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GOST 11018-2000
INTERSTATE STANDARD
Traction rolling stock of railways
gauge 1520 mm
WHEELS
General specifications
INTERSTATE COUNCIL
ON STANDARDIZATION, METROLOGY AND CERTIFICATION
Minsk
Foreword
1 DEVELOPED by the Interstate Technical Committee for Standardization MTK 236 "Diesel Locomotives and Track Machines" and the State Unitary Enterprise All-Russian Research Institute of Diesel Locomotives and Track Machines (GUP VNITI) of the Ministry of Railways of Russia
INTRODUCED by Gosstandart of Russia
2 ADOPTED by the Interstate Council for Standardization, Metrology and Certification (Minutes No. 18 of the IGU dated 10/18/2000)
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State name |
Name of the national standardization body |
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The Republic of Azerbaijan |
Azgosstandart |
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Republic of Armenia |
Armstate standard |
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Republic of Belarus |
Gosstandart Republic of Belarus |
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The Republic of Kazakhstan |
State Standard of the Republic of Kazakhstan |
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Republic of Kyrgyzstan |
Kyrgyzstandart |
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The Republic of Moldova |
Moldovastandard |
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Russian Federation |
Gosstandart of Russia |
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The Republic of Tajikistan |
Tajik State Standard |
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Turkmenistan |
Main State Inspectorate "Turkmenstandartlary" |
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Gospotrebstandart of Ukraine |
3 Appendix A of this standard is the authentic text of clause 3 international standard ISO 1005-7-82 “Railway rolling stock. Part 7 Wheel sets for rolling stock. Quality Requirements"
4 Decree of the State Committee Russian Federation on standardization and metrology dated January 10, 2001 No. 4-st interstate standard GOST 11018-2000 was put into effect directly as state standard Russian Federation since January 1, 2002
5 INSTEAD OF GOST 11018-87
6 REVISION. March 2006
GOST 11018-2000
INTERSTATE STANDARD
Traction rolling stock of 1520 mm gauge railways
WHEEL COUPLES
General technicalterms
Introduction date 2002-01-01
1 area of use
1.1 This standard establishes the requirements for newly manufactured wheelsets of locomotives and motor wheelsets of multi-unit rolling stock (traction rolling stock, hereinafter referred to as traction rolling stock) of 1520 mm gauge railways of climate modification UHL according to GOST 15150, operated at a speed of not more than 200 km/h.
The requirements of the standard are mandatory.
2 Normative references
GOST 8.051-81 State system ensuring the uniformity of measurements. Errors allowed when measuring linear dimensions up to 500 mm
GOST 9.014-78 Unified system of protection against corrosion and aging. Temporary anticorrosive protection of products. General requirements
GOST 12.0.003-74 Occupational safety standards system. Dangerous and harmful production factors. Classification
GOST 12.3.002-75 Occupational safety standards system. Manufacturing processes. General safety requirements
GOST 398-96 Carbon steel tires for rolling stock of broad gauge railways and subways. Specifications
GOST 5267.10-90 Profile for bandage rings. Assortment
GOST 9036-88 Solid-rolled wheels. Designs and dimensions
GOST 10791-2004 Solid-rolled wheels. Specifications
GOST 15150-69 Machinery, instruments and other technical products. Versions for different climatic regions. Categories, conditions of operation, storage and transportation in terms of the impact of environmental climatic factors
GOST 16530-83 Gear transmissions. General terms, definitions and designations
GOST 1129-93* Sunflower oil. Specifications
GOST 5791-81 Industrial linseed oil. Specifications
GOST 7931-76 Drying oil natural. Specifications
GOST 30803-2002/GOST R 51175-98 Gear wheels for traction drives of traction rolling stock of mainline railways. Specifications
GOST 30893.1-2002 (ISO 2768-1-89) Basic standards of interchangeability. General tolerances. Limit deviations of linear and angular dimensions with unspecified tolerances”;
* On the territory of the Russian Federation, GOST R 52465-2005 applies.
** On the territory of the Russian Federation, GOST R 52366-2005 applies.
(Revised edition, Rev. No. 1).
3 Terms and definitions
For the purposes of this International Standard, the following terms apply with their respective definitions:
pair of wheels: Assembly assembly consisting of an axle with fixed running wheels mounted on it, as well as one or two gear wheels of the traction drive (axle gearbox) and other parts, including axial bearings of the traction motor or gearbox, brake discs that cannot be dismantled without dismantling wheel pair.
wheel (running): One-piece part or assembly unit, consisting of a wheel center with a bandage and a bandage ring fixing it.
wheel rim: Tire of composite or solid wheel rim.
wheel hub: Part of a wheel center or solid wheel with a hole for mounting it on the axle and a protrusion (elongated hub) for mounting a gear wheel (and other parts) on it.
bandage ring: A part made of rolled products in accordance with GOST 5267.10 and installed to secure the bandage to the wheel center immediately after its landing.
wheel center: Definition according to GOST 4491.
fine axis: Definition according to GOST 30237.
bandage: Definition according to GOST 398.
solid wheel: Definition according to GOST 9036, GOST 10791.
gear wheel: Solid part or assembly unit according to GOST 16530.
variability of the diameter in the cross section of the seating surface: The difference between the largest and smallest unit diameters measured in the same cross section.
diameter variation tolerance in cross section: The largest allowable diameter variability in cross section.
variability of the diameter in the longitudinal section of the seating surface: The difference between the largest and smallest diameters measured in the same longitudinal section.
tolerance for diameter variability in longitudinal section: The largest allowable variability of the diameter in the longitudinal section.
wheelset formation: The technological process of installation by the method of thermal or press fit on the axle of wheels, gears and other parts.
fretting corrosion: A physical and chemical process, a type of metal corrosion at the points of contact of tightly compressed or rolling parts over one another, if, as a result of deformation of their surfaces, microscopic shear displacements occur under the influence of a corrosive environment, for example, air.
(Revised edition, Rev. No. 1).
4 Technical requirements
4.1 Wheel sets must comply with the requirements of this standard, design and technological documentation.
The formation of wheelsets is carried out by organizations that have received the right to do so in the prescribed manner.
4.2 The wheelset (Figures 1, 2) must consist of:
axles (solid or hollow):
With necks for axle box bearings located outside the wheels or between them;
With pre-hub and sub-hub parts;
With a smooth middle part or with seating parts for gears, axial support bearings of the traction motor, gearbox, brake discs or any other parts mounted on the axle between the wheels that cannot be dismantled without dismantling the wheelset;
two wheels (running):
Solid (rolled, stamped, forged, cast);
Composite: wheel centers (rolled, stamped, forged, cast disk, box-shaped or spoke, or with elastic elements), including those with an elongated hub designed to fit parts, tires and retaining rings securing them;
gear (one or two):
Whole;
Composite: ring gear, hub and other connecting parts;
Other parts or assemblies, including axial bearings of the traction motor, gearbox, brake discs, hollow shaft of the traction drive, which are located between the wheels and cannot be dismantled without dismantling the wheelset.
(Revised edition, Rev. No. 1).
BUT AT- wheel rim width;
FROM- the distance between the thrust end of the pre-hub part of the axle and the inner end of the wheel rim;
D- diameter of the wheels in a circle of skating; E
F G- geometric axis of the wheelset
Figure 1 - Wheel pair with one gear on the axle
BUT- the distance between the inner ends (faces) of the wheel rims; AT - wheel rim width;
D- the diameter of the wheels in the circle of skating; E- tolerance of the radial runout of the wheel tread;
F- tolerance of the end runout of the inner end of the wheel rim; G- geometric axis of the wheelset;
To- axis symmetry plane; T - size symmetry tolerance BUT
Figure 2 - Wheel pair with two gear wheels on elongated wheel hubs
4.3 Parts of the wheelset, ready for assembly, must meet the requirements:
Axes - GOST 22780, GOST 30237;
Solid-rolled wheels - GOST 9036, GOST 10791;
Cast wheel centers - GOST 4491;
Bandages - GOST 398;
Bandage rings - GOST 5267.10;
Gear wheels - GOST 30803.
Rolled and stamped wheel centers and other parts of the wheelset - regulatory documentation (hereinafter - RD), approved in the prescribed manner, and the requirements of this standard.
4.3.1 Axle requirements
4.3.1.1 The roughness parameter of the axle surfaces shall be:
Necks for rolling bearings and wheel hubs - Ra*? 6.3 µm;
Necks for axial plain bearings for TPS with design speed V to:
Vto? 100 km/h - Ra? 1.25 µm;
Vto> 100 km/h - Ra? 0.63 µm;
middle part - Ra? 2.5 µm;
Hub parts for gear wheels - Ra? 1.25 µm;
for thrust and plain bearings - Ra? 2.5 µm;
non-working - Ra? 10 µm;
Galteley:
bearing journals - Ra? 1.25 µm;
instep necks - Ra? 2.5 µm.
For hollow axles, the surface roughness parameter of the central hole should be Ra? 10 µm.
4.3.1.2 Tolerance for variability of the diameter** of the axis in transverse and longitudinal sections must be:
Necks for rolling bearings - no more than 0.015 mm;
Necks for axial plain bearings - no more than 0.05 mm;
Hub parts for wheels - no more than 0.05 mm, in the case of a conical shape, the larger diameter should face the middle of the axle;
Hub parts for gears or hubs of gear rims - no more than 0.05 mm.
Pre-wheel parts under the thrust rings of bearings axle boxes no more than 0.03 mm
The errors allowed when measuring linear dimensions are in accordance with GOST 8.051.
“** Hereinafter, instead of the variability of the diameter in the cross section, it is allowed to measure the deviation from roundness, instead of the variability of the diameter in the longitudinal section, to measure the profile of the longitudinal section. The tolerance of roundness and profile of the longitudinal section should be 0.5 of the value of the tolerance of the variability of the diameter in the transverse or longitudinal section”;
4.3.1.3 Tolerance of radial runout when checking in the centers of the axle journals for rolling and plain bearings, wheel hubs and gears should be no more than 0.05 mm.
4.3.1.4 The tolerance of end runout of the ends of the pre-hub parts of the axle when checking in the centers must be no more than 0.05 mm.
4.3.1.5 The axle must be subjected to ultrasonic testing and magnetic flaw detection in accordance with GOST 30237, GOST 30272.
4.3.1.6 The surfaces of the axle journals, pre-hub, hub and middle parts, as well as the fillets of the transition from one part of the axle to another, shall be subjected to hardening by rolling with rollers in accordance with GOST 30237.
4.3.2 Wheel and wheel center requirements
4.3.2.1 The difference in hardness values of wheel rims for one wheel pair shall not exceed 24 HB units.
4.3.2.2 Difference in wheel rim width (dimension AT, figures 1, 2) should be no more than 3 mm. The width of the compound wheel tire is measured along the circumference at a distance of at least 100 mm from the extreme numbers of the marking.
4.3.2.3 The roughness parameter of the seating surfaces shall be:
Wheel hub or wheel center bores:
with the thermal method of formation - Ra? 2.5 µm;
with the press method of formation - Ra? 5 µm;
The outer surface of the wheel center for the nozzle of the bandage - Ra? 5 µm;
Extended hub for gear fit - Ra? 2.5 µm.
4.3.2.4 The tolerance for diameter variability should be:
Holes of the wheel hub or wheel center in transverse and longitudinal sections - no more than 0.05 mm. In the case of a taper, the larger diameter should face the inner end of the hub;
The outer surface of the wheel center for landing the bandage in cross section - no more than 0.2 mm, in the longitudinal section - no more than 0.1 mm.
In the case of taper, the direction of the taper must coincide with the direction of the taper of the inner seating surface of the bandage, and the difference in the tolerance values for the variability of the diameter of the seating surfaces in the longitudinal section must not exceed 0.05 mm.
4.3.2.5 Deviation from the nominal value of the diameter of the pairing of the axle and wheel hub (wheel center) mm is allowed. The difference in the thickness of the wheel hub (wheel center) at the ends, except for the elongated part of the hub, is not more than 5 mm around the circumference.
4.3.2.6 The final boring of the hole of the wheel hub (wheel center) should be made before their formation with the axle. On a wheel center with an elongated hub for fitting a gear, the bore of the hub hole is made after the gear or hub of the compound gear is fitted.
4.3.2.7 The roughness parameter of the inner seating surface of the band shall be Ra? 5 µm. At a width of up to 10 mm from the thrust shoulder and the undercut for the shroud ring, blackouts are not allowed. On the rest of this surface, no more than two black holes are allowed with a total area of not more than 16 cm 2 with a maximum black hole length of not more than 40 mm.
4.3.2.8 The junction radii of the profile elements of the tread undercut for the tread ring must be at least 2.5 mm, the junction radius of the seating surface and the thrust collar must be at least 1.5 mm. The surface roughness parameter of the undercut for the shroud ring and for the thrust shoulder should be Ra? 10 µm. On the edges of the undercut for the shroud ring, facing the inner seating surface of the shroud and the thrust collar on both sides, there must be chamfers of 1.5 mm in size at an angle of 45°. It is allowed to round the edges with a radius of 2 mm instead of chamfers.
4.3.2.9 Tolerance of variability of the diameter of the seating surface of the bandage in the cross section should be no more than 0.2 mm, in the longitudinal section - no more than 0.1 mm. In the case of taper, the direction of the taper shall comply with the requirements for the mating surface of the wheel center according to 4.3.2.4.
4.3.2.10 It is allowed to deviate the diameter of the tyre/wheel center interface from the nominal value mm.
4.3.2.11 Wheel centers and solid wheels shall be subjected to ultrasonic testing in accordance with GOST 4491 and GOST 10791.
4.3.2.12 The bandage must be subjected to ultrasonic testing in accordance with GOST 398 and magnetic flaw detection for the absence of defects on the inner seating surface in accordance with the requirements of RD.
4.3.2.13 Solid wheels and wheel centers, as well as gear wheels (at the request of the customer) of wheel sets of TRS with a design speed of more than 100 to 160 km/h (up to 130 km/h - for MVPS) must be subjected to static balancing, except for wheel centers for wheel sets subjected to dynamic balancing. Residual unbalance of the wheel and wheel center should be no more than 12.5 kg?cm. The location of the unbalanced mass must be marked on the rim of the wheel center by marking the number "0" with a height of 8 to 10 mm.
4.3.2.14 Landing of the tire on the wheel center is carried out by the thermal method with an interference of 1.2? 10 -3 to 1.6? 10 -3 wheel center rim diameter. The shrinkage of the wheel center rim due to plastic deformation after assembly should be no more than 20% of the maximum interference.
4.3.2.15 The heating temperature of the tire before fitting onto the rim of the wheel center shall be from 220°C to 270°C. Temperature control is carried out by devices that make it possible to control its value during the heating process, to record on the stored information carrier a graph of the temperature change (heating diagram) of the bandage over time, and also to automatically turn off the heater when its permissible value is exceeded.
4.3.2.16 The shroud ring is driven into the groove of the shroud with the thickened side at a shroud temperature of at least 200 °C and the shroud shoulder is finally crimped with a force from 44 10 4 to 49 10 4 N (from 45 to 50 tf) at a temperature of at least 100 °C . After compression of the shoulder, the shroud ring must be tightly clamped in the recess without a gap at the end. A gap between the ends of the ring is not more than 2 mm.
4.3.2.17 To create a measuring base, the clamping shoulder of the bandage after the end of the compression must be machined for a length of (7 ± 1) mm from the end to the actual outer (fitting) diameter of the wheel center rim with maximum deviations of ± 0.2 mm.
4.3.2.18 On the outer ends of the tire and the rim of the wheel center, after the tire has landed on a straight line along the radius of the wheel, control marks are applied to control the rotation of the tire on the wheel center in operation. Control marks on the bandage in the form of 4 - 5 cores with a depth of 1.5 to 2.0 mm are applied at a distance of 10 to 15 mm from the edge of the bandage thrust collar and are placed at a length of 24 to 30 mm at equal intervals between the cores. A reference mark on the rim of the wheel center with a depth of up to 1.0 mm and a length of 10 to 20 mm is applied with a blunt tool.
4.3.2.19 Control strips are applied: - on the bandage with red enamel and on the rim of the wheel center - white (yellow) color after applying the control marks in the places of their setting for the entire thickness of the bandage.
4.3.3 Gear requirements (solid or composite)
4.3.3.1 The surface roughness parameter of the hole of a gear or hub of a compound gear before fitting onto an axle or elongated hub of a wheel center shall be:
With the thermal method - Ra? 2.5 µm;
With the press method Ra? 5 µm.
4.3.3.2 Tolerance of variability in the diameter of the gear hole in the transverse and longitudinal sections should be no more than 0.05 mm. In the case of taper, the direction of the taper must match the direction of the taper of the seating surface of the axle or extended wheel center hub.
4.3.3.3 The requirements for the treatment of seating surfaces and the installation of gears on the parts of the traction drive of the wheelset, located between the wheels, must comply with the requirements of the design documentation.
4.3.3.4 The teeth of the gear wheel (crown) shall be subjected to magnetic flaw detection for the absence of surface defects.
4.3.4 Parts and assemblies of a wheelset resting on an axle, wheel hubs, wheel centers or gear wheels with the possibility of relative rotation and/or movement and requiring disassembly of the wheelset for their dismantling must comply with the requirements of this standard.
(Revised edition, Rev. No. 1).
4.3.4.1 - 4.3.4.2 (Deleted, Rev. No. 1).
4.4 Wheel set requirements
4.4.1 Nominal basic dimensions of the wheelset (Figures 1, 2):
BUT= 1440 mm;
AT= 140 mm - for locomotives; 130 mm - for multi-unit rolling stock (hereinafter referred to as MVPS) and tenders;
FROM- according to the agreed design documentation (hereinafter - DD);
D- in accordance with GOST 3225 - for wheel sets of locomotives; GOST 9036 - for MVPS wheels; GOST 5000 - for bandaged wheels of MVPS and tenders.
4.4.2 Parameters of wheel rim profiles: in accordance with Figure 3 - for wheel sets of locomotives and with Figure 4 - for MVPS. It is allowed, upon agreement between the customer and the manufacturer, to use the wheel rim profile with other parameters. It is allowed to use wheel sets without ridges with a rim profile according to design documentation.
