1、BSI Standards PublicationBS 5892-7:2014Incorporating Corrigendum No. 1Railway rolling stockmaterialsPart 7: Specification for product andtechnical approval requirements forcast wheelsPublishing and copyright informationThe BSI copyright notice displayed in this document indicates when the documentwa
2、s last issued. The British Standards Institution 2015Published by BSI Standards Limited 2015ISBN 978 0 580 89910 2ICS 45.040The following BSI references relate to the work on this document:Committee reference RAE/3Draft for comment 14/30236255 DCPublication historyFirst published November 2014Amendm
3、ents issued since publicationDate Text affectedApril 2015 C1, Correction to Figure G.1BS 5892-7:2014 BRITISH STANDARDContentsIntroduction 11 Scope 22 Normative references 23 Terms and definitions 34 Product definition 35 Technical approval 186 Parameters for the technical approval process 187 Assess
4、ment of the geometric parameters 208 Assessment of the thermomechanical behaviour (tread braked wheelsonly) 209 Assessment of the mechanical behaviour 2210 Assessment of the acoustic behaviour 2411 Technical approval documents 2412 Qualification 24AnnexesAnnex A (normative) Product qualification 25A
5、nnex B (normative) Product delivery 29Annex C (informative) Example of a test method for the determination offatigue characteristics 33Annex D (informative) Strain gauge method for determining the variation ofcircumferential residual stresses located deep under the tread (destructivemethod) 34Annex
6、E (informative) Parameters for drag brake assessment 39Annex F (normative) Assessment of the thermomechanical behaviour 39Annex G (normative) Assessment of the mechanical behaviour 46Bibliography 53List of figuresFigure 1 Location of test pieces 5Figure 2 Readings taken on a radial section of the ri
7、m 6Figure3Testpieces taken from the rim 8Figure 4 Location of sample for the micrographic examination 9Figure 5 Standard hub for ultrasonic examination 12Figure 6 Symbols 15Figure 7 Application points for each load 23Figure B.1 Location of hardness measurements 32Figure C.1 Test rig 34Figure D.1 Fit
8、ting of strain gauges 35Figure D.2 Cutting operations 36Figure D.3 Method for determining the variation of the circumferential stresslocated deep under the tread 38Figure F.1 Assessment flow chart 40Figure G.1 Mechanical assessment flow chart 47Figure G.2 Mechanical behaviour test assessment schedul
9、e 48Figure G.3 Functional diagram 50Figure G.4 Rotational bending fatigue test rig 51Figure G.5 Rotational bending fatigue test rig 52List of tablesTable 1 Maximum content of main elements within cast wheels 4Table 2 Maximum content of residual elements within cast wheels 4BRITISH STANDARD BS 5892-7
10、:2014 The British Standards Institution 2015 iTable 3 Rim and web characteristics of the wheels 5Table 4 Minimum hardness values 6Table5Average and minimum impact test values 7Table 6 Minimum fatigue characteristics 7Table7Average surface roughness 13Table 8 Geometric tolerances 16Table A.1 Radial s
11、tress levels 27Table B.1 Type and number of controls to be carried out 31Table E.1 Drag brake parameters for European interoperability 39Table E.2 Drag brake parameters for vehicles operating solelyin Great Britain 39Summary of pagesThis document comprises a front cover, an inside front cover, pages
12、 i to iv,pages 1 to 54, an inside back cover and a back cover.BRITISH STANDARDBS 5892-7:2014ii The British Standards Institution 2015ForewordPublishing informationThis part of BS 5892 is published by BSI Standards Limited, under licence fromThe British Standards Institution, and came into effect on
13、30 November 2014. Itwas prepared by Panel RAE/3/-/1, Wheels and Wheelsets, under the authority ofTechnical Committee RAE/3, Railway rolling stock materials. A list oforganizations represented on this committee can be obtained on request to itssecretary.Information about this documentText introduced
14、or altered by Corrigendum No. 1 is indicated in the text by thetags. Minor editorial corrections are not tagged.Relationship with other publicationsBS 5892 is published in the following parts: BS 5892-1, Railway rolling stock materials Part 1: Specification for axles fortraction and trailing stock;
15、BS 5892-2, Railway rolling stock materials Part 2: Specification for forgedand rolled wheel centres; BS 5892-3, Railway rolling stock materials Part 3: Specification formonobloc wheels for traction and trailing stock; BS 5892-4, Railway rolling stock materials Part 4: Specification for forgedand rol
16、led tyres; BS 5892-5, Railway rolling stock material (metric) Part 5: Specification forsteel bars for retaining rings for tyred wheels; BS 5892-6, Railway rolling stock materials Part 6: Specification forwheelsets for traction and rolling stock; BS 5892-7, Railway rolling stock materials Part 7: Spe
