SIST EN 13262:2004+A2:2011

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Bahnanwendungen - Radsätze und Drehgestelle - Räder - ProduktanforderungenApplications ferroviaires - Essieux montés et bogies - Roues - Prescriptions pour le produitRailway applications - Wheelsets and bogies - Wheels - Product requirements45.040Materiali in deli za železniško tehnikoMaterials and components for railway engineeringICS:Ta slovenski standard je istoveten z:EN 13262:2004+A2:2011SIST EN 13262:2004+A2:2011en,fr,de01-maj-2011SIST EN 13262:2004+A2:2011SLOVENSKI
STANDARD



SIST EN 13262:2004+A2:2011



EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM
EN 13262:2004+A2
March 2011 ICS 45.040 Supersedes EN 13262:2004+A1:2008English Version
Railway applications - Wheelsets and bogies - Wheels - Product requirements
Applications ferroviaires - Essieux montés et bogies - Roues - Prescriptions pour le produit
Bahnanwendungen - Radsätze und Drehgestelle - Räder - Produktanforderungen This European Standard was approved by CEN on 18 March 2003 and includes Amendment 1 approved by CEN on 23 September 2008 and Amendment 2 approved by CEN on 24 January 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.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION EUROPÄISCHES KOMITEE FÜR NORMUNG
Management Centre:
Avenue Marnix 17,
B-1000 Brussels © 2011 CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Members. Ref. No. EN 13262:2004+A2:2011: ESIST EN 13262:2004+A2:2011



EN 13262:2004+A2:2011 (E) 2 Contents Page 1 Scope .5 2 Normative references .6 3 Product definition .7 3.1 Chemical composition .7 3.1.1 Values to be achieved .7 3.1.2 Location of the sample .7 3.1.3 Chemical analysis .7 3.2 Mechanical characteristics .7 3.2.1 Tensile test characteristics .7 3.2.2 Hardness characteristics in the rim .9 3.2.3 Impact test characteristics . 10 3.2.4 Fatigue characteristics . 11 3.2.5 Toughness characteristic of the rim . 12 3.3 Heat treatment homogeneity . 13 3.3.1 Values to be achieved . 13 3.3.2 Test pieces . 13 3.3.3 Test method . 13 3.4 Material cleanliness . 13 3.4.1 Micrographic cleanliness . 13 3.4.2 Internal integrity . 14 3.5 Residual stresses . 17 3.5.1 General . 17 3.5.2 Values to be achieved . 17 3.5.3 Test piece . 18 3.5.4 Measurement methods . 18 3.6 Surface characteristics . 18 3.6.1 Surface appearance . 18 3.6.2 Surface integrity. 19 3.7 Geometric tolerances . 19 3.8 Static imbalance. 22 3.9 Protection against corrosion . 22 3.10 Manufacturer's marking . 23 Annex A (normative)
Control of the hydrogen content in the steel for solid wheels at the melting stage . 24 A.1 Sampling . 24 A.2 Analysis methods . 24 A.3 Precautions . 24 Annex B (informative)
Example of test method for the determination of fatigue characteristics. 25 B.1 Test piece . 25 B.2 Test rig . 25 B.3 Test monitoring . 25 B.4 Analysis of results . 25 Annex C (informative)
Strain gauge method for determining the variations of circumferential residual stresses located deep under the tread (Destructive method) . 26 C.1 Principle of the method . 26 C.2 Procedure . 26 C.3
Calculation of the variation of the circumferential residual stress located deep under the tread . 27 SIST EN 13262:2004+A2:2011



EN 13262:2004+A2:2011 (E) 3 Annex D (informative)
Ultrasonic method for determining the residual stresses in the rim (non-destructive method) . 32 D.1 Introduction . 32 D.2 Method of measurement . 32 D.3 Evaluation of results . 33 Annex E (informative)
Product qualification . 34 E.1 General . 34 E.2 Requirements . 34 E.3 Qualification procedure . 35 E.4 Qualification certificate . 37 E.5 Qualification file . 38 Annex F (informative)
Product delivery . 39 F.1 General . 39 F.2 Delivery condition . 40 F.3 Controls on each wheel . 40 F.4 Batch control . 40 F.5 Quality plan . 43 F.6 Allowable rectification . 43 Annex ZA (informative)
#Relationship between this European Standard and the essential requirements of Directive 2008/57/EC$ . 44
SIST EN 13262:2004+A2:2011



