000 C.Grade of steel Heat treatment c
40、ondition on delivery (see 4.2)Mechanical propertiesTensile strengthRmElongationA, min.aMinimum charpy U impact value at 20 C KUbBrinell hardness rangeN/mm2%JHBR1 U 600 to 720 12 179 to 217N 600 to 720 18 15 179 to 217R2 U 700 to 840 9 207 to 248N 700 to 840 14 10 207 to 248R3 U 800 to 940 7 235 to 2
41、77N 800 to 940 14 10 235 to 277R6 T (Rim) 770 to 890 15 15 229 to 262E (Rim) 730 to 890 15 15 217 to 262T (Web) 740 16 R7 T (Rim) 820 to 940 14 15 241 to 277E (Rim) 780 to 940 14 15 229 to 277T (Web) 760 16 R8 T (Rim) 860 to 980 13 15 255 to 285E (Rim) 820 to 980 13 15 241 to 285T (Web) 820 16 R9 T
42、(Rim) 900 to 1 050 12 10 262 to 311E (Rim) 860 to 1 050 12 10 255 to 311T (Web) 880 14 aA is the percentage elongation after fracture on a gauge length Lo= 5.65Sowhere Sois the original cross-sectional area of thetest piece.Mean value of three tests: one of the individual results may be lower than t
43、he minimum value given in this table provided it is not less than 70 % of the minimum.BS 5892-3:1992+A2:2009Appendix F of BS 4490:1989. Ingots shall be bottom # $max.#$max.#$max.#$max.T (Rim)bc900 to 1 020 max. 13 15 262 to 302 RS8#T (Web) 900 max. 16$designed to R8T requirements. It should not be u
44、sed for tread-braked wheels. If it is to be considered for applications involvingRS8T offers improved rolling contact fatigue (RCF) resistance. It may be used as an alternative to disc-braked wheelsets c#$higher permissible design stresses than R8T then it should be demonstrated that it is appropria
45、te for such applications. BSI 2008Licensed Copy: Wang Bin, ISO/EXCHANGE CHINA STANDARDS, 13/05/2009 01:21, Uncontrolled Copy, (c) BSI4After forging or rolling and stamping of the identification marks, the wheels shall be left to cool in still air.5.3 Hydrogen cracking (flakes)If the steel has not be
46、en vacuum degassed precautions shall be taken to avoid the formation of hydrogen cracks (flakes).5.4 Non-conforming materialNon-conforming material which would prevent compliance with 10.8 shall be removed before or during the manufacture of the wheels. The wheels shall be sound throughout without d
47、efects detrimental to their end use.5.5 Identification of the wheels during manufactureAll ingots, bars, forgings and wheels shall be marked at each stage of manufacture so that each wheel can be identified as specified in clause 6.Where the identification marks are stamped, and differ from the fina
48、l identification marks specified in clause 6, they shall not be visible on the finished wheel after machining.5.6 Heat treatmentAfter hot working wheels shall undergo the specified heat treatment (see item e) of clause 3and 4.2). Details of heat treatment temperatures and times shall be recorded.In
49、the case of rim chilled (T) and immersion quenched and tempered (E) wheels the tempering temperature shall be not less than 500 C.The required heat treatment operations shall ensure:a) uniformity of structure and properties of comparable parts of the same wheel;b) uniformity of structure and properties in all wheels of the same heat treatment batch;c) that the forging is sufficiently undistorted to enable the wheel to be produced as specified in 10.9.5.7 DimensionsUnless ot
