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Association of American Railroads SAFETY AND OPERATIONS
MANUAL OF STANDARDS AND
RECOMMENDED PRACTICES SECTION G
WHEELS AND AXLES
Effective March 2011
Compiled under the direction of the Committees responsible for the subjects shown herein.
Published by
The Association of American Railroads 425 Third Street, SW., Washington, D.C. 20024 © Copyright Association of American Railroads
Printed in U.S.A.
03/2011
Copyright © 2011 by the Association of American Railroads (AAR) Safety and Operations 425 Third Street SW. Washington, D.C. 20024 All rights reserved, including the right to reproduce this book in any form. It is the AAR’s intention that this publication be used to promote the objectives of the AAR and its members for the safe, efficient, and uniform interchange of rail equipment in North America. To this end, only excerpts of a rule or specification may be reproduced by the purchaser for their own use in promoting this objective. No portion of this publication may be displayed or otherwise made available to multiple users through any electronic distribution media including but not limited to a local area network or the Internet. No portion may be sold or used for advertisement or gain by any entity other than the AAR and its authorized distributor(s) without written permission from the AAR.
AAR Manual of Standards and Recommended Practices Wheels and Axles
ORDERING INFORMATION Copies of the various sections of this manual can be obtained as follows: ORDERS FOR PUBLICATIONS
Publications Department Transportation Technology Center, Inc. P.O. Box 11130 55500 DOT Road Pueblo, CO 81001 Email:
[email protected] [email protected] Phone: Toll-free 877-999-8824, Direct 719-584-0538 Fax: 719-584-7157 TTCI Web page: http://www.aar.com Online ordering: http://www.aarpublications.com/
CIRCULAR Subscriptions to Circular Letters of the AAR Safety and Operations’ Technical Technical Services are available in LETTER hardcopy or electronic format (online access via AAR’s Web page at www.aarcirculars.aar.org www.aarcirculars.aar.org). ). Circulars SUBSCRIPTIONS are issued at least monthly and include industry letter ballots and results, arbitration decisions, notification of rules and standards revisions, industry early warning and maintenance advisories, and other information related to mechanical rules and standards. Subscriptions are valid for one year. For ordering information, contact the following: Phone: Toll-free 877-999-8824, Direct 719-584-0538 Fax: 719-584-7157 Email:
[email protected] [email protected] AAR Web page: page: http://www.aar.org TTCI Web page: http://www.aar.com MSRP-A1 INDEX
The MSRP-A1 Table Table of Contents is an inclusive index of all MSRP specifications, standards, and recommended practices. It is available online at http://www http://www.aar.com .aar.com/aar_standards-publications.ht /aar_standards-publications.htm m This easy-to-access document is a convenient way to quickly identify in which manual a specific document resides. The index is updated weekly, enabling the user to see in "real-time" which documents have been updated via Circular Letter.
TECHNICAL QUESTIONS
For technical questions regarding this manual, contact the following: Technical Committee Coordinator Transportation Technology Center, Inc. P.O. Box 11130 55500 DOT Road Pueblo, CO 81001 Email:
[email protected] [email protected] Phone: 719-584-0670 Fax: 719-585-1895
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AAR Manual of Standards and Recommended Practices Wheels and Axles
TO THE USER Section G—Wheels and Axles, Manual of Standards and Recommended Practices , covers three main components: the wrought (or forged) steel wheel, the cast steel wheel, and the steel axle. Because of the critical functions of all these components, exhaustive details are given on design, metallurgy, manufacture, inspection, acceptance, assembly, wear limits, reclamation, and machining for reuse. Wheels and axles are medium-range carbon steels containing a maximum of less than 1% manganese and minimal levels of phosphorus, sulfur, and silicon. Wheels subjected to severe ser vice conditions have rims heat-treated and quenched to produce wear-resistant surfaces, followed by overall tempering and controlled cooling. Axles must always be normalized and, when used under high-capacity freight cars, passenger cars, and locomotives, are to be heat-treated, normalized, quenched, and tempered. A specification included in this volume treats electrochemical metal deposition for restoration of journal surfaces of roller bearing axles. There also are standards and recommended practices for dimensions, marking, inspection, gauges, condemning limits, wheel mounting, and manufacturing tolerances. USER’S GUIDE
Section G contains three specifications, twenty-one standards, and thirteen recommended practices. It consists of the following: • Preface: A listing of the subjects covered in the 25 individual sections, the volumes making up this manual. This preface is part of each section. • Table of Contents—Alphabetical: An alphabetical listing of the specifications (M prefix), standards (S prefix), and recommended practices (RP prefix). • Table of Contents—Numerical: A numerical listing of the specifications (M prefix), standards (S prefix), and recommended practices (RP prefix). • Section G: A generalized subject listing that indicates applicable specifications, standards, and recommended practices. • Specifications, Standards, and Recommended Practices : The body of this volume. RELATED SECTIONS
Section G—Wheels and Axles, should be used in conjunction with Section G, Part II—Wheel and Axle (shop) Manual. Other sections containing pertinent information are as follows: • Section D—Trucks and Truck Details • Section H—Journal Bearing and Lubrication • Section H, Part II—Roller Bearing (Shop) Manual • Section H, Part III—Lubrication Manual • Section J—Specifications for Quality Assurance, M-1003 RESPONSIBILITY
The coverage of Section G—Wheels and Axles, is the responsibility of the AAR Wheels, Axles, Bearings, and Lubrication Committee.
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PREFACE The Manual of Standards and Recommended Practices of the Safety and Operations Department, Association of American Railroads, is issued by authority of the Management Committee of the Division and includes all regularly adopted specifications, standards, and recommended practices of the Association of American Railroads. The manual is composed of the following sections: • Section AS—Administrative Supplement serves as a suplement to all MSRP sections (this is available as a free download at http://www.aar.com/aar_standards-publications.htm) • Section A—Table of Contents, Alphabetical and Numerical Index of Sections B through S inclusive (this is available as a free download at http://www.aar.com/aar_standards-publications.htm) • Section B—Couplers and Freight Car Draft Components (100 Series) • Section C—Car Construction—Fundamentals and Details (200 and 2000 Series) • Section C, Part II—Design, Fabrication, and Construction of Freight Cars, M-1001 • Section C, Part III—Specifications for Tank Cars, M-1002 • Section D—Trucks and Truck Details (300 and 3000 Series) • Section E—Brakes and Brake Equipment (300, 400, and 4000 Series) • Section E, Part II—Electronically Controlled Brake Systems • Section F—Sensors • Section G—Wheels and Axles (600 Series) • Section G, Part II—Wheel and Axle (Shop) Manual (600 Series) • Section H—Journal Bearings and Lubrication (700 Series) • Section H, Part II—Roller Bearing (Shop) Manual (700 Series) • Section H, Part III—Lubrication (Shop) Manual (700 Series) • Section I—Intermodal Equipment Manual • Section J—Specification for Quality Assurance, M-1003 • Section K—Railway Electronics (5700 Series) • Section K, Part II—Railway Electronics (5800 Series) • Section K, Part III—Railway Electronics (5900 Series) • Section L—Lettering and Marking of Cars (900 Series) • Section M—Locomotives and Locomotive Interchange Equipment • Section N—Multi-Level Manual • Section S—Casting Details • Section S, Part II—Truck Details and Casting Codes • Section S, Part III—Coupler and Yoke Details Specifications are designated with an “M” prefix (e.g., M-900). Standards are prefixed “S” (e.g., S-900). Recommended Practices carry the prefix “RP”( e.g., RP-900).
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TABLE OF CONTENTS—ALPHABETICAL Subject
Standard
Page
Axle for Passenger Cars (Amfleet) Inboard Roller Bearing— Raised Wheel Seat
S-658
G[S-658]101
Axle, Weight—Machined Finish, Raised Wheel Seat
RP-622
G[RP-622]157
Axles, Carbon Steel, Heat-Treated
M-101
G[M-101]1
Axles—Manufacturing Facility Inspection By Technical Services
S-649
G[S-649]97
Circumference Measure (Tape) for 27-in. to 38-in. Steel Wheels
S-612
G[S-612]73
Circumference Measure (Tape) for 38-in. to 52-in. Steel Wheels
S-613
G[S-613]75
Electrochemical Metal Deposition for Repairing Roller Bearing Axle Journals
M-967
G[M-967]61
Gauge, Axle—Master Gauge For Verifying Axle Journal and Fillet Gauge S-614
RP-613
G[RP-609]145
Gauge, Axle—Reference Gauge For Verifying Axle Journal and Fillet Gauge S-614
S-616
G[S-616]81
Gauge, Wheel—Application Drawing For AAR 1B Wheel Gauges S-661 and S-665
RP-637
G[RP-637]165
Gauge, Wheel—Application Drawing For AAR 1B Wheel Gauges S-662 and S-667
RP-636
G[RP-636]163
Gauge, Wheel—Application Drawing For Reference Gauge To RP-638 Verify Wheel Gauges S-661, S-662, S-663, S-664, S-665, S666, S-667, and S-668
G[RP-638]167
Gauge, Wheel—Application for Measuring Condemnable Overheated Wheels
RP-630
G[RP-630]161
Gauge, Wheel—Combination Gauge For Wheel Measurements
S-627
G[S-627]87
Gauge, Wheel—Combination Gauge For Wheel Measurements Including Locomotive Flange Limit Of 0.875 In.
