1、raising standards worldwideNO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAWBSI Standards PublicationRailway applications Wheelsets and bogies Powered and non-poweredaxles with inboard bearings Design methodBS 8535:2011Incorporating Corrigendum No. 1BS 8535:2011 BRITISH STANDARD
2、Publishing and copyright informationThe BSI copyright notice displayed in this document indicates when the document was last issued. The British Standards Institution 2013 Published by BSI Standards Limited 2013ISBN 978 0 580 81922 3ICS 45.040The following BSI references relate to the work on this s
3、tandard: Committee reference RAE/3 Draft for comment 10/30204582 DCPublication historyFirst published, August 2011Amendments issued since publicationDate Text affected February 2013 C1: See Foreword. The British Standards Institution 2013 iBS 8535:2011BRITISH STANDARDContentsForeword iiiIntroduction
4、 11 Scope 12 Normative references 23 Symbols 24 General 45 Forces and moments to be taken into consideration 46 Determination of geometric characteristics of the various parts of the axle 187 Maximum permissible stresses 25AnnexesAnnex A (informative) Sample axle calculation sheet template Load case
5、 1 26Annex B (informative) Sample axle calculation sheet Friction blocks on each wheel 28Annex C (informative) Sample axle calculation sheet Two brake discs mounted on the axle 29Annex D (informative) Sample axle calculation sheet Two brake discs mounted inboard on the hub 30Annex E (informative) Sa
6、mple axle calculation sheet One brake disc mounted on the axle 31Annex F (informative) Sample axle calculation sheet One brake disc mounted inboard on the hub 32Annex G (informative) Sample axle calculation sheet One brake disc mounted outboard on the hub 33Annex H (informative) Sample axle calculat
7、ion sheet Two brake discs mounted outboard on the hub 34Bibliography 35List of figuresFigure 1 Influence of masses in motion 5Figure 2 Load balance for load case 1 7Figure 3 Forces for calculating bending moment Mx 8Figure 4 Load balance for load case 2 10Figure 5 Moments generated by braking 11Figu
8、re 6 Diameters of solid and hollow axles 18Figure 7 Stress concentration factor K as a function of D/d and r/d 19Figure 8 Stress concentration factor K as a function of D/d and r/d (groove bottom) 20Figure 9 Wheel, brake disc, pinion and bearing ring press-fitted onto a seat 21Figure 10 Journal show
9、ing bearing overhang 22Figure 11 Wheel seat showing wheel hub overhang 22Figure 12 Transition between bearing seat and wheel seat 23Figure 13 Transition between axle body and bearing, brake disc or gear seat 24List of tablesTable 1 Masses to be taken into account for the main types of rolling stock
10、6Table 2 Calculation of Mxfor each axle zone and general outline of variations in Mxalong the axle 9Table 3 Values of components Mx, Mzand Myfor different methods of braking 14BS 8535:2011ii The British Standards Institution 2013BRITISH STANDARDTable 4 Maximum permissible stresses for axles in steel
11、 grades EA1N and EA1T 25Table 5 Maximum permissible stresses for axles in steel grade EA4T 25Summary of pagesThis document comprises a front cover, an inside front cover, pages i to iv, pages 1 to 36, an inside back cover and a back cover. The British Standards Institution 2013 iiiBS 8535:2011BRITIS
12、H STANDARDForewordPublishing informationThis British Standard is published by BSI Standards Limited, under licence from The British Standards Institution, and came into effect on 31 August 2011. It was prepared by Technical Committee RAE/3, Railway rolling stock material. A list of organizations rep
13、resented on this committee can be obtained on request to its secretary.Information about this documentThe start and finish of text introduced or altered by Corrigendum No. 1 is indicated in the text by tags .Test laboratory accreditation. Users of this British Standard are advised to consider the de
14、sirability of selecting test laboratories that are accredited to BS EN ISO/IEC 17025 by a national or international accreditation body.Presentational conventionsThe provisions of this standard are presented in roman (i.e. upright) type. Its requirements are expressed in sentences in which the princi
15、pal auxiliary verb is “shall”.Commentary, explanation and general informative material is presented in smaller italic type, and does not constitute a normative element.Contractual and legal considerationsThis publication does not purport to include all the necessary provisions of a contract. Users a
16、re responsible for its correct application.Compliance with a British Standard cannot confer immunity from legal obligations.BS 8535:2011iv The British Standards Institution 2013BRITISH STANDARDThis page deliberately left blank The British Standards Institution 2013 1BS 8535:2011BRITISH STANDARDIntro