Wheel rim width tolerance (size AT, figures 1, 2) should be, mm:
For locomotives;
For MVPS.
Deviations of other sizes - according to the 14th grade of GOST 30893.1
4.4.3 Tolerance of the diameter of the wheels along the rolling circle, taking into account the fulfillment of the requirements of 4.4.7, must comply with GOST 9036 and GOST 3225 for locomotives, GOST 5000 - for MVPS.
The difference in wheel diameters for one wheel pair in the plane of the rolling circle should be no more than 0.5 mm.
4.4.4 Radial run-out tolerance of wheel tread (dimension E) relative to the centers of the axis ( G V to should be, mm, no more than:
1.0 - at V to? 70 km/h;
0.5 - at 70 km/h< V to? 120 km/h;
0.3 - at 120 km/h< V to? 200 km/h
4.4.5 Distance between the inner ends of the wheel rims (size BUT) for TPS with design speed V to should be mm:
At V to? 120 km/h;
1440 ± 1 - at 120 km/h< V to? 200 km/h
4.4.6 Tolerance of end runout of inner ends of wheel rims F about the centers of the axis G for TPS with design speed V to should be, mm, no more than:
1.0 - at V to? 120 km/h;
0.8 - at 120 km/h< V to? 160 km/h;
0.5 - at 160 km/h< V to? 200 km/h
4.4.7 The roughness parameter of tread surfaces and wheel flanges should be Ra? 10 microns, inner ends of wheel rims - Ra? 20 µm.
Figure 3 - Wheel rim profile for locomotives
Figure 4 - Wheel rim profile for MVPS
4.4.8 On the inner ends of the wheel rims of the finished wheelset, dispersed blacks with a depth of not more than 1 mm are allowed, not extending to the radius of mating with the wheel flange. The total area of black holes is not more than 50 cm 2 .
4.4.9 The difference in distances from the inner ends of the wheel rims to the ends of the pre-hub parts of the axle (dimension difference FROM) for one wheel pair should be no more than 2.0 mm.
When used in the production of wheelsets as a base for the middle of the axle (Figure 2, base TO) symmetry tolerance T the distance between the inner ends of the wheel rims must be equal to the value of the tolerance field for the size BUT.
The thickness of the clamping collar when turning the inner ends of the bandages must be at least 6 mm.
4.4.10 Wheel sets with a fixed gear (gears) with a design speed of more than 100 to 120 km/h for locomotives (up to 130 km/h for MVPS) are subjected to a test for residual static imbalance. The value of the residual static imbalance of the wheelset must not exceed 25 kg?cm. It is allowed for the wheelsets to provide the value of the residual static imbalance when they are formed, taking into account 5.1.2.
4.4.11 Wheelsets with a fixed gear wheel with a design speed of over 120 km/h for locomotives (over 130 km/h for MVPS) are subjected to a residual dynamic unbalance test.
The value of the residual dynamic unbalance of the wheelset in the plane of each wheel for the TRS with a design speed V to should be, kg? cm, no more than:
12.5 - at 120 km/h< V to? 160 km/h;
7.5 - at 160 km/h< V to? 200 km/h
For MVPS wheelsets with a design speed over 130 to 160 km/h, a residual dynamic unbalance value of not more than 25 kg?cm in the plane of each wheel is allowed.
4.4.12 The wheel pair, on which the gear wheel is mounted on a bearing support mounted on the traction motor, and the torque is transmitted by means of a hollow shaft, which has the possibility of relative movement in the longitudinal and transverse directions relative to the axis, is subjected to a test for residual dynamic imbalance when fixing the bearing supports with a gear wheel in the middle position relative to the axis. The value of the residual dynamic unbalance - according to 4.4.11.
Such a wheelset is allowed to be checked for residual static imbalance, the value of which is to be provided separately for the constituent elements of the wheelset during its formation, taking into account 5.1.2.
The total value of the residual static unbalance of the wheelset of the TRS with a design speed V k should be, kg cm, not more than:
25 - at 120 km/h< V к? 160 км/ч;
15 - at 160 km/h< V к? 200 км/ч.
4.4.13 Paint coatings of finished wheelsets - according to GOST 22896 or GOST 22947.
4.4.14 The electrical resistance of the wheelset should be no more than 0.01 Ohm.
4.4.15 Each wheel pair is accompanied by a form or technical data sheet. In the form or technical passport of the wheelset indicate:
Type (name);
Name and conditional number of the manufacturer;
date of manufacture;
Date and number of the acceptance certificate by the manufacturer;
Designation of the wheel pair drawing;
Data on the axle, solid wheels or wheel centers and tires (casting manufacturer, heat number), manufacturer and drawing designation of the axle, solid wheels or wheel centers and tires.
In addition, the form or technical passport indicates the initial dimensions of the main parts of the axle (diameters of journals for rolling and plain bearings, pre-hub and sub-hub parts, diameter of the middle part of the axle), fitting diameters of wheel hubs or wheel centers, external fitting diameters of wheel centers and internal diameters tires, wheel diameters in a circle of skating and the thickness of the ridges, as well as the thickness of the tires.
In the form or technical passport of the wheelset, pages must be provided for indicating the inspections and repairs carried out at the depot or at the repair plant (date, type of repair, mileage, actual dimensions).
In addition to the form or technical passport, the wheel set is accompanied by a form or technical passport of the gear (gear wheels), as well as (if necessary) other parts.
4.4.16 Marking and branding after the formation of the wheelset is applied on the right end of the axle in accordance with Figure 5. In case of a one-sided drive, the end of the axle from the gear wheel side is considered the right end. With a double-sided drive, marking and branding is performed on any end free for branding and marking. In the future, the end face with marking and branding is considered right. Marking and branding of MVPS wheelsets is carried out in accordance with GOST 30237.
When establishing mandatory certification, wheelsets are marked with a sign of conformity (circulation on the market) in places where stamps are placed related to the repair of the wheelset, as well as in the form or technical passport. If a design features wheelsets do not allow marking the mark of conformity (market circulation) on the end of the axle, the conformity mark (market circulation) is placed on another surface indicated in the design documentation or only in the form (technical passport).
4.4.17 The fatigue resistance of the axle and wheels (wheel centres) must exclude cases of failure of the wheelset of the corresponding TRS during operation.
4.4.18 The use of wheel rims (wheel centers) in wheel pairs, the deformation of the shape of which causes during operation to exceed the tolerances for the distance between the inner ends of the wheel rims (size BUT, 4.4.5) due to heating of the elements of the wheelset during prolonged and (or) intensive braking by the pads on the rolling surface of the wheels (tires), reduction in the thickness of the rim of the wheels (tires) due to wear and repair turning of the rolling surface of the wheels is not allowed.
4.4.19 It is allowed, upon agreement between the customer and the wheel set manufacturer, to establish other additional requirements for the parts of the wheel set.
(Revised edition, Rev. No. 1).
For axles with plain and rolling bearings without end fastening with a nut
For axles with rolling bearings with end nut
For axles with rolling bearings with washer end mounting
Zone I(applied during the manufacture of the axis)
1
- conditional number or trademark of the manufacturer of the raw axle; 2
- month and year (last two digits) of the production of the rough axle; 3
- serial number of the axis; 4 -
stamps of technical control of the manufacturer and the representative of the acceptance, who checked the correctness
transferring the marking and accepting the finishing axis; 5 -
conditional number or trademark of the manufacturer who processed the rough axis
Zone II(applied when forming a wheelset)
6 -
designation of the wheel pair formation method (FT - thermal, F - press, TK - combined with the thermal method of landing the wheel (wheel center) and the press method of landing the gear on the axle, TZ - combined with the thermal method
landing of the gear wheel and the pressing method of landing the wheel (wheel center) on the axle); 7
- conditional number or trademark of the enterprise that produced the formation of the wheelset; 8
- month and year of wheelset formation; 9
- stamps of technical control of the manufacturer and the acceptance representative who accepted the wheelset; 10 -
balancing mark
(Revised edition, Rev. No. 1).
Note - If the ends of the axles are working elements of the design of the axlebox units, then the markings and stamps are knocked out on the cylindrical surface of the collars or other non-working surface indicated on the working drawing; the height of numbers and letters is from 6 to 10 mm.
Figure 5 - Marking and branding of wheelsets
5 Formation of wheelset
5.1.1 The wheelset is formed by thermal, pressing or combined methods.
5.1.2 For TRS wheelsets with a design speed over 100 km/h, unbalanced masses of wheel centers are recommended to be located in the same plane on one side of the axle.
(New edition, Rev. No. 1).
5.1.3 The design of the wheelset must provide channels for supplying oil under pressure to the connection area of the wheel (wheel center) and the gear (hub of the gear) with the axle to disassemble the wheelset (oil scraping).
5.2 Thermal Formation Method
5.2.1 Wheel sets are formed by the thermal method in accordance with the requirements of the ND.
5.2.2 Local heating of a solid wheel hub, gear wheel or wheel center assembly with a tire is not allowed.
5.2.3 The preload value for the thermal fit method should be:
for hubs of wheel centers and wheels - from 0.85 10 -3 to 1.4 10 -3 diameters of mating parts;
for gear wheel hubs - from 0.5 10 -3 to 1.0 10 -3 diameters of mating parts.
5.2.4 Natural drying oil according to GOST 7931 or heat-treated vegetable oil (sunflower oil according to GOST 1129 or linseed oil according to GOST 5791) and other anticorrosion coatings that have passed tests for resistance to fretting corrosion of mating parts and not reducing the fatigue strength of the axle.
5.2.5 Before heat fit, the parts mounted on the axle, except for gears, are uniformly heated to a temperature of 240 - 260 °C with recording of the heating diagram. The heating temperature of gears made of alloy steels is not more than 200 °C; it is allowed to heat gears made of steel grade 55 (F) up to 260 °C.
5.2.6 After completion of the heat fit and cooling of the joint to the temperature environment the strength of the connection must be checked for shear by a test axial load R:
636 ± 20 kN (65 ± 2 tf) for every 100 mm diameter of the wheel hub of electric locomotives and diesel locomotives for wheel fit (wheel centers);
540 ± 20 kN (55 ± 2 tf) for every 100 mm of the diameter of the MVPS axle hub for the fit of the wheels (wheel centers);
294 ± 20 kN (30 ± 2 tf) for every 100 mm of the diameter of the hub part of the axle for the fit of the gear wheel (composite gear hub);
245 ± 20 kN (25 ± 2 tf) for every 100 mm diameter of the extended wheel center hub for gear fit.
By agreement with the customer, it is allowed to increase the control axial load when checking the shear strength of the joint, taking into account the requirements of 5.2.3.
It is allowed to check the fit of the gear wheel on the elongated hub of the wheel center by the control torque (123 ± 10) kN m [(12.5 ± 1) tf m] per square of every 100 mm of the diameter of the elongated hub of the wheel center.
Sliding or turning in the connection is not allowed.
(Revised edition, Rev. No. 1).
5.3 Press forming method
5.3.1 Parts mounted on the axle (wheels, wheel centers or wheel centers complete with tires, gear wheels) and the axle must have the same temperature before pressing.
5.3.3 The seating surfaces of the parts mounted on the axle and the axle must be covered with an even layer of natural drying oil or heat-treated vegetable (hemp, linseed or sunflower) oil. Other oils may be used upon agreement with the customer.
5.3.4 The parts are pressed onto the axle using a special hydraulic press. The press must be equipped with a calibrated force indication device and an automatic recorder that plots the pressing force diagram as a function of the displacement of the wheel (wheel center), gear wheel relative to the seat during the entire pressing operation.
The accuracy class of the recording device must be at least 1.5%, the error of the chart course should not exceed 2.5%, the thickness of the recording line should not exceed 0.6 mm, the width of the chart tape should be at least 100 mm, the recording scale along the length should be not less than 1:2, along the height of the diagram 1 mm must correspond to a force of not more than 25 kN (2.5 tf).
5.3.5 The axle is pressed into the wheels (wheel centers) and the gears are pressed in with final pressing forces, which must correspond to those indicated in Table 1, at a hydraulic press plunger speed of not more than 3 mm/s.
Table 1 - Final pressing forces when forming a wheel pair by pressing
(Changed edition, Change No. 1).
5.3.6 A normal pressing-in indicator diagram should have the form of a smoothly increasing, somewhat upwardly convex, curve along the entire length from the beginning to the end of the pressing-in (Figure 6). The following deviations from the normal shape of the pressing pattern are allowed:
5.3.6.1 At the starting point of the diagram (the zone of transition of the conical part into the cylindrical part), an abrupt increase in force up to 49 kN (5 tf) followed by a horizontal section up to 5% of the theoretical length of the diagram L.
5.3.6.2 Presence of areas or depressions on the diagram at the location of recesses for oil channels on the hubs, the number of which must correspond to the number of recesses.
5.3.6.3 Concavity of a diagram with a continuous increase in force, provided that the entire curve, except for the lands and valleys specified in 5.3.6.2, is placed above the straight line connecting the beginning of the curve with a point indicating the minimum allowable force in this diagram Rmin for of this type axes.
5.3.6.4 Horizontal straight line on the diagram at the end of the press-in for a length not exceeding 15% of the theoretical length of the diagram L or force drop no more than 5% of the pressing force P max over a length not exceeding 10% of the theoretical diagram length L.
5.3.6.5 An abrupt increase in force at the end of the diagram, if the design of the wheelset or the technology of formation provides for pressing to the stop into any element.
5.3.6.6 Force fluctuation at the end of the press-in with an amplitude of not more than 3% of the press-in force P max over a length not exceeding 15% of the theoretical diagram length ( L).
5.3.6.7 When determining the maximum maximum force from the diagram, a deviation from the measurement accuracy of up to 20 kN (2 tf) is allowed.
5.3.6.8 If the final pressing force is up to 10% less or more limit value range specified in Table 1 (excluding the allowable stepwise increase in force according to 5.3.6.1), the manufacturer, in the presence of the customer, must check the press fit by applying a test axial load three times in the opposite direction from the pressing force. To check the reduced final press-in force, the reference axial load must be equal to 1.2 times the actual press-in force. To check the increased press-in force, the reference axial load must correspond to the maximum press-in force according to table 1.
(New edition, Rev. No. 1).
5.3.6.9 The actual length of the pressing pattern shall be at least 85% of the theoretical length of the pattern L.
6 Acceptance rules
6.1 Wheel sets are subjected to acceptance (PS), periodic (P) and type (T) tests.
The list of parameters controlled during the tests is given in Table 2.
1
- field of satisfactory pressing diagrams, 2
- maximum curve, 3
- minimum curve,
R- pressing force, kN; Rmax, Pmin- maximum and minimum final pressing forces in accordance with table 1; L- theoretical length of the chart, mm
Figure 6 - Template-diagram of pressing
Table 2 - List of controlled parameters and test methods
|
Controlled parameter |
Clause of the standard containing the requirements that are checked during testing |
Test method * |
||
|
acceptance |
periodical |
|||
|
Dimensions, tolerances and shape |
4.3.1.2, 4.3.1.3, 4.3.1.4, 4.3.2.2, 4.3.2.4, 4.3.2.5, 4.3.2.8, 4.3.2.9, 4.3.2.10, 4.3.2.16, 4.3.2.17, 4.3.2.18, 4.3.3.2, 4.4.1, 4.4.2, 4.4.3, 4.4.4, 4.4.5, 4.4.6, 4.4.8, 4.4.9 |
7.3.2, 7.3.4, 7.3.5 |
||
|
Appearance and condition (quality) of the surface, including the finish (roughness) |
4.3.1.1, 4.3.2.3, 4.3.2.7, 4.3.2.8, 4.3.3.1, 4.3.3.3, 4.4.7, 4.4.8 |
7.3.1 (PS), 7.4 (P) |
||
|
Mechanical properties and chemical composition |
7.3.15 (PS), 7.5 (P) |
|||
|
Roll hardening |
||||
|
Heating temperature of mating parts |
4.3.2.15, 4.3.2.16, 5.2.2, 5.2.5, 5.3.1 |
|||
|
The presence of defects in the metal: |
||||
|
ultrasonic control |
4.3.1.5, 4.3.2.11 (for solid wheels), 4.3.2.12 |
4.3.2.11 (for wheel centers) |
||
|
magnetic flaw detection |
4.3.1.5, 4.3.2.12, 4.3.3.4 |
|||
|
Imbalance: |
||||
|
static |
4.3.2.13, 4.4.10, 4.4.12, 5.1.2 |
|||
|
dynamic |
||||
|
Preload value of mating parts |
4.3.2.14, 5.2.3, 5.3.2 |
|||
|
Strength of connection of mating parts |
4.3.2.16, 5.2.6, 5.3.5, 5.3.6 |
7.3.11 (PS), 7.4 (P) |
||
|
Profile parameters of wheel rims (tires) in a skating circle |
||||
|
Electrical resistance |
||||
|
Wheel center shrinkage due to plastic deformation |
||||
|
Distance change (size BUT) from heating during braking and reducing the thickness of tires (wheel rims) |
||||
|
Fatigue resistance and reliability of parts and their interfaces |
||||
|
Marking |
||||
|
Color quality |
4.3.2.19, 4.4.13 |
|||
|
* For parameters not marked by types of tests, tests are carried out for all types of tests |
||||
(Changed edition, Change No. 1).
6.2 Acceptance tests
6.2.1 Acceptance testing of parts of a wheel set and a complete wheel set is carried out before they are painted with the presentation of certificates, other documents confirming the quality, diagrams for checking wheels for shear or pressing diagrams, as well as a form or technical passport for a wheel set and gear wheels.
6.2.2 The parts and wheelset that have passed the acceptance tests must bear the acceptance stamps of the manufacturer and the representative government agency management of railways in the places provided for by the DD.
6.2.3 In case of non-compliance with at least one checked requirement, the parts of the wheelset prepared for assembly and the wheelset are rejected.
6.3 Periodic testing
6.3.1 Periodic tests are carried out at least once a year in the scope of acceptance tests, while additionally control:
The quality of surface treatment - on two parts of each design;
The quality of rolling hardening - according to GOST 30237;
The strength of the fit of the bandage and compression of the bandage ring - on two wheelsets from each standard size of the bandage.
6.3.2 In case of unsatisfactory results of periodic tests for any of the requirements being checked on at least one wheel set, the tests according to this requirement are repeated on twice the number of wheel sets.