S-628
G[S-628]89
Gauge, Wheel—for Measuring Condemnable Overheated Wheels
RP-629
G[RP-629]159
Gauge, Wheel—Former Standard 1976
S-618
G[S-618]85
Gauge, Wheel—Former Standard 1980
S-617
G[S-617]83
Gauge, Wheel—Master Gauge For Verifying Wheel Gauges S- RP-614 617 and S-618
G[RP-614]151
Gauge, Wheel—Maximum Flange Thickness, Height, and Throat Radii Gauge for AAR-1B Narrow-Flange Steel Wheel
S-661
G[S-661]109
Gauge, Wheel—Maximum Flange Thickness, Height, and S-665 Throat Radii Gauge for AAR-1B Wide-Flange Steel Wheels
G[S-665]117
Gauge, Wheel—Minimum Flange Thickness, Height, and Throat Radii Gauge for AAR-1B Narrow-Flange Steel Wheel
G[S-662]111
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AAR Manual of Standards and Recommended Practices Wheels and Axles Subject
Standard
Page
Gauge, Wheel—Minimum Flange Thickness, Height, and S-667 Throat Radii Gauge for AAR-1B Wide-Flange Steel Wheels
G[S-667]121
Gauge, Wheel—Reference Gauge For Verifying Combination S-629 Wheel Gauge S-627
G[S-629]91
Gauge, Wheel—Reference Limit Gauge For Verifying AAR 1B S-663 Narrow Flange Wheel Gauge S-661
G[S-663]113
Gauge, Wheel—Reference Limit Gauge For Verifying AAR 1B S-664 Narrow Flange Wheel Gauge S-662
G[S-664]115
Gauge, Wheel—Reference Limit Gauge For Verifying AAR 1B S-666 Wide Flange Wheel Gauge S-665
G[S-666]119
Gauge, Wheel—Reference Limit Gauge For Verifying AAR 1B S-668 Wide Flange Wheel Gauge S-667
G[S-668]123
Analytic Evaluation of Locomotive Wheel Designs
S-669
G[S-669]125
Gauge, Wheel—Reference Master Disk For Verifying Wheel Circumference Gauges S-612 and S-613
RP-608
G[RP-608]143
Gauge, Wheel—Simplified
RP-615
G[RP-615]153
Gauge, Wheel—Standard
S-630
G[S-630]95
Inspection Stand for Use with Master Disks
RP-609
G[RP-609]145
Mounting Pressures for Wrought and Cast Steel Wheels on Gear-Driven and Idler Axles of Locomotives Other than Steam
RP-612
G[RP-612]147
Reference Groove for Multiple-Wear Diesel Wheels
RP-619
G[RP-619]155
Wheel Defect—Worn Journal Collar and Journal Fillet Gauge S-614
G[S-614]77
Wheel Defect—Worn Journal Collar and Journal Fillet Gauge S-615
G[S-615]79
Wheel Designs, Locomotive and Freight Car—Analytic Evaluation
S-660
G[S-660]103
Wheel, Passenger Car (Amfleet)
S-657
G[S-657]99
Wheels, Carbon Steel
M-107/M-208
G[M-107/M-208]21
Wheels—Manufacturing Facility Inspection By Technical Services
S-601
G[S-601]69
Wheels—Measuring Wheel Circumference (Tape) Using Wheel Gauges S-612 and S-613
S-611
G[S-611]71
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TABLE OF CONTENTS—NUMERICAL Standard
Subject
Page
M-101
Axles, Carbon Steel, Heat-Treated
G[M-101]1
M-107/M-208
Wheels, Carbon Steel
G[M-107/M-208]21
M-967
Electrochemical Metal Deposition for Repairing Roller Bearing Axle Journals
G[M-967]61
S-601
Wheels—Manufacturing Facility Inspection By Technical Services
G[S-601]69
S-611
Wheels—Measuring Wheel Circumference (Tape) Using Wheel Gauges S-612 and S-613
G[S-611]71
S-612
Circumference Measure (Tape) for 27-in. to 38-in. Steel Wheels
G[S-612]73
S-613
Circumference Measure (Tape) for 38-in. to 52-in. Steel Wheels
G[S-613]75
S-614
Wheel Defect—Worn Journal Collar and Journal Fillet Gauge G[S-614]77
S-615
Wheel Defect—Worn Journal Collar and Journal Fillet Gauge G[S-615]79
S-616
Gauge, Axle—Reference Gauge For Verifying Axle Journal and Fillet Gauge S-614
G[S-616]81
S-617
Gauge, Wheel—Former Standard 1980
G[S-617]83
S-618
Gauge, Wheel—Former Standard 1976
G[S-618]85
S-627
Gauge, Wheel—Combination Gauge For Wheel Measurements
G[S-627]87
S-628
Gauge, Wheel—Combination Gauge For Wheel Measurements Including Locomotive Flange Limit Of 0.875 In.
G[S-628]89
S-629
Gauge, Wheel—Reference Gauge For Verifying Combination G[S-629]91 Wheel Gauge S-627
S-630
Gauge, Wheel—Standard
G[S-630]95
S-649
Axles—Manufacturing Facility Inspection By Technical Services
G[S-649]97
S-657
Wheel, Passenger Car (Amfleet)
G[S-657]99
S-658
Axle for Passenger Cars (Amfleet) Inboard Roller Bearing— Raised Wheel Seat
G[S-658]101
S-660
Wheel Designs, Locomotive and Freight Car—Analytic Evaluation
G[S-660]103
S-661
Gauge, Wheel—Maximum Flange Thickness, Height, and Throat Radii Gauge for AAR-1B Narrow-Flange Steel Wheel
G[S-661]109
S-662
Gauge, Wheel—Minimum Flange Thickness, Height, and Throat Radii Gauge for AAR-1B Narrow-Flange Steel Wheel
G[S-662]111
S-663
Gauge, Wheel—Reference Limit Gauge For Verifying AAR 1B G[S-663]113 Narrow Flange Wheel Gauge S-661
S-664
Gauge, Wheel—Reference Limit Gauge For Verifying AAR 1B G[S-664]115 Narrow Flange Wheel Gauge S-662
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Subject
Page
S-665
Gauge, Wheel—Maximum Flange Thickness, Height, and G[S-665]117 Throat Radii Gauge for AAR-1B Wide-Flange Steel Wheels
S-666
Gauge, Wheel—Reference Limit Gauge For Verifying AAR 1B G[S-666]119 Wide Flange Wheel Gauge S-665
S-667
Gauge, Wheel—Minimum Flange Thickness, Height, and G[S-667]121 Throat Radii Gauge for AAR-1B Wide-Flange Steel Wheels
S-668
Gauge, Wheel—Reference Limit Gauge For Verifying AAR 1B G[S-668]123 Wide Flange Wheel Gauge S-667
S-669
Analytic Evaluation of Locomotive Wheel Designs
G[S-669]125
RP-608
Gauge, Wheel—Reference Master Disk For Verifying Wheel Circumference Gauges S-612 and S-613
G[RP-608]143
RP-609
Inspection Stand for Use with Master Disks
G[RP-609]145
RP-612
Mounting Pressures for Wrought and Cast Steel Wheels on Gear-Driven and Idler Axles of Locomotives Other than Steam
G[RP-612]147
RP-613
Gauge, Axle—Master Gauge For Verifying Axle Journal and Fillet Gauge S-614
G[RP-609]145
RP-614
Gauge, Wheel—Master Gauge For Verifying Wheel Gauges S- G[RP-614]151 617 and S-618
RP-615
Gauge, Wheel—Simplified
G[RP-615]153
RP-619
Reference Groove for Multiple-Wear Diesel Wheels
G[RP-619]155
RP-622
Axle, Weight—Machined Finish, Raised Wheel Seat
G[RP-622]157
RP-629
Gauge, Wheel—for Measuring Condemnable Overheated Wheels
G[RP-629]159
RP-630
Gauge, Wheel—Application for Measuring Condemnable Overheated Wheels
G[RP-630]161
RP-636
Gauge, Wheel—Application Drawing For AAR 1B Wheel Gauges S-662 and S-667
G[RP-636]163
RP-637
Gauge, Wheel—Application Drawing For AAR 1B Wheel Gauges S-661 and S-665
G[RP-637]165
RP-638
Gauge, Wheel—Application Drawing For Reference Gauge To G[RP-638]167 Verify Wheel Gauges S-661, S-662, S-663, S-664, S-665, S666, S-667, and S-668
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REQUIREMENTS FOR WHEELS AND AXLES MANUFACTURED TO AAR SPECIFICATIONS The requirements of these standards, recommended practices, and specifications represent the minimum acceptable requirements. All manufacturers of wheels and/or axles are urged to exceed the intent of these requirements as much as possible. These specifications have been developed on the basis of extensive field experience and tests. Each specification contained herein should be read as including an additional requirement for satisfactory performance under a field test if such test is deemed appropriate after consideration by the Assistant Vice President of Technical Services and Chief of Technical Standards, working with the appropriate technical committee(s). Normally, periodic inspections of manufacturers’ facilities will be conducted by AAR personnel approximately every year. These periodic inspections will include wheel mounting facilities, where applicable. When inspection of manufacturing processes or facilities of companies manufacturing wheels and/ or axles for use on cars in interchange service involve travel, the out-of-pocket expenses involved to conduct such required inspections will be paid by the company offering such products for this ser vice. Expenses will be prorated when more than one facility is visited in the same geographic area.