17、cification for productand technical approval requirements for cast wheels; BS 5892-8, Railway rolling stock materials Part 8: Railway applications Wheelsets and bogies Powered and non-powered wheelsets with inboardbearings Product requirements.Presentational conventionsThe provisions of this standar
18、d are presented in roman (i.e. upright) type. Itsrequirements are expressed in sentences in which the principal auxiliary verb is“shall”.Commentary, explanation and general informative material is presented insmaller italic type, and does not constitute a normative element.Contractual and legal cons
19、iderationsThis publication does not purport to include all the necessary provisions of acontract. Users are responsible for its correct application.Compliance with a British Standard cannot confer immunity from legalobligations.BRITISH STANDARD BS 5892-7:2014 The British Standards Institution 2015 i
20、iiBRITISH STANDARDBS 5892-7:2014This page deliberately left blankiv The British Standards Institution 2015IntroductionBefore the publication of this part of BS 5892, the only standards available todefine quality and technical approval requirements for monobloc wheels wereBS 5892-3, BS EN 13262 and B
21、S EN 13979-1, which apply only to forged androlled wheels, and DD CEN/TS 13979-2 and DD CEN/TS 15718, which werepublished as reference documents for cast wheels.Cast wheels are commonly used by railways applying the Association ofAmerican Railroads (AAR) standards and have been introduced into Europ
22、e onsome applications for freight wagons. The product and technical approvalrequirements of this British Standard are derived from BS 5892-3,BS EN 13262 and BS EN 13979-1.This British Standard provides a complete definition of the product and deliveryprocedures for cast wheels by:a) defining all the
23、 wheel characteristics;NOTE 1 These are either verified during the qualification procedures or for thedelivery of the product (see Clause 4).b) defining qualification procedures (see Annex A); andc) defining delivery conditions (see Annex B).NOTE 2 A choice is given to the supplier, of either:1) a t
24、raditional delivery procedure with a control by batch sampling as inexisting documents (see B.4); or2) a delivery procedure using quality assurance concepts (see B.4.6).This British Standard also describes how to assess the wheel design, followingthe principles of BS EN 13979-1 as set out for cast w
25、heels in DD CEN/TS 13979-2.To be able to apply the specifications, the use of the wheel needs to be defined;this standard also states how to define this use.At least four aspects are described with different purposes: a geometric aspect to allow interchangeability of different solutions forthe same
26、application; a thermomechanical aspect for tread braked wheels to manage wheeldeformations and to ensure that braking does not cause wheels to break; a mechanical aspect to ensure that no fatigue cracks occur in the web; and an acoustic aspect to ensure that the solution chosen is as good as therefe
27、rence wheel, for the use in question.For each of these three latter aspects, the rules tend to limit the procedure;thus, the easier the objectives are to attain by the wheel under study.The main content of the technical approval clauses of this standard is derivedfrom BS EN 13979-1 with differences
28、linked to the needs of the cast process forthe product as proposed in DD CEN/TS 13979-2.BRITISH STANDARD BS 5892-7:2014 The British Standards Institution 2015 11 ScopeThis British Standard specifies the characteristics of, and technical approvalrequirements for, cast railway wheels for conventional
29、rail operation. It can beapplied in conjunction with BS or BS EN standards for axles and wheelsets. Thisstandard is not applicable to urban rail.Three steel grades, C48, C56 and C64, are defined in this standard.NOTE 1 For the purpose of this British Standard, the steels referred to as C48,C56 and C
30、64 are based on those defined as AAR Class L, A and B respectively.This British Standard is applicable to cast wheels which are rim-chilled and havetheir wheel webs shot peened.NOTE 2 9Rim-chilled9 is a heat treatment of the rim, the aim of which is to hardenthe rim and to create compressive residua
31、l stresses in the rim.NOTE 3 Cast wheels are shot peened to improve the web fatigue strength.The wheels defined in this British Standard are for applications up to 120 km/h(i.e. 75 mph).It only applies to wheels of new design or new application.These requirements are intended to be used to assess th
32、e validity of the designchoice for the proposed use and constitute the technical approval procedure.This British Standard does not cover assessment of the hub nor of the staticmechanical dimensioning of the wheel.2 Normative referencesStandards publicationsFor dated references, only the edition cite
33、d applies. For undated references, thelatest edition of the referenced document (including any amendments) applies.ASTM E399-90:1997, Test method for plane-strain fracture toughness of metallicmaterialsASTM E1245, Standard practice for determining the inclusion or second-phaseconstituent content of