6.3.3 Unsatisfactory results of periodic tests according to 6.3.2 are considered final, acceptance of wheelsets is stopped until the cause of unsatisfactory test results is eliminated.
6.4 Type tests
6.4.1 Type tests are carried out:
For each new wheel set design;
When changing in the existing structure, including when using materials with other mechanical properties;
When it changes technological process manufacture of wheel pair parts and their blanks, the method of forming a wheel pair or changing the manufacturer;
With an increase in the axial load on the wheelset or design speed;
With changes to the brake system.
6.4.2 The conditions for conducting type tests must correspond to the operating conditions of wheel sets in terms of the main factors (static and dynamic loads from the wheel set on the rails, travel speed, traction and braking force).
6.4.3 Type tests are carried out in the scope of acceptance tests with additional control:
Absence of increased shrinkage (more than 20% of the maximum tightness) of the wheel center rim due to plastic deformations after assembly with a bandage;
Stress state and strength assessment of wheel pair parts;
Changes in the distance between the inner ends of the wheel rims due to heating during shoe braking and a decrease in the thickness of the wheel rim (bandage) due to wear, repair turning;
Fatigue resistance of the axle, solid and compound wheels, tires, gear teeth;
The strength of the connection of wheel centers with tires, axles with wheels and the strength of the gear wheel fit;
Strength of gear teeth.
6.4.4. It is allowed to carry out type tests in the scope of checks of elements of wheel sets according to the factors listed in 6.4.1.
7 Test methods
7.1 Control of the conformity of the wheelset and its parts is carried out by the certified personnel of the manufacturer with the involvement (if necessary) of the customer's representative.
Note - If necessary, take into account the information provided by the consumer when ordering a wheel pair (Appendix A).
7.2 The test results of the wheelset and its parts before, during and after assembly are recorded in the technical passport.
7.3 During acceptance testing, compliance with the requirements of this standard is determined by the following means and methods.
7.3.1 The appearance and quality of surface treatment is checked by visual inspection using samples (standards) of surface quality.
7.3.2 The dimensions of the elements and the shape of the wheelset surfaces are controlled by measuring instruments, including gauges and standards, providing an accuracy of a class higher than the tolerance value established by this standard.
7.3.3 The preload value before assembling the wheelset is checked by measuring the fit diameters of the mating parts.
7.3.4 The correctness of the actual combinations of tapers of the seating surfaces is checked by comparing the directions of the tapers of the seating surfaces before assembly.
7.3.5 Dimensions (absolute and differences) are determined as the arithmetic mean of the results of at least three measurements at points equidistant along the corresponding circles.
7.3.6 The profile of the wheel rim (tire) is checked with an appropriate template. Limit deviations for template dimensions ±0.1 mm. A probe with a thickness of more than 0.5 mm along the tread surface and the thickness of the ridge, 1 mm - along the height of the ridge, should not pass into the allowable gap between the template and the wheel rim profile, while the template must be pressed against the inner end of the tire (wheel rim).
7.3.7 The absence of internal and surface defects of the axle, wheel center (wheel), tire, as well as the gear wheel (crown) is checked by magnetic flaw detection and ultrasonic control applied at the enterprise according to the relevant ND.
Note - When evaluating the results of measurements by the method of ultrasonic testing, samples (standards) identifying the defect are used.
7.3.8 Checking for residual dynamic and static imbalance of the wheelset is carried out in accordance with the requirements of the RD.
When checking for residual dynamic unbalance, the stand on which the wheelset is installed must ensure that the unbalance is recorded at least 0.2 of the maximum value established by the requirements of this standard.
7.3.9 The heating temperature of the parts of the wheelset before their landing is controlled according to the heating diagram using instruments and devices that control the increase, not allowing the temperature limit to be exceeded.
7.3.10 The strength of the connection of parts with the axis is checked when:
Press fitting method - according to the form of the pressing diagram and its correspondence to the final pressing forces in accordance with Table 1;
The thermal method of landing - three times the application to the connection of the regulated control axial (shear) load or the control moment (for cranking) according to 5.2.6 with the recording of the loading diagram.
To check the validity of the pressing diagrams, an overlay template developed in accordance with ND is used.
7.3.11 The tightness of the fit of the tire and compression of the tire ring on each wheel pair is checked after the wheel has cooled down by tapping with a metal hammer (GOST 2310) on the tread surface and the tire ring at different points. Muffled sound is not allowed.
7.3.12 The electrical resistance is checked on a wheel pair installed on the supports of a device that allows measuring the electrical resistance between the wheel rims of a particular pair.
(Revised edition, Rev. No. 1).
7.3.13 The marking is checked visually. A wheel pair with illegible markings is rejected.
7.3.14 Methods for quality control of wheel sets painting - according to GOST 22896 and GOST 22947.
7.3.15 The mechanical properties and chemical composition of the metal parts of wheel sets must be confirmed by certificates. In case of non-compliance with the requirements of ND, a control chemical analysis is carried out.
7.4 During periodic tests, the following are additionally checked:
The quality of surface treatment of parts before the formation of a wheelset - instrumental control of surface roughness parameters in accordance with GOST 2789;
The quality of hardening by rolling - cutting out longitudinal sections from the axes in the neck, sub-hub, middle part, and also selectively at the locations of the fillets. The cross section of the longitudinal sections determine the hardness;
The strength of the bandage connection with the wheel center - by measuring the actual tightness after removing the bandage.
7.5 The mechanical properties of the metal of wheels, axles, wheel centers and tires are checked on samples cut from them in accordance with GOST 30272, GOST 398, GOST 4491 and GOST 10791 during periodic testing of wheel sets.
7.6 Additional control during type tests of wheel sets
7.6.1 The decrease in the actual tightness (shrinkage) of the wheel center is determined by measuring the diameters of the fitting surfaces of the mating parts in three planes at an angle of 120° along the entire circumference before installation and after removing the tire, while the decrease in the tightness should not exceed that specified in 4.3.2.14.
7.6.2 The change in the distance between the inner ends of the wheel rims due to heating during braking with the blocks on the wheel tread is determined by the calculation or experimental method by reproducing the modes of long-term braking on long descents and stopping braking following long ones, according to RD.
7.6.3 The change in the distance between the inner ends of the wheel rims due to a decrease in the thickness of the rim (bandage) due to wear and repair turning of the tread profile is determined by the calculation or experimental method by comparing the deformation of wheels with the maximum and minimum allowable thickness of the rim (bandage).
7.6.4 Fatigue resistance and margin of safety of wheels, wheel centers with tires, the quality of the connection of wheels (wheel centers) with the axle and the quality of the gear wheel fit are checked in accordance with the RD for test methods.
8 Transport and storage
8.1 When loading wheelsets onto a railway platform or a motor vehicle, they are positioned symmetrically to the longitudinal axis of the platform (body), fixing the wheels with wooden wedges nailed to spacer boards attached to the floor of the vehicle. Wheel sets are firmly fixed to the floor with annealed wire with a diameter of 6 mm in order to avoid possible impacts of wheel sets against each other.
8.2 During storage and transportation of the wheelset, the journals, the hub parts of the axles and the rims of the gear wheels must be coated with an anti-corrosion compound in accordance with protection group 1-2, protection option B 3-1 in accordance with GOST 9.014.
Before transportation, the necks of the axles and the teeth of the gears are protected with tires - belts made of wooden planks strung on a wire or rope or nailed to a metal or keeper tape. Gear teeth should be wrapped with moisture-proof paper and protected from damage.
Metal tape and nails must not touch the axle neck.
For long-term storage, it is allowed to additionally wrap the necks and gear wheels with burlap or glassine.
8.3 The bearings of the gearbox support must be covered with a protective casing, and the bearings of the levers of the reaction moments of the wheel pairs of diesel trains must be wrapped with burlap.
8.4 During transportation and storage it is not allowed:
Discard wheelsets and their elements;
To seize with hooks and chains of hoisting mechanisms the necks and bearing parts of the wheelset axles;
Store wheelsets on the ground without mounting on rails.
8.5 For each wheel pair, the sender attaches a metal or wooden plate with the following data embossed or painted:
The name of the sender;
Destination
Date and wheel set number.
In the case of delivery of a wheel pair with axle boxes, a metal plate with the wheel pair number stamped on it is attached to the bolt of the front cover of the right axle box, if it is not stamped on the axle box body or the front cover.
9 Manufacturer's warranties
9.1 The manufacturer guarantees the conformity of finished wheelsets with the requirements of this standard, subject to the rules of operation, transportation and storage.
9.2 The warranty period of the wheelset in terms of the strength of the connection of parts (axle, wheel center, wheel) is 10 years.
Note - The warranty is terminated in case of re-formation of the wheelset.
9.3 Warranty periods wheelset details:
Axes - according to GOST 30237;
Bandages - according to GOST 398;
Wheel centers - according to GOST 4491;
Solid wheels - according to GOST 10791;
Other parts (gear wheels, etc.) - according to ND for the corresponding part.
Note - Warranty periods are calculated from the moment the wheelset is put into operation.
10 Safety requirements and environmental protection
10.1 Occupational safety during the inspection, survey and formation of wheelsets is ensured in accordance with the requirements of GOST 12.3.002.
10.2 Additional labor safety requirements, due to the peculiarities of the formation of wheel sets, are established in labor protection instructions for workers of relevant professions, technological documentation for production processes and labor safety standards of enterprises.
10.3 When carrying out work on the formation of wheel sets, measures are taken to protect workers and the environment from the effects of hazardous and harmful production factors according to GOST 12.0.003.
10.4 The concentration of substances with harmful properties, and the levels of dangerous and harmful production factors at workplaces in industrial premises should not exceed the maximum allowable values in accordance with GOST 12.0.003.
10.5 Technological areas that are a source of emission of harmful substances (painting, cleaning, washing) are located in isolated places and are provided with exhaust ventilation equipment.
APPENDIX A
(reference)
Information provided by the customer to the manufacturer when ordering a wheel pair
(corresponds to Clause 3 of ISO 1005-7-82)
When ordering a wheel pair, the customer specifies:
Characteristics of the wheelset (pictures 1, 2, 3, 4):
a) appointment of traction rolling stock,
b) information about the design speed of the wheelset (for example, V? 100 km/h; 100 km/h< V? 120 km/h; 120 km/h< V? 160 km/h; 160 km/h< V? 200 km/h),
c) the nominal static load from the wheelset on the rails and its permissible deviations;
Parts mounted on axles (4.2 and 4.3 of this standard);
Requirements for hardening knurling, indicating the parts of the axle to be knurled (wheel hub, gear seat, etc.) - according to GOST 30237;
Requirements for the cleanliness of the surfaces of axle journals for plain or rolling bearings, axle journals for traction motor bearings or axle drive bearings;
Method of mounting parts of the wheelset (5.2 and 5.3) on the axle;
With the press forming method - the value of the interference in the connection of the axle with the hub, the range of pressing forces (5.3.2 and table 1), the type of coating used (5.2.4);
With the thermal method of formation - the value of the preload in the connection of the axle with the hub and the control axial load (5.2.3, 5.2.6);
Requirements for the tread profile (4.4.2) and the quality of the tread surfaces (4.4.7);
Marking points (4.4.16 and Figure 5);
Control operations (table 2);
Electrical resistance (4.4.14) and method for measuring it;
Type of balancing and allowable unbalance (4.3.2.13, 4.3.4.2, 4.4.10, 5.1.2);
Braking modes (5.2.2);
Requirements for paint coatings (4.4.13) and other means of protection against corrosion (5.2.4);
Necessary design changes (6.4.1);
Additional requirements (4.4.19).
(Revised edition, Rev. No. 1).
Keywords: traction rolling stock, 1520 mm gauge, wheelsets, wheel (running), axle, wheel center, tire, tire ring, gear wheel, wheel rim, wheel hub, technical requirements, wheelset formation, marking, acceptance rules, control methods, manufacturer's guarantees, safety requirements, environmental protection
(with amendments and additions approved by the order of the Ministry of Railways of Russia dated 23.08.2000 No. K-2273u)
1. INTRODUCTION………………………………………………………………………………………………….. 3 2. GENERAL PROVISIONS ……… ………………………………………………………………………… 3 3. TECHNICAL CONTENT AND BASIC REQUIREMENTS FOR THE WHEELS IN OPERATION ………………… . 5 4. TYPES, TERMS AND PROCEDURE OF SURVEY OF WHEELS9 5. FAULTS OF WHEELS AND WAYS TO ELIMINATE THEM …………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 12 12………………………………………. GENERAL REQUIREMENTS……………………………………………………………………………………………………. 20 6.2. PROCESSING OF NEW AND OLD YEAR AXES. ………………………………………………………………….. 21 6.3. PROCESSING OF NEW AND OLD CENTERS, SOLID-ROLLED AND GEARS…… 23 6.4. REPAIR OF GEARS. ………………………………………………………………………………………….. 25 6.5. BORING OF NEW AND OLD BANDAGES. ……………………………………………………………. 26 6.6. NOZZLE (CHANGE) OF BANDAGES. ……………………………………………………………………………………… 27 6.7. PRESS WORKS …………………………………………………………………………………………………… 29 6.8. THERMAL METHOD OF FORMING WHEELS…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. The turn of the bandages and rims of whole -roll wheels in the profile ……………………… 36 6.10. ФОРМИРОВАНИЕ КОЛЕСНЫХ ПАР………………………………………………………………………………… 44 7. ПРОВЕРКА, ПРИЕМКА И ИСКЛЮЧЕНИЕ ИЗ ИНВЕНТАРЯ КОЛЕСНЫХ ПАР 45 8. МАРКИРОВАНИЕ AND STAMPING OF WHEELS AND THEIR ELEMENTS … 46 THEIR ELEMENTS …………………………………………………………………………………………………… 53 11. SAFETY REQUIREMENTS AND ENVIRONMENTAL MEASURES ……… ……………………………………………………………………………………. 54 12. METROLOGICAL PROVISION…………………………………………………….. 54 APPENDIX 1………………………………………………………… …………………………………………………………… 56 APPENDIX 2………………………………………………………………… …………………………………………………… 59 APPENDIX 3………………………………………………………………………… …………………………………………… 59 APPENDIX 4………………………………………………………………………………… …………………………………… 60 APPENDIX 5………………………………………………………………………………………… …………………………… 61 APPENDIX 6……………………………………………………………………………………………… …………………… 66 APPENDIX 7……………………………………………………………………………………………………… …………… 68 APPENDIX 8……………………………………………………………………………………………………………… …… 70 APPENDIX 9…………………………………………………………………………………………………………………… 74 APPENDIX 10…………………………………………………………………………………………………………………. 76 APPENDIX 11………………………………………………………………………………………………………………. 78 APPENDIX 12………………………………………………………………………………………………………………. 78 APPENDIX 13………………………………………………………………………………………………………………. 78
1. INTRODUCTION
1.1. This Instruction applies to wheelsets of all types of locomotives and multi-unit rolling stock (MVPS) of 1520 mm gauge. Locomotives and MVPS are hereinafter referred to as traction rolling stock (TPS).
1.2. The instruction establishes the procedure, terms, norms and requirements that must be met by wheel sets during their formation, repair (survey) and technical maintenance.
1.3. All newly issued operational and repair documentation for wheelsets must strictly comply with this Instruction and GOST 11018, and the current documentation must be brought in accordance with them.
1.4. The requirements of this Instruction are obligatory in the manufacture, repair, maintenance and operation of wheel sets.
(As amended by the instruction of the Ministry of Railways of Russia dated 23.08.2000 No. K-2273u)
1.5. Instruction dated 31.12.85. No. TsT / 4351 is valid in terms of the manufacture and repair of wheel pairs of steam locomotives.
2. GENERAL PROVISIONS
2.1. According to the rules technical operation railways of the Russian Federation (hereinafter PTE), each wheel pair must meet the requirements of this Instruction. Wheel sets of TRS with rolling bearings must also meet the requirements of the current Instructions for the maintenance and repair of units with rolling bearings of locomotives and multiple unit rolling stock.
The wheelsets of the TPS operating at speeds over 140 km/h must, in addition, meet the requirements of the current Instructions for the maintenance and operation of structures, rolling stock devices and the organization of traffic in the areas of circulation of high-speed passenger trains.
Manufacture and repair of driven gears of traction gearboxes with elastic rubber-metal elements, assemblies and parts of wheel pair drives with support-frame and support-axial suspension of traction motors must be carried out in accordance with the requirements of the relevant existing drawings, repair rules, technological instructions, repair manuals and GOST 11018.
Compliance with the requirements of the specified technical documentation is mandatory for all employees associated with the formation, examination, repair and operation of wheel sets.
2.2. Each wheel pair must have clearly marked marks on the axle indicating the time and place of formation, complete examination and a stamp confirming its acceptance during formation and complete examination. Elements of the wheelset must have signs and stamps established by the relevant standards, specifications and this Instruction. After repair in the CIS countries and Latvia, the operation of wheel sets and their individual elements without the “Hammer and Sickle” stamp is allowed, provided that the other prescribed stamps are present (section 8).
2.3. Wheelsets must be subject to inspection under the TPS, ordinary and complete survey, in accordance with the procedure established by this Instruction.
2.4. A complete survey should be carried out at factories and in locomotive depots that have a permit from the Ministry of Railways and a mandatory minimum of equipment, fixtures, measuring and control instruments in accordance with Annexes 1 and 2.
2.5. Responsibility for the maintenance of tools and measuring instruments in good condition, as well as for the timely verification (calibration) of measuring instruments, rests with the head of the wheel shop or the foreman who manages the repair and formation of wheel pairs.
Control over the organization and timeliness of verification (calibration) of measuring instruments is carried out by:
at the plant - the head of the technical control department;
in the depot - chief engineer or deputy head of the repair depot.
(As amended by the instruction of the Ministry of Railways of Russia dated 23.08.2000 No. K-2273u)
2.6. The condition of equipment, fixtures and tools for the repair (examination) of wheel sets, as well as compliance with the requirements of this Instruction at plants and depots, must be annually checked by commissions chaired by the chief engineer (or his deputy at the plant) with the participation of the Quality Control Department and locomotive inspectors ( acceptance inspectors at the factory).