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M-101
AAR Manual of Standards and Recommended Practices Wheels and Axles
AXLES, CARBON STEEL, HEAT-TREATED Specification M-101 Adopted: 1914; Last Revised: 20
1.0 SCOPE These specifications cover heat-treated axles of all sizes for passenger cars and freight cars to designs shown in Section G. These specifications also cover heat-treated locomotive axles. The grades of carbon steel axles are as follows:
Grade F—Double normalized and tempered. (All freight axles over 6 1/2 in. nominal diameter at center shall be Grade F.) Grade G—Quenched and tempered. Grade H—Normalized, quenched, and tempered. Grades F, G, and H—Axles are used in heavy duty service on locomotives, cars, and other equipment. 2.0 QUALIFICATION AS MANUFACTURER Qualification as a manufacturer of axles for use in AAR interchange service must be in accordance with Appendix C of this specification. Qualification is effective until revoked for cause by the Committee. Failure to maintain reasonable quality standards in manufacturing is an example of cause. Axle manufacturers must meet the requirements of the AAR Manual of Standards and Recommended Practices , Section J, Specification M-1003, “Specification for Quality Assurance.” 3.0 MANUFACTURE 3.1 Process The steel shall be made by any of the following processes: open hearth, electric furnace, or basic oxygen. Proposed changes to material or manufacturing processes must be submitted to the AAR for consideration. Approval of a new material or process may include meeting the requirements stated in Appendix C. 3.2 Discard A sufficient discard shall be made from each ingot to ensure freedom from piping and undue segregation. 3.3 Reduction Practice The axles may be made directly from the ingot or from blooms. The total reduction from ingot or strand-cast bloom to forging or rolling shall be not less than 3 to 1, unless otherwise specified. Note: The process for manufacturing strand-cast blooms shall be designed to ensure freedom from center porosity and undue segregation. 4.0 COOLING AND HEATING 4.1 After axle blooms are produced, they shall be slow-cooled in closed containers, hoods, or furnaces. 4.2 Blooms shall be reheated for working in a manner that will prevent internal bursts and overheating. 4.3 After reduction, axles shall be slow-cooled in closed containers, covered conveyors, or in hoods. If axles (Grades F, G, and H) are heat-treated directly from reduction, they shall be slow-cooled following the final heat treatment. 03/2011
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M-101
4.4 Axles (Grades F, G, and H) that are heat-treated directly from reduction 1) shall be cooled below the transformation temperature or to approximately 1,000 °F before any reheating operation; and 2) must not be permitted to cool below 500 °F without slow-cooling as defined in paragraph 4.3. Note: As the temperature of the axles approaches the minimum of 500 °F, a supplemental heat source may be necessary to ensure an effective slow-cooling cycle. 4.5 When properly vacuum-degassed steel is used, the slow-cooling requirements of paragraphs 4.1, 4.3, and item 2 of paragraph 4.4 may be omitted, but axle blooms must then be pile cooled. 4.6 The slow-cooling requirements of paragraphs 4.1, 4.3, and item 2 of paragraph 4.4 may be accomplished by piling and covering the piled blooms or axles with insulating materials in lieu of using closed containers, hoods, furnaces, and covered conveyors. Covered piles must be capable of providing effective cooling rates in accordance with the manufacturer’s procedure or specification. 5.0 HEAT TREATMENT 5.1 Axles for heat treatment shall be reheated gradually and uniformly to a suitable temperature to refine the grain structure. 5.2 Normalizing After being heated to a suitable temperature, the axles shall be withdrawn from the furnace and allowed to cool uniformly in air. A furnace charge thus treated is termed a normalizing charge. Cooling may be accelerated by increased air circulation, which must be controlled to provide reasonably uniform cooling. 5.3 Double Normalizing The procedure shall consist of two separate normalizing treatments. The second treatment shall be performed at a lower temperature than the first treatment. A furnace charge thus treated is termed a double normalizing charge. Cooling may be accelerated by increased air circulation, which must be controlled to provide reasonably uniform cooling. Note: A single normalizing treatment shall be permitted when all other requirements for Grade F can be met. 5.4 Quenching After being heated to a suitable temperature, the axles shall be quenched in a suitable medium under reasonably uniform conditions. A furnace charge thus treated is termed a quenching charge. 5.5 Tempering Axles shall be reheated gradually to, and held at, a suitable temperature below the critical range and shall then be allowed to cool under suitable conditions. A furnace charge thus treated is termed a tempering charge. 5.6 Heat treatment may be performed in either batch-type furnaces or continuous furnaces. 6.0 STRAIGHTENING Straightening shall be done before machining and preferably at a temperature not lower than 950 °F. Straightening performed at temperatures lower than 950 °F shall be followed by stress relieving or an applicable heat treatment.
G [M-101] 2
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AAR Manual of Standards and Recommended Practices Wheels and Axles
7.0 7.0 CH CHEM EMIC ICAL AL COMPO COMPOSI SITI TION ON The steel shall conform to the requirements for chemical composition shown in Tabl able e 7.1 7.1.. Table 7.1 7.1 Chemical Chemical composi composition tion Grade F
Grades G and H Heat-Treated
Min.
Max.
Min.
Max
Carbon, percentage
0.45
0.59
—
—
Manganese, percentage
0.60
0.90
0.60
0.90
Phosphorus, percentage
—
0.045
—
0.045
Sulphur, percentage
—
0.050
—
0.050
Silicon, percentage
0.15
—
0.15
—
8.0 8.0 LADL LADLE E ANAL ANALYS YSIIS
analysis of each heat of steel shall be made made by the the manufacturer to determine the percent8.1 An analysis age of carbon, manganese, phosphorus, sulfur, and silicon. The chemical composition thus determined shall be reported to the purchaser or purchaser’s representative and shall conform to the requirements of paragr paragraph aph 7.0 7.0.. 8.2 Identificatio Identification n of Heats in Consecut Consecutive ive Strand Castings Castings If more than one heat is consecutively strand cast at one time, ladle analyses shall be obtained of each heat. If the ladle analysis of one heat does not meet the requirements of the specification, the bloom or blooms that comprise a mix of the two consecutive co nsecutive heats shall be deemed to be outside the requirements of the specification unless additional chemical analyses prove compliance. If both ladle analyses are in compliance with the specification, the heat number assigned to the cast product shall remain unchanged until all of the steel in the bloom is from the following heat. Alternatively, when all of the mixed portion of two consecutive heats is in one bloom, that bloom may be given the heat number that comprises the larger portion of the bloom on either side of the mixed portion. 9.0 9.0 CH CHEC ECK K ANAL ANALYS YSIS IS Analysis may be made by the purchaser from one axle representing each heat. The chemical composition thus determined shall conform to the requirements of paragr paragraph aph 7.0 7.0,, subject to tolerances included in Tabl able e 9. 9.1 1. The sample for these analyses shall be taken from one end of the test axle or full-size prolongation at a point midway between the center and surface. If drillings are taken, they shall be obtained using a 5/8-in.-diameter drill, or turnings may be taken from a tensile test specimen. Table Table 9.1 Permissibl Permissiblee variations variations for check analysis analysis Permissible Variations, Over the Maximum Limit or Under the Minimum Limit Elements
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Percentage
Manganese
0.030
Phosphorus
0.008
Sulphur
0.008
Silicon
0.020
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M-101
10.0 10.0 TENSI ENSION ON TES TESTS TS
able e 10. 10.1 1. 10.1 Grades F, G, and H axles shall conform to the requirements in Tabl Table 10.1 Tensile Tensile requirements for carbon steel heat-treated axles Size (Solid Diameter or Thickness) (in.)
Tensile Strength (psi)
Yield Strength (psi)
Elongation in 2 in. (percentage)
Reduction of Area (percentage)
Grade
Over
Not Over
Min.
Min.
Min.
Min.
F (Double Normalized and Tempered)
—
8
88,000
50,000
22
37
—
4
90,000
55,000
20
39
(Quenched
4
7
85,000
50,000
20
39
and Tempered)
7
10
85,000
50,000
19
37
(Normalized,
—
7
115,000
75,000
16
35
Quenched,
7
10
105,000
65,000
18
35
G
H
and Tempered) 10.2 The size classification shall be determined by the finished diameter of the journal. 10.3 The diameter of the test prolongation shall be at least equal to the as-formed diameter of the journal.
able 10. 10.1 1 shall be determined by the 10.4 The tensile properties for all grades listed in Table procedure described in ASTM A 370, “Standard Methods and Definitions for Mechanical Testing of Steel Products.” The yield strength shall be determined using the 0.2% offset technique. A Class B2 or more accurate extensometer extensometer shall be be used. 10.5 The use of automated devices that determine the offset yield strength without the need for plotting a stress-strain curve are acceptable. 10.6 Tests shall be made only after final heat treatment of Grades F, G, and H axles. 11.0 11.0 TENSION ENSION TEST SPECIME SPECIMENS NS 11.1 Tension test specimens shall be taken from the test prolongation or an axle in accordance with the provisions of paragraph paragraph 12.0 12.0.. 11.2 Unless otherwise specified, the axis of the specimen shall be located at any point midway between the center and surface of the axle or full-sized prolongation and shall be parallel to the axis of the axle.
Tension test specimens shall conform to dimensions shown in Fig. Fig. C.1. .1. 11.3 Tension 11.4 Tension tests from the prolongations shall have minimum tensile strength and yield point values 5% greater than shown in Tabl able e 10. 10.1 1. For example, Grade F tension tests from axle prolongations shall have 92,500 psi minimum tensile strength and 52, 500 psi minimum yield point. 11.5 Tension test specimens from axles shall be taken from the journal of the axle at the mid-radius, halfway halfway between the surface and center, center, with the gauge dimension parallel to the axis of the axle. For tensile specimens removed from the prolongation, samples shall be taken from the mid-radius, halfway halfway between the surface and center, center, with the gauge dimension parallel to the axis of the axle.
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12.0 12.0 PROLO PROLONG NGATI ATION ON FOR FOR TES TEST T 12.1 For test purposes, prolongations shall be attached to at least 5% of the axles in each size classification of each heat in each heat-treating lot. 12.2 If axles with prolongations have been expended, then axles may be used for test procurement.
prolongation sizing prior to test or the use of axles for test. 12.3 Test reports shall state prolongation 13.0 MICROSCOPIC MICROSCOPIC TEST TEST FOR FOR HEAT-TREATED HEAT-TREATED AXLES (GRADES (GRADES F, F, G, AND H) H) 13.1 A specimen, representing each size classification of each heat in each heat-treatment lot, shall be taken for microscopic test from the tension test s pecimen. This section for microscopic test shall be cut from the large undistorted portion of the tension test specimen in such a way as will give a face transverse to the axis of the axle. 13.2 The face shall be polished practically free from scratches and shall be etched to define the microstructure. microstructure. The specimen shall be examined under a magnification of 100 diameters. 13.3 The entire specimen shall show a uniform, fine-grained structure, and shall have a grain size of 5 or finer as measured in accordance with ASTM Standard Method E112, latest version. 14.0 14.0 NUMB NUMBER ER OF TESTS ESTS
purchaser, mechanical tests for grades and sizes shown in 14.1 Unless otherwise specified by the purchaser, Tabl able e 10.1 10.1 shall shall be made from heat-treated axles as covered in paragraph paragraph 14.2 14.2 One test per grade, per heat, per size classification is required, but each test shall represent no more than 70 axles, including the test axle. The axles represented by this test shall be called a heat-treatment lot . Each heat-treatment lot of axles shall be heat-treated together, whether in batch-type or continuous furnaces. In the event that the mechanical properties of a test do not conform to the requirements specified, all of the axles from the heat-treatment lot are to be retreated in accordance with paragr paragraph aph 15. 15.2 2 of this specification.
apparatus, it may be 14.3 If any test specimen fails because of mechanical condition of the testing apparatus, discarded and another specimen taken. 15.0 RETEST 15.1 If the results of the mechanical tests of any lot do not conform to the requirements specified because a flaw developed in the test specimen during testing, a retest shall be allowed if the defect is not caused by ruptures, cracks, or flakes in the steel. 15.2 If the result of the mechanical test of any lot of Grade F, G, or H axles does not conform to the requirements specified, the axles may be retreated, but not more than three additional times, and retests shall be made in accordance with paragraph paragraph 10.0 10.0..
