SIST EN 13260:2004

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Railway applications - Wheelsets and bogies - Wheelsets - Products requirementsApplications ferroviaires - Essieux montés et bogies - Essieux montés - Prescriptions pour le produitBahnanwendungen - Radsätze und Drehgestelle - Radsätze - ProduktanforderungenTa slovenski standard je istoveten z:EN 13260:2003SIST EN 13260:2004en45.040ICS:SLOVENSKI
STANDARDSIST EN 13260:200401-junij-2004







EUROPEAN STANDARDNORME EUROPÉENNEEUROPÄISCHE NORMEN 13260June 2003ICS 45.040English versionRailway applications - Wheelsets and bogies - Wheelsets -Products requirementsApplications ferroviaires - Essieux montés et bogies -Essieux montés - Prescriptions pour le produitBahnanwendungen - Radsätze und Drehgestelle -Radsätze - ProduktanforderungenThis European Standard was approved by CEN on 13 February 2003.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 references concerning such nationalstandards may be obtained on application to the 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 into its own language and notified to the Management Centre has the same status as the officialversions.CEN members are the national standards bodies of Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece,Hungary, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Slovakia, Spain, Sweden, Switzerland and UnitedKingdom.EUROPEAN COMMITTEE FOR STANDARDIZATIONCOMITÉ EUROPÉEN DE NORMALISATIONEUROPÄISCHES KOMITEE FÜR NORMUNGManagement Centre: rue de Stassart, 36
B-1050 Brussels© 2003 CENAll rights of exploitation in any form and by any means reservedworldwide for CEN national Members.Ref. No. EN 13260:2003 E



EN 13260:2003 (E) 2 Contents Page Foreword.4 Introduction.5 1 Scope.5 2 Normative references.6 3 Product definition.6 3.1 Assembly of components.6 3.1.1 General.6 3.1.2 Interference between axle wheelseat and wheel hub bore.6 3.1.3 Press-fitting diagram.7 3.2 Wheelset characteristics.7 3.2.1 Mechanical resistance of the assemblies.7 3.2.2 Fatigue characteristics.8 3.2.3 Electrical resistance.9 3.2.4 Imbalance.9 3.2.5 Dimensions and tolerances.9 3.2.6 Residual stresses.14 3.2.7 Protection against corrosion and impacts.14 3.2.8 Marking.14 Annex A (normative)
Characteristics of the press-fitting curve.15 Annex B (normative)
Fatigue characteristics for a wheelset with an axle of steel grade EA1T or EA4T.17 Annex C (informative)
Drawing of the test piece for fatigue tests.18 Annex D (informative)
Documents for the identification of wheelset components.19 Annex E (informative)
Product qualification.23 E.1 General.23 E.2 Requirements.23 E.2.1 Requirements to be met by the supplier.23 E.2.2 Qualification of personnel.23 E.2.3 Requirements to be met by the product.23 E.3 Qualification procedure.24 E.3.1 General.24 E.3.2 Documentation required.24 E.3.3 Evaluation of the manufacturing installations and processes.24 E.3.4 Laboratory tests.25 E.3.5 Testing of finished products.25 E.4 Qualification certificate.25 E.4.1 Condition of validity.25 E.4.2 Modification and extension.25 E.4.3 Transference.26 E.4.4 Lapsed certification.26 E.4.5 Cancellation.26 E.5 Qualification file.26 Annex F (informative)
Product delivery.27 F.1 General.27 F.2 Specific verifications.27 F.3 Optional checks.28 F.3.1 Dimensional check.28



EN 13260:2003 (E) 3 F.3.2 Ultrasonic examination.28 F.4 Allowable rectifications.28 F.5 Documents.29 F.5.1 Shrink-fitting.29 F.5.2 Press-fitting.29 F.5.3 Components.29 F.6 Quality plan.30 F.6.1 General.30 F.6.2 Objectives.30 F.6.3 Validity.30 Annex ZA (informative)
Clauses of this European Standard addressing essential requirements or other provisions of EU Directives.31 Bibliography.32



EN 13260:2003 (E) 4 Foreword This document EN 13260:2003 has been prepared by Technical Committee CEN/TC 256 “Railway applications”, the secretariat of which is held by AFNOR. This European Standard shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by December 2003, and conflicting national standards shall be withdrawn at the latest by December 2003 This document has been prepared under a mandate given to CEN by the European Commission and the European Free Trade Association and supports essential requirements of EU Directive(s). For relationship with EU Directive(s), see informative annex ZA which is an integral part of this document Annexes A and B are normative.
Annexes C, D, E and F are informative This document contains a bibliography. According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Slovakia, Spain, Sweden, Switzerland and the United Kingdom.