EN 13262:2004+A2:2011 (E) 4 Foreword This document (EN 13262:2004+A1:2008) has been prepared by Technical Committee CEN/TC 256 ―Railway applications‖, the secretariat of which is held by DIN. 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 30 September 2011 and conflicting national standards shall be withdrawn at the latest by 30 September 2011. This document includes Amendment 1 approved by CEN on 2008-09-23. This document supersedes EN 13262:2004. The start and finish of text introduced or altered by amendment is indicated in the text by tags !". #This document has been created under a mandate granted to CEN/CENELEC/ETSI by the European Commission and the European Free Trade Association and supports the essential requirements of Directive 2008/57/EC.$ #For the relationship with Directive 2008/57/EC, see informative Annex ZA, which is an integral part of 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, 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. SIST EN 13262:2004+A2:2011



EN 13262:2004+A2:2011 (E) 5 Introduction Normative documents which have been used until now in Europe for the wheel delivery (UIC leaflets, national standards) had for the main purpose, a complete definition of the delivery procedures and the wheel characteristics that were to be measured.
Product qualification was sometimes mentioned, but the procedures and the characteristics that had to be verified for the qualification were not given.
This standard addresses these requirements by:
a)
definition of all the wheel characteristics. These are either verified during the qualification or delivery of the product (see clause 3);
b)
definition of the qualification procedures (see informative annex E);
c)
definition of the delivery conditions (see informative annex F). Here, a choice is given to the supplier of
either:
- a traditional delivery procedure with a control by batch sampling as in existing documents (see F.4), or
-
a delivery procedure using quality assurance concepts (see F.5).
The standard defines the wheel product qualification, the technical approval procedure is not within the scope of this standard.
1 Scope This European Standard specifies the characteristics of railway wheels for use on European networks.
!Four steel grades, ER6, ER7, ER8 and ER9 are defined in this standard; for European freight wagon interoperability purposes only grades ER6, ER7 and ER8 are applicable. NOTE 1 Grade ER6 is not normally fit for the duty of application to freight wagons; it is normally applied in low axleload situations."
!Certain characteristics are defined according to a category 1 or a category 2. Category 1 is generally chosen when the train speed is higher than 200 km/h. Freight vehicles running at speeds lower than 200 km/h generally use wheels of Category 2."
These categories can sometimes be subdivided, depending upon the characteristics.
This standard is applicable to solid forged and rolled wheels which are made from vacuum degassed steel and have a chilled rim. They are to have already been used in commercial conditions on a European network in a significant quantity, or to have satisfied a technical approval procedure according to EN 13979-1 for their design.
!NOTE 2"
The definition of other wheels may be found in other documents, such as UIC leaflets or ISO standards.
!NOTE 3"
The technical approval procedure is not within the scope of this standard. !NOTE 4"
Rim-chilled" describes heat treatment of the rim, the aim of which is to harden the rim and to create compressive residual stresses in the rim. SIST EN 13262:2004+A2:2011



EN 13262:2004+A2:2011 (E) 6
2 Normative references The following referenced 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 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 ISO 6506-1, !Metallic materials - Brinell hardness test - Part 1: Test method (ISO 6506-1:2005)"
!Deleted text"
ISO 1101, !Geometrical Product Specifications (GPS) - Geometrical tolerancing - Tolerances of form, orientation, location and run-out"
ISO 4967:1998, Steel - Determination of content of non-metallic inclusions - Micrographic method using standard diagrams
ISO 5948:1994, Railway rolling stock material - Ultrasonic acceptance testing
ISO 6933:1986, Railway rolling stock material - Magnetic particle acceptance testing
ISO/TR 97691), Steel and iron - Review of available methods of analysis
ISO 14284:1996, !Steel and iron - Sampling and preparation of samples for the determination of chemical composition"
!ASTM E399.90:1997", Standard test method for plane-strain fracture toughness of metallic materials
1) See also CR 10261:1995 SIST EN 13262:2004+A2:2011