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16.0 ULTRASONIC TESTING (NEW AXLES ONLY—RADIAL AND AXIAL) 16.1 Scope 16.1.1 This paragraph becomes effective July 1, 2009. 16.1.2 This paragraph applies to all new axles. 16.2 Time of Inspection 16.2.1 Axial—anytime during production following axle end facing and center drilling, but before drilling cap screw holes. 16.2.2 Radial—anytime during production following initial rough turn (forged s urfaces cannot be effectively radial UT-tested). 16.3 Test Equipment Type
Pulse-echo-type broadband pass amplifier
Quantity
One or more. Multiple transducer arrays must be capable of monitoring individual transducers.
Couplant
A couplant must be used between the face of the transducer and the test surface. Same couplant to be used for test and calibration.
Machine Calibration
At least annually and each time the system receives maintenance that affects system performance.
16.3.1 Axial Transducers Frequency
1.0– 2.25 MHz
Size/shape
0.75–1.00 in. diameter or 1.00 in. 2
16.3.2 Radial Transducers Frequency Range
1.0–5.0 MHz
Size/shape
0.50–1.00 in. diameter or 1.00 in. 2
16.4 Personnel 16.4.1 All personnel performing ultrasonic inspection operations must be prequalified to non-destructive testing (NDT) Level 1, at a minimum, in accordance with American Society for Nondestructive Testing (ASNT), Recommended Practice SNT TC-1A, latest edition. All personnel setting up ultrasonic inspection systems must be prequalified to NDT Level 2, at a minimum, in accordance with ASNT, Recommended Practice SNT TC-1A, latest edition. 16.4.2
Each manufacturer must employ the services of an individual who is prequalified to NDT Level 3, at a minimum, in accordance with ASNT, Recommended Practice SNT TC-1A, latest edition. 16.4.3
16.5 Records Each facility must maintain the following records for the duration indicated. Records must be accessible within 4 hours upon request by any AAR representative.
• A procedural specification for each validated UT process (current revision) • A posted controlled copy of each UT specification in each UT testing equipment area(s) (current revision) • All individual axle test results in printable form, including individual heat, axle serial number, and date of inspection (10 years from date of manufacture)
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16.5.1 Personnel certifications for UT testing must be, at a minimum, in accordance with ASNT, Recommended Practice SNT TC-1A, latest edition. Each certification must be endorsed by a responsible official of that facility and the verifying level III (10 years). 16.5.2 Reference block semiannual validation record, including the inspector’s name/ID, revalidation date, and measured surface finish of the reference block. (10 years) 16.6 Validation Validation (system testing) must be performed using the same couplant used during axle testing. All contact surfaces must be smooth with a surface roughness better than 125 microinch for axial test and 500 microinch for the radial test. It also should be free from dirt and grit. 16.6.1 Axial 16.6.1.1 Calibration and System Tests The ultrasonic inspection system must be validated initially upon installation and at least once every year after initial installation. 16.6.1.1.1 Calibration—1/8-in. flat-bottom hole at 15-in. depth, set up at 20% full-screen height using 16-in.-long reference block manufactured from a Grade F axle forging. 16.6.1.1.2 Detection Capabilities 1/8-in. flat-bottom hole
From 2 in. to 15 in. depth, detectable in reference axle
1/4-in. flat-bottom hole
From 15 in. to 30 in. depth, detectable in reference axle
3/8-in. flat-bottom hole
From 30 in. to 46 in. depth, detectable in reference axle
16.6.1.2 Alternate reference standards may be used to calibrate or test system sensitivity, pro vided the output from the alternate standard is cross-referenced with the reference block and axle of paragraph 16.6.1.1.1. Example: the following alternates provide equivalent sensitivity:
• 1-in. indication from a #1 series “A” Alcoa block • 1 1/2-in. indication from an ASTM E-127 block #1-0300 16.6.1.3 Reference standards must be inspected and certified semiannually for surface finish on the inspection face(s) of 80 microinch to 125 microinch. 16.6.1.4 Periodic 16.6.1.4.1 Periodic tests shall be made during production testing against the 16-in.-long reference block described above, and adjustments shall be made to instrument controls to ensure compliance with the specifications. 16.6.1.4.2 Periodic tests must be made at least once every 4 hours of use. 16.6.1.5 Continuous 16.6.1.5.1 Unscheduled system tests shall be made during production testing against the 16-in.-long reference block described above, and adjustments shall be made to instrument controls to ensure compliance with the specifications. 16.6.1.5.1.1 Tests must be made every time there is a change of system operators. 16.6.1.5.1.2 Tests must be made every time there is a change of transducers, cables, or any other system hardware or accessories. 16.6.1.5.1.3 Tests must be made every time there is an equipment malfunction or upon powering on. 03/2011
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16.6.2 Radial 16.6.2.1 Calibration and System Tests 16.6.2.1.1 The ultrasonic inspection system must be validated initially upon installation and at least once every year after initial installation. 16.6.2.1.2 Calibration—The system must be calibrated to exhibit an 80% full-screen-height indication from the backface reflection in the thickest part of the production axle section (wheel seat). 16.6.2.1.3 Tests must be made every time there is an equipment malfunction or upon powering on. 16.6.2.1.4 When a change to the equipment power source, transducer, operator, or coaxial cable occurs, the system set-up must be reverified. 16.7 Inspection 16.7.1 General 16.7.1.1 Inspection surfaces must be free of all dirt and grit prior to the start of testing. 16.7.1.2 The same couplant must be used for calibration and examination. 16.7.1.3 During the axial discontinuity inspection test and the radial loss of back face reflection test, an additional 6 dB shall be added to the reference or sensitivity level for scanning purposes. Discontinuity evaluation shall be performed at the original recorded sensitivity level prior to final disposition. 16.7.2 Axial 16.7.2.1 The amplitude of the ultrasonic indication must be considered in relation to its distance from the testing surface to evaluate its significance. This can be accomplished by an electronic device or by distance amplitude curves that are described in Appendix B, paragraph 2.0. 16.7.2.2 The variation in cross-section of the axle may produce spurious indications. These expected indications must be recognized and are not cause for rejection. 16.7.2.3 Both end faces of the axle must be scanned to the full extent of the surfaces (100% area coverage). The axle end faces must be prepared with a surface finish of 125 microinch or better. 16.7.2.3.1 If the amplitude of any indication exceeds the DAC curves as defined in Appendix B, the axle is rejected. 16.7.2.3.2 If any backface reflection does not exceed 40% of screen height, the axle is rejected. 16.7.3 Radial 16.7.3.1 The variation in cross-section of the axle may produce spurious indications. These expected indications must be recognized and are not cause for rejection. 16.7.3.2 Scan the entire length of the axle radially through the diameter along one line only. At a minimum, the axle surface must be rough-turned with a surface finish of 500 microinch or better. 16.7.3.3 The axle will be rejected for a location if a loss of back reflection of 80% or greater is experienced, unless the loss is attributed to geometry. 16.8 Marking All axles that are to be tested radially must have the character “R” immediately following the axle grade marking. All axles failing the radial test must be immediately identified and segregated for scrapping.
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17.0 DIMENSIONS AND TOLERANCES 17.1 For other than the standard freight and passenger car axles referenced in this specification, standard tolerances and allowances will apply, if not specified in axle drawings provided by the purchaser. 17.2 Axle centers shall conform to Fig. C.5. 17.3 For all axles ordered for finished end facing by the purchaser, the overall length shall range from 1/8 in. to 1/4 in. over the specified minimum length. 17.4 Rough machined journals and wheel seats shall be 1/8 in. to 1/4 in. over the finished diameters and longitudinally 1/8 in. to 1/4 in. of metal shall be allowed at each change of cross section for finish machining. 17.5 The smooth machined body shall be to the specified size, with no more than 1/8 in. over on the diameters and shall have no more than 1/8 in. allowance longitudinally at each change of cross section, unless specified otherwise in Fig. C.3. 18.0 WEIGHT The approximate weights of the passenger and freight car axles covered by this specification are shown in Specification M-101. 19.0 WORKMANSHIP AND FINISH 19.1 Axles shall be machined to a smooth machined finish between the wheel seats. The wheel seats and journals shall be rough machined; the rough machining shall be free from objectionable ridges and chatter marks. Journals, dust guard seats, and wheel seats of axles supplied in finished form will comply with applicable provisions of the AAR Manual of Standards and Recommended Practices, Section G, Part II, “Wheel and Axle Manual.” 19.2 Finish The axles shall be free from injurious defects. The machining shall be done in a workmanlike manner. 19.3 The interpretation of injurious defects in axles shall comply with Appendix A , “Interpretation of Defects Considered Injurious in Axles.” 20.0 MARKING Axles shall be legibly cold stamped with characters not less than 1/4 in. high in accordance with the AAR standard marking requirements shown in Fig. C.2. 21.0 INSPECTION 21.1 The inspector representing the purchaser shall have free entry, at all times while the work on the contract of the purchaser is being performed, to all parts of the manufacturer’s works that concern the manufacture of the material ordered. The manufacturer shall afford the inspector, free of charge, all reasonable facilities and necessary assistance to satisfy the inspector that the material is being furnished in accordance with these specifications. Tests and inspection for acceptance shall be made at the place of manufacture. 21.2 The purchaser may make tests to cover the acceptance or rejection of the material in purchaser’s own laboratory or elsewhere. Such tests shall be made at the expense of the purchaser. 21.3 The inspector shall examine each axle in each heat for workmanship, defects, and conformity to the dimensions given on the order or drawing. If in this inspection defects are found that the manufacturer can remedy, manufacturer may correct such defects.