The wheelset refers to rail transport and can be used in the running gear of railway rolling stock. The invention solves the problem of increasing the resource of the wheelset, improving maintainability, reducing the cost of Maintenance and repair, improving driving performance, improving traffic safety and environmental safety in the face of increasing speed, train weight and axle loads of the wheelset. The wheel pair includes two wheels with internal flanges on one solid hollow axle with a ratio of diameters ranging from 0.4 to 0.8, a conical interface, an average wheel tread line T with a tread circle diameter L, two outer and inner axle boxes, radial channels in the axle connecting the internal cavities of the axle and the cavities of the axle boxes, which are filled with liquid lubricant, sealing devices that prevent leakage of liquid lubricant from the axle boxes, a hydraulic pump placed on the axle is designed to circulate the coolant in the cavities of the bearing axle boxes. 1 ill.
The invention relates to rail transport, in particular to the running gear of railway rolling stock. A wheel pair is known, selected as an analogue, containing two wheels with internal flanges on one solid solid or hollow axle with two outer axle boxes that transfer the axle load with the help of bearings (Cars. Edited by L.A. Shadur. M .: Transport, 1980, p. 94, figure V.3). Known wheel pair, selected for the prototype, containing two wheels with internal flanges on one solid axle with two internal or external axle boxes, transmitting axle load through the support bearings (International standard ISO 1005/7. Rolling stock of railways, part 7. Wheel sets for rolling stock Quality requirements, Figure 2, page 17). However, the above known wheel sets (analogue, prototype) are made according to the traditional scheme, providing on one solid axle either only two external axle boxes, or two only internal ones, and have the following disadvantages, which reduce the resource, maintainability, increase the cost of maintenance and repair , reduce driving performance, traffic safety and environmental safety in the conditions of increasing speed, train weight and axle loads of the wheelset:
Increased stresses from bending in dangerous sections of the axle due to its asymmetric loading relative to the center line of the wheel, which, under conditions of cyclic bending deformations during movement, is the cause of the observed fatigue failures (statistics of wagon cuts show that due to the appearance of transverse at least 40% of the axles are rejected in parts of the axle, see Serensen SV, Shneiderovich OM, Groman MB Shafts and axles, Moscow, Gosmashtekhizdat, 1959);
Increased vertical asymmetric load on the axlebox assembly, thrust bearings, which leads with grease lubrication to conditions of semi-dry friction, heating of the axlebox assembly, intense wear, fatigue failure of cages, rings and rollers in rolling bearings, antifriction layer in plain bearings (statistics show that the proportion wagon cuts due to axle box heating due to bearing failures is up to 70%: see Proceedings of VNIIZhT, 1982, issue 654);
The impossibility of maintaining the wheel rolling circle in the vertical plane, which reduces driving performance, causes additional lateral impact of the wheel flange on the rail head and leads to the action of dynamic transverse forces on the axle bearing by means of a reflected shock wave, to the disorder of the rail-sleeper lattice, the transverse friction of the wheel on the rail, causing , as is known, the greatest wear on the contact surfaces;
The absence and impossibility of implementing, with the existing design of the wheelset (prototype), a closed system of forced lubrication with cooling of the axle bearings, which does not require the addition of lubrication for a long time of operation, and a reliable sealing system - due to watering of the lubricant, its dilution, ejection through the labyrinth seal and, for this reason, excessive wear of the centering surfaces and webs of the rolling bearing cage, depending on the class of cars, from 35 to 65%; see Tr VNIIZhT, 1978, issue 583). The objective of the invention is to increase the resource of the wheelset, improve maintainability, reduce maintenance and repair costs, improve driving performance, improve traffic safety and environmental safety in the face of increasing speed, train weight and axle loads of the wheelset. To solve this problem, a wheel pair containing two wheels with internal flanges on one solid hollow axle with two outer axle boxes is simultaneously equipped with two inner axle boxes, each of which with a corresponding outer axle box is placed on the axle symmetrically with respect to the centerline of the wheel tread, the ratio of the diameter of the hole of the hollow axle to its outer diameter in the range from 0.4 to 0.8, the interface of the wheel with the axle has a conical shape, while the small diameters of the cone are facing the ends of the axle, the internal cavities of the axle and the axle box are filled with an environmentally friendly lubricating-cooling fluid and are connected by radial channels made in the axle , a hydraulic pump is placed on the axis, the axle boxes are equipped with sealing devices in relation to liquid lubrication. The presence of new elements and connections makes it possible, while maintaining both the existing loads on the axle of the wheelset and the tendency to increase them, to increase the resource, maintainability, reduce maintenance and repair costs, improve driving performance, improve traffic safety and economic security due to the symmetrical relative wheel centerline of the load distribution on the axle and bearings, maintaining the wheel rolling circle in the vertical plane and at the same time halving: a) vertical equivalent loads on the support bearings, b) bending moment in the near-hub sections of the axle from vertical static load, complete unloading of the middle part axles from bending with an increase in fatigue strength and durability of axlebox units by more than two times, bending deformations of the axle by more than three times, providing a closed lubrication system for bearings. The specified new set of essential features is necessary and sufficient to solve the specified problem, which proves compliance with the criterion of eligibility for "novelty". Comparison of the proposed invention not only with the prototype, but also with other technical solutions in this field of technology did not reveal in them the features that distinguish the proposed invention from the prototype, which allows us to conclude that the criterion "inventive step" is met. The drawing shows a symmetrical part of the proposed wheelset. The wheel pair includes two wheels with internal flanges 1 on one solid hollow axle 2 with a ratio of inner and outer diameters d1/d2 ranging from 0.4 to 0.8, a conical shape of interface 3 of axle 2 and wheels 1, the middle line of rolling of the wheel T with a diameter rolling circle L, two outer 4 and two inner 5 axleboxes, radial channels 6 in the axle connecting the inner cavity 7 of the axle 2 and the cavity 8 of the axleboxes 4, 5, which are filled with a liquid lubricant such as, for example, "Tormob" fluid of the Canadian company "Thordon" , end-type sealing devices 9 are similar to the Sederval and Sons seal, Sweden (see "Shipbuilding Technology", 1991, No. 7), hydraulic pump 10, placed, for example, inside the axle cavity. The wheel pair works as follows. With a symmetrical arrangement of the inner and outer bearing boxes 4.5 relative to the center line T of the wheel 1, only the near-hub sections of the Z axis are subjected to bending, while the middle part of the axis of length A is completely unloaded from static bending. At the same time, the deflections and angles of rotation of the axle sections are reduced by more than three times, the difference between the angular displacements of the characteristic near-hub sections of the axle is significantly reduced: sections coinciding with the planes of adjacent rolling bearings axle boxes 4.5, with outer and inner planes of sealing devices 9 axle boxes 4.5; as a result, this reduces the effect of axial amplitude forces dangerous for bearings and sealing devices, caused by constraint of bending deformations, which, under conditions of rotation of a curved axis, leads to shock, friction and wear of the contacting parts. Further, if the stress in the calculated sections of the axis from the vertical static force acting on one bearing is halved, then the fatigue strength in accordance with the known experimental data and with the formulas of the probabilistic method for assessing the strength of the axis (see "Norms for the calculation and design of new and modernized of 1520 mm gauge MRS railway carriages (non-self-propelled)") more than doubled. Such a significant increase in the fatigue strength of axle 2 in dangerous sections and the unloading of its middle part due to redistribution of the load justifies the possibility of safely weakening the axle cross section by introducing an internal symmetrical capacitance in the axle without increasing the standard outer diameter by replacing the solid section with an annular one. This reduces the mass of the axle (on average by 100 kg) with all the known beneficial consequences, and the internal cavity 7 allocated due to the appeared reserve of axle strength is involved in the proposed closed lubrication system of the axleboxes 4.5 as a reservoir that simultaneously performs the functions of storing and cooling the lubricant washing axle bearings during movement. The range of 0.4 - 0.8 of the ratio of the diameters of the hollow axis d1 / d2 was chosen: a) the optimality conditions between the requirement to ensure strength, on the one hand, and an increase in the volume of the internal cavity used for the lubrication system (with a simultaneous decrease in the mass of the axis) - on the other; b) technology for manufacturing axles with a variable ratio d1/d2 along the length of the axle; c) the experience of using hollow axles, described, for example, in the book "Cars", ed. L.A. Shadur, M. : "Transport", 1980, pp. 94, 95, d) the behavior of the functions f=1-(d1/d2) 2 , w= 1-(d1/d2) 4 , respectively characterizing the cross-sectional area of the tubular axis and moment of resistance. Halving the equivalent radial forces acting on one bearing causes a significant increase in bearing life in millions of kilometers in accordance with the formula for evaluating the life of journal bearings (see "Calculation standards ..." mentioned above). Thus, the axle boxes turn out to be low-maintenance and with an increased resource, which leads to a decrease operating costs. With a symmetrical distribution of the load on the axlebox units 4.5, the plane of the rolling circle of diameter L of the wheel 1 is automatically set to a vertical position, which improves the driving performance of the vehicle and eliminates additional lateral forces on the rail and sleeper grid, reduces the effect of lateral friction of the wheel on the rail, wear of their surfaces. Environmental safety is also ensured in the event of an emergency (explosion, destruction of the box body, etc.), because the leaking lubricant does not pollute the environment, as it is environmentally friendly, soluble in water. The maintainability of the wheelset increases, and the repair costs are reduced due to the conical shape of the landing surface of the wheel 1 and axle 2, because injection of liquid onto such a mating surface provides convenient disassembly of the wheels. The hydraulic pump 10, located on the axle asymmetrically with respect to the wheels 1, causes the circulation of liquid lubricant in the cavity 7 of the axle 2 during movement, providing a closed lubrication system for axleboxes 4.5. An invention including such systemic related factors, as a conical connection of both wheels with the axle, allowing for a symmetrical distribution of the vertical load on the axle and bearings relative to the center line of the wheel, maintaining the wheel rolling circle in the vertical plane, significant unloading of the axle from bending, and bearings from radial forces and axial forces arising from - due to the constraint of bending deformations, as well as the creation of a closed system of environmentally friendly lubrication of bearings and a low-maintenance axle box, leads to such systemically related consequences as an increase in service life, an increase in maintainability, a reduction in maintenance and repair costs, an improvement in driving performance, an increase in traffic safety, which together create a super-effect under conditions of an increase in the speed of movement, the weight of trains and the loads on the axle of the wheelset.
CLAIM
A wheel set for rolling stock of railways, containing two wheels with internal flanges on one hollow solid axle with two axle boxes external to the wheels, transferring the axle load by means of support bearings, characterized in that it is simultaneously equipped with two axle boxes internal to the wheels , each of which, with the corresponding outer axle box, is placed on the axle symmetrically relative to the centerline of the wheel, the ratio of the diameter of the axle bore to the outer diameter is in the range from 0.4 to 0.8, the interface of the wheel with the axle has a conical shape, while the small diameters of the cone face to the ends of the axle, the internal cavities of the axle and the axle box are filled with an environmentally friendly lubricating and cooling liquid and are connected by radial channels made in the axle, a hydraulic pump is placed on the axle, the axle boxes are equipped with sealing devices for liquid lubricant.INTERSTATE COUNCIL FOR STANDARDIZATION, METROLOGY AND CERTIFICATION
INTERSTATE COUNCIL FOR STANDARDIZATION, METROLOGY AND CERTIFICATION
INTERSTATE
STANDARD
General specifications
(ISO 1005-7:1982, NEQ)
Official edition
Standartinform
Foreword
The goals, basic principles and basic procedure for carrying out work on interstate standardization are established by GOST 1.0-92 “Interstate standardization system. Basic Provisions” and GOST 1.2-2009 “Interstate Standardization System. Interstate standards, rules and recommendations for interstate standardization. Rules for the development, adoption, application, updating and cancellation "
About the standard
1 DESIGNED BY OPEN joint stock company"Scientific-Research and Design-Technological Institute of Rolling Stock" (JSC "VNIKTI")
2 INTRODUCED by the Federal Agency for Technical Regulation and Metrology
3 ADOPTED by the Interstate Council for Standardization, Metrology and Certification (Minutes No. 40 dated November 29, 2011)
4 This standard has been developed taking into account the main provisions of the international standard ISO 1005-7:1982 “Railway rolling stock. Part 7. Wheel sets for rolling stock. Quality requirements" (ISO 1005-7:1982 "Railway rolling stock materia - Part 7: Wheelsets for tractive and trailing stock - Quality requirements", NEQ)
5 By order of the Federal Agency for Technical Regulation and Metrology of March 5, 2012 No. 14-st, the interstate standard GOST 11018-2011 was put into effect as the national standard of the Russian Federation from January 1, 2013.
For the Russian Federation, this standard fully implements the requirements of the technical regulation "On the safety of railway rolling stock" in relation to the object of technical regulation - wheel sets of locomotives and multiple unit rolling stock, as well as the requirements of the technical regulation "On the safety of high-speed railway transport" in relation to the object of technical regulation - wheel pairs of high-speed railway rolling stock:
4.3.2-4.3.13, 4.3.15, 4.3.17, 5.2.6, 5.3.4-5.3.7, 5.3.7.1-5.3.7.9 contain the minimum required safety requirements;
Subsection 6.5 establishes the rules for sampling for conformity assessment;
7.1.1, 7.1.2, 7.1.4, 7.1.5, 7.1.8, 7.1.10, 7.1.12-7.2, 7.3.4 establish methods for checking the minimum necessary requirements security.
6 INSTEAD OF GOST 11018-2000
Information about changes to this standard is published in the annually published information index "National Standards", and the text of changes and amendments - in the monthly published information indexes "National Standards". In case of revision (replacement) or cancellation of this standard, a corresponding notice will be published
in the monthly published information index "National Standards". Relevant information, notification and texts are also placed in information system general use - on the official website of the Federal Agency for Technical Regulation and Metrology on the Internet
© Standartinform, 2012
In the Russian Federation, this standard cannot be fully or partially reproduced, replicated and distributed as an official publication without the permission of the Federal Agency for Technical Regulation and Metrology
1 Scope ...............................................................1
3 Terms and definitions...............................................2
4 Specifications....................................................4
5 Formation of the wheelset...............................................14
6 Acceptance Rules...............................................17
7 Test Methods...............................................20
8 Transport and storage...............................................22
9 Manufacturer's Warranty...............................................22
10 Occupational safety requirements...............................................23
Annex A (mandatory) Checking residual static and dynamic imbalances. . 24 Bibliography............................................... 25
INTERSTATE STANDARD
WHEELS OF TRACTION ROLLING STOCK OF 1520 MM RAILWAYS
General specifications
Introduction date - 2013-01-01
1 area of use
This standard establishes the requirements for the drive wheel sets of locomotives (tenders), motor cars of multiple unit rolling stock (traction rolling stock) of 1520 mm gauge railways with UHL climate modification in accordance with GOST 15150.
This standard uses normative references to the following interstate standards:
GOST 8.051-81 State system for ensuring the uniformity of measurements. Errors allowed when measuring linear dimensions up to 500 mm
GOST 9.014-78 Unified system of protection against corrosion and aging. Temporary anticorrosive protection of products. General requirements
GOST 12.0.003-74 Occupational safety standards system. Dangerous and harmful production factors. Classification
GOST 12.3.002-75 Occupational safety standards system. Manufacturing processes. General safety requirements
GOST 12.4.011-89 System of labor safety standards. Means of protection for workers. General requirements and classification
GOST 12.4.021-75 System of labor safety standards. Ventilation systems. General requirements
GOST 15.309-98 System for the development and production of products. Testing and acceptance of manufactured products. Basic provisions
GOST 398-2010 Carbon steel tires for rolling stock of broad gauge railways and subways. Specifications
GOST 868-82 Indicator calipers with a division value of 0.01 mm. Specifications
GOST 1129-93 Sunflower oil. Specifications
GOST 2310-77 Steel metalwork hammers. Specifications
GOST 2789-73 Surface roughness. Parameters and characteristics
GOST 3225-80 Rough tires for locomotives of broad gauge railways. Types and times
GOST 4491-86 Cast wheel centers for rolling stock of 1520 mm gauge railways. General specifications
GOST 5000-83 Rough tires for wagons and tenders of 1520 mm gauge railways. Once
GOST 5267.10-90 Profile for bandage rings. Assortment
Official edition
GOST 5791-81 Industrial linseed oil. Specifications GOST 7931-76 Drying oil natural. Specifications GOST 8989-73 Hemp oil. Specifications
GOST 9378-93 Samples of surface roughness (comparison). General specifications GOST 10791-2011 Solid-rolled wheels. Specifications GOST 11098-75 Staples with a reading device. Specifications GOST 12503-75 Steel. Methods of ultrasonic control. General requirements GOST 12549-2003 Passenger carriages on 1520 mm gauge mainline railways. Coloring. Specifications
GOST 15150-69 Machinery, instruments and other technical products. Versions for different climatic regions. Categories, conditions of operation, storage and transportation in terms of the impact of environmental climatic factors
GOST 18321-73 Statistical quality control. Methods for random selection of samples of piece products
GOST 20415-82 Non-destructive testing. Acoustic methods. General provisions GOST 21105-87 Non-destructive testing. Magnetic particle method GOST 23479-79 Non-destructive testing. Optical view methods. General requirements GOST 25346-89 Basic interchangeability standards. Unified system of tolerances and landings. General provisions, series of tolerances and main deviations
GOST 30803-2002 Gear wheels for traction drives of traction rolling stock of mainline railways. Specifications
GOST 31334-2007 Axles for rolling stock of 1520 mm gauge railways. Specifications
GOST 31365-2008 Paint and varnish coatings for electric locomotives and diesel locomotives of 1520 mm gauge mainline railways. Specifications
GOST 31373-2008 Wheel sets of locomotives and multiple unit rolling stock. Strength calculations and tests
Note - When using this standard, it is advisable to check the validity of reference standards in the territory of the state according to the corresponding index of standards compiled as of January 1 of the current year, and according to the corresponding information indexes published in the current year. If the reference standard is replaced (modified), then when using this standard, you should be guided by the replacing (modified) standard. If the referenced standard is canceled without replacement, the provision in which the reference to it is given applies to the extent that this reference is not affected.