EN 13262:2004+A2:2011 (E) 7 3 Product definition 3.1 Chemical composition
3.1.1 Values to be achieved
The maximum percentages of the various specified elements are given in Table 1.
Table 1 — Maximum percentages of the various specified elements
Maximum content in % a Steel grade
C
Si
Mn
Pb
Sbc
Cr
Cu
Mo
Ni
V
Cr + Mo + Ni ER6 0,48
0,40 0,75 0.020 0,015 0,30 0,30 0,08 0,30 0,06 0,50
ER7
0,52 0,40 0,80 0,020 0,015 0,30 0,30 0,08 0,30 0,06 0,50 ER8
0,56 0,40 0,80 0,020 0,015 0,30 0,30 0,08 0,30 0,06 0,50 ER9
0,60 0,40 0,80 0,020 0,015 0,30 0,30 0,08 0,30 0,06 0,50 a For special applications, variations within the maximum limit of these values may be agreed.
b A maximum phosphorus content of 0,025% may be agreed at the time of enquiry and the order.
c A minimum sulfur content may be agreed at the time of enquiry and the order according to the steelmaking process in order to safeguard against hydrogen cracking.
3.1.2 Location of the sample
The sample for determining the chemical composition shall be taken 15 mm below the tread at its nominal diameter.
3.1.3 Chemical analysis
This chemical composition analysis shall be performed according to the methods and requirements described in ISO/TR 9769.
3.2 Mechanical characteristics
3.2.1 Tensile test characteristics
3.2.1.1 Values to be achieved
Rim and web characteristics are given in Table 2.
SIST EN 13262:2004+A2:2011



EN 13262:2004+A2:2011 (E) 8
Table 2 — Rim and web characteristics of the wheels Steel grade Rim Web
ReH (N/mm2) a Rm (N/mm2) A5%
Rm reduction (N/mm2)
b A5% ER6
500 780/900
15
100
16 ER7
520 820/940
14
110
16 ER8
540 860/980
13
120
16 ER9
580 900/1050
12
130
14 a If no distinctive yield strength is present, the proof stress Rp0,2 shall be determined.
b Reduction of tensile strength as compared to tensile strength of the rim on the same wheel
3.2.1.2 Location of test pieces
The test pieces shall be taken from the rim and the web of the wheel. Their positions are indicated in figure 1.
Key 1
Tensile test piece 2
Tensile test piece 3
Impact test piece 4
Nominal diameter 5
Notch
SIST EN 13262:2004+A2:2011



EN 13262:2004+A2:2011 (E) 9 Figure 1 — Location of test pieces 3.2.1.3 Test method
The test shall be carried out in accordance with EN 10002-1.
The test piece diameter shall be at least 10 mm in the parallel length and the gauge length shall be 5 times the diameter.
If the test piece cannot be taken from the web, a smaller diameter shall be agreed between the customer and the supplier.
3.2.2 Hardness characteristics in the rim
3.2.2.1 Values to be achieved
The minimum Brinell hardness values applicable to the whole wear zone of the rim shall be equal to or greater than the values given in Table 3. These values are to be achieved up to a maximum depth of 35 mm under the tread, even if the wear depth is greater than 35 mm.
In the rim-web transition (point A in Figure 2), hardness values should be at least 10 points less than the wear limit values.
Table 3 — Values to be achieved for hardness characteristics in the rim
Minimum Brinell hardness value
Steel grade
Category 1 Category 2 ER6
- 225 ER7
245 235 ER8
245 245 ER9
- 255
3.2.2.2 Location of readings Four readings are carried out on a radial section of the rim as shown in Figure 2. SIST EN 13262:2004+A2:2011



EN 13262:2004+A2:2011 (E) 10
Key 1
Limit of wear or last turning diameter (according to customer's requirements) 2
Inside surface of finished wheel 3
Nominal diameter
Figure 2 — Readings taken on a radial section of the rim 3.2.2.3 Test method
The test shall be performed in accordance with EN ISO 6506-1. The ball diameter is 5 mm.
3.2.3 Impact test characteristics
3.2.3.1 Values to be achieved
They are shown in Table 4. For each temperature, they represent the average value and the minimum value for the three test pieces defined in 3.2.3.2. At +20°C, U-notch specimens shall be used. At -20°C, V-notch specimens shall be used. SIST EN 13262:2004+A2:2011