17、ductionRailway axles were among the first train components to give rise to fatigue problems.Many years ago, specific methods were developed in order to design these axles. They were based on a feedback process from the service behaviour of axles combined with the examination of failures and on fatig
18、ue tests conducted in the laboratory, so as to characterize and optimize the design and materials used for axles.A European working group under the aegis of UIC (Union International des Chemins de fer) started to harmonize these methods at the beginning of the 1970s. This led to an ORE (Office de Re
19、cherches et dEssais de lUIC) document applicable to the design of trailer stock axles 1, which was subsequently incorporated into national standards (French, German, and Italian).This method was successfully extrapolated in France for the design of powered axles and the French standard also applies
20、to such axles. Consequently this method was converted into an UIC leaflet 2.Work continued in Europe and standards were prepared under a mandate given to CEN/CENELEC/ETSI by the European Commission and the European Free Trade Association, which supports the essential requirements of Directives 96/48
21、/EC 3 and 2001/16/EC 4 amended by Directive 2004/50/EC 5. These Directives have now been superseded by Directive 2008/57/EC 6.The resulting European standards BS EN 13103 and BS EN 13104 for the design methods for outboard bearing axles were derived based largely on the UIC leaflet 2.This British St
22、andard takes these considerations into account and they have been adopted and amended accordingly, for the axle configurations having inboard journal bearings. UK practice, including TM/TC0001 Design guide for the calculation of stresses in axles with inboard journals 7, BASS 503 Design guide for th
23、e calculation of stresses in axles driven by axle hung traction motors 8 and BASS 504 Design guide for the calculation of stresses in non-driving axles 9, has also been used in the preparation of this document.The method described in these reference documents is largely based on conventional loading
24、s for axles and applies the beam theory for the stress calculation. The shape and stress recommendations are derived from design verification, and the outcome is validated by many years experience on the UK mainline railway system.1 ScopeThis British Standard specifies a design method for powered an
25、d non-powered axles with inboard bearings for railway applications.This standard: specifies the forces and moments to be taken into account with reference to masses, traction and braking conditions; specifies the stress calculation method for axles with inboard axle journals;BS 8535:20112 The Britis
26、h Standards Institution 2013BRITISH STANDARD specifies the maximum permissible stresses to be assumed in calculations for steel grades EA1N, EA1T and EA4T as defined in BS EN 13261 and steel grades A1N and A1T as specified in BS 5892-1; specifies a method for determining the diameters for the variou
27、s sections of the axle. It also gives recommendations for the preferred shapes and transitions to ensure adequate service performance.This standard is applicable to: solid and hollow powered axles for railway rolling stock; solid and hollow non-powered axles of motor bogies; solid and hollow non-pow
28、ered axles of locomotives; axles defined in BS EN 13261 and in BS 5892-1; UK standard gauge.This standard is applicable to axles fitted to rolling stock intended to run under normal UK mainline conditions. Before using this standard, if there is any doubt as to whether the railway operating conditio
29、ns are normal, it is necessary to determine whether an additional design factor has to be applied to the maximum permissible stresses. The calculation of wheelsets for special applications (e.g. tamping/lining/levelling machines) may be made according to this standard only for the load cases of free
30、-running and running in train formation. This standard does not apply to workload cases. They are calculated separately.2 Normative referencesThe following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated r
31、eferences, the latest edition of the referenced document (including any amendments) applies.BS 5892-1, Railway rolling stock materials Part 1: Specification for axles for traction and trailing stockBS EN 13261, Railway applications Wheelsets and bogies Axles Product requirements3 SymbolsFor the purp
32、oses of this British Standard, the following symbols apply.m1Mass on journals (including bearings and axle boxes), in kilograms (kg)m2Wheelset mass and masses on the wheelset between running surfaces (brake disc, etc.), in kilograms (kg)m1+ m2For the wheelset considered, portion of the mass of the v
33、ehicle on the rails, in kilograms (kg)g Acceleration due to gravity, in metres per second squared (m/s2)P Half the vertical force per wheelset on the rail, mmg122+(), in newtons (N) The British Standards Institution 2013 3BS 8535:2011BRITISH STANDARDP0Vertical static force per journal when the wheel