3 Terms and definitions
In this standard, the following terms are used with their respective definitions:
3.1 wheelset of locomotives and motor cars of multi-unit rolling stock;
MVPS: An assembly unit consisting of an axle with fixed running wheels mounted on it, as well as one or two gear wheels of the traction drive (axial gearbox), twin drive pins and other parts, including a hollow shaft, axial bearing housing, axial bearings of the traction engine or gearbox, brake discs, axle bearings with labyrinth bushings (when axle boxes are installed between running wheels), which cannot be dismantled without dismantling the wheelset.
3.2 traction (railway) rolling stock; TPS: A set of types of railway rolling stock, including locomotives and MVPS, that has traction properties for carrying out the transportation process.
Note - MVPS includes electric trains, diesel trains, diesel electric trains and railcars (rail buses) intended for the carriage of passengers.
3.3 wheel (running): An element of a wheel pair, which is a solid part or assembly unit, during rotation of which, in direct contact with the rail, the TRS is moved.
3.4 one-piece wheel (running): One-piece part of a wheel pair with a rim, disk part and hub.
3.5 composite wheel (running): An assembly unit of a wheel pair, consisting of a wheel center, a tire and a tire ring fixing it.
3.6 wheel hub: The central part of a solid wheel or wheel center with a hole that forms a seating surface for a fit with a guaranteed tightness, excluding rotation on the axle under the action of permissible loads.
Note - The hub can be with an elongated protrusion (elongated hub) to form a seating surface for mounting a gear wheel (and other parts) on it.
3.7 wheel rim: The outer thickened part of a solid wheel, which has a special profile that ensures its contact with the rail and specified contact conditions.
3.8 bandage: A part of a composite wheel having a special profile that ensures its contact with the rail and the specified contact conditions.
3.9 tread collar: Part of the tread located between the outer side surface of the tread and the inclined surface associated with the seating surface of the tyre, designed to stop the side part of the rim of the wheel center.
3.10 clamping collar of the bandage: Part of the bandage located between the inner side surface of the bandage and the undercut for the bandage ring, designed to fix the bandage ring in the groove of the bandage.
3.11 wheel center
3.12 wheel center rim
3.13 tire ring: A part designed to fix the tire on the wheel center.
3.14 gear wheel: An integral part or assembly unit, which is a gear link with a closed system of teeth, which ensures the continuous movement of another gear link (wheel).
Finished Axle: An axle that has been finished machined, roll-hardened along its entire length, and ultrasonic and magnetically inspected.
[GOST 31334-2007, article 3.2]_
3.16 variability of diameter in the cross section of the seat: The difference between the largest and smallest unit diameters measured in the same cross section.
3.17 diameter variation tolerance in cross section
3.18 diameter variability in the longitudinal section of the seating surface: The difference between the largest and smallest single diameters measured in the same longitudinal section.
3.19 diameter variability tolerance in longitudinal section
3.20 formation of wheelset: Technological process of installation by the method of thermal or press fit on the axle of wheels, gears (one or two) and other parts.
3.21 fretting corrosion: a physical and chemical process, a type of metal corrosion at the points of contact of tightly compressed or rolling mating surfaces of parts, if, as a result of deformation of their surfaces, microscopic displacements occur under the influence of a corrosive environment, for example, air, moisture.
3.22 wheel set pin of twin-driven locomotives: A part installed in the running wheel and designed to transmit torque from the drive mechanism to the wheel set.
3.23 roughness
3.24 brake disc: An element of a wheel pair designed to brake traction rolling stock and installed on the middle part of the axle or on the sides of the wheel discs in the case of such a braking scheme.
3.25 hollow shaft: Traction drive element enclosing the middle part of the wheelset axle and transmitting torque from the wheelset gear.
4 Technical requirements
4.1 The wheelset (see figures 1-3) should consist of:
From a solid or hollow axis:
with necks for axle bearings located outside the wheels or between them,
with pre-hub and sub-hub surfaces for running wheels,
with a smooth middle part and (or) with seats for gears, axial bearings of the traction motor, gearbox, brake discs or any other parts mounted on the axle between the wheels;
From two running wheels:
solid (rolled, stamped, forged, cast),
composite with wheel centers (rolled, stamped, forged, cast), bandages and fixing them with bandage rings;
From a gear wheel (one or two, except for wheel sets of locomotives with twin drive):
a) whole
b) composite: ring gear, hub and other connecting parts between them;
From other parts or assembly units, including axial bearings of the traction motor or gearbox, axial bearing housings, brake discs mounted on the sides of the wheel discs, a hollow shaft that are located between the wheels and cannot be dismantled without dismantling the wheelset, as well as brake discs mounted on the wheels .
4.2 Parts of the wheelset intended for assembly must comply with the technical requirements:
Axes - GOST 31334;
Solid-rolled wheels - GOST 10791;
Wheel cast centers - GOST 4491;
Bandages - GOST 398, GOST 3225*;
Bandage rings - GOST 5267.10;
Gears - GOST 30803**;
Wheel rolled and stamped centers and other parts of the wheelset - according to the regulatory document (RD), approved in the prescribed manner.
Gear
Riding circle
A - the distance between the inner ends (edges) of the tires (rims) of the wheels; B - the width of the tire (rim) of the wheel; C is the distance between the thrust end of the pre-hub part of the axle and the inner end of the tire (rim) of the wheel; D is the diameter of the wheels in the skating circle; E-tolerance of the radial runout of the wheel tread; G - tolerance of the end runout of the inner end of the bandage
Figure 1 - Wheel pair with one gear on the axle
* On the territory of the Russian Federation, GOST R 52366-2005 applies (hereinafter).
** On the territory of the Russian Federation, GOST R 51175-98 applies (hereinafter).
Gear wheels Rolling circle
A - the distance between the inner ends (edges) of the tires (rims) of the wheels; B - the width of the tire (rim) of the wheel; C is the distance between the thrust end of the pre-hub part of the axle and the inner end of the tire (rim) of the wheel; D is the diameter of the wheels in the skating circle; E is the tolerance of the radial runout of the wheel tread; G - tolerance of the end runout of the inner end of the tire (rim) of the wheel; B - geometric axis of the wheelset; K is the plane of symmetry of the axis; T - symmetry tolerance of dimension A relative to plane K (in diametrical terms)
Figure 2 - Wheel pair with two gear wheels on elongated wheel hubs
Brake discs
A - the distance between the inner ends (edges) of the tires (rims) of the wheels; B - the width of the tire (rim) of the wheel; C is the distance between the thrust end of the pre-hub part of the axle and the inner end of the tire (rim) of the wheel; D - diameter of the wheel in a circle of skating; E is the tolerance of the radial runout of the wheel tread; G - tolerance of the end runout of the inner end of the bandage
(rim) wheels; B - geometric axis of the wheelset
Figure 3 - Wheelset with axle gear and disc brakes
4.2.1 Axle requirements
4.2.1.1 The roughness parameter Ra* of axle surfaces shall be:
Necks for rolling bearings and wheel hubs - no more than 1.25 microns;
Necks for axial plain bearings for TPS with design speed v K:
no more than 100 km/h - no more than 1.25 microns;
more than 100 km / h - no more than 0.63 microns;
The middle part - no more than 2.5 microns;
Hub parts for gear wheels and brake discs - no more than 1.25 microns;
for thrust bearings of rolling and sliding - no more than 2.5 microns;
non-working - no more than 6.3 microns;
Galteley:
bearing journals - no more than 1.25 microns;
hub journals - no more than 2.5 microns.
For hollow axles, the roughness parameter Ra of the surface of the central hole should be - no more than 6.3 microns.
4.2.1.2 Variability tolerance of the diameter** of the axis in transverse and longitudinal sections must be, mm, not more than:
0.015 - for journals for rolling bearings;
0.05 - for journals for axial plain bearings;
0.05 - for wheel hubs, in the case of a conical shape, the larger diameter should face the middle of the axle;
0.05 - for hub parts for gear wheels or for hubs of gear rims and brake discs;
0.03 - for pre-wheel parts under thrust rings of axle bearings.
4.2.1.3 Radial run-out tolerance when checking in the centers of the axle journals for rolling and plain bearings, wheel hubs, brake discs and gears shall be no more than 0.05 mm.
4.2.1.4 The runout tolerance of the thrust ends of the pre-hub parts of the axle when checking in centers of more than 0.05 mm is not allowed.
4.2.1.5 The axle must be subjected to ultrasonic testing for internal defects and soundness according to GOST 20415 and magnetic testing of surface defects according to GOST 21105.
Requirements for permissible and impermissible defects detected by ultrasonic and magnetic testing, and requirements for the soundness of axes - according to GOST 31334.
4.2.1.6 The surfaces of the axle journals, pre-hub, hub and middle parts, as well as the fillets of the transition from one part of the axle to another, shall be subjected to hardening by rolling with rollers in accordance with GOST 31334.
4.2.2 Wheel and wheel center requirements
4.2.2.1 The difference in the hardness values of solid wheel rims or composite wheel tires for one wheel pair of more than 24 HB units is not allowed.
4.2.2.2 The difference in width of the tire (rim) of the wheel (see Figures 1,2 and 3, size B) is not allowed to exceed 3 mm.
4.2.2.3 The roughness parameter Ra of the seating surfaces shall be:
Wheel hub or wheel center bores:
with the thermal method of formation - no more than 2.5 microns;
with the press method of formation - no more than 5 microns;
The outer surface of the wheel center for the fit of the bandage - no more than 5 microns;
The inner landing surface of the bandage - no more than 5 microns;
Elongated hub for gear wheel fit - no more than 2.5 microns.
** Here and below it is allowed to measure the deviation from the steepness instead of the variability of the diameter in the cross section, and to measure the profile of the longitudinal section instead of the variability of the diameter in the longitudinal section. The tolerance for the steepness and profile of the longitudinal section must be 0.5 of the tolerance value for the variation of the diameter in the transverse or longitudinal section.
4.2.2.4 Variation in diameter is not allowed:
For wheel hub or wheel center bore:
more than 0.05 mm - in cross section;
more than 0.05 mm - in the longitudinal section, in the case of a conical shape, the larger diameter should face the inner end of the hub;
For the outer surface of the wheel center for the fit of the tire:
0.2 - in cross section;
0.1 - in the longitudinal section, in the case of tapering, the direction of the taper of the outer surface of the wheel center must coincide with the direction of the taper of the inner seating surface of the tire, and the difference in the tolerance values for the variability of the diameter of the seating surfaces in the longitudinal section must be no more than 0.05 mm.
4.2.2.5 The upper and lower limit deviations from the nominal value of the diameter of the pairing of the axle and wheel hub (wheel center) by more than plus 2 and minus 1 mm, respectively, are not allowed. The difference in the thickness of the wheel hub (wheel center) at the ends, measured in the radial direction, except for the elongated part of the hub, is not more than 5 mm along the perimeter of the circle.
4.2.2.6 On a wheel center with an elongated hub for fitting a gear wheel, the wheel center hub hole is bored after the gear wheel (composite gear hub) is seated relative to the axis of the pitch circle of the gear wheel, while the alignment tolerance of the hole axis of the hub of the wheel center and the pitch circle of the gear wheel - no more than 0.15 mm.
4.2.2.7 The locations of the holes in the disk part of the wheel for fastening the brake disks shall be located taking into account the minimization of stresses from the action of operational loads.
4.2.2.8 On the inner seating surface of the bandage with a width of up to 10 mm, located at the thrust shoulder and at the undercut for the bandage ring, blackings are not allowed. On the rest of this surface, no more than two drafts with a total area of not more than 16 cm 2 are allowed with a maximum draft length of not more than 40 mm.
4.2.2.9 The junction radii of the profile elements of the tread undercut for the tread ring shall be at least 2.5 mm, the junction radius of the seating surface and the thrust collar shall be at least 1.5 mm. The roughness parameter Ra of the surfaces of the undercut for the retaining ring and for the thrust shoulder should be no more than 10 µm. On the edges of the undercut for the shroud ring, facing the inner seating surface of the shroud and the thrust collar, there must be chamfers of 1.5 mm in size at an angle of 45°. It is allowed to round edges with a radius of 2 mm instead of chamfers.
4.2.2.10 Tolerance of variability of the diameter of the seating surface of the bandage in the cross section should be no more than 0.2 mm, in the longitudinal section - no more than 0.1 mm. In the case of taper, the direction of the taper shall comply with the requirements for the mating surface of the wheel center according to 4.2.2.4.
4.2.2.11 The upper and lower deviations from the nominal value of the tire and wheel center mating diameter by more than plus 3 and minus 1.5 mm, respectively, are not allowed.
4.2.2.12 Cast wheel centers and solid-rolled wheels shall be subjected to ultrasonic testing in accordance with GOST 4491 and GOST 10791, respectively. Rolled, stamped and forged wheel centers must be subjected to ultrasonic testing in accordance with approved regulatory documentation.
By agreement with the consumer, it is allowed to control surface defects in rolled and stamped wheel centers, cast wheel centers, solid wheels using magnetic particle or acoustic methods.
4.2.2.13 The bandage must be subjected to ultrasonic testing in accordance with GOST 398, as well as to magnetic testing for the absence of defects (longitudinal and transverse cracks, hairline, captivity, delamination, etc.) on the inner seating surface.
4.2.2.14 Solid wheels and wheel centers of locomotives with a design speed over 100 to 160 km/h (up to 130 km/h - for MVPS wheel sets) shall be statically balanced, except for wheel centers for wheel sets subjected to dynamic balancing. The residual unbalance of the solid wheel and the wheel center must be no more than 12.5 kg cm. The location of the unbalanced mass must be marked on the rim of the wheel or wheel center by marking the number "0" with a height of 8 to 10 mm.
4.2.2.15 Landing of the bandage on the wheel center is carried out by the thermal method with an interference fit from 1.2-10 -3 to 1.6-10 -3 of the wheel center rim diameter. The shrinkage of the wheel center rim due to plastic deformation after assembly should be no more than 20% of the interference determined before forming.
4.2.2.16 The temperature of the tire before landing on the rim of the wheel center must be from 220 °C to 270 °C. In the process of heating, it is necessary to record on the storage medium a graph of the change in temperature (heating diagram) of the bandage over time, and also to ensure automatic shutdown of the heater when the maximum allowable temperature is reached.
4.2.2.17 The shroud ring is inserted into the groove of the shroud with the thickened side at a shroud temperature of at least 200 °C, and the clamping shoulder of the shroud is finally crimped with a force from 44 10 4 to 49 10 4 N (from 45 to 50 tf) at a temperature of at least 100 °C. After compression of the clamping shoulder, the retaining ring must be tightly clamped in the recess. A gap between the ends of the shroud ring is allowed no more than 2 mm.
4.2.2.18 The clamping shoulder of the tire after the end of the compression must be machined to a diameter corresponding to the outer (fitting) diameter of the wheel center rim with maximum deviations of + 0.2 mm, at a length of (7 + 1) mm from the inner end of the tire, with traces of processing on the bandage ring are not allowed.
4.2.2.19 To control the absence of rotation of the tire on the wheel center during operation, after landing the tire on the outer ends of the tire and the rim of the wheel center on one straight line along the radius of the composite wheel, control marks are applied. Control marks in the form of four to five cores with a depth of 1.5 to 2.0 mm with equal intervals between cores of at least 5 mm are applied no closer than 10 and no further than 45 mm from the inner diameter of the edge of the bandage thrust collar. A reference mark on the rim of the wheel center in the form of a groove with a depth of 0.5 to 1.0 mm and a length of 10 to 20 mm is applied with a blunt tool.
To control the minimum thickness of the rim of a solid wheel, an annular groove in the form of a groove 6 +1 mm wide and 2 +1 mm deep should be applied on the outer end of the rim in accordance with Figure 4.
D - limiting diameter of a wheel with a worn rim
Figure 4 - Annular groove
4.2.2.20 On the control marks apply control strips with a width of 30 to 40 mm:
On the bandage with red enamel for the entire thickness of the bandage;
On the rim of the wheel center - white (yellow) color.
4.2.3 Gear requirements (solid or composite)
4.2.3.1 Roughness parameter Ra of the hole surface of the gear wheel or the hub of the composite gear before fitting onto the axle or elongated hub of the wheel center shall be, µm, not more than:
2.5 - with the thermal method;
5 - with the press method.
4.2.3.2 Tolerance of variability in the diameter of the hole of the gear or the hub of the composite gear in the transverse and longitudinal sections should be no more than 0.05 mm. In the case of Tapered™, the direction of the taper must match the direction of the taper of the seating surface of the axle or wheel center extension hub.
4.2.3.3 The teeth of the gear wheel (crown) shall be subjected to magnetic testing for the absence of surface defects in accordance with GOST 30803.
4.2.3.4 At the request of the customer, the gear wheels of wheel sets of locomotives with a design speed of more than 100 to 160 km/h (up to 130 km/h - for wheel sets of MVPS) must be subjected to static balancing. The residual unbalance should be no more than 12.5 kg cm. The location of the unbalanced mass should be marked with a marking - the number "0" with a height of 8 to 10 mm.
4.3 Wheel set requirements
4.3.1 Nominal basic dimensions of the wheelset (see figures 1, 2, 3):
H = 140 mm - for locomotives (B = 150 mm - for tires without a comb);
H \u003d 130 mm - for MVPS;
C - according to technical documentation;
Composite wheels of locomotives - according to GOST 3225;
Solid-rolled wheels MVPS - according to specifications or drawings;
Composite wheels MVPS - according to GOST 5000.
4.3.2 Profile parameters of solid wheel rims and wheel tires according to:
Figure 5 - for wheel sets of locomotives with a design speed of up to 200 km/h;
Figure 6 - for MVPS wheelsets with design speed up to 130 km/h.
Figure 6 - Profile of the rim of a solid wheel or bandage of a prefabricated wheel of MVPS wheel sets
It is allowed, upon agreement between the manufacturer, the customer and the owner of the infrastructure*, to use the profile of tires (rims) of wheels with other parameters (including wheels without a flange), taking into account that the permissible impact on the track is not exceeded.
For locomotives and MVPS with a design speed up to 200 km/h inclusive, it is not allowed to increase the value of the nominal width of the solid wheel rim or the combined wheel rim in the wheel pair (see Figures 1,2 and 3, size B) by more than 3 mm, and reduce - more than 2 and 1 mm, respectively; for TPS wheelsets with a design speed over 200 km/h - + 1 mm.