EN 13260:2003 (E) 5 Introduction The main purpose of normative documents used until now for the delivery of wheelsets (UIC leaflets, national standards) was a complete definition of the acceptance procedures and of the wheelset characteristics which were to be verified. Product qualification was sometimes mentioned but the procedures used and the product characteristics to be verified during qualification were not given. This standard addresses these points by: a) definition of all the wheelset characteristics that are assembly characteristics and finished product characteristics and do not arise from a choice of design parameters such as diameters, interferences, materials etc. They are verified during either qualification or delivery of the product (see clause 3); b) definition of qualification procedures (see informative annex E); c) definition of delivery conditions (see informative annex F).
They are based on quality assurance concepts.
1 Scope This European Standard specifies the characteristics of new wheelsets for use on European networks: This standard is applicable to wheelsets comprising elements that conform to the following European Standards: - prEN 13262 for wheels; - prEN 13261 for axles; - EN 12080 for axlebox rolling bearings. This standard is not applicable to repaired wheelsets. Some characteristics are given as a function of a category 1 or of a category 2.
These categories can sometimes be divided according to the characteristics defined.
Category 1 is generally chosen when the operating speed exceeds 200 km/h.
The wheelset then comprises wheels and axle of category 1 as specified in prEN 13262 for the wheels and prEN 13261 for the axles.



EN 13260:2003 (E) 6 2 Normative references This European Standard incorporates by dated or undated reference, provisions from other publications. These normative references are cited at the appropriate places in the text and the publications are listed hereafter. For dated references, subsequent amendments to or revisions of any of these publications apply to this European Standard only when incorporated in it by amendment or revision. For undated references the latest edition of the publication referred to applies (including amendments). EN 13103, Railway applications – Wheelsets and bogies – Non-powered axles – Design method. EN 13104, Railway applications – Wheelsets and bogies – Powered axles – Design method. prEN 13261 Railway applications – Wheelsets and bogies – Axles – Product requirements. prEN 13262 Railway applications – Wheelsets and bogies – Wheels – Product requirements.
3 Product definition 3.1 Assembly of components 3.1.1 General Before being assembled, all elements which comprise the wheelset shall meet the geometric requirements of the documents which define them.
In particular, the wheels and the axle shall be in the "ready for assembly" state
defined in prEN 13262 for the wheels and prEN 13261 for the axle. The elements comprising the wheelset may be shrink-fitted or press-fitted.
The interferences to be used for fitting shall be defined by the designer of the element to be fitted and are a function of the characteristics of the element material and the forces and torque to be transmitted by the fitting.
This interference shall be defined according to the geometric tolerances of the axle seats specified in prEN 13261. For the wheel fittings, unless otherwise specified by the wheel designer, the interference values to be used are given in 3.1.2.
In the case of shrink-fitting, the whole wheel should be heated and its temperature shall not exceed 250 °C.
If a different heating method is used, proof shall be provided that there has been no effect on the wheel characteristics as defined in prEN 13262. If a different fitting method is used, this shall be the subject of an agreement between the customer and the supplier.
In this agreement, the supplier shall demonstrate at least that the axle and wheel characteristics as defined in prEN 13261 and prEN 13262 are not modified by the fitting.
Then, the mechanical resistance of the assembly (see 3.2.1) shall be demonstrated and the traceability documents for each fitting shall be defined so as to give the same type of information as specified in F.5.
The static imbalance of the two wheels of each wheelset shall be within the same diametric plane and on the same side of the axle.
The static imbalance of the gearwheels and brake discs shall be in the same plane as those of the wheels, but on the opposite side of the axle. 3.1.2 Interference between axle wheelseat and wheel hub bore Unless otherwise specified by the wheel designer, the interference values "s" to be adhered to are, in mm:



EN 13260:2003 (E) 7 - for shrink-fitting:
0,0009 dm ≤ j ≤ 0,0015 dm - for press-fitting:
0,0010 dm ≤ j ≤ 0,0015 dm + 0,06 where dm is the mean diameter in mm.
3.1.3 Press-fitting diagram 3.1.3.1 Results to be achieved For press fitting, the force-displacement curve gives confidence that the fitting has not damaged the contact surfaces and that the specified interference has been effective. The shape of the curve to be obtained is defined in normative annex A. The final fitting force, in MN, is a function of the force F defined in 3.2.1 and shall be within the range: 0,85 F < final fitting force < 1,45 F 3.1.3.2 Measurement methods The press used for the assemblies shall have a calibrated system to plot the diagram of the force value at each position of the element to be fitted obtained during the displacement of the latter on the axle. The abscissa scale of displacement shall be at least equal to 0,5 times the actual displacement of the element to be fitted.
The ordinate scale of force shall allow the force to be read at each point of the curve with an accuracy of 0,025 MN.
The accuracy of the force sensor shall be 0,01 MN.
The abscissae and ordinates may be reversed. In the case of point recording, at least one point shall be plotted per millimetre of relative displacement of the elements to be fitted and per 0,025 MN variation in force.
3.2 Wheelset characteristics 3.2.1
Mechanical resistance of the assemblies 3.2.1.1 Results to be achieved In order to be able to transmit forces and torques between the fitted elements, the assemblies shall be capable of withstanding an axial force F for 30 s without there being any displacement between one element and another. This force F shall be defined by the designer of the element to be fitted. For wheels, unless otherwise specified by the designer, the value of the force F in MN is: F = 4
. 10-3 dm when
0,8 dm < L< 1,1 dm where dm is the mean diameter of the seat in mm and L is the length of the fitting in mm.



EN 13260:2003 (E) 8 3.2.1.2 Test method The test shall be carried out on a press equipped with a device to record forces. The force is applied gradually up to F between one of the faces of the fitted component hub and the axle.
The test shall be carried out at least 48 h after fitting. 3.2.2 Fatigue characteristics 3.2.2.1 General The rotational bending fatigue limit values for 107 cycles are defined here.
These values are used to calculate the maximum permissible axle seat stresses and are required for application of EN 13103 and EN 13104.
These fatigue characteristics are not the same for a solid axle as for a hollow axle.
This is the result of the axle bore effect on stress distribution.
For a solid axle, only one fatigue limit (F3) shall be determined under the fitting areas. For a hollow axle, given that the fitting effect is greater on the journals than on the other fittied areas because of the different metal thicknesses, two fatigue limits shall be determined: - under the fitted parts , except for journals, limit F4, - under fitted parts of the journal, limit F5
NOTE The fatigue characteristics F1 and F2 of the axle are defined in prEN 13261. 3.2.2.2 Values to be achieved The minimum values for wheelsets using an axle of EA1N grade steel are given in Table 1. Table 1 — Minimum values for wheelsets with an axle made of EA1N steel Fatigue limit F3 F4 F5 N/mm2 120 110 94
For other steel grades, the values are given in normative annex B. 3.2.2.3 Fatigue test specimens The area of the test piece where the crack initiates shall have the same geometry, environment and surface condition as the axle under consideration. For the fatigue testing of the wheelsets, one wheel or test piece with similar dimensions (particularly the hub) shall be press-fitted or shrink-fitted on the wheel seat.
The interference shall meet the requirements of 3.1.2.
For testing in the journal area, the corresponding inner ring of a bearing shall be mounted. It is not mandatory to use a wheelset as the test piece.
Examples of test pieces are given in informative annex C.



