EN 13749:2011

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.YBahnanwendungen - Radsätze und Drehgestellte - Spezifikationsverfahren für Festigkeitsanforderungen an DrehgestellrahmenApplications ferroviaires - Essieux montés et bogies - Méthode pour spécifier les exigences en matière de résistance des structures de châssis de bogieRailway applications - Wheelsets and bogies - Method of specifying the structural requirements of bogie frames45.040Materiali in deli za železniško tehnikoMaterials and components for railway engineeringICS:Ta slovenski standard je istoveten z:EN 13749:2011SIST EN 13749:2011en,fr,de01-oktober-2011SIST EN 13749:2011SLOVENSKI
STANDARDSIST EN 13749:20051DGRPHãþD

EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM
EN 13749
March 2011 ICS 45.040 Supersedes EN 13749:2005English Version
Railway applications - Wheelsets and bogies - Method of specifying the structural requirements of bogie frames
Applications ferroviaires - Essieux montés et bogies - Méthode pour spécifier les exigences en matière de résistance des structures de châssis de bogie
Bahnanwendungen - Radsätze und Drehgestelle - Festlegungsverfahren für Festigkeitsanforderungen an Drehgestellrahmen This European Standard was approved by CEN on 26 February 2011.
CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the CEN-CENELEC 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 translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC Management Centre has the same status as the official versions.
CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.
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Symbols and units used in the informative annexes . 13A.1Forces . 13A.2Accelerations . 13A.3Masses . 14A.4Other symbols and units . 14A.5Co-ordinate system . 14A.6Bogie classification . 16Annex B (informative)
Load cases . 17Annex C (informative)
Loads due to bogie running . 19C.1General . 19C.2Examples of loads for bogies of passenger rolling stock - categories B-I and B-II . 20C.2.1Exceptional loads . 20C.2.2Normal service loads . 21C.3Examples of loads for freight bogies with a central pivot and two sidebearers - category B-V . 21C.3.1Bogie types . 21C.3.2Relationship of vertical forces . 21C.3.3Exceptional loads . 22C.3.4Normal service loads . 23C.4Examples of loads for bogies of locomotives (with two bogies) - category B-VII . 23C.4.1Exceptional loads . 23C.4.2Normal service loads . 24C.5Examples of loads for bogies of metro, rapid transit, light rail vehicles and trams - categories B-III and B-IV . 25C.5.1Application . 25C.5.2Load cases . 25C.5.3General expressions for the basic load cases . 26Annex D (informative)
Loads due to components attached to the bogie frame . 27D.1General . 27D.2Component inertia loads . 27SIST EN 13749:2011

Analysis methods and acceptance criteria. 30E.1General . 30E.2Loads . 30E.3Analysis and acceptance . 30E.4Structural acceptance criteria . 30E.4.1Principle . 30E.4.2Utilisation . 31E.4.3Safety factor . 31E.4.4Material strength . 32E.4.4.1Requirement . 32E.4.4.2Static strength . 33E.4.4.3Fatigue strength . 34E.4.4.4Stiffness criteria . 36Annex F (informative)
Examples of static test programmes . 37F.1General . 37F.2Static test programme for bogies of passenger rolling stock with body supported directly to the sideframes (categories B-I and B-II) . 38F.2.1Tests under exceptional loads . 38F.2.2Tests under normal service loads . 38F.3Static test programme for bogies with central pivot and two sidebearers (category B-V) . 40F.3.1Bogie types . 40F.3.2Tests under exceptional loads . 40F.3.3Tests under normal service loads . 40F.4Static test programme for bogies of locomotives . 42F.5Static test programme for bogies of light rail vehicles and trams . 42F.5.1General . 42F.5.2Tests under exceptional loads . 42F.5.3Tests under normal service loads . 43Annex G (informative)
Examples of fatigue test programmes . 44G.1General . 44G.2Fatigue test programme for bogies with the body supported directly on the sideframes (categories B-I and B-II) . 45G.3Fatigue test programme for a freight bogie with a central pivot and two sidebearers (category B-V) . 48G.3.1General . 48G.3.2Vertical loads . 48G.3.3Transverse loads . 48G.4Fatigue test programme for locomotive bogies (category B-VII) . 50G.5Fatigue test programme for bogies of light rail vehicles and trams (category B-IV) . 50Annex ZA (informative)
Relationship between this European Standard and the Essential Requirements of EU Directive 2008/57/EC . 51Bibliography . 53 SIST EN 13749:2011