Deviations of other sizes - according to the 14th grade (GOST 25346).
4.3.3 Permissible deviation from the nominal value of the diameter in the rolling circle:
Tires of wheel pairs of locomotives according to GOST 3225;
Tires of MVPS wheelsets and tenders in accordance with GOST 5000.
For TRS with a design speed of not more than 200 km/h, the difference in wheel diameters in the plane of the rolling circle for one wheel pair should be no more than 0.5 mm.
For wheel pairs of TRS with a design speed of over 200 km/h, the difference in wheel diameters in the plane of the rolling circle for one wheel pair of more than 0.3 mm is not allowed.
4.3.4 The tolerance of the radial runout of the wheel tread (see Figures 1, 2 and 3, value E) when checking in the centers (axis B) for the TRS should not be, mm, more than:
0.5 - at v K not more than 120 km/h;
0.3 - at v K more than 120 km/h.
4.3.5 The distance between the inner ends of the tires (rims) of the wheels (size L) for the TRS should be:
(1440! h) mm - P R I v k no more than 120 km/h;
(1440 + 1) mm - at v K more than 120 km/h.
4.3.6 The tolerance of end runout of the inner ends of the tires (rims) of the wheels (G) when checking in the centers (axis B) for the TRS should not exceed, mm:
1.0 - at v K not more than 120 km/h;
0.8 - at v K over 120 km/h up to and including 160 km/h;
0.5 - at v K over 160 km/h up to and including 200 km/h;
0.3 - at v K over 200 km/h.
4.3.7 The roughness parameter Ra of the tread profile surfaces and wheel flanges of TRS wheelsets with a design speed of not more than 200 km/h should not be more than 10 µm, the inner ends of the tires (rims) of the wheels - more than 20 µm.
* In the Russian Federation, the owner of the infrastructure is determined by the federal law in the field of railway transport.
For wheel pairs of TRS with a design speed of over 200 km/h, the roughness parameter Ra of the tread profile surfaces, wheel flanges, the inner surface of the tires (rims) of the wheels, as well as the disk part and the wheel hub should not be more than 6.3 microns.
4.3.8 On the inner ends of the wheel rims of wheel sets of TRS with a design speed of not more than 120 km/h, dispersed blacks with a depth of not more than 1 mm, not extending to the radius of mating with the wheel flange, are allowed. The total area of black holes is not more than 50 cm 2 .
4.3.9 The difference in distances from the inner ends of the tires (rims) of the wheels to the thrust ends of the front axle parts (see Figures 1, 2 and 3, size difference C) for one wheel pair should not exceed 2.0 mm at a design speed of up to 200 km /h inclusive.
For wheel sets of TRS with a design speed over 200 km/h, the difference in dimensions C for one wheel set shall not exceed 1.0 mm.
Symmetry tolerance T of the distance between the inner ends of the tires (rims) of the wheels must be equal to the value of the tolerance field for size L according to 4.3.5 when using the middle of the axle as the base (see Figure 2, base K).
4.3.10 Wheel sets with a gear wheel (gear wheels) fixed on the axle (elongated hub of the wheel center) for locomotives with a design speed of over 100 to 120 km/h (up to 130 km/h for MVPS wheel sets) are subjected to a check for residual static imbalance. The value of the residual static unbalance of the wheelset must not exceed 25 kg cm. It is allowed for the wheelsets to provide the value of the residual static unbalance during their formation, taking into account the requirements of 5.1.3.
It is allowed to replace the check for residual static unbalance of wheel sets with a check for residual dynamic unbalance. The value of the residual dynamic unbalance of the wheelset should be no more than 25 kg cm in the plane of each wheel of the wheelset.
4.3.11 For wheel pairs of locomotives with a design speed of over 100 to 120 km/h with a toothed wheel (gears) fixed on the axle (elongated hub of the wheel center) and with an axial bearing housing fixed with the possibility of its rotation relative to the axle, the value of the residual static imbalance must be ensured when forming the wheelset. Wheel center imbalances are located in the same plane on one side of the wheelset axle. The total value of the residual static imbalance of the wheel centers should not exceed 25 kg cm.
It is allowed to replace the check for residual static unbalance of wheel sets with a check for residual dynamic unbalance.
4.3.12 Wheel sets with a gear wheel fixed on the axle for locomotives with a design speed of over 120 km/h (over 130 km/h for MVPS wheel sets) are subjected to a residual dynamic unbalance check.
The value of the residual dynamic unbalance in the plane of each wheel of the wheelset for locomotives must not exceed, kg cm:
12.5 - at v K over 120 to 160 km/h inclusive;
7.5 - at v K over 160 to 200 km/h inclusive.
The value of the residual dynamic unbalance in the plane of each wheel for MVPS wheelsets should not exceed, kg cm:
25 - at v K over 130 to 160 km/h inclusive;
For TRS wheelsets with a design speed over 200 km/h, the value of the residual dynamic imbalance in the plane of each wheel should not exceed 5.0 kg cm.
4.3.13 A wheel set of the TRS, on which the gear wheel is installed in a bearing support, enclosing the axle of the wheel set and fixed on the traction motor, and the transmission of torque to the wheel set is carried out by means of a hollow shaft or an axial gearbox, having the possibility of relative movement in the longitudinal and transverse directions relative to the axis of the wheelset, subjected to a test for residual dynamic imbalance when fixing the bearing support with the gear wheel in the middle position relative to the axis. The value of the residual dynamic unbalance - according to 4.3.12.
It is allowed to subject such a wheel pair to a test for residual static imbalance and provide the value of static imbalance separately for the constituent elements of the wheel pair (wheel centers of composite wheels, parts of the drive of the wheel pair connected to the wheel set).
trom, located on the side opposite to the gear wheel) during its formation, taking into account the requirements of 5.1.3.
The total value of the residual static imbalance of the wheelset should not exceed, kg - cm:
25 - at v K over 120 to 160 km/h inclusive;
15 - at v K over 160 to 200 km/h inclusive.
4.3.14 Paint coatings for wheel sets of locomotives and tenders - in accordance with GOST 31365, wheel sets of MVPS - in accordance with GOST 12549.
For wheel sets of TRS with a design speed of more than 200 km/h, the disk parts of the wheels and the open parts of the axle must be protected with an anti-corrosion coating.
4.3.15 The electrical resistance between the tires (rims) of wheelset wheels should be no more than 0.01 Ohm.
4.3.16 Use in wheelsets of a wheel center with a disk part, the deformation of the shape of which during operation causes an excess of tolerances for the distance between the inner ends of the wheel rims (dimension A, 4.3.5) due to heating of the wheelset elements during prolonged and / or intensive braking by brake pads about the tread surface of the tires, reduction of the thickness of the treads due to wear and repair turning of the tread surface of the tires is not allowed.
4.3.17 Permissible safety factor for axle and wheel fatigue resistance as part of a wheel set for a specific TRS, taking into account the effect of technological and operational loads - in accordance with GOST 31373.
4.3.18 Probability (calculated) of failure-free operation of an axle and a wheel as part of a wheel pair for a specific TRS, taking into account the effect of technological and operational loads - according to GOST 31373.
4.3.19 The endurance limit of the axle and wheel as part of a wheel pair for a specific TRS, taking into account the effect of technological and operational loads - according to GOST 31373.
4.3.20 Permissible safety factor of the static strength of the axle and wheels as part of the wheelset, taking into account the effect of technological and operational loads - according to GOST 31373.
4.4 Marking
Marking and branding of axles of MVPS wheelsets - according to GOST 31334.
The marking of the axles of wheel pairs of locomotives after formation and branding after acceptance tests are applied on the right end of the axle according to Figure 7.
With a one-sided drive, the right end is considered the end of the axis from the side of the gear. With a double-sided drive or a symmetrical arrangement of the gear, marking and branding is performed on any end free for branding and marking. Such an end face with marking and branding is considered right.
When conformity is confirmed after certification, the wheelsets are marked with the sign of circulation on the market in the places where the hallmarks related to the repair of the wheelset are placed, as well as in the wheel set form. If the design features of the wheelset do not allow marking the mark of circulation on the market at the end of the axle, the mark of circulation on the market is put on another surface indicated in the technical documentation or only in the form.
a) For axles with plain and rolling bearings without end fastening with a nut
b) For axles with rolling bearings with end nut fastening
c) For axles with rolling bearings with washer end fastening
Zone / (applied during the manufacture of the axis)
1 - conditional number or trademark of the manufacturer of the raw axle; 2 - month and year (the last two digits) of the production of the draft axis; 3 - the serial number of the melt and the number of the axis; 4 - stamps of technical control of the manufacturer and the representative of the acceptance, who checked the correctness of the transfer of the marking and accepted the finishing axis; 5 - conditional number or trademark of the manufacturer who processed the rough axis
Zone //(applied when forming a wheelset)
6 - designation of the wheel pair formation method [FT - thermal, F - press, TK - combined with the thermal method of landing the wheel (wheel center) and the press method of landing the gear wheel on the axle, TZ - combined with the thermal method of landing the gear and the press method of landing wheel (wheel center) per axle]; 7 - conditional number or trademark of the enterprise that produced the formation of the wheelset; 8-month and year of wheelset formation; 9 - stamps of technical control of the manufacturer and the acceptance representative who accepted the wheel pair; 10 - balancing mark
Note - If the ends of the axles are working elements of the design of the axlebox units, then the markings and stamps are knocked out on the cylindrical surface of the collars or other non-working surface indicated on the working drawing; the height of numbers and letters is from 6 to 10 mm.
Figure 7 - Marking and branding of wheelset axles
4.5 Requirements for accompanying documentation
A form is attached to each wheel pair. In the wheel pair form indicate:
Type (name);
Name and conditional number of the manufacturer;
date of manufacture;
Date and number of the acceptance certificate by the manufacturer;
Designation of the wheel pair drawing;
Data on the axle, solid wheels or wheel centers and tires (casting manufacturer, heat number);
Manufacturer and designation of the drawing of the axle, solid wheels or wheel centers and tires;
The initial dimensions of the main parts of the axle (diameters of journals for rolling and plain bearings, pre-hub and hub parts, diameter of the middle part of the axle), fitting diameters of wheel hubs or wheel centers, outer fitting diameters of wheel centers and inner diameters of tires, wheel diameters along the tread circle and thickness ridges, as well as the thickness of bandages.
The wheel pair form must contain pages for indicating the inspections and repairs carried out at the depot or at the repair plant (date, type of repair, mileage, actual dimensions).
The form for the gear wheel(s) must be attached to the form for the wheelset.
5 Formation of wheelset
5.1 General
5.1.1 The wheelset should be formed by thermal, pressing or combined methods.
5.1.2 With the combined method of forming a wheel pair, the wheels (wheel centers) and the hubs of the brake discs are mounted on the axle by the pressing method, and the gear wheel - by the thermal method. Other combinations of methods for forming the constituent elements of the wheelset are allowed.
5.1.3 In the formation of wheeled part RTPs with a design speed of more than 100 km/h, the unbalanced masses of the wheel centers should be located in the same plane on one side of the axle.
5.1.4 The design of the wheelset must provide channels for supplying oil under pressure to the connection area of the wheel, gear wheel (gear wheel hub) and brake disc hub with the axle to disassemble the wheel pair (oil removal).
5.2 Thermal shaping method
5.2.1 Wheelsets are formed by the thermal method in accordance with the requirements of ND* approved in the prescribed manner.
5.2.2 Local heating of a solid wheel hub, gear wheel or wheel center assembly with a tire is not allowed.
From 0.85 10 _3 to 1.4 10 _3 diameters of mating parts for hubs of wheel centers and wheels;
From 0.5 10 -3 to 1.0 10 -3 diameters of mating parts for gear wheel hubs and brake discs.
5.2.4 The seating surface of the axle must be coated with an anti-corrosion coating.
It is recommended to use natural drying oil according to GOST 7931 or heat-treated vegetable oil (sunflower oil according to GOST 1129** or linseed oil according to GOST 5791) as an anti-corrosion coating for the seating surfaces of the axle. It is allowed to use other anti-corrosion coatings that have passed the tests for resistance to fretting corrosion of mating parts and do not reduce the fatigue strength of the axis.
5.2.5 Before forming, the parts mounted on the axle, except for gear wheels, are uniformly heated to a temperature from 240 °C to 260 °C and the heating diagram is recorded. The heating temperature of gears made of alloyed steels - no more than 200 °C, gears made of steel grade 55 (F) *** - no more than 260 °C. The heating temperature of gears containing non-metallic elastic elements should not exceed 170 °C.
* On the territory of the Russian Federation, these requirements are established in GOST R 53191-2008.
** On the territory of the Russian Federation, GOST R 52465-2005 applies (hereinafter).
*** On the territory of the Russian Federation, these requirements are established in GOST R 51220-98.
5.2.6 After completion of the formation by the thermal method and cooling of the assembled wheel set to a temperature not exceeding the ambient temperature by more than 10 °C, the strength of the connection of the elements of the wheel set for the TRS with a design speed of not more than 200 km/h must be checked for a shift of the control axial load:
(636 + 20) kN [(65 + 2) tf] - for every 100 mm of the diameter of the axle hub parts for the landing of running wheels or wheel centers for wheel sets of locomotives;
(568 + 20) kN [(58 + 2) tf] - for every 100 mm of the diameter of the axle hub parts for the fit of running wheels or wheel centers for MVPS wheel sets;
(432 + 20) kN [(44 + 2) tf] - for every 100 mm of the diameter of the hub parts of the axle for fitting a gear wheel or hub of a compound gear wheel (one or two) for wheel sets of locomotives with a nominal wheel diameter in the tread circle of at least 1200 mm;
(294 + 20) kN [(30 + 2) tf] - for every 100 mm of the diameter of the hub parts of the axle for fitting a gear wheel or hub of a compound gear wheel (one or two), a brake disc hub (one or two) for TPS wheelsets with a nominal diameter of the wheel in a circle of rolling up to 1200 mm;
(245 + 20) kN [(25 + 2) tf] - for every 100 mm of the diameter of the elongated hub of the wheel center for the fit of the gear wheel.
It is allowed to increase the set maximum value of the control axial load by 10%, taking into account the established interference.
It is allowed to check the fit of the gear wheel on the elongated hub of the wheel center with the control torque (9.8 + 0.8) kN m [(1.0 + 0.08) tf m] per square of every 100 mm of the diameter of the elongated hub of the wheel center. After landing the gear wheel on the elongated hub of the wheel center, a control mark is applied to the plane adjacent to the seating surface. The control mark is applied with a blunt tool in the form of a groove with a depth of not more than 0.5 mm and a length of not more than 10 mm.
For wheel sets of TRS with a design speed of over 200 km/h, the control axial load in kilonewtons should be taken in the range of 5.2 - 5.8 d (d is the diameter of the axle hub, mm) in accordance with the preloads for this connection established in the design documentation (running wheel, wheel center, gear wheel, compound gear wheel hub, brake disc hub with axle).
Shift or rotation (displacement of control marks) in the connection is not allowed.
5.3 Press forming method
5.3.1 Parts mounted on the axle (wheels, wheel centers or wheel centers complete with tires, gear wheels, brake disc hubs) and the axle must have the same temperature before pressing. It is allowed to exceed the temperature of the wheel above the temperature of the axle by no more than 10 °C.
5.3.3 The seating surfaces of the axle and parts mounted on the axle must be covered with an even layer of natural drying oil in accordance with GOST 7931 or heat-treated vegetable (hemp in accordance with GOST 8989, linseed in accordance with GOST 5791 or sunflower in accordance with GOST 1129) oil. It is allowed to use other anti-corrosion coatings that have passed the tests for resistance to fretting corrosion of mating parts and do not reduce the fatigue strength of the axle.
5.3.4 Pressing the parts onto the axle and checking for shear by the control-axial load is carried out on a hydraulic press. The press must be equipped with a calibrated force control device and an automatic recording device that records on paper or electronic media a diagram of the pressing force of the wheel (wheel center), gear wheel, brake discs relative to the seat during the entire pressing operation.
The accuracy class of the recording device must be at least 1.5%, the error of the chart course should not exceed 2.5%, the thickness of the recording line should not exceed 0.6 mm, the width of the chart tape should be at least 100 mm, the recording scale along the length should be not less than 1:2, along the height of the diagram 1 mm must correspond to a force of not more than 24.5 kN (2.5 tf).
5.3.5 Pressing the wheels (wheel centers) onto the axle and pressing the gears onto the axle or wheel center (brake disks) for wheel sets of the TRS with a design speed of not more than 200 km/h is carried out with final pressing forces, which must correspond to those indicated in the table 1, when the speed of the hydraulic press plunger is not more than 3 mm/s.
Table 1 - Final pressing forces when forming a wheel pair by pressing
* When pressed onto an extended wheel center hub.
** In the numerator, the values are for wheelsets with wheel diameters up to 1200 mm, in the denominator - over 1200 mm.
5.3.6 The pressing of wheels, brake discs and gears onto the axle for wheel pairs of the TRS with a design speed of over 200 km/h is carried out at a diameter d in millimeters with final pressing forces in kilonewtons in the range from 3.9 to 5.8 d with a length conjugation from 0.8 d to 1.1 d.
5.3.7 A normal pressing indicator diagram should have the form of a smooth curve, slightly convex upwards, growing along the entire length from the beginning to the end of the pressing. A template - a diagram of the pressing of wheel sets is shown in Figure 8.
The following deviations from the normal shape of the pressing pattern are allowed.
R. - 01Р ■ "min w, ll min
1 - field of satisfactory pressing diagrams;
2 - maximum curve; 3 - minimum curve; Р-pressing force, kN; P max, P t \ n - respectively, poppy
49.0 maximum and minimum final pressing forces in
0 according to table 1; L - theoretical length dia
grams, mm
Figure 8 - Template - pressing diagram
5.3.7.1 At the starting point of the diagram (the zone of transition of the conical part into the cylindrical part), an abrupt increase in force is not more than 49 kN (5 tf) followed by a horizontal section of not more than 5% of the theoretical length of the diagram L.
5.3.7.2 Presence of areas or depressions on the diagram at the location of recesses for oil channels on the hubs, the number of which must correspond to the number of recesses.
