SIST EN 13262:2004

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Railway applications - Wheelsets and bogies - Wheels - Product requirementsApplications ferroviaires - Essieux montés et bogies - Roues - Prescription pour le produitBahnanwendungen - Radsätze und Drehgestelle - Räder, ProduktanforderungenTa slovenski standard je istoveten z:EN 13262:2004SIST EN 13262:2004en45.040ICS:SLOVENSKI
STANDARDSIST EN 13262:200401-september-2004







EUROPEAN STANDARDNORME EUROPÉENNEEUROPÄISCHE NORMEN 13262March 2004ICS 45.040English versionRailway applications - Wheelsets and bogies - Wheels - ProductrequirementApplications ferroviaires - Essieux montés et bogies -Roues - Prescription pour le produitBahnanwendungen - Radsätze und Drehgestelle - Räder -ProduktanforderungenThis European Standard was approved by CEN on 18 March 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 Central Secretariat 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 Central Secretariat has the same status as the officialversions.CEN members are the national standards bodies of Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France,Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Slovakia,Slovenia, Spain, Sweden, Switzerland and United Kingdom.EUROPEAN COMMITTEE FOR STANDARDIZATIONCOMITÉ EUROPÉEN DE NORMALISATIONEUROPÄISCHES KOMITEE FÜR NORMUNGManagement Centre: rue de Stassart, 36
B-1050 Brussels© 2004 CENAll rights of exploitation in any form and by any means reservedworldwide for CEN national Members.Ref. No. EN 13262:2004: E



EN 13262:2004 (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.11 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



EN 13262:2004 (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.39 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)
Clauses of this European Standard addressing essential requirements or other provisions of EU Directives.44 Bibliography.46



EN 13262:2004 (E) 4 Foreword This document (EN 13262:2004) 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 September 2004, and conflicting national standards shall be withdrawn at the latest by September 2004. 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 According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Slovakia, Slovenia, Spain, Sweden, Switzerland and the United Kingdom.



EN 13262:2004 (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.
Some 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.
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 1 The definition of other wheels may be found in other documents, such as UIC leaflets or ISO standards.
NOTE 2
The technical approval procedure is not within the scope of this standard. NOTE 3 "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.



EN 13262:2004 (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 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 6506-1:1999)
ISO 377-2:19891) Selection and preparation of samples and test pieces of wrought steels - Part 2 : Samples for the determination of the chemical composition
ISO 1101, Technical drawings - Geometrical tolerancing - Tolerancing of form, orientation, location and run-out - Generalities, definitions, symbols, indications on drawings
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 97692), Steel and iron; review of available methods of analysis
ASTM E 399.90, Standard test method for plane-strain fracture toughness of metallic materials
1) Replaced by ISO 14284:1996 "Steel and iron. Sampling and preparation of samples for the determination of chemical composition" 2) See also CR 10261:1995



EN 13262:2004 (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.



EN 13262:2004 (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
Figure 1 — Location of test pieces



EN 13262:2004 (E) 9 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



EN 13262:2004 (E) 10 3.2.2.2 Location of readings Four readings are carried out on a radial section of the rim as shown in Figure 2.
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.
Table 4 — Values to be achieved for impact test characteristics
Steel grade KU (in joules) at + 20°C KV (in joules) at - 20°C
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



EN 13262:2004 (E) 11
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 ∆σ 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 ∆σ 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.
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.



EN 13262:2004 (E) 12
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/mm2√m, 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.
3.2.5.2 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 E 399.90.
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 E 399.90);
- 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 E 399.90);



EN 13262:2004 (E) 13
- 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 E 399.90).
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
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.



EN 13262:2004 (E) 14
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.
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.



EN 13262:2004 (E) 15 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.
3.4.2.3 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.
Defect estimation shall be made by comparison to artificial defects in the standard rim described by Figures 1 and 2 of ISO 5948.
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.



EN 13262:2004 (E) 16
The thickness “e” of the web is defined as:
e = 2nm+
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 mm diameter flat bottom holes located 5 mm,
2emm and (e - 5) mm below the inner
surface of the web
- three 5 mm diameter flat bottom holes located 5 mm, ,
2emm and (e - 5) mm below the inner
surface of the web
3.4.2.5
Hub
The hub examination shall to be made from its two faces. The direction of the examination shall be perpendicular to the surface.
Defect estimation shall be made by comparison to artificial defects in the standard hub described by Figure 5.



EN 13262:2004 (E) 17
NOTE Calibration references are: - three 3 mm diameter holes located at different depths - three 5 mm diameter holes located at different depths spaced as shown in the figure above. Figure 5 — Standard hub for ultrasonic examination 3.5 Residual stresses
3.5.1
General
Wheel heat treatment shall induce a compressive circumferential residual stress field inside the rim.
3.5.2 Values to be achieved
The level of compressive circumferential stresses measured near the surface of the tread shall be in the range 80 N/mm2 to 150 N/mm2.
These stresses shall be equal to zero at a depth of between 35 mm
and 50 mm.
The stress distribution is shown in Figure 6 below the rolling contact line.
Key 1
Ci
...