34、metals by automatic image analysisBS EN 13103, Railway applications Wheelsets and bogies Non-poweredaxles Design methodBS EN 13104, Railway applications Wheelsets and bogies Powered axles Design methodBS EN 13979-1:2003+A2:2011, Railway applications Wheelsets and bogies Monobloc wheels Technical app
35、roval procedure Part 1: Forged and rolledwheelsBS EN ISO 148-1, Metallic materials Charpy pendulum impact test Part 1: TestmethodBS EN ISO 6506-1, Metallic materials Brinell hardness test Part 1: Test methodBS EN ISO 6506-2, Metallic materials Brinell hardness test Part 2: Verificationand calibratio
36、n of testing machinesBS EN ISO 6506-3, Metallic materials Brinell hardness test Part 3: Calibrationof reference blocksBS EN ISO 6892-1:2009, Metallic materials Tensile testing Part 1: Method oftest at ambient temperatureBRITISH STANDARDBS 5892-7:20142 The British Standards Institution 2015BS EN ISO
37、9712, Non-destructive testing Qualification and certification of NDTpersonnel (ISO 9712:2012)ISO 5948:1994, Railway rolling stock material Ultrasonic acceptance testingISO 6933:1986, Railway rolling stock material Magnetic particle acceptancetestingISO/TR 9769, Steel and iron Review of available met
38、hods of analysisOther publicationsN1SOCIETY OF AUTOMOTIVE ENGINEERS. SAE J827, High-carbon cast-steelshot. Warrendale, PA: SAE International, 2013.N2SOCIETY OF AUTOMOTIVE ENGINEERS. SAE J444, Cast shot and grit sizespecifications for peening and cleaning. Warrendale, PA: SAEInternational, 2012.N3SOC
39、IETY OF AUTOMOTIVE ENGINEERS. SAE J442, Test strip, holder and gagefor shot peening. Warrendale, PA: SAE International, 2013.N4SOCIETY OF AUTOMOTIVE ENGINEERS. SAE J443, Procedures for usingstandard shot peening Almen strip. Warrendale, PA: SAE International, 2013.N5ASSOCIATION OF AMERICAN RAILROADS
40、. AAR Manual of standards andrecommended practices: Section G Wheels and axles SpecificationM 107 M 208. AAR, 2011.1)N6ERRI report B169/RP12. Production of a universal matrix representative ofdamage to a railway component with a view to performing fatigue tests.October 1997.N7ERRI report B169 RP10.
41、Definition of a specification for solid axisymmetricalwheels Verification of mechanical design: fatigue strength Towards abetter shape for the wheel centre. January 1999.3 Terms and definitionsFor the purposes of this part of BS 5892, the following terms and definitionsapply.3.1 Heatidentification o
42、f all the wheels produced from a single furnace load ofliquid steel3.2 technical specificationdocument describing the specific parameter/product requirements in addition tothe requirements of this standard4 Product definition4.1 GeneralThe application for which the wheel is to be approved shall be d
43、efined by theparameters in accordance with this British Standard and the additionalrequirements defined in the technical specification.1)Available from last viewed10 November 2014.BRITISH STANDARD BS 5892-7:2014 The British Standards Institution 2015 3The product sample shall be taken from the locat
44、ions as indicated in this BritishStandard. Where the characteristics of the wheel vary due to the nature of thesteel casting process, the test shall be taken from a worst case location asdefined in the technical specification.For any process change the locations shall be reviewed and, if necessary,
45、definedagain.4.2 Chemical composition4.2.1 RequirementsThe defined chemical composition shall be within the ranges definedin Table 1 and Table 2.To safeguard against hydrogen cracking the minimum sulfur content shall notbe less than 0.005%; greater values may be defined in the technicalspecification
46、.4.2.2 Location of the sampleThe sample for determining the chemical composition shall either be taken fromthe molten steel during the casting process or from a position 15 mm below thetread at its nominal diameter.For product approval, both samples shall be taken.4.2.3 Chemical analysisThe chemical
47、 composition analysis shall be performed in accordancewith ISO/TR 9769.4.2.4 Hydrogen analysisThe hydrogen content shall be determined for each Heat. The Heat shallconform to a maximum hydrogen percentage limit of 2.5 ppm.Table 1 Maximum content of main elements within cast wheelsSteelgradeMaximum c
48、ontent %CSiMnPS(see Note)C48 0.450.52 0.60 0.90 0.025 0.025C56 0.520.60 0.60 0.90 0.025 0.025C64 0.600.67 0.60 0.90 0.025 0.025NOTE For special applications, variations within the maximum limit of these values maybe defined in the technical specification.Table 2 Maximum content of residual elements
49、within cast wheelsSteelgradeMaximum content %Cr Cu Mo Ni V Al Ti Nb Cr + M+NiC48 0.25 0.35 0.10 0.25 0.06 0.06 0.03 0.05 0.50C56 0.25 0.35 0.10 0.25 0.06 0.06 0.03 0.05 0.50C64 0.25 0.35 0.10 0.25 0.06 0.06 0.03 0.05 0.50NOTE For special applications, variations within the maximum limit of these values maybe defined in the technical specification.BRITISH STANDARDBS 5892-7:20144 The British Stand