EN 13262:2004+A2:2011 (E) 11
Table 4 — Values to be achieved for impact test characteristics
Steel grade KU (in joules) at + 20C KV (in joules) at - 20C
Average values Minimum values Average values Minimum values ER6
17 12 12
8 ER7
17 12 10 7 ER8
17 12 10
5 ER9
13
9
8
5
3.2.3.2 Location of the test pieces
The positions of the three test pieces are indicated in Figure 1. The bottom notch axis shall be parallel to the
A-A axis of Figure 1.
3.2.3.3 Test method
The test shall be performed in accordance with EN 10045-1.
3.2.4 Fatigue characteristics
3.2.4.1 Values to be achieved
Independent of the steel grade, the web shall withstand the stress variation
given by Table 5 during 107 cycles without any crack initiation, with a probability of 99,7%.
Table 5 — Values to be achieved for fatigue characteristics
State of delivery of the web
N/mm2 Machined
450 As rolled
315
NOTE The aim of these characteristics is to guarantee that product characteristics are higher than those used for the definition of permissible stresses for the fatigue design of the web. As there are many approximations in a fatigue calculation, it is not realistic to distinguish between the four steel grades.
3.2.4.2 Test pieces for fatigue test
Test pieces shall consist of wheels as delivered. Their surface appearances are those defined in 3.6.
3.2.4.3 Test method
The test method shall allow bending stresses to be created in a web section.
SIST EN 13262:2004+A2:2011



EN 13262:2004+A2:2011 (E) 12 The tests to demonstrate the fatigue properties shall be performed in such a manner that statistical evaluation to assess the results can be applied.
The tests are monitored by measuring the radial stresses that exist in the crack initiation area.
An example of the method is given in the informative annex B.
3.2.5 Toughness characteristic of the rim
3.2.5.1 General
This characteristic need only be verified on tread braked wheels (service brake or parking brake), for
category 1 or category 2. 3.2.5.2 Values to be achieved
For wheels of steel grade ER6, the average value obtained from six test pieces shall be greater than or equal to 100 N/mm2 m, and no single value shall be less than 80 N/mm2 m.
For wheels of steel grade ER7, the average value obtained from six test pieces shall be greater than or equal to 80 N/mm2m, and no single value shall be less than 70 N/mm2 m.
For wheels of other steel grades, the values to be achieved are to be agreed between the customer and the supplier.
3.2.5.3 Location of test pieces
Six test pieces shall be taken from the rim as indicated in Figure 3.
The test pieces shall be evenly distributed around the rim.
Key 1 Nominal diameter Figure 3 — Test pieces taken from the rim 3.2.5.4 Test method
The test shall be performed according to ASTM E399.90. SIST EN 13262:2004+A2:2011



EN 13262:2004+A2:2011 (E) 13
The particular conditions which shall be used are as follows:
- compact tensile test pieces: 30 mm thick (CT 30), with chevron notch with aperture angle of 90° (Figure 4 of !ASTM E399.90:1997)";
- temperature during the test to be between +15 °C and +25 °C;
- measurement of the crack displacement of the test piece (Figure 3 of !ASTM E399.90:1997");
- rate of increase of stress intensity K/s should be within the range from 0,55 N/mm2 m/s to
1 N/mm2 m/s (8.3 of !ASTM E399.90:1997").
The value of the toughness to be considered is the value KQ which is calculated from the value of the load FQ from the load-displacement record.
3.3 Heat treatment homogeneity
3.3.1 Values to be achieved
For category 1 wheels, the hardness values which are measured on the rim shall be no greater than 30 HB.
3.3.2 Test pieces
The hardness measurement shall be undertaken at three points equally distributed on the outside surface of the rim. The impressions shall be made on the same diameter in the area located as defined in Figure 8.
3.3.3 Test method
The test shall be performed according to EN ISO 6506-1. The ball diameter is 10 mm.
3.4 Material cleanliness
3.4.1 Micrographic cleanliness
3.4.1.1 Level to be achieved
It shall be measured by micrographic examination as defined in 3.4.1.2.
The values to be achieved are given in Table 6.
Table 6 — Level to be achieved for micrographic examination
Type of inclusions Category 1
Category 2
Thick series (maximum) Thin series (maximum) Thick series (maximum) Thin series (maximum) A (Sulfur)
1,5 1,5 1,5 2 B (Aluminate)
1 1,5 1,5 2 C (Silicate)
1 1,5 1,5 2 D (Globular oxide)
1 1,5 1,5 2 B + C + D
2 3 3 4 SIST EN 13262:2004+A2:2011