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22.0 REJECTION 22.1 Any axle that fails to meet the requirements of these specifications will be rejected. 22.2 Axles that show injurious defects subsequent to their original inspection and acceptance at the manufacturer’s works or elsewhere will be rejected and the manufacturer shall be notified. 23.0 REHEARING Samples of axles tested in accordance with these specifications that represent rejected material shall be held for 14 days from date of the test report. In case of dissatisfaction with the results of the tests, the manufacturer may request a hearing within that time. 24.0 CERTIFICATION Upon request of the purchaser in the contract or order, a manufacturer’s certification that the material was manufactured and tested in accordance with this specification, together with a report of the test results, shall be furnished at the time of shipment. 25.0 The following supplementary requirements shall apply only when specified by the purchaser. Details shall be agreed upon by the manufacturer and the purchaser. 25.1 Macroscopic Tests The prolongation from the largest axle in each heat shall be sawed normal to the axis of the axle and shall then be split longitudinally. The transverse and the longitudinal face shall be etched for microscopic examination. Reference shall be made to Specification ASTM E381, “Standard Method of Macroetch Testing Steel Bars, Billets, Blooms, and Forgings.” 25.2 The purchaser may specify axle wheel seat diameters 1/8 in. larger than those shown under dimension “I” in Fig. C.3. 26.0 This specification includes Appendices A , B, C, Figs. C.1 through C.5, and Specification M-101.
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APPENDIX A
APPENDIX A INTERPRETATION OF DEFECTS CONSIDERED INJURIOUS IN AXLES 1.0 The conditions that have been most difficult for inspectors to evaluate are light lines visible to the normal unaided eye, variously described as actual seams, hairlines, stringers, shadow seams, ghost lines, etc., that appear after the axles have been finish-machined and burnished or ground. It is therefore advisable to describe these conditions in more detail. 2.0 The interpretation of injurious defects as enumerated below is not to be considered as precluding other unforeseen or objectionable conditions not specifically listed. The right of the purchaser is reserved to reject temporarily such axles and make final settlement on the basis of further negotiations between representatives of the manufacturer and the purchaser who are especially qualified to decide such questions. 3.0 Any transverse or circumferential seams, cracks, or laps of indeterminate depth on the axle surfaces other than the discolorations listed in paragraph 4.0, regardless of their location, are considered to be injurious and are cause for rejection without further machining. 4.0 Ghost lines, shadow marks, or other similar discolorations, visible to the normal unaided eye that are not actual separations in the metal are not considered injurious, regardless of location. 5.0 Any longitudinal discontinuity, variously termed hairline, stringer, or fine seam, in machined fillets is considered to be injurious and is cause for rejection without further conditioning. 6.0 JOURNALS AND DUST GUARDS 6.1 Roller Bearing Axles Fine longitudinal discontinuities on the finished (burnished or ground) surfaces variously termed hairlines, stringers, or fine seams are not considered injurious if they meet the following conditions: 6.1.1 Must not extend into fillets. 6.1.2 Must not be over 3/4 in. long individually in the journal or 1/2 in. long individually in the dust guard seat. 6.1.3 Total length of such imperfections over 1/4 in. long must not exceed 2 in. in any one end of axle. 7.0 WHEEL AND GEAR SEATS 7.1 Freight Car Axles (Roller Bearing) Longitudinal seams in wheel seats of freight car axles are not considered injurious if they meet the following conditions: 7.1.1 Must not extend into the dust guard or body fillets. 7.1.2 Must not be over 2 in. long individually. 7.1.3 Total length of such imperfections, 1/4 in. to 2 in. long, must not exceed 4 in. in any one end of axle.
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7.2 All Other Axles Longitudinal discontinuities on the finished machined surface of wheel and gear seats, variously termed hairlines, stringers, fine seams, tight seams, surface imperfections, etc., are not considered injurious if they meet the following conditions: 7.2.1 Must not extend within 1 1/2 in. of either end of wheel or gear seat. 7.2.2 Must not be over 1/2 in. long individually. 7.2.3 Total length of such imperfections, 1/4 in. to 1/2 in. long, must not exceed 3 in. in any one end of axle. 8.0 AREAS BETWEEN WHEEL (AND GEAR) SEATS (BODY) 8.1 Machined Bodies Longitudinal discontinuities on the finished surfaces, variously termed hairlines, stringers, or fine seams, are not considered injurious if they meet the following conditions: 8.1.1 Must not extend into fillets adjacent to wheel or gear seat. 8.1.2 Must not be over 1/2 in. long individually. 8.1.3 Total length of such imperfections, 1/4 in. to 1/2 in. long, must not exceed 1 1/2 in. in any 12 in. of body length. 8.1.4 Axles containing longitudinal discontinuities in the body in excess of those described in paragraphs 8.1.2 and 8.1.3 above may be reconditioned by grinding or machining, provided the diameter is not reduced below the specified limit.
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APPENDIX B
APPENDIX B DISTANCE AMPLITUDE CORRECTION 1.0 ALTERNATE REFERENCE STANDARDS Alternate references may be used to establish the test sensitivity if they are cross-referenced with the reference test block described in paragraph 16.6.1.1.1. For example, the following are alternate references for heat-treated axles that give equivalent sensitivity: 1) a 1-in. indication from a #1 series “A” Alcoa block; and 2) a 1 1/2-in. indication from an ASTM E-127 block #1-0300. 2.0 DISTANCE-AMPLITUDE CORRECTION The amplitude of an ultrasonic indication from a given discontinuity size varies with its distance from the test surface. To compensate for this effect, a distance-amplitude relationship is employed. The relationship can be established by an electronic device or by curves. Because the distance-amplitude relationship is influenced primarily by the ultrasonic transducer and instrument, it is necessary to relate this factor to the specific equipment used. Appropriate distance-amplitude curves shall be developed. A typical example is shown in Fig. B.2 as related to the axle in Fig. B.1. 3.0 SPURIOUS ULTRASONIC INDICATIONS FROM CONTOUR VARIATIONS Because an axle varies in cross-section, it is possible to produce spurious indications, particularly at changes of cross-section. These must be recognized and are not reason for rejection. It is not practical to define these indications in the specification, but the competent operator or technician will recognize these spurious indications as responses from axle contours. 4.0 NEAR-FIELD RESOLUTION It should be recognized that detection of discontinuities near the test surface is limited by the ultrasonic test frequency. In the case of heat-treated axles, this is approximately 1 in. from the test surface.
Fig. B.1 Showing location of reference holes in axles
Fig. B.2 Typical distance-amplitude curve for heat-treated axle (as determined with a Sperry reflectoscope, Type UM using a 1 1/8-in.-diameter, 2.25 MHz quartz transducer) 03/2011
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APPENDIX C QUALIFICATION OF MANUFACTURER’S PLANT AS A PRODUCER OF AXLES FOR AAR INTERCH INTERCHANGE ANGE SERVICE SERVICE 1.0 Applications for approval are to be submitted to the AAR. Applications shall be provided in electronic file format and must provide a general description of the facility and the equipment to be used in the production of axles. In the event it is desired to deliver mounted wheel sets, information indicating that equipment is available to comply with the wheel mounting requirements of the AAR Manual of Standards and Recommended Practices, Section G, Part II, “Wheel and Axle Manual,” should be included. 2.0 After satisfactory review of the data submitted with the application, the Committee will authorize the applicant to contact the AAR for information concerning product testing. This will consist of the applicant furnishing three axles, at applicant’s expense, for testing by the AAR. All costs are to be paid by the applicant upon notification of the testing charges. 3.0 Subsequent to the satisfactory completion of the tests and approval by the Committee of test results, the AAR will inspect for proper equipment the plant where the axles are to be produced per S-649. S-649. If mounted wheels are to be provided, an AAR inspection will be arranged for the wheel shop. These inspections will require that all costs be paid by the applicant. Upon the granting of AAR approval, company company marks to be be stamped on the axle axle end face will be assigned. assigned. 4.0 All plants desiring to maintain their status as an AAR-approved manufacturer of axles for use in AAR interchange service must be inspected as described in S-649. S-649. The costs of inspection are to be borne by the axle producer. In the event that a facility fails to satisfy inspection or testing expense obligation, the AAR, in conjunction with the Committee, reserves the right to withhold or withdraw approval. 5.0 In the event that a facility ceases production for less than a year and has not received its scheduled annual inspection, an inspection of the facility is required prior to the delivery of any items for use in interchange service. In the event a plant ceases production of axles for AAR interchange service for more than 60 days and less than 1 year, the AAR must be notified no later than 2 weeks prior to reopening. 6.0 In the event a plant does not receive its annual inspection or ceases production of axles for AAR interchange service for more than 1 year, year, requalification will be required prior to delivery of any items for use in AAR interchange service. 7.0 In addition to the foregoing, axle manufacturers must meet the requirements of the AAR Manual of Standards and Recommended Practices , Section J, Specification M-1003, “Specification for Quality Assurance.” 8.0 All plants desiring to maintain their status as an AAR-approved manufacturer of axles for use in AAR interchange service must also have their steel suppliers and heat-treating subcontractors inspected if they do not use their own facility. These inspections will be made in conjunction with the facility inspection, and the cost will be borne by the applicant. 9.0 Axle manufacturers using a native language other than English are responsible for the accurate communication of all applicable AAR and customer requirements within the plant. 9.1 Plant practices and the final product must conform to the English language versions of any applicable standards or specifications. 9.2 Critical records are defined as the standards, internal procedures, and forms necessary to demonstrate compliance with this Specification M-101 M-101 and with MSRP Section J, Specification M-1003. Critical records must be kept up to date with production and be maintained in English.
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NOTE: THE GAUGE LENGTH, PARALLEL SECTION, AND FILLETS SHALL BE AS SHOWN, BUT THE ENDS MAY BE OF ANY SHAPE TO FIT THE HOLDERS OF THE TESTING MACHINE IN SUCH A WAY THAT THE LOAD SHALL BE AXIAL.