5.3.7.3 Diagram concavity with a continuous increase in force, provided that the entire curve, except for the platforms and depressions specified in 5.3.7.2, is placed above the straight line connecting the beginning of the curve with a point indicating in this diagram the minimum allowable force P min for this type of axle.
5.3.7.4 A horizontal straight line on the diagram at the end of the press-in for a length not exceeding 15% of the theoretical diagram length L, or a force drop of not more than 5% of the pressing force Pmax over a length not exceeding 10% of the theoretical diagram length L.
5.3.7.5 Stepwise increase in force at the end of the diagram, if the design of the wheelset or the technology of formation provides for a fit to the stop in any element.
5.3.7.6 Force fluctuation at the end of pressing with an amplitude of not more than 3% of the pressing force Pmax over a length not exceeding 15% of the theoretical length of the diagram L when pressing in wheels with an extended hub.
5.3.7.7 Deviation from measurement accuracy up to 20 kN (2 tf) when determining the maximum maximum force from the diagram.
5.3.7.8 If the final pressing force of wheel pairs is up to 10% less or greater than the limit value of the range specified in Table 1 (without taking into account the permissible stepwise increase in force according to 5.3.7.5), the manufacturer, in the presence of the customer, must check the press fit by applying a test axial load three times in the opposite direction from the pressing force. To check the reduced final press-in force, the reference axial load must be equal to 1.2 times the actual press-in force. To check the increased final press-in force, the reference axial load must correspond to the maximum press-in force according to table 1.
5.3.7.9 The actual length of the pressing pattern shall be at least 85% of the theoretical length of the pattern L, mm, which is calculated by the formula
L \u003d (C + L 2)i,
where L 1 is the length of the contact area of the hub of the wheel center with the axle, mm;
/_ 2 - additional advancement of the hub (if provided in the design documentation), mm;
/ - chart scale in length.
The actual length of the pressing pattern for the brake disc hub must be at least 105 /".
5.3.7.10 If an unsatisfactory diagram is obtained or the value of the final pressing force does not correspond to the value specified in Table 1, it is allowed to re-press (no more than two times) the wheel (wheel center) onto the axle without additional machining of the seating surfaces in the absence of burrs on the seating surfaces of the axle and wheel hub ( wheel center).
When re-pressing the wheel (wheel center) onto the axle, the value of the lower limit of the final force specified in Table 1 must be increased by 15%.
6 Acceptance rules
6.1 Wheel sets are subjected to control for compliance with the requirements of this standard during acceptance tests (PS), periodic (P), type (T) tests in accordance with GOST 15.309 and tests for confirmation of conformity (C).
The list of controlled parameters and test methods for the wheelset is given in Table 2.
table 2
|
Controlled parameter |
Clause of the standard containing the requirements that are checked during testing |
tests* |
|||
|
delivery |
periodical |
for confirmation of compliance |
|||
|
1 Dimensions, tolerances and shape |
4.2.1.2-4.2.1.4, 4.2.2.2, 4.2.2.4, 4.2.2.5, 4.2.2.9-4.2.2.11, 4.2.2.17^t.2.2.19, 4.2.3.2, 4.3.1-4.3.6, 4.3.8, 4.3.9 |
4.3.3-4.3.6, 4.3.9 |
7.1.2, 7.1.4 (PS, P, T), 7.1.5 |
||
|
2 Appearance and condition (quality) of the surface, including the finish (roughness) |
4.2.1.1,4.2.2.3, 4.2.2.8, 4.2.2.E, 4.2.3.1,4.3.7, 4.3.8 |
7.1.1 (PS, S), 7.2 (P, S) |
|||
|
3 Mechanical properties and chemical composition |
7.1.15 (PS), 7.2 (P) |
||||
|
4 Roll hardening | |||||
|
5 Heating temperature of mating parts |
4.2.2.16, 4.2.2.17, 5.2.2, 5.2.5, 5.3.1 | ||||
|
6 The presence of defects in the metal: Ultrasonic control Magnetic control Acoustic control |
4.2.1.5,4.2.2.12,4.2.2.13 4.2.1.5.4.2.2.13.4.2.3.3.4.2.11 | ||||
|
7 Imbalance: Static Dynamic |
4.2.2.14, 4.3.10, 4.3.11,4.3.13, 5.1.3 4.3.12 | ||||
|
8 Preload value of mating parts |
4.2.2.15, 5.2.3, 5.3.2 | ||||
|
9 Strength of connection of mating parts |
4.2.2.17, 5.2.6, 5.3.5-5.3.7 |
5.2.6, 5.3.4- 5.3.6 |
7.1.10 (PS, C), 7.1.11 (PS), 7.2 (P,S) |
||
|
10 Profile parameters of the tire (rim) of the wheel in a circle of rolling | |||||
|
11 Electrical resistance | |||||
|
12 Wheel center shrinkage due to plastic deformation | |||||
|
13 Change in distance (dimension A) from heating during braking and reduction in the thickness of bandages during turning | |||||
|
14 Fatigue resistance factor of the axle and wheels as part of the wheelset | |||||
|
15 Static strength factor of the axle and wheels as part of a wheel pair | |||||
|
16 Endurance limit of the axle and wheel as part of the wheelset | |||||
End of table 2
* For parameters not marked by types of tests, tests are carried out for all types of tests.
6.2 Acceptance tests
6.2.1 Acceptance testing of parts of a wheel set and each wheel set as an assembly must be carried out prior to their painting with the presentation of certificates, other documents confirming the quality, charts for checking wheels for shear or pressing charts, as well as forms for wheelset and gears.
6.2.2 On the elements and the wheelset that have passed the acceptance tests, the manufacturer's acceptance stamps must be applied, and if they are also carried out by another control organization, its acceptance stamp.
6.2.3 In case of non-compliance with the requirements of this standard, the parts of the wheelset prepared for assembly and the wheelset must be rejected.
6.3 Periodic testing
6.3.1 Periodic tests should be carried out at least once a year in the scope of acceptance tests, and it is necessary to additionally control:
The quality of surface treatment - on two parts of each design;
Roll hardening quality - according to GOST 31334;
The strength of the bandage connection with the wheel center is on two pairs of wheels from each standard size of the bandage.
6.3.2 In case of non-compliance with the requirements of this standard on at least one sample (part), the tests are repeated on twice the number of wheel sets. In case of unsatisfactory test results, the acceptance of wheel sets is stopped until the cause is eliminated.
6.4 Type tests
6.4.1 Type tests should be carried out:
When changing the design of the wheelset (by parameters 1-3, 5, 7-17 of Table 2);
When using materials with other mechanical properties, changing the technological process for manufacturing wheel pair parts and their blanks, or changing the manufacturer (by parameters 1-6, 8-10, 12, 14-17 of Table 2);
When changing the method of forming a wheelset (by parameters 1,2,4,5,8,9,12 of Table 2);
In case of changes in the brake system that affect the mechanical or thermal load on the wheel pair (wheel) (according to parameters 1-3, 5, 8, 9, 13 of Table 2);
With an increase in the axial load on the wheelset or design speed, a change in the loading scheme (by parameters 1-5, 7-9, 13-17 of Table 2).
6.4.2 The conditions for carrying out type tests must correspond to the operating conditions of wheel sets in terms of the main parameters (static and dynamic loads from the wheel set on the rails, speed, traction and braking force).
6.5 Sampling rules for wheel sets
Tests to confirm the conformity of wheel sets are carried out on samples selected by random selection in accordance with GOST 18321, which have passed acceptance tests. The number of samples for testing to confirm the conformity of wheel sets is taken at least two.
7 Test methods
7.1 During acceptance tests, compliance with the requirements of this standard is determined by the following means and methods.
7.1.1 The appearance and quality of surface treatment must be checked by visual inspection using surface roughness samples in accordance with GOST 9378 or with a profilometer. The control of roughness parameters is carried out at three points equidistant from each other along the circumference.
7.1.2 Errors allowed when measuring linear dimensions - according to GOST 8.051.
When controlling dimensions over 500 mm, the maximum error of the particular measuring instrument used should not exceed 1/3 of the tolerance value established by this standard.
The radial and end runout is checked with a dial indicator and is determined as the arithmetic mean of the results of at least three measurements.
7.1.3 The value of the interference fit of the mating parts is determined before the formation of the wheel pair by measuring the fit diameters of their mating points with a micrometric caliper according to GOST 868 and a micrometric clamp according to GOST 11098 in three sections along the length of the fit and in two mutually perpendicular planes. The average value of the results from every six measurements should be taken as the value of the diameter of the measured place of mating of the parts.
It is allowed to use another measuring tool that provides the necessary measurement accuracy.
7.1.4 The correctness of the actual combinations of seating surface tapers should be checked by comparing the measurement results according to 7.1.3 according to the measurement values in two extreme sections along the seating surface fit length in two mutually perpendicular planes. For the value of the diameter in the extreme section of the landing, the average value of two measurements in each section should be taken.
7.1.5 The width of the compound wheel tire is measured in three sections along the circumference at a distance of at least 100 mm from the extreme numbers of the marking.
7.1.6 The profile of the tire (rim) of the wheel should be checked with an appropriate template with maximum deviations for its dimensions + 0.1 mm. In the permissible gap between the template and the profile of the tire (rim) of the wheel, a probe with a thickness of more than 0.5 mm along the tread surface and the thickness of the ridge, 1 mm - along the height of the ridge, while the template must be pressed against the inner end of the tire (rim) of the wheel .
7.1.7 The absence of surface defects of the axle, wheel, tire, as well as the gear wheel (crown) must be checked by visual inspection methods in accordance with GOST 23479, magnetic inspection in accordance with GOST 21105, the absence of internal defects - by ultrasonic inspection in accordance with GOST 12503. Absence of internal defects of the wheel center must be checked by ultrasonic testing according to GOST 12503, the absence of surface defects - by visual testing according to GOST 23479, magnetic testing according to GOST 21105 and acoustic testing - according to GOST 20415.
Note - When evaluating the results of ultrasonic testing, samples of the enterprise that identify the defect and have valid verification certificates are used.
7.1.8 Residual static or dynamic unbalance is checked on the wheelset or separately for the components when forming the wheelset in accordance with Appendix A.
7.1.9 The heating temperature of the parts of the wheelset before their landing should be controlled according to the heating diagram using instruments and devices that control the temperature rise, not allowing it to exceed its limit value. Measurement error - + 5 °C.
7.1.10 The strength of the connection of parts with the axis must be checked:
With the press fitting method - according to the shape of the pressing diagram and its correspondence to the final pressing forces in accordance with Table 1. To check the validity of the pressing diagrams, it is recommended to use an invoice template;
With the thermal method of landing - three times the application of a regulated control axial (shear) load to the joint, while loading diagrams are recorded.
The strength of the fit of the gear wheel on the elongated hub of the wheel center is checked by the control torque (for rotation) according to 5.2.6, while loading diagrams are recorded.
7.1.11 The tightness of the fit of the tire and compression of the tire ring on each wheel pair should be checked after the wheel has cooled down by tapping with a metal hammer (GOST 2310) on the tread surface and the tire ring at least at four equidistant points. Muffled sound is not allowed.
7.1.12 The electrical resistance should be checked on the wheelset installed on the supports of the device, which allows measuring the electrical resistance between the tires (rims) of the wheelset wheels according to ND *, approved in the prescribed manner.
7.1.13 Markings should be checked visually. Wheels with illegible markings must be rejected.
7.1.14 Quality control methods for painting wheel sets of locomotives in accordance with GOST 31365, MVPS in accordance with GOST 12549.
7.1.15 The mechanical properties and chemical composition of the metal of wheel pair parts must be confirmed by documents on the quality of the enterprises producing blanks (forgings).
7.2 During periodic testing, compliance with the requirements of this standard is determined by the following means and methods:
The quality of surface treatment of parts before the formation of a wheelset - control of surface roughness parameters in accordance with GOST 2789;
The quality of hardening by rolling - cutting out longitudinal sections from the axes in the neck, sub-hub, middle part, as well as selectively at the locations of the fillets according to the ND **, approved in the prescribed manner;
The strength of the bandage connection with the wheel center - by measuring the actual dimensions of the connection after removing the bandage, calculating the preload value and comparing it with the initial preload value;
The mechanical properties of the metal must be checked on cut samples - wheels according to GOST 10791, axles according to GOST 31334, wheel centers according to GOST 4491, tires according to GOST 398 or other approved RD.
7.3 For type tests, compliance with the requirements of this standard is determined by the following means and methods.
7.3.1 The decrease in the actual tightness (shrinkage) of the wheel center must be determined by measuring the diameters of the fitting surfaces of the mating parts in three planes at an angle of 120° along the entire circumference, before installation and after removing the bandage - according to 7.2, while the decrease in tightness should not exceed the specified in 4.2.2.15.
7.3.2 The change in the distance between the inner ends of the wheel rims due to heating during braking with the shoes on the wheel tread surface must be determined by the calculation method finite elements with idealization (breakdown) of the wheel by three-dimensional elements or an experimental method, by reproducing a long braking mode for 20 minutes at a brake pad pressure coefficient of up to 0.5 of the maximum at a speed of at least 40 km / h on long descents and stopping braking following lengthy.
7.3.3 The change in the distance between the inner ends of the wheel tires due to a decrease in the thickness of the tire (rim) due to wear and repair turning of the tread profile is determined by the finite element calculation method with the idealization (breakdown) of the wheel by volumetric elements or by the experimental method of layer-by-layer turning of the tread surface of the tire (rim) wheels from the maximum to the maximum thickness established in the rules for the technical operation of railways ***.
7.3.4 Determination of the value of the fatigue resistance factor of the axle and wheel as part of the wheelset for a specific TRS, taking into account the effect of technological and operational loads - in accordance with GOST 31373.
7.3.5 Determination of the value of the endurance limit of the axle and wheel as part of a wheel pair for a specific TRS, taking into account the effect of technological and operational loads - according to GOST 31373.
7.3.6 Determination of the value of the static strength factor of the axle and wheels and the probability (calculated) of the failure-free operation of the axle and wheels as part of the wheel pair, taking into account the effect of technological and operational loads - according to GOST 31373.
7.4 The test results are recorded in the test reports.
The test report must contain the following data:
date of testing;
Type of tests;
Wheel pair designation;
Measuring tool;
Test results.
* On the territory of the Russian Federation, these requirements are established in GOST R 52920-2008.
** On the territory of the Russian Federation, these requirements are established in.
*** On the territory of the Russian Federation, these requirements are established in.
7.5 The measuring instruments used must have type approval certificates and valid verification certificates.
The equipment used must be certified in accordance with the legislation on ensuring the uniformity of measurements.
8 Transport and storage
8.1 When loading wheelsets onto a railway platform or a car with wooden floors, they should be positioned symmetrically to the longitudinal axis of the platform (body), fixing the wheels with wooden wedges nailed to spacer boards attached to the floor of the vehicle. The wheelsets must be firmly attached to the floor with annealed wire 6 mm in diameter to prevent possible impacts of the wheelsets against each other. When transporting wheelsets on a railway platform or a car with metal floors, wheelsets should be installed on special supports, which are fixedly fixed on the vehicle.
8.2 During storage and transportation of the wheelset of the neck, the hub parts of the axles and the rims of the gear wheels must be coated with an anti-corrosion compound in accordance with protection groups 1-2, protection option VZ-1 in accordance with GOST 9.014.
Before transporting the wheelset, the necks of the axles and the teeth of the gears must be protected by tires - belts made of wooden planks strung on a wire or rope or nailed to a metal or keeper tape. Gear teeth should be wrapped with moisture-proof paper and protected from damage.
Metal tape, wire and nails should not touch the axle neck.
For long-term storage, it is allowed to additionally wrap the necks and gear wheels with burlap, glassine.
8.3 The axial bearings of the gearbox or traction motor must be covered with protective covers, and the bearings of the levers of the reactive moments of wheel pairs of diesel trains must be wrapped with burlap.
8.4 During transportation and storage it is not allowed:
Discard wheelsets and their elements;
Grab hooks and chains of lifting mechanisms of the neck and the tread parts of the axles of wheel pairs;
Store wheelsets on the ground without mounting on rails.
8.5 Each wheel pair must be affixed by the sender to a metal or wooden plate stamped or painted with the following data:
The name of the sender;
Destination,
Wheelset number.
In the case of delivery of a wheel pair with axle boxes, the bolt of fastening of the front cover of the right axle box must be attached metal plate with the wheel pair number stamped on it, if it is not stamped on the axle box body or front cover.
9 Manufacturer's warranties
9.1 The manufacturer guarantees the compliance of the wheel sets with the requirements of this standard, provided that the operating rules * and the requirements of section 8 are observed.
9.2 The warranty period for the strength of the connection of parts (axle, wheel, wheel center, gear wheel) is 10 years.
Note - The warranty is terminated in case of re-formation of the wheelset.
9.3 Warranty periods for the operation of wheel pair parts:
Axes - according to GOST 31334;
Solid-rolled wheels - according to GOST 10791;
Cast wheel centers - according to GOST 4491;
Bandages - according to GOST 398;
* On the territory of the Russian Federation, these requirements are established in.
Gears - according to GOST 30803;
Other parts - according to specifications for a specific part.
Note - Warranty periods are calculated from the date of commissioning of the wheelset, indicating in the form the date of installation of the wheelset under the TRS.
10 Occupational safety requirements
10.1 When inspecting, surveying and forming wheelsets, labor safety requirements in accordance with GOST 12.3.002 must be met.
10.2 When carrying out work on the formation of wheelsets, measures should be taken to protect workers and the environment from the effects of hazardous and harmful production factors in accordance with GOST 12.0.003.
10.4 Work related to the production and testing of wheel sets must be carried out in rooms equipped with supply and exhaust ventilation in accordance with GOST 12.4.021.
10.5 Indicators of the microclimate of industrial premises must comply with the requirements of ND **, approved by the authorized national executive body.
10.6 The level of noise and vibration at workplaces should not exceed the standards established in the RD **, approved by the authorized national executive body.
10.7 Illumination of industrial premises and workplaces must comply with the requirements of building codes and regulations.
10.8 Personnel involved in the production of wheelsets must be provided with personal protective equipment in accordance with GOST 12.4.011.