Changes were necessary to make the standard compatible with more recent Euronorms. Certain areas of the normative text had to be revised to make correct reference to the structural analysis and validation processes now specified in the new bogie and running gear standard EN 15827. Other new normative references are to EN 15085 and
EN 15663. The other main changes that have been made concern the informative annexes and are summarized as follows: a) to comply with CEN rules, the symbols and units have been removed from the normative text and added as informative Annex A, as they apply only to the other informative annexes; b) the old informative Annex C has been removed and reference made to EN 15663, which now covers vehicle mass data; c) the informative Annex E has been re-written to present the structural analysis and acceptance process as specified in EN 15827; d) a number of errors in the example load case equations in informative Annex C have been corrected; e) the guidance on component loads in informative Annex D has been revised to better reflect present practice; f) the limitations of the example load case data in informative Annexes C, D, F and G have been given greater emphasis and it has been stressed that the loads should be used as presented only when it can be shown that they are applicable to the specific design. This document has been prepared under a mandate given to CEN by the European Commission and the European Free Trade Association to support Essential Requirements of EU Directive 2008/57/EC. For relationship with EU Directive 2008/57/EC, see informative Annex ZA, which is an integral part this document. According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.
— Part 4: Production requirements EN 15085-5, Railway applications — Welding of railway vehicles and components — Part 5: Inspection, testing and documentation EN 15663, Railway applications — Definition of vehicle reference masses
EN 15827:2011, Railway applications — Requirements for bogies and running gear 3 Terms and definitions For the purposes of this document, the terms and definitions given in EN 15827:2011 and the following apply. NOTE Annex A identifies the symbols, units, co-ordinate system and bogie categories used in the informative annexes to this European Standard. 3.1 axlebox assembly comprising the box housing, rolling bearings, sealing and grease 3.2 bogie frame load-bearing structure generally located between primary and secondary suspension 3.3 bolster transverse load-bearing structure between vehicle body and bogie frame 3.4 static force force which is constant with time NOTE Force due to gravity is an example of static force. SIST EN 13749:2011

3.11 sideframe longitudinal structural member of the bogie frame 3.12 primary suspension suspension system consisting of the resilient elements (and associated connecting and locating parts) generally located between the axlebox and bogie frame 3.13 secondary suspension suspension system consisting of the resilient elements (and associated connecting and locating parts) generally located between the bogie frame and vehicle body or bolster 3.14 track testing performing of tests under expected service conditions, on railway infrastructure that represents the actual operating environment, and monitoring and recording the responses 3.15 validation process of demonstrating by analysis and/or test that the system under consideration meets in all respects the technical specification, including requirements due to regulations, for that system
3.16 verification process of demonstrating by comparison or testing that an analytical result or estimated value is of an acceptable level of accuracy SIST EN 13749:2011

The technical specification shall also identify all appropriate mandatory regulations and define the parts of the validation and acceptance procedure (Clause 6) and the quality requirements (Clause 7), which are specifically required, and the way in which evidence to show that the requirements have been met is to be provided. NOTE If the customer is unable to define the technical specification completely the supplier may propose a technical specification and submit it to the customer (and the approval authority where relevant) for agreement. 4.2 General requirements The technical specification shall indicate the type of bogie required in terms of its use. It shall also indicate the intended life of the bogie, its average annual distance run and its total distance run and all the information that is applicable to a bogie frame associated with the Essential Requirements of a TSI as indicated in EN 15827. Information that is particularly relevant to bogie frame design is indicated in the following clauses. 4.3 Design load cases The technical specification for the bogie frame shall consist primarily of the load cases required for the design of the bogie as specified in EN 15827, plus any additional load cases required by that standard or arising from the application. The load cases shall be based on the vehicle mass states given in EN 15663. However, for some applications and fatigue assessment methods it will be necessary to use additional vehicle loading conditions (expressed as functions of the cases in EN 15663) to obtain an accurate description of the vehicle payload spectrum for design purposes. The development of the design load cases is discussed in Annex B and examples of design load cases associated with bogie running and due to the attachment of equipment are given in Annexes C and D respectively. NOTE If it is proposed to use the endurance limit approach to fatigue strength assessment the data on the number of events is not required and only the extreme repetitive load conditions need to be defined. 4.4 Vehicle conditions and interfaces The technical specification shall also include the following information from the requirements of EN 15827 interpreted for applicability to the bogie frame:  vehicle body interfaces and clearances;  gauge reference profile and bogie movement envelope;  suspension geometry and attachments;  interfaces to traction and braking systems and all other attached equipment;  electrical and pneumatic system connections;  environmental requirements;  maintenance requirements. SIST EN 13749:2011

and static tests, programmes for fatigue tests, routes for track tests);  the values of the different load cases;  the acceptance criteria (treatment of measured or calculated values, limiting stresses, criteria for completion of fatigue tests, etc.). 6.2 defines which parts of the validation plan should be included in any particular case. NOTE In order that the acceptance procedure is completely defined, the supplier should identify the methods of demonstrating conformance to the requirements if they are not incorporated into the technical specification. 6.2 The validation plan 6.2.1 Content The validation plan shall comprise a list of the validation steps planned to demonstrate compliance to the requirements defined in the technical specification. SIST EN 13749:2011

