1、BRITISH STANDARD BS 5892-4: 1992 Railway rolling stock materials Part 4: Specification for forged and rolled tyresBS5892-4:1992 This British Standard, having been prepared under the directionof the Iron and Steel Standards Policy Committee, was published under the authority of the Standards Board an
2、d comes into effect on 15 November 1992 BSI 06-1999 First published May 1986 Secondedition November 1992 The following BSI references relate to the work on this standard: Committee reference ISM/69 Draft for comment 91/37393 DC ISBN 0 580 20533 9 Committees responsible for this British Standard The
3、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 Industry Asso
4、ciation of Great Britain Amendments issued since publication Amd. No. Date CommentsBS5892-4:1992 BSI 06-1999 i Contents Page Committees responsible Inside front cover Foreword ii 1 Scope 1 2 Information to be supplied by the purchaser 1 3 Classification and heat treatment 1 4 Manufacture 2 5 Manufac
5、turers brand marks 3 6 Inspection 5 7 Type and number of tests 5 8 Test methods 9 9 Test results 10 10 Conclusion of inspection 10 11 Certification 10 12 Protection in transport 10 Figure 1 Keys to the symbols used in Table 4 4 Figure 2 Position of brand marks on tyres 5 Figure 3 Position of tensile
6、 and impact test pieces 7 Figure 4 Position of the impact test pieces 8 Figure 5 Position of the Brinell hardness indentations 9 Table 1 Chemical composition 1 Table 2 Permitted variations of product analysis from the specified rangeforsignificant elements 2 Table 3 Heat treatment condition and mech
7、anical properties 3 Table 4 Dimensional rolling tolerances relative to nominal finished sizes 3 Table 5 Type and number of tests 6 Publication(s) referred to Inside back coverBS5892-4:1992 ii BSI 06-1999 Foreword This Part of BS 5892 was prepared under the direction of the Iron and Steel Standards P
8、olicy Committee and supersedes BS 5892-4:1986, which is withdrawn.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 forged and rolled wheel centres; Part 3: Specif
9、ication 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 stock. The format of this Part of BS 5892 has been
10、revised to incorporate the requirements for dimensional tolerancing for tyres which were previously included in BS 5892-6. This Part of BS 5892 is related to ISO 1005-1 and ISO1005-2; however, it has not been possible to obtain equivalence. It is related to UIC 810-1 and UIC 810-2. BS 5892-1 to BS 5
11、892-3 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 conformity with this British Standard based on testing and conti
12、nuing surveillance, which may be coupled with assessment 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 Certification Bodies. If a third party certification s
13、cheme does not already exist, users should consider approaching an appropriate body from the 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 wi
14、th a British Standard does not of itself confer immunity from legal obligations. Summary of pages This document comprises a front cover, an inside front cover, pages i and ii, pages1 to 10, an inside back cover and a back cover. This standard has been updated (see copyright date) and may have had am
15、endments incorporated. This will be indicated in the amendment table on the inside front cover.BS5892-4:1992 BSI 06-1999 1 1 Scope This Part of BS 5892 specifies requirements for the manufacture, inspection and testing of forged and rolled steel tyres for traction and trailing stock. This Part of BS
16、 5892 includes requirements for the dimensions and tolerances that are to be adopted unless otherwise specified in the design drawing. NOTEThe titles of the publications referred to in this Part of BS 5892 are listed on the inside back cover. 2 Information to be supplied by the purchaser The followi
17、ng 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.BS5892-4; b) a fully dimensioned drawing of the tyre; c) the grade of steel required (see 3.1); d) the type of heat treatment required (see 3.2); e) the type
18、 of inspection and quality assurance system required (see clause 6); f) whether ultrasonic testing is required (see7.3.5); g) whether a Brinell hardness test is required (see 7.3.4); h) whether a statement giving the cast analysis and/or results of mechanical or other tests is required (see clause 1
19、1); i) whether a product check analysis is required (see 9.1); j) whether any special marking is required (seeclause 5); k) the method of protection against mechanical damage (see clause 12). 3 Classification and heat treatment 3.1 Grade of steel The grade(s) of steel shall be selected from those li
20、sted in Table 1 and Table 3 (see item d) of clause2). Grades B1, B2, B3, B4, BS, B6 and B7 shall have the composition and properties given in Table 1, Table 2 andTable 3. 3.2 Heat treatment condition The tyres shall be supplied in one of the following conditions (see item d) of clause 2 and Table 3)
21、: a) normalized or normalized and tempered, which shall be designated by the letter N; b) immersion quenched and tempered, which shall be designated by the letter E. Examples. B2N is steel grade B2, delivered in the normalized or normalized and tempered condition. B5E is steel grade B5 delivered in
22、the immersion quenched and tempered condition. Table 1 Chemical composition Grade of steel Chemical composition C max. Si max. Mn max. P max. S max. Cr max. Cu max. Mo max. Ni max. V max. (Cr + Mo + Ni) max. % % % % % % % % % % % B1 0.48 0.50 1.20 0.040 0.040 0.30 0.30 0.08 0.30 0.05 0.60 B2 0.58 0.