Fig. C.1 Standard Standard round tension tension test specimen specimen with 2-in. gauge length length Paragraph Paragraph 11.3 11.3
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Wheels and Axles
APPENDIX C
M-101
AAR STANDARD STANDARD AXLE MARKINGS NOTES: 1. LAB LAB ORATORY ACCEPTANCE STAMP—FOR USE BY PURCHASER TO SIGNIFY ACCEPTANCE ACCEPTANCE OF AXLES SO SO MARKED PRIOR PRIOR TO SHIPMENT SHIPMENT BY PRODUCER PRODUCER 2. SERIAL NUMBER. 3. MANUFACTURER’S NAME OR BRAND (SEE TABLE BELOW) 4. MONTH AND YEAR YEAR MADE 5. GRADE GRADE OF AXLE AXLE F =Double Normalized and Tempered Tempered G =Quenched and Tempered H =Normalized, Quenched and Tempered Tempered
GENERAL NOTES: • REFER TO THE LATEST LATEST MECHANICAL MECHANICAL DIVISION DIVISION CIRCULAR LETTER LISTING OF AAR-APPROVED AXLE MANUFACTURERS FOR CURRENT APPROVAL STATUS. • ALL MARKS WILL BE DEEPLY DEEPLY AND LEGIBLY LEGIBLY STAMPED STAMPED WITH CHARACTERS CHARACTERS NOT LESS THAN 1/4 IN. HIGH. • ALL MARKS FOR FREIGHT CAR CAR ROLLER BEARING BEARING AXLES MUST BE LOCATED ADJACENT TO THE PERIPHERY OF THE CENTERING HOLE. • MANUFACTURERS MANUFACTURERS MUST FINISH FINISH ONE END OF THE AXLE FOR STAMPING. • THE ABOVE ARE ARE THE MINIMUM MARKING REQUIREMENTS, REQUIREMENTS, BUT BUT THE LOCATIONS ON INDIVIDUAL ITEMS MAY VARY FROM THAT ILLUSTRATED.
6. HEAT IDENTIFICATION IDENTIFICATION NUMBER 7. IF AXLE IS RADIALLY UT’D, THEN STAMP IMMEDIATELY IMMEDIATELY FOLLOWING AXLE AXLE GRADE = R.
Manufacturer’s Name or Brand AXIS BF
QRSS
Qiqihar Railway Rolling Stock Ltd.
Qiqihar, P.R.C.
RW SCOTa/
S. C. SMR S.A. Scot Forge
Bals, Romania Clinton, Wisconsin
AXIS LLC Bumar-Fablock S.A.
Paragould AR Chrzanow. Poland
BSa/
Bethlehem Steel Corporation
Johnstown, PA
CAF CBa/
Co ns ns trtr uc ucc io ion es es y Au Au xi xi lili ar ar de de Fe Fe rrrr oc oc ar ar riri le les (C (C AF AF) Cobrasma
Be as as ai ai n, n, Sp Spa in in Brazil
SFC or Sa/
Standard Forgings
SMI
Sumitomo Metal Industries LTD.
Osaka, Japan
British Steel
Templebourough Works, England
CCC
CN R C ha ha ng ngc hu hun Ra il wa way Ve hi hi cl cl e F ac ac ilil it ie ies Co.,Ltd.
Jilin Province, China
SPTa/
CF
Valdunes (formerly Creusot-Loire)
Dunkerque, France
SSD
Standard Steel LLC.
CHB
Baotou
Burnham, Pennsylvania
SW
SWASAP Works
Ta/
British Steel
Germiston, South Africa Trafford Park Works, England
Tai yu yua n He av av y I nd nd us us trtr ie s C om omp an an y LT D. D.
Tai yu yua n, n, S ha han xi xi Province, P.R.C
CHT CHT
Baotou Inner Mongolia PRC Jinx Jinxii Axl Axlee Com Compa pany ny LTD. TD. (For (Forme merl rlyy Nori Norinc ncoo Jinx Jinxi) i) Taiyu aiyuan an,, Sha Shanx nxii Province, P.R.C
DDAP
DDAP/RAX
Dneprderzhinsk, Ukraine
T HM HM or T Z
DSS
JSC Dneprospetsstal, Zaporozhye (DSS)
TW plus a/
Hawker Siddeley
Trenton Canada
UF USS-Fa/
Ural Forge United States Steel Corp.
Chebarkul, Russia Fairfield Works
HM
Huta Gliwice-Osie Sp. zo.o
Zaporozhye, Ukraine Gliwice, Poland
JAW
Standard Forged Products Klockner
Johnstown, PA West Germany
USS-Ga/
United States Steel Corp.
Gary Works
USS-Ha/ V
United States Steel Corp. Valdunes (formerly Creusot-Loire)
Homestead Works Valenciennes, France
Ra il Wh Whe el el Fa Fac to tor y I nd nd ian Ra Ra il wa wa ys ys (F (F or or m meer ly ly Wheel and Axle Plant) Bonatrans a.s. (Formerly ZAD)
Yelahanka, Bagalore, India Bohumin, Czech Republic
KWa/ L
Lucchini Sidermeccanica SpA (Formerly Temi)
Lovere, Italy
LCKZ
LugCentroKuZ
Lugansk, Ukraine
LP MKa/
Hu ta ta L. W. ( Fo For m mee rlrl y L uc uc ch chi ni ni Po la land ) Makrotek
Wa rs rs aw aw, Po la nd nd Mexico
WAP
MRF
Standard Forged Products
McKees Rocks, Pennsylvania
ZB
MW
MWL Rodas & Eixos LTDA (Formerl y Mafers a) a)
Cacapavz , Sao Paulo, Brazil
a/ No Longer in Production
Fig. C.2 AAR standar standard d marking marking requirements requirements Paragraph Paragraph 20.0 G [M-101] 16
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M-101
APPENDIX C
RP-634, Fig.5.8
NOTES: 1. “I” DIMENSION TOLERANCE IS +0.015 –0.015. 2. MAXIMUM ALLOWABLE RUNOUT BETWEEN “G” AND “H” IS .006" TOTAL DIAL INDICATOR. 3. MAXIMUM ALLOWABLE RUNOUT BETWEEN “G” AND “I” IS .008" TOTAL DIAL INDICATOR. 4. FOR 7" × 12" JOURNALS, END CHAMFER IS 4° 15' 5/8" ±1/8". 5. REQUIRED FOR PRESS FIT OF ROLLER BEARING BACKING RING WHERE THE “H” DIAMETER IS TOLERANCED. FINISH TO 125 ΜIN. MAXIMUM WHEN TOLERANCED. 6. THE "W" DIMENSION CANNOT EXCEED THE TOLERANCE LIMITS OF THE GAUGE SHOWN IN MSRP SECTION G-II, RP-634, FIG. 5.27. 7. RUNOUT ON JOURNAL SURFACE “G”, WHEN ROTATED ON CENTERS, MUST NOT EXCEED .015" TOTAL DIAL INDICATOR. 8. DIMENSIONS “B” AND “N” ARE CONSIDERED ENGINEERING DATA FOR TRUCK DESIGN AND DO NOT NECESSARILY AGREE WITH AXLE MANUFACTURING TOLERANCES. 9. JOURNAL FINISH MUST NOT EXCEED 63 ΜIN., IF GROUND OR TURNED ONLY. IF TURNED AND ROLLED, THE TURNED FINISH MUST NOT EXCEED 125 ΜIN., AND THE ROLLED FINISH MUST NOT EXCEED 16 ΜIN.
G [M-101] 17
Fig. C.3 Axle for freight car roller bearing—raised wheel seat (page 1 of 2) Standard 1963; Revised 1984, 1998; Effective March 1, 1985 Paragraph 17.5 and Paragraph 25.2
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Wheels and Axles
APPENDIX C
M-101
" Y 8 ° 2
" 8 ° 2
" 8 ° 2
" 5 1 ° 4
° 0 1
—
4 " / 4 " / 4 " / 0 8 " 1 4 1 " 4 1 4 / 0 2 . - / - / - 8 / 1 5 0 X / 1 / 1 / 1 / — . ± 1 0 1 0 1 0 5 ± 2 + + + " " " 6 " " 6 6 " 1 4 1 7 1 / / 1 / / 3 0 5 3 W 1 1 9 2 1 . . 1 0 1 8 8 1 0 1 1 1
S N O I S N E M I D
" 8 V / 7 1
" 2
" U 6 6
" 8 / 1 6 6
—
— " 0 0 0 . 9
" 8 / 1 2 " 8 / 1 6 6
" 4 / 1 2 " 8 / 1 7 6
" 8 / 1 2 " 4 9 2 . 9 6
7 – " 8 / 1 1
7 – " 4 / 1 1
7 – " 8 / 1 1
8 – " 1
7 – " 8 / 1 1
7 " 6 1 / 3 1 1
7
7
7
7
" 6 1 / 5 2
" 7 9 3 . 3
3 9 2 . 3
0 0 5 . 3
" 6 1 / 7 6
" 6 1 / 5 1 5
" 3 5 8 . 4
7 5 4 . 4
0 5 7 . 4
" 2 " 6 8 0 . 9 6
" 8 / 1 2 " 0 0 5 . 9 6
) 2 f o 2 e g " " " 6 " " " 6 " a 6 4 1 8 8 1 8 / / / 1 / / / p / R 3 ( 5 1 5 1 5 1 1 1 t 1 2 2 2 2 1 1 a e " " " " " s 6 " 0 8 8 4 l / " / / 5 5 0 . 8 5 1 1 5 e O 1 . 5 . 8 6 9 9 7 e 8 7 8 8 8 8 8 h w " " " " " " " 8 9 9 9 8 9 N 7 d 7 7 7 7 7 7 7 e " " " " " " " s i 2 2 2 2 / 2 2 2 / / / / / / a 1 1 1 1 1 1 M 1 r 2 2 2 2 2 2 2 6 6 6 6 6 6 6 — g " " " " " n 6 6 8 8 8 i 1 / " / 1 " / / r K / 7 3 8 3 8 7 7 a 5 7 7 6 6 e b " " " " " " " r 6 6 6 6 4 8 8 1 / 1 / 1 1 e / / / / J / l 3 7 l 5 9 7 5 9 6 7 o 7 8 7 7 8 r " r " " " " " " 6 a 4 4 2 4 4 2 1 / / / / / / I / c 1 3 1 3 1 1 9 t 8 8 9 8 8 9 7 h g " 2 0 2 0 2 0 2 0 2 0 2 0 i 8 3 3 3 3 0 0 3 3 3 3 3 3 / e H 3 0 0 5 5 0 0 5 5 0 0 5 5 . . . . . . . . . . . . r 7 7 7 7 8 8 7 7 7 7 7 7 f 6 r o 5 5 5 5 5 5 4 3 5 5 5 5 0 0 f 1 0 1 0 1 0 0 0 1 0 1 0 4 3 9 9 9 9 9 9 0 0 9 9 9 9 0 0 e 1 . 6 . 6 . 1 . 1 . . . 1 . 1 . 6 . 6 . 5 . 5 . l . 1 G 5 5 5 5 6 6 7 7 5 5 6 6 x . 6 6 . x . x . x . x . x . A x n n x n a i n n n n a i a i a i a i a i a i m m m m m m m m m m m m m m 3 . " " " " " " C E " 3 3 3 3 3 3 3 . g " " " " " " " i 8 8 8 8 8 8 8 / / / / / / F D / 5 5 5 5 5 5 5 9 – T " 8 / 7
8 – " 1
7
7 " 6 1 / 3 1 1 " 6 1 / 5 1 5
" 4 C / 3 1 " 2 B / 1 5 0 1 × 2 / 1 5
1 1 × 6
2 1 × 2 / 1 6
2 1 × 7
9 × 2 / 1 6
8 × 6
9 × 7
I E F I N L O S X I S A D T A A F L C C O
E
F
G
K
L
M
L F A O N R E Z I U O S J
G [M-101] 18
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AAR Manual of Standards and Recommended Practices Wheels and Axles
APPENDIX C
Freight Car Axles Class
Size (in.)