EN 13260:2003 (E) 9 3.2.2.4 Test method The tests shall be carried out on machines capable of creating rotating bending stresses in the area where it is required to initiate a crack. For each limit, F3, F4 and F5, it shall be verified on three specimens that no crack has appeared after 107 cycles of a load creating a surface stress equal to F3, F4 or F5. These stress levels shall be calculated on the seat, in accordance with the beam theory, disregarding the interference stresses. 3.2.3 Electrical resistance The electrical resistance of each wheelset measured between the treads of the two wheels shall not exceed 0,01 Ω. The means and method used for this measurement shall be defined in agreement between the customer and the supplier. 3.2.4 Imbalance
3.2.4.1 Values to be achieved For a non-powered wheelset capable of running at a speed of greater than 120 km/h, a maximum dynamic imbalance shall be specified. The maximum values are given in Table 2. They are measured in the plane of the wheels. Table 2 — Maximum imbalance values Speed (km/h) Maximum imbalance x measuring plane (g.m) 120 < V ≤ 200 V > 200 75 50
3.2.4.2 Test piece The imbalance is measured on a fully assembled and machined wheelset. 3.2.4.3 Test method The customer and the supplier shall agree the means of measurement. 3.2.5 Dimensions and tolerances 3.2.5.1 General The dimensions of the wheelset shall be in accordance with the design drawings and the dimensional and geometric tolerances to be applied when assembling the different parts of the wheelset are given in the following subclauses:
They are dependent on the category of the wheelset.



EN 13260:2003 (E) 10 The values are given for a measurement with no load on the wheelset. 3.2.5.2 Wheels The tolerances of the parameters defined in Figure 1 shall be those given in Table 3.
Figure 1 — Wheel parameters



EN 13260:2003 (E) 11 Table 3 — Tolerances on wheel parameters Description Symbol Category b mm Category a Mm
a b
Distance between internal wheel faces1) a1 + 2 b 0 + 2 b 0 Difference in distances between the internal face of each wheel and the plane on the journal side defining the corresponding bearing collar c – c1 or c1 - c ≤ 1 ≤ 1 Difference in tread circle diameter d – d1 or d1 – d
≤ 0,5
≤ 0,3 ≤ 0,3 Radial deviation in tread circle
h
≤ 0,5
≤ 0,3
≤ 0,3 Axial deviation of the internal wheel face a
g
≤ 0,8
≤ 0,5
≤ 0,3 a Measurement at 60 mm beneath the top of the flange b The tolerances may be changed for special designs of wheelsets
3.2.5.3 Brake discs 3.2.5.3.1 General The tolerances on the parameters defined in Figures 2 and 3 shall be those required in Tables 4, 5 and 6. Table 4 — Axial deviation of the internal face Description Symbol Category 2 a
mm Category 2 b
mm Category 1
mm Axial deviation of the internal face1) g1 ≤ 0,75 ≤ 0,5 ≤ 0,5 1) See Figures 2 and 3.
Measurements at 30 mm from the external diameter



EN 13260:2003 (E) 12 3.2.5.3.2 Single-seat axle for one or two brake discs
Figure 2 — Single-seat axle for one or two brake discs Table 5 — Tolerances for single-seat axles for one or two brake discs Description Symbol Category 1 and 2 mm Distance between the internal face of the disc crown and the plane on the journal side defining the corresponding bearing collar f ≤ 0,5
3.2.5.3.3 Double-seat axles for two or four brake discs
Figure 3 — Double-seat axles for two or four brake discs



EN 13260:2003 (E) 13 Table 6 — Tolerances for double-seat axles for two or four brake discs Description Symbol Category 1 and 2 mm
Distance between the internal faces of the disc crowns
a3
± 0,5 Difference in distances between the internal face of each disc and the plane on the journal side defining the corresponding bearing collar
f – f1 or f1 - f
≤ 1
3.2.5.3.4 More than two seats If there are more than two seats for the brake discs, the tolerances on the dimensions such as a3 or f – f1 (see Figure 3) are the same as in 3.2.5.3.3. 3.2.5.4 Cylindrical gear wheels for motor axle, reducing gears etc. The tolerances of the parameters defined in Figure 4 are given in Table 7. Table 7 — Tolerances for cylindrical cog wheels for motor axle, reducing gears etc. Description Symbol Category 2 mm Category 1 mm
Radial deviation a
h1
b
b
Axial deviation a
g2
b
b Distance between the lateral reference surface of the gear wheel and the plane on the journal side defining the corresponding bearing collar a
c2
± 0,5
± 025 a See Figure 4. b In accordance with the specifications of the designer.
Figure 4 – Cylindrical gear wheels for motor axle, reducing gears etc.