This will determine the scope and objectives for the laboratory and track tests. The load cases for freight wagon bogies are often based on the experience of the railways over a long period of time and these loads are generally applicable to all similar freight bogie designs. It is common practice that a freight bogie which has passed an appropriate fatigue test will not be subject to structural assessment track tests (only to those validating the dynamic behaviour). The general requirements of the individual validations records are:  definition of the validation objective;  documentation of the method applied (including its limitations);  presentation of the results;  definition of acceptance criteria;  statement of compliance. In principle the same acceptance criteria should be applied to both the design and testing phases. For example, if the endurance limit approach is used for the analytical verification of the design it shall also be applied for the testing phase. However if during testing the design cannot be verified using the basis of the endurance limit approach then a life assessment using an appropriate cumulative damage approach can be undertaken. Where the design is a development of an earlier product any previous data, or other evidence of satisfactory performance that is still applicable, can be offered as validation of the revised product. In the case of an existing design of bogie frame intended for a new application, or a modification to an existing design, a reduced programme can be used, depending on the significance of the differences.
If the differences are small, analysis, supported if necessary by measurements made during a limited test programme, will be sufficient to validate the design. Static tests and fatigue tests shall be carried out in accordance with the technical specification and applicable regulations and to a level that is considered necessary to validate the design satisfactorily. SIST EN 13749:2011

Annexes C and D does not take account of differences in the bogie suspension or the vehicle body characteristics or of load changes resulting from active suspension (e.g. tilt) systems, etc. The structural analysis shall be carried out using the validation process and acceptance criteria as required by EN 15827. Annex E gives further guidance on factors to be considered in defining an analysis programme and includes the structural acceptance criteria as specified in EN 15827. 6.2.3 Static tests The purpose of static tests is described in F.1. In addition to the general requirements for validation records in 6.2.1, laboratory static test reports shall include the following:  documentation of the test program performed including magnitudes and combinations, direction and position of the loads (nominal values and actual values that have been applied); SIST EN 13749:2011

 simplification is unavoidable in the extrapolation of the test results to the total design life of bogie and the assessment of the results has to take into account the degree to which the test program was able to represent the total real life conditions;  the design life prediction is based on a theoretical fatigue hypothesis and therefore has a level of confidence limited by the hypothesis itself (including any uncertainties in the classification of the assessed detail). 7 Quality requirements For the validation to be applicable, all manufactured bogie frames shall be of a quality consistent with the requirements of the technical specification and the assumptions and data used as the basis of the design. The bogie frame design and manufacture shall be covered by a quality plan as required by EN 15827. Welded fabrication shall be carried out in accordance with the requirements of EN 15085-1 to EN 15085-5 or to a process that gives an equivalent level of control. SIST EN 13749:2011

Symbols and units used in the informative annexes NOTE Certain symbols used in this European Standard may have a different meaning to those adopted in related standards (e.g. EN 13103, EN 13104 and EN 13979-1). A.1 Forces Table A.1 — Forces Force
(N) Position Symbol Static Quasi-Static Dynamic Vertical Load applied to bogie Fz
Force on sideframe 1 or sidebearer 1 Fz1
Fz1qs Fz1d Force on sideframe 2 or sidebearer 2 Fz2
Fz2qs Fz2d Force on centre pivot Fzp Fzpqs Fzpd Force at (vehicle body) c of g Fzc
Transverse Load applied to bogie Fy
Force on axle 1 Fy1 Fy1qs Fy1d Force on axle 2 Fy2 Fy2qs Fy2d Force at (vehicle body) c of g Fyc
Force due to wind Fw1
Longitudinal Force at each wheel Fx1
Force at (vehicle body) c of g Fxc
Force at (vehicle bogie) c of g Fx
A.2 Accelerations Table A.2 — Accelerations Acceleration (m/s2) Symbol
Vehicle body Bogie (primary spring) Vertical zca zba Transverse (dynamic) yca yba Centrifugal (quasi-static) ycca ycba Longitudinal xca xba
The values assigned to the above symbols should be based on the descriptions of the quantities in EN 15663. A.4 Other symbols and units Table A.4 — Other symbols and units Other Symbol Unit Acceleration due to gravity g 9,806 65 m/s2 Wind pressure q N/m2 Stress σ N/mm2 Determined stress cσ N/mm2 Material proof or yield stress eHR N/mm2 Material 0,2 % proof stress p0,2R N/mm2 Material ultimate stress mR N/mm2 Uncertainty factor or Factor of safety 1S
Car body surface area wA m2 Roll coefficient α
Bounce coefficient β
Adhesion or friction coefficient µ
A.5 Co-ordinate system Figure A.1 shows the co-ordinate system adopted in this European Standard. SIST EN 13749:2011

Key 1 twist 2 lozenge (shear) Figure A.1 — Co-ordinate system
Table A.5 defines movements and deformations and their directions. Table A.5 — Movements and deformations in railway bogie assemblies Direction Symbol Description Longitudinal x Linear in the direction of travel Transverse y Linear parallel to the plane of the track, perpendicular to the direction of travel Vertical z Linear perpendicular to the plane of the track Roll θx Rotation about the longitudinal axis Pitch θy Rotation about the transverse axis Yaw θz Rotation about the vertical axis Twist — Out-of-plane (x-y) movement resulting in relative rotation of the sideframes Lozenging — Shear due to relative longitudinal movement of sideframes
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