1、December 2007DEUTSCHE NORM English price group 15No part of this standard may be reproduced without prior permission ofDIN Deutsches Institut fr Normung e. V., Berlin. Beuth Verlag GmbH, 10772 Berlin, Germany,has the exclusive right of sale for German Standards (DIN-Normen).ICS 45.040!$K#b“1400063ww
2、w.din.deDDIN EN 15049Railway applications Suspension components Torsion bar, steelEnglish version of DIN EN 15049:2007-12Bahnanwendungen Federungselemente Drehstabfedern aus StahlEnglische Fassung DIN EN 15049:2007-12www.beuth.deDocument comprises 40 pagesDIN EN 15049:2007-12 2 National foreword Thi
3、s standard has been prepared by Technical Committee CEN/TC 256 “Railway applications” (Secretariat: DIN, Germany). The responsible German body involved in its preparation was the Normenausschuss Fahrweg und Schienen-fahrzeuge (Railway Standards Committee), Technical Committee NA 087-02-03 AA Federun
4、g, Dmpfung. EUROPEAN STANDARDNORME EUROPENNEEUROPISCHE NORMEN 15049August 2007ICS 45.060.01English VersionRailway applications - Suspension components - Torsion bar,steelApplications ferroviaires - lments de suspension - Barrede torsion, en acierBahnanwendungen - Federungselemente - Drehstabfedernau
5、s StahlThis European Standard was approved by CEN on 13 July 2007.CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this EuropeanStandard the status of a national standard without any alteration. Up-to-date lists and bibliographical r
6、eferences concerning such nationalstandards may be obtained on application to the CEN Management Centre or to any CEN member.This European Standard exists in three official versions (English, French, German). A version in any other language made by translationunder the responsibility of a CEN member
7、 into its own language and notified to the CEN Management Centre has the same status as theofficial versions.CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland,France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvi
8、a, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal,Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.EUROPEAN COMMITTEE FOR STANDARDIZATIONCOMIT EUROPEN DE NORMALISATIONEUROPISCHES KOMITEE FR NORMUNGManagement Centre: rue de Stassart, 36 B-1050 Brussels 2
9、007 CEN All rights of exploitation in any form and by any means reservedworldwide for CEN national Members.Ref. No. EN 15049:2007: EEN 15049:2007 (E) 2 Contents Page Foreword5 Introduction .6 1 Scope 6 2 Normative references 6 3 Terms and definitions .7 4 Symbols and abbreviations 8 5 Requirements.9
10、 5.1 Introduction 9 5.2 Documents to be provided by the customer 9 5.3 Documents to be provided by the supplier.10 5.4 Design analysis10 5.5 Arrangement and design 10 5.6 Straight torsion bar ends and connections 12 5.6.1 General12 5.6.2 Design of the straight torsion bar end 12 6 Product definition
11、 13 6.1 Geometrical characteristics and space envelope 13 6.2 Mechanical requirements13 6.2.1 Loading and allowable stresses.13 6.2.2 Service life 13 6.2.3 Investigation of the strain .13 6.2.4 Evaluation of the strain .14 6.3 Physical requirements 14 6.3.1 Material grade.14 6.3.2 Internal integrity
12、.14 6.3.3 Inclusion cleanliness.14 6.3.4 Forged torsion bar ends .14 6.3.5 Decarburization15 6.3.6 Surface condition.15 6.3.7 Residual compressive stresses on the surface .15 6.3.8 Grain size16 6.4 Surface protection .16 6.4.1 Generalities 16 6.4.2 Temporary protection16 6.4.3 Permanent protection16
13、 6.5 Characteristic moment of torsion / angular displacement17 6.6 Mass 18 7 Mechanical properties for manufacturing.18 7.1 Hardness.18 7.2 Tensile strength .18 7.3 Toughness18 8 Tests and test procedures 19 8.1 General requirements19 8.2 Measuring equipment19 8.3 Tensile strength .19 8.4 Toughness1
14、9 8.5 Hardness.19 EN 15049:2007 (E) 3 8.6 Material .19 8.7 Depth of decarburization 20 8.8 Grain size20 8.9 Forged torsion bar ends .20 8.10 Residual compressive stresses on the surface .20 8.11 Surface defects20 8.12 Surface condition 20 8.13 Dimensional check 21 8.14 Characteristic moment of torsi
15、on / angular displacement21 8.15 Mass21 8.16 Internal integrity 21 8.17 Surface protection.21 8.18 Loading and allowable stresses 21 9 Quality assurance and final approval22 9.1 Quality assurance system and staff qualification22 9.2 Product qualification procedures and samples .22 9.3 Control and mo
16、nitoring of production quality23 9.3.1 General .23 9.3.2 Quality assurance plan .23 9.3.3 Control by sampling lots 23 9.4 Requirements for control and monitoring of production quality .24 9.4.1 General .24 9.4.2 Non-compliance.26 9.4.3 Documentation 26 9.5 Handling instructions26 10 Marking of torsi