A (in.)
B (in.)
C
D (in.)
E
D
5 1/2 × 10
3.5000
6 3/16
5.195
2 3/8
.740
E
6 × 11
3.8750
6 11/16
5.695
2 5/8
.850
F
6 1/2 × 12
4.2500
7 3/16
6.195
2 7/8
.955
G
7 × 12
4.6250
8
7.008
3 1/2
1.080
K
6 1/2 × 9
4.2500
7 3/16
6.195
2 7/8
.955
L
6×8
3.8750
6 11/16
5.695
2 5/8
.850
M
7×9
4.625
7 3/16
6.508
2 7/8
0.955
Amtrak Passenger Car Axles D
5 1/2 × 10
3.0000
6 1/2
5.507
1 7/8
.636
E
6 × 11
3.5000
7
6.007
2 3/8
.749
F
6 1/2 × 12
3.8750
7 1/2
6.507
2 5/8
.749
MATERIAL: ASTM A-576, GRADE 1045 OR EQUIVALENT. PARTS TO BE HARDENED AND SURFACES MARKED “G” ARE TO BE GROUND. BREAK SHARP CORNERS. TOLERANCE ON ALL DIMENSIONS TO BE 1/64 IN. UNLESS OTHERWISE SPECIFIED.
Fig. C.4 Pin-type gauge for cap screw holes in ends of roller bearing axles Standard 1979; Revised 1982, 1998
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APPENDIX C
AAR Manual of Standards and Recommended Practices Wheels and Axles
M-101
NOTE: DEPTH OF COUNTERBORE IN ROUGH AXLE SHALL BE INCREASED FROM THAT SHOWN TO COMPENSATE FOR STOCK ALLOWED TO FACE AXLE. WHEN SECONDHAND AXLES ARE RECENTERED, DIAMETER AND DEPTH MAY BE INCREASED SUFFICIENTLY TO PRODUCE AN ACCURATE 60º CENTER.
Fig. C.5 Axle centering and gauge for axle center and lathe center Adopted 1944; Revised 1966, 1979 Paragraph 17.2
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Wheels and Axles
WHEELS, CARBON STEEL Specification M-107/M-208 Adopted: 1962; Last Revised: 2011 1.0 SCOPE
These specifications cover one-wear, two-wear, and multiple-wear wrought and cast carbon steel wheels for locomotives and cars—Classes L, A, B, C, and D (heat-treated) wheels used in interchange service. All freight car wheels manufactured for AAR interchange service must be heat-treated and of a low-stress design. 1.1
Class B, C, C, or D wheels must be used for freight cars in interchange service.
1.2
Class B, C, C, or D wheels are recommended for use on locomotives.
1.3
For passenger car service, the various classes are intended generally as follows: Class L —High-speed service with more severe braking conditions than other classes and light wheel loads. Class A—High-speed A— High-speed service with severe braking conditions, but with moderate wheel loads. Class B—High-speed B— High-speed service with severe braking conditions and heavier wheel loads. Class C—(1) C— (1) Service with light braking conditions and heavy wheel loads. (2) Service with heavier braking conditions where off-tread brakes are employed.
2.0 DESIGN
Standard wheel types and tread and flange contours for freight car and locomotive steel wheels shall be as shown in this specification. Interchangeability requirements and tolerances and tread and flange contours for the authorized wheel types are shown in Figs. Figs. B.8 B.8 through B.14. B.14. The interchangeability requirements and tolerances are generally limited to those required to ensure the wheel is compatible with the standard axles, bearings, side frames, and track. In the event that design constraints other than these are shown, the wheel producer may request an exception or change by application, with supporting data, to the AAR Technical Services Division (hereinafter termed AAR). Staff will, in turn, submit the application to the Wheels, Axles, Bearings, and Lubrication (WABL) Working Working Committee (hereinafter referred to as the “Committee”) for review. review. 2.1
In the event any company feels there is a need for a wheel type not currently listed, an application, with supporting data, should be made to the AAR, who will obtain the decision of the Committee. 2.2
Authorization for delivery for interchange use of any AAR wheel type must be obtained from the AAR as described in Appendix in Appendix A . 3.0
4.0 Qualification as a manufacturer of wheels for use in AAR interchange service must be in accordance with Appendix with Appendix B. B . Qualification is effective until revoked for cause by the Committee. Failure Failure to maintain reasonable quality standards st andards in manufacturing is an example of cause.
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5.0 5.0 MANU MANUF FACTUR CTURE E 5.1 Discard
A sufficient discard shall be made from the steel used for the manufacture of all steel wheels to to ensure freedom from piping and undue segregation. 5.2 5.2 Tempe empera ratu ture re Cont Contro roll
During manufacture of all wheels, necessary care in the t he regulation of temperature gradients shall be exercised to prevent the development of internal defects or injurious stresses. 6.0 6.0 HEAT HEAT TREAT REATME MENT NT 6.1
All wheels must be rim-quenched rim-quenched and tempered.
6.2 Rim-Qu Rim-Quenc enchin hing g Treat Treatmen mentt
All wheels shall be allowed to cool to a temperature below the critical range and uniformly reheated to the proper temperature to refine the grain, and then the rims shall be quenched. Following quenching, the wheels shall be charged into a furnace for tempering to meet the requirements of paragraph paragraph 10.0 and 10.0 and subsequently cooled under controlled conditions. 7.0 7.0 SHOT SHOT PE PEENI ENING 7.1 Scope
This section covers shot peening of steel wheels to provide improvement in plate fatigue strength. 7.2 7.2 Requ equirem iremen ents ts 7.2.1 Shot
The shot shall be SAE No. 550 or larger hardened steel as specified in SAE J827. 7.2. 7.2.2 2 Shot Shot Size Size Cont Contro roll
The peening machines shall be equipped with a separator for continuously removing broken shot. Sufficient new shot shall be added to ensure that a minimum of 85% of No. 550 or larger shot is maintained in the machines at all times. 7.2. 7.2.3 3 Peeni eening ng Int Inten ensi sity ty
The peening intensity shall be sufficient to produce an average arc height of not less than 0.008 (.0075 +) Almen C on the front plate plate near the hub fillet and on the back plate near the rim fillet of wheels of the standard design and at back plate hub fillet and front plate rim fillet of the reverse plate design. The area to be peened is defined as the plate area extended approximately one-half of the way into the hub and rim fillet radii on the front and on the back of the wheel. 7.2.3. 7.2.3.1 1 Arc Arc Heig Height ht Measur Measureme ement nt
Measurements of arc height shall be made in accordance with SAE Standards J442 or SAE Recommended Practice J443. 7.2 7.2.4 Cove Cover rage age
The minimum peening time shall be sufficient to ensure that full coverage is attained on the Almen C strip as defined in SAE Recommended Practices J443, Alternate Procedure, or MIL-S-13165 C, Paragraph 6.11 7.2 7.2.5 Se Sequ quen enc ce
Shot peening will be performed on all wheels and after any corrective surface preparation on the plate area. Plate area is defined in paragraph paragraph 7.2.3 7.2.3. Peening may be performed prior to inspection.
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7.2. 7.2.6 6 Porta ortabl ble e Pee Peene ners rs
A portable peening device may may be used to re-peen small reconditioned areas areas (no larger than 6 in. 2) on wheel plate surfaces, excluding the critical fillet areas (front hub and back rim fillets of wheels of standard designs and back hub and front plate fillets of wheels of reverse plate design). The portable equipment must be capable of peening an Almen C strip to develop the required average arc height of not less than 0.008 in. with a reasonable time of peening. Peening time of wheel plates must be at least as long as the time required to develop the 0.008-in. arc height. The equipment must be tested on an Almen C strip each 8-hour shift that the portable peener is used. A record of the Almen C test results shall be maintained. 7.3 Qualit Quality y Assu Assuran rance ce Provis Provision ions s 7.3.1 7.3.1 Wheel Wheel Surfac Surface e Condit Condition ion
The peened appearance of rim and hub shall not be cause for rejection. 7.3. 7.3.2 2 Freq Freque uenc ncy y of Tes Testt
Arc height determinations shall be made on Almen C strips attached to a test wheel at the beginning and end of each production run but not less than once in each eight operating hours. 7.3.3 Retest
If a test fails to meet the arc height requirements of 0.008 Almen C, two retests will be made. These retests shall be averaged with the first determination. The average shall be not less than 0.008, and no more than one value of the three shall be less than 0.008. 7.3. 7.3.4 4 Repe Repeen enin ing g
When test values fail to meet the provisions of paragraph paragraph 7.3.3 7.3.3, corrective action shall be initiated and satisfactory test values secured before proceeding with production peening. If the average Almen value of the unsatisfactory test is 0.006 0.006 or 0.007, the last half of the wheels peened prior prior to the unsatisfactory test (but subsequent to a satisfactory test) shall be repeened with at least 1/2 exposure time. If the average Almen value is less than 0.006, all the wheels peened since the last satisfactory test shall be repeened with full exposure.
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8.0 LADLE ANALYSIS 8.1
The steel shall conform to the following chemical requirements: Table 8.1 Chemical requirements Ladle Analysis (%)
Element
Class L
Class A
Class B
Class C
Carbon
0.47 max.