34、set is loaded symmetrically, mg12, in newtons (N)P1Vertical force on the more heavily-loaded journal, in newtons (N)P2Vertical force on the less heavily-loaded journal, in newtons (N)P Portion of P braked by any mechanical braking system, in newtons (N) Y1Wheel/rail horizontal force perpendicular to
35、 the rail on the side of the more heavily-loaded journal, in newtons (N)Y2Wheel/rail horizontal force perpendicular to the rail on the side of the less heavily-loaded journal, in newtons (N)H Force balancing the forces Y1and Y2, in newtons (N)Q1Vertical reaction on the wheel situated on the side of
36、the more heavily-loaded journal, in newtons (N)Q2Vertical reaction on the wheel situated on the side of the less heavily-loaded journal, in newtons (N)FiForces exerted by the masses of the unsprung elements situated between the two wheels brake disc(s), pinion, etc., in newtons (N)FfMaximum force in
37、put of the brake shoes of the same shoe holder on one wheel or interface force of the brake pads on one brake disc, in newtons (N)MxBending moment due to the masses in motion, in newton millimetres (Nmm)Mx, MzBending moments due to braking, in newton millimetres (Nmm)My Torsional moment due to braki
38、ng, in newton millimetres (Nmm)Mx, MzBending moments due to traction, in newton millimetres (Nmm)My Torsional moment due to traction, in newton millimetres (Nmm)MX, MZ Sum of bending moments, in newton millimetres (Nmm)MY Sum of torsional moments, in newton millimetres (Nmm)MR Resultant moment, in n
39、ewton millimetres (Nmm)2b Distance between vertical force input points on axle journals, in millimetres (mm)2s Distance between wheel treads, in millimetres (mm) h1Distance between the centre of the axle and the centre of gravity of the vehicle, in millimetres (mm)yiDistance between the tread of one
40、 wheel and force Fi, in millimetres (mm)yAbscissa for any section of the axle calculated from the section subject to force P1, in millimetres (mm)BS 8535:20114 The British Standards Institution 2013BRITISH STANDARD Average friction coefficient between the wheel and the brake shoe or between the brak
41、e pads and the brake disc Stress calculated in one section, in newtons per square millimetre (N/mm2)maxMaximum stress calculated in one section, due to the masses in motion plus braking or masses in motion plus traction, whichever is the greater, in newtons per square millimetre (N/mm2)K Fatigue str
42、ess concentration factorR Nominal radius of the tread of a wheel, in millimetres (mm)RbRadius of circle on brake disc at which brake force is applied, in millimetres (mm)d Diameter for one section of the axle, in millimetres (mm) d Bore diameter of a hollow axle, in millimetres (mm)D Diameter used f
43、or determining K, in millimetres (mm)r Radius of transition fillet or groove used to determine K, in millimetres (mm)4 GeneralThe major phases for the design of an axle shall be undertaken as follows:a) definition of the forces to be taken into account and calculation of the moments on the various s
44、ections of the axle;b) selection of the diameters of the axle body and journals and, on the basis of these diameters, calculation of the diameters for the other parts;c) verification of the options taken by: stress calculation for each section; comparison of these stresses with the maximum permissib
45、le stresses.NOTE A sample axle calculation sheet template is given in Annex A and some example calculations are given in Annex B to Annex H.5 Forces and moments to be taken into consideration5.1 Types of forcesThree types of forces shall be taken into consideration as a function of: the masses in mo
46、tion; the braking system; the traction. The British Standards Institution 2013 5BS 8535:2011BRITISH STANDARD5.2 Influence of masses in motionNOTE 1 The forces generated by masses in motion are concentrated along the vertical plane of symmetry (y, z) (see Figure 1) intersecting the axle centreline.Un
47、less otherwise specified (for example by the customer), the masses (m1+ m2) to be taken into account for the main types of rolling stock shall be as specified in Table 1.NOTE 2 For particular applications, e.g. suburban vehicles, other masses might be necessary in accordance with the specific operat
48、ing requirements (see Table 1 Footnotes A)and B).Figure 1 Influence of masses in motionBS 8535:20116 The British Standards Institution 2013BRITISH STANDARDTable 1 Masses to be taken into account for the main types of rolling stockType of rolling stock units Mass (m1+ m2)Freight wagons For the axle c
49、onsidered, portion of the wagon mass under maximum permissible loading in serviceTraction units with no passenger accommodation, luggage areas and postal vans For the axle considered, portion of the vehicle mass under maximum permissible loading in serviceTraction units including passenger accommodation, luggage areas and postal vans For the axle considered, portion of the vehicle mass under maximum permissible loading in servi