* On the territory of the Russian Federation, these requirements are established in the hygienic standards "Maximum Permissible Concentrations (MPC) of harmful substances in the air working area"(GN 2.2.5.1313-03), approved by the Ministry of Health of the Russian Federation on April 27, 2003.
** On the territory of the Russian Federation, these requirements are established in the “Hygienic Requirements for the Microclimate of Industrial Premises. Sanitary rules and norms” (SanPiN 2.2.4.548-96), approved by the State Committee for Sanitary and Epidemiological Supervision of Russia on 01.10.1996.
Annex A (mandatory)
Checking residual static and dynamic imbalances
A.1 Checking the residual static unbalance
Residual static unbalance is checked on a wheelset installed with axlebox journals on the supports of a balancing stand. In the event of a spontaneous stop of a wheel pair swinging on the stand, the radius vector of the unbalance is directed downwards.
To determine the value of the residual static imbalance, a load of mass m is selected and attached to the upper part of one of the wheels at a radius r so that its imbalance is equal to the initial imbalance.
If the imbalances are equal, the wheel pair has a state of equilibrium on the horizontal supports of the stand in any of its positions when turning about the axis of rotation.
Residual static unbalance of the wheelset D rest, kg ■ cm, is calculated by the formula
and compared with the allowable values according to 4.3.10, 4.3.11, 4.3.13.
If the permissible value of the residual static imbalance is exceeded, the wheelsets are subjected to additional local turning, followed by a re-check.
stand support
m 1 - unbalanced mass of the wheelset; m - corrective mass; r v g - distance from the axis of rotation to the center of mass
Figure A.1 - Scheme of static balancing of the wheelset
A.2 Checking the residual dynamic unbalance
Dynamic unbalance is checked on a wheelset installed on a balancing stand. The stand must ensure the registration of an imbalance of at least 0.2 of the maximum value established by the requirements of this standard.
The values of the residual dynamic imbalance of the wheelset are determined by measuring the dynamic impact of the inertial forces of the rotating masses of the wheelset with the set speed and fixing their value and direction in the plane of the wheels. To do this, the stand is equipped with appropriate measuring sensors and recording equipment.
The obtained values of the residual dynamic unbalance of the wheelset are compared with the allowable values according to 4.3.12.
If the permissible value of the residual dynamic imbalance is exceeded, it is eliminated similarly to the static imbalance by local turning of the wheel, followed by re-checking.
Bibliography
TI 32 TsT-VNIIZhT-95 Technological instruction for hardening by rolling with rollers of wheel axles
pairs of locomotives and motor cars, approved by the Ministry of Railways of Russia on 19.04.1995
Rules for the technical operation of the railways of the Russian Federation, approved by the Ministry of Transport of Russia on December 21, 2010, order No. 286
UDC 669.4.027.11:006.354 MKS 45.060 D56 OKP 31 8381
Key words: traction rolling stock, 1520 mm track gauge, wheel pairs, wheel (running), axle, wheel center, tire, tire ring, gear wheel, wheel rim, wheel hub, technical requirements, wheel pair formation, marking, acceptance rules, methods of control, manufacturer's guarantees, labor protection, environmental protection
Editor R.G. Goverdovskaya Technical editor N.S. Goishanova Proofreader M.I. Pershina Computer layout V.I. Goishchenko
Handed over to the set 09/25/2012. Signed for publication on October 25, 2012. Format 60x84 1 / 8 . Arial headset. Uel. oven l. 3.72.
Uch.-ed. l. 3.40. Circulation 118 copies. Zach. 947.
FSUE "STANDARTINFORM", 123995 Moscow, Granatny per., 4. Typed in FSUE "STANDARTINFORM" on a PC.
Printed in the branch of FSUE "STANDARTINFORM" - type. "Moscow printer", 105062 Moscow, Lyalin per., 6.
We have made significant changes to this page of the site according to the comments . They are connected, first of all, with GOST 4835-2006, which establishes new types and sizes of wheel sets. We draw the attention of readers to the fact that according to this GOST, RU1 axles (with threads and castellated nuts) are no longer produced, and the wheel diameter along the rolling circle is not 950 mm, as it was before, but 957 mm.
Wheelsets are part of the chassis and are one of the critical elements of the car. They are designed to guide the movement of the car along rail track and the perception of all loads transmitted from the car to the rails during their rotation. Working under difficult loading conditions, wheel sets must provide high reliability, since the safety of train traffic largely depends on them. Therefore, they are subject to special, increased requirements of the State Standard, the Rules for the Technical Operation of Railways, the Instruction for the Survey, Repair and Formation of Carriage Wheel Sets, as well as others. regulations in design, manufacture and maintenance. Construction and technical condition wheelsets affect the smoothness of the ride, the magnitude of the forces arising from the interaction of the car and the track, and the resistance to movement.
Working in modern modes of operation of railways and extreme environmental conditions, the wheelset of the car must meet the following basic requirements: to have sufficient strength, while having a minimum unsprung mass in order to reduce the tare of the rolling stock and reduce the direct impact on the rail track and car elements when passing rail track irregularities; have some elasticity, providing a reduction in the noise level and mitigation of shocks that occur when the car moves along the track; together with the axleboxes, provide, possibly, less resistance during the movement of the car and, possibly, greater resistance to wear of elements subject to wear in operation.
Classification of wheel pairs. Improving their designs
The wheel pair (Fig. 1) consists of axle 1 and two wheels mounted on it 2 . Types, main dimensions and technical conditions for the manufacture of wagon wheelsets are determined by the State Standards, and the maintenance and repair of the "Rules for the technical operation of railways" (PTE) and "Instructions for the inspection, survey, repair and formation of wagon wheelsets TsV / 3429", and as well as other regulatory documents in the design, manufacture and maintenance. The design and technical condition of the wheelsets affect the smoothness of the ride, the magnitude of the forces arising from the interaction of the car and the track, and the resistance to movement.
The type of wheelset is determined by the type of axle and the diameter of the wheels(Table 1). According to GOST 4835-2006, five types of wheelsets are installed with axles of types RU1Sh and RV2Sh and wheels with a diameter of 957 mm along the tread circle, depending on the type of car and the maximum design static load from the wheelset on the rails (table 1).
Table 1 Types of wheel pairs of wagons
|
Wheelset type |
Wagon type |
Car design speed, km/h |
Maximum calculated static load from the wheelset on the rails, kN (tf) |
|
Cargo |
|||
|
Passenger |
|||
|
Non-motorized electric trains |
|||
|
Non-motorized diesel trains |
|||
|
Cargo |
An example of a symbol for a wheel pair for a freight car with a RU1SH type axle and wheels with a diameter of 957 mm with axleboxes:
Wheel set RU1Sh-957-G GOST 4835-2006
The same, without axle boxes:
Wheel set RU1Sh-957 without axle boxes GOST 4835-2006
At present, RU1 axles with end fastening with an M110 nut are excluded from GOST 4835-2006, and most plants have stopped producing axles of this type. Wheel sets RU1-950 and RU1SH-950 can still be found in operation.
Neck diameters 3 , (Fig. 1), sub-hub 5 and middle 6 axle parts are determined based on the calculated load. Pre-incisor part 4 is a stage of transition from the neck to the hub part of the axle and serves to install the sealing devices of the box body. On hub parts 5 wheels firmly attached 2 . On necks 3 bearings are placed.
Rice. 1. Wheelset and axle journal shape: 1 - axis; 2 - wheel; 3 - neck; 4 - pre-hub part; 5 - substand part; 6 - middle part; 7 - threaded part
Wheelsets with axles intended for operation with roller bearings are distinguished from each other by the design of the end fastening of the inner rings of roller bearings on the neck:
with a threaded part 7 for screwing the castellated nut (axis RU1);
with the help of an attachment washer, for which purpose threaded holes are made at the ends for the fastening bolts (axis РУ1Ш Fig. 1). This fastening is made in two versions: three or four bolts.
Much attention was paid to the strength and reliability of wheel sets when creating the first wagons. The normal axle until 1892 had the diameters of the necks, hub and middle parts, respectively, 100, 135 and 126 mm. In connection with the increase in the carrying capacity and tare of wagons, as well as the speed of trains, the loads acting on the wheelsets increased, which required strengthening of their elements. As a result, the diameters of the axles increased, the design of the wheels improved, and the strength of their fit on the axle increased.
In pre-revolutionary Russia, wheel sets were equipped with composite (shroud) wheels, consisting of a wheel center, a bandage and elements reinforcing it. Until 1892, wheels were used, the centers of which were wooden (Fig. 2) (Menzel's wheels). They were made from hard wood. A wooden disk was placed in the wheel center 2 , consisting of 16 teak sectors. He was between the bandage 1 and hub 3 , was fastened to them with rings 4 and 5 bolted 6 .
Fig.2 Wheel with wooden center
As noted, in those days, such wheels had a silent and relatively quiet ride, and softened vertical shocks. However, due to the shrinkage of the tree during operation, the bolts weakened, which violated the safety of train traffic and led to the need for constant monitoring of the condition of the fastening.
Therefore, wheels with wooden centers (Menzel wheels) were removed from service. Until 1900, forged centers became widespread, then cast spoke, steel and cast iron discs. In 1948, the production of cast-iron centers was discontinued due to the large mass, low strength and frequent damage during the formation of wheelsets. The production of spoke centers also stopped due to the uneven rigidity of the rim and the weakening of the connection with the bandage, air turbulence. The swirl of air caused sand to get on the rubbing surfaces of the chassis and increased wear and tear of the metal.
In 1931, a transition was made from shroud wheels to more advanced tireless ones, which was completed in the 70s. In 1953, the production of cast-iron wheels was also discontinued, as they often had dents, shells, and spalls that threatened the safety of train traffic and shortened their service life. Cast steel have proved to be more reliable in operation. Since 1935, the production of solid-rolled wheels has been organized, which have significant advantages over cast ones. Over the years, solid-rolled wheels have improved, and they have become widespread.
For the safe movement of the car along the rail track, wheels 2 are firmly fixed to axle 1 (Fig. 3) with strictly defined dimensions. The distance between the inner edges of the wheels2s is: for new wheelsets intended for cars circulating at speeds up to 120 km / h - (1440 ± 3), over 120, but not more than 160 km / h - (1440) mm. Nominal tread distance2l equal to 1580 mm, and between the centers of the necks2b - 2036 mm.
Fig.3. The main dimensions of the wheelset
To avoid uneven load transfer to wheels and rails size differencek from the end of the axle to the inner edge of the rim, no more than 3 mm is allowed. Wheels mounted on the same axle must not have diameter differenceD more than 1 mm, which prevents one-sided wear of the ridges and does not allow an increase in resistance to movement. In order to reduce inertial forces, the wheel pairs of high-speed cars are subjected to dynamic balancing: for speeds of 140...160 km/h, an imbalance of no more than 6 Nm is allowed; for speeds of 160...200 km/h - no more than 3 Nm. The nominal width of the wheel rim for all types of wheelsets is 130 mm.
In addition to wheelsets manufactured in accordance with GOST 4835-80, they also supply structures made according to special drawings and specifications for industrial transport cars, cars of electric and diesel trains, as well as with wheels that are sliding on the axle for operation on roads with various gauge, etc. In wagons equipped with disc brakes, on the axle 1 (Fig. 4), except for two wheels 2 , firmly reinforced discs 3.
Fig.4 Wheel pair with brake discs (3)
The wheelset of the motor car of an electric train (Fig. 5) consists of an axle 5 and two bandage wheels 6 with cast-spoke wheel centers 2 and tires 1. One wheel center has an elongated flange 7, to which the gear wheel flange 3 of the gearbox is attached with precision bolts. The reducer is mounted on the bearing-reducer unit 4. The wheel pairs of industrial transport cars, designed for operation with increased loads, have increased diameters, in particular, the diameter of the necks is 180 mm.
Rice. Fig. 5. Wheel set of a motor car of an electric train: 1 - bandage; 2 - spoke center; 3 - gear; 4 - bearing-reducer assembly; 5 - axis; 6 - shroud wheel; 7 - flange
Wheel sets with sliding wheels on the axle have a more complex structure. In 1957, at the Bryansk Machine-Building Plant, a wheel pair was created with wheels sliding on the axle (Fig. 6). The movement of the wheels from one position to another occurs automatically when the car moves along a special transfer stand, connected at one end to the 1520 mm gauge, and the other end to the 1435 mm gauge. The sliding wheelset consists of an axle 2 along which the wheels can move 1 at the transition of a wagon from a track of one gauge to a track of another gauge.
Rice. 6. Wheel set with wheels sliding on the axle for rolling stock circulating on 1520 and 1435 mm gauge roads without changing running gear: 1 - wheel; 2 - axis; 3 - sleeve; 4 - locking ring; 5 - drum; 6 - buffer; 7 - lid; 8 - spring
To ensure sliding between the wheel hub 1 and the hub part of the axle 2 kapron bushing installed 3 . On the outer surface of the hub there are two annular grooves for fixing the wheel on the axle by means of sectors 9 . Do the sectors enter one groove when the wheel is in a track of 1520 mm, and the second? in a track of 1435 mm. This position of the sectors is fixed by the drum 5 , reinforced on the axle by means of a shrink fit. To prevent spontaneous exit of sectors from the annular grooves of the hub, a lock ring is provided. 4 bolted to buffer 6 . Springs are located inside the buffer 8 leaning on the lid 7 and pressing the buffer and the lock ring to the middle of the axis. The rotation of the wheel on the axle is prevented by the gearing of the drum and the wheel hub.
The sliding wheel pair is actuated as follows. When the car passes through the transfer stand, the buffer is squeezed out with a special stop 6 , resulting in lock rings 4 move towards the wheels and stop holding the sectors 9 in the recesses of the hub. Then the emphasis of the stand, pressing the wheels 1 , moves them along the axis 2 to the required position. At the beginning of this movement, the wheels squeeze sectors 9 from the annular grooves, at the end of the movement of the wheels, the sectors are opposite the second grooves. At the same time, they are released from buffer pressing 6 and under the action of springs 8 come back with lock rings 4 to the starting position. While the rings 4 click on sectors 9 , as a result of which the sectors enter the second grooves, fixing the wheels in the changed position.
One of the design options for a wheelset with sliding wheels was developed by specialists from Uralvagonzavod and VNIIZhT.
Structures with sliding wheels differ from conventional wheelsets in a more complex device, increased weight and manufacturing cost. However, technical and economic calculations show that during the transportation of certain goods, sliding wheelsets, despite the above disadvantages, including additional costs for repairs and maintenance, can reduce capital investments and operating costs compared to the costs necessary for organizing and performing reloading operations at border stations. Non-reloading communication also ensures the reduction of cargo losses and the acceleration of their delivery to the consumer, which is important especially for perishable goods.
Wheel sets of narrow-gauge wagons are of great diversity. For example, there were 42 types of wheelsets of 750 mm gauge, of which 30 had collars at the ends of the necks and 12 without collars, 14 sizes according to the diameter of the wheels - from 450 to 650 mm. The wheels were bandage with cast-iron or steel (disc or spoke) wheel centers, as well as bandless - cast-iron and steel solid-rolled. On fig. 7 shows a wheel set without collars on the axle journals, used in cars of narrow gauge railways, which were equipped with axle boxes that did not have bearings. on axle 1 on the left is a section of a tire wheel with a disk center 2 on which the bandage is firmly put on 4 , reinforced against shear by a safety ring 3 , and on the right is a tireless wheel 5 . In 1955, the Main Directorate of the Carriage Facilities of the Ministry of Railways carried out the unification of the wheelsets of 750 mm gauge cars, which sharply reduced their diversity.
Rice. Fig. 7. Wheel pair without collars on the neck of the axle of narrow-gauge wagons of 750 mm gauge: 1 - axle; 2 - disk center; 3 - safety ring; 4 - bandage; 5 - solid-rolled wheel
The wagon axle (Fig. 1) is an integral part of the wheelset and is a steel bar with a round, variable cross-section along the length. On the hub parts of the 3rd axle there are wheels fixed rigidly or movably, and bearings are placed on the necks 1. Carriage axles differ in size, determined depending on the given load; the shape of the axle neck in accordance with the type of bearing used - for rolling bearings and plain bearings; round cross-sectional shape - solid or hollow; the way of end fastening of rolling bearings on the axle neck - with a castellated nut or washer.
Rice. 1. Types of wagon axles: 1 - neck; 2 - pre-hub part; 3 - hub part; 4 - middle part
In addition, axles are classified according to material and manufacturing technology. Between necks 1i hub parts 3 are pre-hub parts 2, which serve to accommodate the parts of the rear sealing devices of the axle boxes, as well as to reduce the stress concentration in the transition sections from the hub parts to the axle journals. In places where diameters change, to reduce stress concentration, there are smooth mates - fillets, made with certain radii: from the neck 1 - to the sub-hub 2, from the pre-hub - to the sub-hub 3 and from the middle 4 - to the sub-hub. Reducing the concentration of stresses caused by the fit of the inner ring of the roller bearing is provided by a relief groove located at the beginning of the rear fillet of the axle journal (Fig. 8, G). Axles for rolling bearings at the ends of the necks have a threaded part To(fig.1, a) for screwing a castellated nut, at the end there is a groove with two threaded holes for setting and fastening with two bolts of the locking bar.
In wagon axles with mounting of rolling bearings, threaded holes for bolts are made at the ends of the necks with the help of an attachment washer (Fig. 1, b) in two versions: with the help of three or four bolts. Center holes are provided at the ends of all types of axles (Fig. 1, d, e), serving to install and secure the axle or wheelset in the centers when processing on a lathe. The shape and dimensions of the center holes are standardized. Axles of wheel sets equipped with a disc brake, as well as axles on which the undercarriage generator drive is provided, have seating surfaces for installing brake discs or gearbox parts. The main dimensions and permissible loads for standard types of axles of wide gauge cars, except for cars of electric and diesel trains, are given in Table. 2.
Roller bearings with an outer diameter of 250 mm are installed on the journals of the axles RU1 and RU1SH.
For all types of axles, the distances between the centers of application of the load to the journals are the same and amount to 2036 mm. For freight cars with increased loads from the wheelset on the rails up to 245 kN, a reinforced axle with increased diameters is provided.
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