23、50 0.90 0.040 0.040 0.30 0.30 0.08 0.30 0.05 0.60 B3 0.60 0.50 1.10 0.040 0.040 0.30 0.30 0.08 0.30 0.05 0.60 B4 0.70 0.50 0.90 0.040 0.040 0.30 0.30 0.08 0.30 0.05 0.60 B5 0.60 0.50 0.80 0.040 0.040 0.30 0.30 0.08 0.30 0.05 0.60 B6 0.65 0.50 0.90 0.040 0.040 0.30 0.30 0.08 0.30 0.05 0.60 B7 0.80 0.
24、50 1.00 0.040 0.040 0.30 0.30 0.20 0.30 0.05 0.70BS5892-4:1992 2 BSI 06-1999 Table 2 Permitted variations of product analysis from the specified range for significant elements 4 Manufacture 4.1 Steel making The tyres shall be made from steel produced by the electric process or the basic oxygen proce
25、ss. The steel shall be killed in the furnace or in the ladle and treated to ensure that the finished tyre has a grain size of 5 to 8 as determined by the method in appendix F of BS 4490:1989. Ingots shall be bottom poured. 4.2 Manufacture of tyres The tyres shall be hot rolled from one of the follow
26、ing: a) ingots; or b) rolled or forged bars; or c) continuously cast bars. The ingot or bar sections shall be rough shaped and punched using a forging hammer or press and finally shaped by rolling. Precautions shall be taken during hot working to ensure that material is not damaged by overheating or
27、 by grain growth due to high finish working temperatures. NOTEGenerally, forging should not be done at temperatures above 1 260 C and should terminate between 850 C and 1 000 C. 4.3 Hydrogen cracking (flakes) Precautions shall be taken by the manufacturer throughout the process route to avoid the fo
28、rmation of hydrogen cracks (flakes). 4.4 Appearance The tyres shall be free from forging or rolling defects. The surface shall not show any mark other than those specified (see clause 5). NOTEBrinell hardness testing indentations may be left on the surface of the tyre, however. 4.5 Identification of
29、 the tyres during manufacture All ingots, rolled bars, concast bars and forged tyres shall be marked at each stage of manufacture so that before delivery each tyre can be identified as specified in clause 6. Where the identification marks are stamped, and differ from the final identification marks s
30、pecified in clause 5, they shall not be visible on the finished tyre after machining. 4.6 Heat treatment After hot working, tyres shall undergo the specified heat treatment (see item d) of clause 2 and 3.2). Details of heat treatment temperatures and times shall be recorded. The required heat treatm
31、ent operations shall ensure: a) uniformity of structure and properties in comparable parts of the same tyre; b) uniformity of structure and properties in all tyres from the same heat treatment batch; c) that the rolled tyre shall be free from distortion and is capable of being machined as specified
32、in4.8. 4.7 Rectification of ovality and buckle NOTEIt is permissible for any ovality and buckle of tyres, when formed and heat treated, and which does not exceed 6 mm to be corrected by cold forming without renewal of the heat treatment. If the ovality and/or buckle exceeds 6 mm, hot rectification s
33、hall be carried out and all such tyres shall be subjected to a stress relief at a temperature not greater than 50 C below the tempering temperature (if applicable) and in any case not greater than 600 C. 4.8 Dimensions Unless otherwise specified on the drawing and order, the dimensional rolling tole
34、rances relative to finished size shall be those given in Table 4 (seealsoFigure 1). Element Range in which maximum of specified element falls Variation on specified range % % Carbon Up to and including 0.50 Over 0.50, up to and including 0.80 Silicon Up to and including 0.50 Manganese Up to and incl
35、uding 1.00 Over 1.00, up to and including 1.20 Phosphorus Up to and including0.040 Sulfur Up to and including0.040 +0.03 0 +0.04 0 +0.03 0 +0.04 0 +0.08 0 +0.006 0 +0.006 0BS5892-4:1992 BSI 06-1999 3 Table 3 Heat treatment condition and mechanical properties Table 4 Dimensional rolling tolerances re
36、lative to nominal finished sizes The bore of the tyre shall be perpendicular to the plane of the tyre and concentric with the rim within the run-out requirements of the finished assembly as defined in BS 5892-6. 4.9 Removal of surface defects Rectified surfaces shall have no heat cracking, shall be