EN 13262:2004+A2:2011 (E) 14 3.4.1.2 Location of the micrographic sample
The examination field is situated in the shaded area of Figure 4. Its centre "F" is situated 15 mm below the tread.
Key 1 Nominal rolling circle Figure 4 — Location of the micrographic sample
3.4.1.3 Test method
Determination of the level of cleanliness shall be made in accordance with the requirements of
ISO 4967:1998, method "A".
3.4.2 Internal integrity
3.4.2.1 General Internal integrity shall be defined from ultrasonic examination. Standard defects are flat-bottom holes with different diameters.
3.4.2.2 Level to be achieved
3.4.2.2.1 Rim
The rims shall have no internal defects which give echo magnitudes higher than or equal to those obtained for a standard defect situated at the same depth.
The diameter of this standard defect is given in Table 7. SIST EN 13262:2004+A2:2011



EN 13262:2004+A2:2011 (E) 15
Table 7 — Diameter of standard defect
Category 1
Category 2 Diameter of the standard defect (mm)
1
2
3
There shall be no attenuation of the back echo greater than or equal to 4 dB during axial examination.
3.4.2.2.2 Web
The web shall not have:
- more than 10 echoes with magnitudes greater than or equal to those obtained for standard
defects of ø 3 mm;
- echoes with magnitudes greater than or equal to those obtained for standard defects of
ø 5 mm.
The distance between two acceptable defects shall be at least 50 mm.
3.4.2.2.3 Hub
The hub shall not have:
- more than 3 echoes with magnitudes greater than or equal to those obtained for standard
defects of ø 3 mm;
- echoes with magnitudes greater than or equal to those obtained for standard defects of
ø 5 mm.
The distance between two acceptable defects shall be at least 50 mm.
For one circumferential examination, no attenuation of the back echo equal to or greater than 6 dB is permitted.
3.4.2.3 Test piece
Examination shall be made of the complete wheel, after heat treatment, either before machining or in the finish machined condition, before corrosion protection is applied.
3.4.2.4 Methods of examination
3.4.2.4.1 General
The general conditions for ultrasonic examination are given by ISO 5948 in accordance with the following special conditions:
3.4.2.4.2
Rim
The rim examination shall be made according to the D1 and D2 methods of Table 1 of ISO 5948:1994.
SIST EN 13262:2004+A2:2011



EN 13262:2004+A2:2011 (E) 16 Defect estimation shall be made by comparison to artificial defects in the standard rim described by Figures 1 and 2 of !ISO 5948:1994".
3.4.2.4.3 Web
The web examination shall be made from its two faces. The direction of the examination is perpendicular to the surface.
Defect estimation shall be made by comparison to artificial defects in a standard web.
The web is defined as the part of the wheel between the two diameters where ―m‖ and ―n‖ are defined in Figure 7.
The thickness ―e‖ of the web is defined as:
e =
The location of the artificial defects is given as a function of ―e”. They shall be at least 100 mm apart in a cicumferential orientation.
- e
10 mm
- one 3 mm diameter flat bottom hole located 5 mm below the inner surface of the web
- one 5 mm diameter flat bottom hole located 5 mm below the inner surface of the web
- 10 mm
e
20 mm
- two 3 mm diameter flat bottom holes located 5 mm and (e - 5) mm below the inner surface
of the web
- two 5 mm diameter flat bottom holes located 5 mm and (e - 5) mm below the inner surface
of the web
- e
20 mm
- three 3
...