17、on bars.26 11 Packaging.27 Annex A (normative) Material for hot formed and quenched and tempered torsion bars 28 A.1 General .28 A.2 Material for torsion bars, steel .28 Annex B (normative) Inspection of torsion bars made of round bars by the magnetic crack detection method.30 B.1 Object30 B.2 Tests
18、 .30 B.3 Safety measures 30 Annex C (normative) Checking shot peening efficiency by ALMEN method .31 C.1 Field of application31 C.2 Checking the procedure .31 C.3 Equipment and installations.31 C.3.1 ALMEN A2 test piece.31 C.3.2 Test piece holder .32 C.3.3 ALMEN measuring device 33 Annex D (normativ
19、e) Examination for inclusions34 D.1 Object34 D.2 Test methods .34 D.2.1 Test method according to DIN 50602 34 D.2.2 Test method according to NF A 04-106.35 D.2.3 Test method according to SS 11111635 Annex E (normative) Taking of test pieces - Areas of the location of test pieces .36 Bibliography38 E
20、N 15049:2007 (E) 4 Figures Figure 1 Example for a straight torsion bar with mounted levers 11 Figure 2 Example for a bended torsion bar.11 Figure 3 Cylindrical or conical tooth system 12 Figure 4 Frictional shrink fit12 Figure 5 Example of the distribution of stresses produced by shot peening as a f
21、unction of depth .16 Figure 6 Torsion bar diagram .17 Figure C.1 ALMEN test arrangements32 Figure C.2 ALMEN measuring sytem .33 Figure E.1 Area “e“ with constant diameter of the torsion bar to take test pieces.36 Figure E.2 Location of the test pieces for the tensile strength test36 Figure E.3 Locat
22、ion of the test pieces for the notch impact test37 Tables Table 1 Symbols and definitions 8 Table 2 Elements to be defined in the technical specification and agreed by the parties.10 Table 3 Checks and tests to be carried out.24 Table 4 Test pieces for statistical tests, number of tests 25 Table A.1
23、 Guidance values for the maximum mechanical properties of quenched and tempered test pieces 29 Table D.1 Degree of cleanliness under the microscope according to DIN 50602 (procedure K), valid for non metallic oxide inclusions .34 Table D.2 Acceptable number of fields (small series and wide series) o
24、f each type35 Table D.3 Degree of cleanliness by microscopic examination according to SS 111116 (maximum values)35 EN 15049:2007 (E) 5 Foreword This document (EN 15049:2007) has been prepared by Technical Committee CEN/TC 256 “Railway applications”, the secretariat of which is held by DIN. This docu
25、ment shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by February 2008 and conflicting national standards shall be withdrawn at the latest by February 2008. According to the CEN/CENELEC Internal Regulations, the national st
26、andards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland,
27、 Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom. EN 15049:2007 (E) 6 Introduction Work on this European Standard started at the beginning of 2002 with the aim of incorporating the existing documents, such as UIC leaflets (International Union of Railways) and the
28、 internal standards of the various railways as well as national standards into one standard. 1 Scope This European Standard applies to torsion bars made of steel for anti-roll bar systems used on railway vehicles. This European Standard includes straight and bended torsion bars, but does not detail
29、the other components of the anti-roll bar systems such as levers, bearings, bushes etc. This European Standard constitutes guidelines on the following topics: design; specification of technical requirements; production requirements; tests; supply conditions. 2 Normative references The following refe
30、renced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN 473, Non-destructive testing Qualification and certification of
31、NDT personnel General principles EN 10002-1, Metallic materials Tensile testing Part 1: Method of test at ambient temperature EN 10045-1, Metallic materials Charpy impact test Part 1: Test method EN 10089, Hot-rolled steels for quenched and tempered springs Technical delivery conditions EN 10204, Me
32、tallic products Types of inspection documents EN 10228-1, Non-destructive testing of steel forgings Part 1: Magnetic particle inspection EN 10247, Micrographic examination of the non-metallic inclusion content of steels using standard pictures EN 13925-2, Non-destructive testing X-ray diffraction fr
33、om polycrystalline and amorphous materials Part 2: Procedures EN ISO 643, Steels Micrographic determination of the apparent grain size (ISO 643:2003) EN 15049:2007 (E) 7 EN ISO 1302, Geometrical Product Specifications (GPS) Indication of surface texture in technical product documentation (ISO 1302:2
34、002) EN ISO 2162-3:1996, Technical product documentation Springs Part 3: Vocabulary (ISO 2162-3:1993) EN ISO 3887, Steel Determination of depth of decarburization (ISO 3887:2003) EN ISO 4288, Geometrical Product Specifications (GPS) Surface texture: Profile method Rules and procedures for the assess