37、within specified tolerances and surface finishes and shall be smoothly blended into the surrounding area. Rectification by welding, chemical deposition of metal, metal spraying or by use of local heating shall not be carried out. 5 Manufacturers brand marks Unless the purchaser indicates that specia
38、l marking is required (see item j) of clause 2), each tyre shall be identified by the manufacturer with stamp marks in the position shown in Figure 2. The markings shall include the following: a) the number of this British Standard, i.e.BS5892-4 1) b) the manufacturers mark; c) the cast number; d) t
39、he grade of steel and the heat treatment condition, e.g. B2N; e) the date of manufacture (month and last two figures of the year of production; f) the inspectors mark. NOTEItems a) to e) should be hot-stamped and item f) should be cold-stamped. Grade of steel Heat treatment condition on delivery (se
40、e 3.2) Mechanical properties Tensile strength R m Elongation A min. a Minimum charpy U impact value at 20 C KU b Brinell hardness range N/mm 2 % J HB B1 N 600 to 720 18 5 179 to 212 B2 N 700 to 820 14 10 207 to 241 B3 N 750 to 880 12 10 212 to 262 B4 N 800 to 940 10 10 235 to 277 B5 E 800 to 920 14
41、15 235 to 269 B6 E 920 to 1 050 12 10 269 to 311 B7 E 1 050 to 1 200 10 5 311 to 352 a A is the percentage elongation after fracture on gauge length L o= 5.65S o , where S ois the original cross-sectional area of the test piece. b Mean value of three tests: one of the individual results may be lower
42、 than the minimum value given in this table provided it is not less than 70 % of the minimum Dimensions (see Figure 1 for symbols) Rolling tolerance mm Bore diameter A Tread diameter B Tyre width (see note 1) C Snip height D Snip width E Quality See note 2 Buckle Eccentricity NOTE 1Subject to a mini
43、mum allowance of 3.0 mm on each side. NOTE 2To be within the limits on bore, tread diameter and width. 9 15 +6 +12 +6 +9 +0 +3 +6 +9 1) Marking BS 5892-4 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 the pro
44、duct 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 be confused with third party certification of conformity, which may also be desirable.BS5892-4:1992 4 BSI 06-1999 Figure 1 Key to th
45、e symbols used in Table 4BS5892-4:1992 BSI 06-1999 5 6 Inspection The inspection of tyres shall be undertaken in one of the following ways (see item e) of clause 2): a) by the purchaser or his nominated representative, who shall inspect the tyres ordered and witness any of the tests; or b) by delega
46、tion of the responsibility for the inspection by the purchaser to the manufacturer; or c) within the application of a quality assurance system (see BS 5750 and the foreword). 7 Type and number of tests 7.1 Type of test The type and number of tests to be carried out shall be in accordance with Table
47、5. 7.2 Test unit, subdivision into batches and number of test pieces The test unit for the various types of test shall be in accordance with Table 5. For the purpose of testing, the tyres shall be grouped in batches. Each batch shall comprise tyres produced from the same cast having undergone a simi
48、lar heat treatment, if applicable. NOTEIt is permissible to include, within a batch, tyres of different size and shape. The number of tyres per batch to be subjected to the tests, the number of tests per tyre and the condition of the tyre when submitted for testing shall be in accordance with Table
49、5. NOTEFor orders of eight or less tyres which cannot be grouped with other batches the supplier, with the agreement of the purchaser, may carry out the tests on a separate forged test sample. Figure 2 Position of brand marks on tyresBS5892-4:1992 6 BSI 06-1999 If a separate test sample is used, it shall: a) be from the same cast of material; b) be of an equivalent ruling section to the tyre; c) have undergone a similar degree of hot work; d) be heat treated with the tyres. The axis of the tes