EN 13260:2003 (E) 14
3.2.6 Residual stresses 3.2.6.1 General The different manufacturing operations leading to a "ready to assemble" state for the axle shall not create residual stresses likely to facilitate fatigue crack initiation. 3.2.6.2 Values to be achieved On the axle seats at a depth of 0,1 mm below the surface, the residual stresses shall be ≤ 100 N/mm2 in tension. 3.2.6.3 Test piece and position of the measuring points The test piece is the axle in the "ready to assemble" state.
The measuring points are located at the centre and at one end of the seats.
On each circumference, two points are measured at 120°. 3.2.6.4 Measurement method The measurements can be made either with conventional gauges or by X-ray diffraction. 3.2.7 Protection against corrosion and impacts The wheelset components shall be protected according to the requirements of their relevant standards. Cavities arising from the overhang of the wheel hub on the wheelseats shall be filled with an anticorrosion product. 3.2.8 Marking The constituent parts of the wheelsets shall be marked according to the relevant standards. The wheelset shall be identified by as a minimum by the following marks (in accordance with the purchase order): -- type of wheelset; - serial number; -
assembler's marks; - date of assembly; - owner's marks. These marks shall be located at the end of the journal which already bears the axle marks defined in
EN 13261 and be below the latter marks. At the other end of the journal, one half the surface shall be free of any marks.
It is reserved for maintenance identification.
The other half of this surface is free for any other marking. The marks shall be stamped.
Any protruding burrs resulting from the stamping shall be levelled to allow ultrasonic examination to be carried out in service.



EN 13260:2003 (E) 15 Annex A (normative)
Characteristics of the press-fitting curve The characteristics of the press-fitting curve are described in Figure A.1.
The fitting force shall start to increase before the wheelseat displacement on to the wheel hub reaches 30 mm.
The force shall then increase continuously without falling outside the limit curve values given by the curves stated
by the designer of the component to be fitted. Nevertheless, the following cases are permitted: - a reduction in the fitting force at a location of the groove for removal by oil injection .
The maximum force reached prior to the groove shall be reached again within a further displacement of 25 mm.
During this decrease, the fitting force value may be lower than that defined by the lower curve. - a maximum decrease of 5 MN over the last 25 mm of displacement; - curves showing local deviation if previously agreed between the customer and supplier, or on qualification of the product.



EN 13260:2003 (E) 16
NOTE
- AB, BC, HE and ED are portions of a straight line, AG is equal to the length of the seat; - for the wheels, the positions of the different points are as follows:
YH = 1,3 ∅; Yc = 0,85; YD = YE = 1,45 F,
∅ = nominal diameter of the wheelseat, in metres
F = fitting force specified by the designer of the component to be fitted (wheel, disc, gearwheel, etc.) Key x
Distance in mm y
Fitting force F (mN)
Figure
A.1 - Characteristics of the press-fitting curve



EN 13260:2003 (E) 17 Annex B (normative)
Fatigue characteristics for a wheelset with an axle of steel grade EA1T or EA4T
The fatigue characteristics for a wheelset with an axle of steel grade EA1T or EA4T are defined in Table B.1. Table B.1 Minimum stress values in N/mm2 Grade F3 F4 F5 EA1T 120 110 94 EA4T 144 132 113



EN 13260:2003 (E) 18 Annex C (informative)
Drawing of the test piece for fatigue tests The drawing of the test piece for fatigue tests is shown in Figure C.1.
Key 1
Centre-to-centre distance of journals 2000 2
Rounded edge
Figure C.1 — Drawing of the test piece for fatigue tests



EN 13260:2003 (E) 19 Annex D (informative)
Documents for the identification of wheelset components Two documents are given in this informative annex:
- Figure D.1 shows the document to be used for a single wheelset, usually of category 1 or a powered
wheelset
-
Figure D.2 shows the document that may be used for a number of wheelsets.
For these two documents, a summary of the information contained therein is given in Figure D.1.



EN 13260:2003 (E) 20
Type 22 Order number 4 Wheelset Ownership mark
1- Constituent elements
Axle LH wheel RH wheel Axle box bearings LH RH Drawings 34
Type 30 Wheel ref.
36 36 Supplier 41 Supplier 35 37 37 Serial no. 42 42 Grade 7 11 11 Date of manufacture 43 43 Cast no. /order no. 5/6 9 9 Assembly date 44 Delivery date 8 10 10
Wheel dia.
14 14
...