35、ment of surface texture (ISO 4288:1996) EN ISO 6508-1, Metallic materials Rockwell hardness test Part 1: Test method (scales A, B, C, D, E, F, G, H, K, N, T) (ISO 6508-1:2005) EN ISO 9934-1, Non-destructive testing Magnetic particle testing Part 1: General principles (ISO 9934-1:2001) EN ISO 14284,
36、Steel and iron Sampling and preparation of samples for the determination of chemical composition (ISO 14284:1996) EN ISO 18265, Metallic materials Conversion of hardness values (ISO 18265:2003) DIN 50602, Metallographic examination microscopic examination of special steels using standard diagrams to
37、 assess the content of non-metallic inclusions NF A04-106, Iron and steel. Methods of determination of content of non metallic inclusions in wrought steel. Part II: micrographic method using standards diagrams SS 111116, Steel Method for estimation of the content of non-metallic inclusions Microscop
38、ic methods Jernkontorets inclusion chart II for the assessment of non-metallic inclusions 3 Terms and definitions For the purposes of this document, the terms and definitions given in EN ISO 2162-3:1996 and the following apply. 3.1 anti-roll bar system suspension system having an influence on the ro
39、lling behaviour of the vehicle. Generally, it includes the torsion bar and any other components 3.2 anti-roll bar spring bar which is mainly stressed by a torsional moment. It can either be produced as bended bar or a straight torsion bar with levers 3.3 straight torsion bar straight spring bar whic
40、h is mainly stressed by a torsional moment NOTE The term “torsion bar made of steel“ refers to the finished end product. For the purpose of simplification, the term “torsion bar“ is used in the wording of this European Standard for anti-roll bars with torsion bars of round cross section and made of
41、steel. 3.4 bended torsion bar mainly U-shaped and manufactured out of round spring material EN 15049:2007 (E) 8 4 Symbols and abbreviations The symbols and abbreviations used in this standard are listed in table 1. All parameters are expressed as SI basic units and units derived from SI basic units.
42、 Decimal multiples and submultiples of units defined in Table 1 can be used. Table 1 Symbols and definitions Symbols Units Definitions A % Elongation at rupture d m Outer diameter of the middle part of the torsion bar dam Outer diameter of the torsion bar in the area of bearing dfm Root diameter of
43、the head profile dpm Diameter of shrink fite m Area to take test pieces F N Applied load at the lever l m Distance between load application and middle of torsion bar Lfm Distance between the two load application points Lam Length between the centre of the two bearings Lsm Length between the centre o
44、f the two levers lxm Crank depth in the middle part of the torsion bar lzm Distance between load application and centre of the bearing MtNm Torsional moment MtmaxNm Max. torsional moment MtNm Difference of torsional moments r M Bending radius of bended torsion bar EN 15049:2007 (E) 9 Table 1 (conclu
45、ded) Symbols Units Definitions RmPa Material strength Rp0,2 Pa Yield strength RtNm/degree Torsional spring rate Z % Percentage reduction of area after fracture - Depth of residual stress DPa Residual stress degree Angle of twist maxdegree Max. angle of twist Adegree Angle of twist at the beginning o
46、f stress degree Difference of angles of twist zulPa Permissible shear stress 5 Requirements 5.1 Introduction The component shall be defined in a technical specification which consists of the following documents (see 5.2 and 5.3). The definition of type of drawing is given in ISO 10209-1. 5.2 Documen
47、ts to be provided by the customer The customer shall provide a technical specification including: An interface drawing (possibly, a general assembly drawing of the mechanical system or a sub-assembly drawing) defining at least: the space envelope; the functional dimensions and their tolerances; the
48、application points of the forces; a technical specification detailing at least: the conditions of utilisation (forces, movements, temperatures, assembly, environment, maintenance, storage etc.); the requirements (characteristics of the product, tolerances and expected service life); the approval pro
49、cedure and type test requirements (e.g. characteristics to be checked and tests to be carried out, order of tests and checks). EN 15049:2007 (E) 10 The product requirements given in Table 2 shall be defined by the customer: Table 2 Elements to be defined in the technical specification and agreed by the parties Characteristic to be defined Reference Space envelope 6.1 Spring rate 5.5 Maximum anti-roll angle or moment, for static (exceptional lo