0.47–0.57
0.57–0.67
0.67–0.77
Manganese
0.60–0.90
0.60–0.90
0.60–0.90
0.60–0.90
Phosphorous
0.030 max.
0.030 max.
0.030 max.
0.030 max.
Sulfur
0.005–0.040
0.005–0.040
0.005–0.040
0.005–0.040
Silicon
0.15–1.00
0.15–1.00
0.15–1.00
0.15–1.00
Residual Elements Nickel
0.25 max.a/
0.25 max.a/
0.25 max.a/
0.25 max.a/
Chromium
0.25 max.a/
0.25 max.a/
0.25 max.a/
0.25 max.a/
Molybdenum
0.10 max.a/
0.10 max.a/
0.10 max.a/
0.10 max.a/
Vanadium
0.040 max.a/
0.040 max.a/
0.040 max.a/
0.040 max.a/
.35 max.
.35 max.
.35 max.
.35 max.
Aluminum
0.060 max.
0.060 max.
0.060 max.
0.060 max.
Titanium
0.03 max.
0.03 max.
0.03 max.
0.03 max.
Colunbium (niobium)
0.05 max.
0.05 max.
0.05 max.
0.05 max.
Copper
a/
If the manufacturer chooses to vary from the above limits for nickel, chromium, molybdenum, and vanadium, the following formula must be met:
930 – [570 × % carbon] – [80 × % manganese] – [20 × % silicon] – 50 × % chromium] – [30 × % nickel] – [20 × % molybdenum + % vanadium] > 390
An analysis of each heat of steel shall be made by the manufacturer to determine the percentage of the elements specified in paragraph 8.1. This analysis shall be made on a test specimen taken during the pouring of the heat. The chemical composition thus determined, together with such identifying records as may be desired, shall be reported to the purchaser or purchaser’s representative and shall conform to the requirements specified in paragraph 8.1. 8.2
8.3 Chemical Analysis
Chemical analysis of each heat of steel shall be made by one of the test methods listed below. All analyses should note which method is used for the carbon and/or chemical determinations. 8.3.1 Test Method 1
The carbon determinations should be one of the following test methods: Total carbon by the combustion gravimetric method, ASTM E-350 “Standard Test Methods for Chemical Analysis of Carbon Steel, Low-Alloy Steel, Silicon Electrical Steel, Ingot Iron, and Wrought Iron.” 8.3.1.1
Total carbon by the combustion thermal conductivity method, ASTM E-1019 “Standard Test Methods for Determination of Carbon, Sulfur, Nitrogen, Oxygen, and Hydrogen in Steel and in Iron, Nickel, and Cobalt Alloys.” 8.3.1.2
Total carbon by combustion, followed by quantitative infrared analysis, ASTM E-1019 “Standard Test Methods for Determination of Carbon, Sulfur, Nitrogen, Oxygen, and Hydrogen in Steel and in Iron, Nickel, and Cobalt Alloys.” 8.3.1.3
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8.3.2 Test Method II
ASTM E-415 “Standard Test Method for Optical Emission Vacuum Spectrometric Analysis of Carbon and Low-Alloy Steel.” 8.4 Check Analysis
An analysis may be made by the purchaser from a sample furnished by the manufacturer that represents the heats, from a wheel block, or from finished wheels selected by the purchaser from each heat in question. Samples from wheel blocks must be drilled from the end of the block midway between the center and outside. When a finished wheel is used, the sample must be obtained from the rim face or the hub in a manner that will not impair the usefulness of the wheel. No drilling of the finished wheel plate is permitted. Each sample must be thoroughly mixed together and must be clean and free of oil, scale, and other foreign substances. 8.4.1 Sampling Method
When wheel blocks or whole wheels are not available for chemical analysis, the laboratory conducting the chemical analysis shall follow a standard sampling method. This standard method of sampling shall be ASTM E-1806, “Standard Practice for Sampling Steel and Iron for Determination of Chemical Composition.” Then use either ASTM E-350, E-1019, or ASTM E-415 as specified in paragraph 8.3 for chemical analysis of the sample. 9.0 INTERIOR CONDITION/MICROCLEANLINESS STANDARDS 9.1 Sample Frequency
The metallurgical cleanliness of the wheel steel shall be determined from samples taken from randomly selected finished wheels representing the heat. A minimum of one 33-in. wheel and one 36-in. wheel of different heats produced quarterly per facility shall be tested. • Facilities that produce only 33-in. or 36-in. wheels shall test two wheels of different heats quarterly. • Facilities producing different size wheels to AAR specifications during a quarter shall test at least two wheels of different heats during the subject quarter. • Facilities not producing wheels to AAR specifications during four successive quarters shall, at a minimum, test at least two wheels from a heat specially produced to AAR specifications for the scheduled facility certification continuation inspection once a year. The purchaser reserves the right to more frequent testing should it be deemed necessary by mutual agreement between the purchaser and producer. 9.2 Sample Size and Location
A minimum of six samples shall be taken from each wheel tested approximately equidistant around the circumference of the wheel. Each sample shall be 7/8 in. long in the circumferential direction (the rolling direction), 3/4 in. wide in the axial direction (the rim width), and 1/2 in. thick in the radial direction (the rim thickness). The circumferential surface for microcleanliness evaluation shall be located 1/2 in. below the wheel tread and 2 1/2 in. to 3 1/4 in. from the back rim face. Dimension tolerances are ±1/8 in.
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9.3 Sample Preparation and Evaluation
Each 7/8 in. × 3/4 in. × 1/2 in. sample shall be carefully prepared and evaluated to ASTM Standard Practice E1245. The flicker method shall be used to establish the correct setting of the gray-level threshold limits. 9.3.1
The total area evaluated for each sample shall be not less than 1/4 in. 2 or 161 mm 2. All inclusions greater than 2.5 µm shall be counted. The WABL Committee must approve alternates to this method. 9.3.2
Effective January 1, 2008, average and worst field area percentage oxides, voids, and sulfides will be recorded. The AAR shall be advised quarterly when the six samples representative of the heat tested average more than 0.100% oxide plus voids; or the worst field area percentage of any one sample is more than 0.750% oxide plus voids; or 0.750% sulfides. If AAR is advised in two successive quarters, the provisions of AAR Manual of Standards and Recommended Practices , Administrative Standards, Standard S-060, paragraph 5.3, shall apply. In such cases, a special facility inspection may be required to demonstrate that the root cause has been identified and addressed. 9.3.3
Each sample shall be permanently marked according to heat and wheels represented and retained for a period of 1 year after the wheels are shipped. Records of test results shall be kept for 10 years after the wheels are shipped. Inspection results will be available for review by the AAR or other interested parties. AAR or other interested parties may have the test samples evaluated by other accredited laboratories at their expense. 9.3.4
10.0 BRINELL HARDNESS
The hardness of the rim, when measured in accordance with the requirements of paragraph 10.2, shall show the following values: 10.1
Table 10.1 Brinell hardness of rim Class
Minimum Hardness
Maximum Hardness
L
197 BHN
277 BHN
A
255 BHN
321 BHN
B
302 BHN
341 BHN
C
321 BHN
363 BHN
D
341 BHN
415 BHN
Note: Class D alloy steel wheels must meet
approval of the AAR WABL Committee.
all chemical requirements for Class C wheels and have
10.2 Method of Measurement
Measurement must be made in accordance with ASTM E-10 (latest revision) on the front face of the rim with the edge of the impression not less than 3/16 in. from the radius joining face and tread. Before making the impression, any decarburized metal shall be removed from the front face of the rim at the point chosen for measurement. The surface of the wheel rim shall be properly prepared to permit accurate determination of hardness.
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11.0 NUMBER OF TESTS
Where continuous heat-treating furnaces are used, BHN measurements shall be made on 10% of the wheels from each heat. Where batch-type heat-treating furnaces are used, BHN measurements shall be made on 10% of the wheels from each heat-treatment lot. For batch-type heat-treating, at least one wheel from each heat in the heat-treatment lot must be tested. For either heat-treatment process, BHN measurements must be made on a minimum of one wheel in a heat or heat-treatment lot of 10 or less, and on a minimum of 2 wheels in a heat or heat-treatment lot of 11 to 20. 11.1
If all the wheels tested meet the requirements of paragraph 10.0, all of the wheels represented shall be accepted. 11.2
If any wheel tested fails to meet the requirements of paragraph 10.0, it shall be checked by making two additional hardness measurements, one on each side of the point first measured and each approximately 1 in. from that point. If both of these check measurements meet the requirements of paragraph 10.0, the wheel shall be considered to have met the requirements of paragraph 10.0. 11.3
When continuous heat-treating furnaces are used, should any of the wheels tested fail on check test to meet the requirements of paragraph 10.0, the manufacturer may test for individual hardness measurements all of the wheels of that heat in the lot submitted for inspection, and those meeting the requirements of paragraph 10.0 shall be accepted. Where batch heat-treating furnaces are used, should any of the wheels tested fail on check test to meet the requirements of paragraph 10.0, the manufacturer may test all of the wheels in the heat-treatment lot for individual hardness measurement, and those meeting the requirements of paragraph 10.0 shall be accepted. 11.4
On new wheel designs or existing designs to which process changes are made, hardness gradient tests shall be performed on a minimum of one wheel from each of the first five heats of steel produced. The hardness shall be taken per Fig. 11.1 utilizing an approved hardness test machine. Values shall meet the requirements as shown in Table 11.1. 11.5
Table 11.1 Acceptable hardness ranges Class B C D
Minimum
Maximum
285 HB
341 HB
28 Rc
40 Rc
301 HB
363 HB
30 Rc
42 Rc
321 HB
415 HB
32 Rc
44 Rc
If values do not meet the requirements in Table 11.1, an additional five wheels from five heats shall be tested. All five wheels must meet the requirements in Table 11.1. If one or more wheels fail to meet the requirements in Table 11.1, testing per paragraph 11.5 shall be repeated after a process and/or design change is made. All wheels from heats that have a test wheel that failed to meet the requirements in Table 11.1 shall be reheat-treated, and one wheel from the heat shall be tested. If this wheel fails to meet the requirements in Table 11.1, all wheels from the heat shall be scrapped. Only one reheat treatment shall be allowed.
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Fig. 11.1 Hardness mapping locations 12.0 RETREATMENT
Any wheel failing to meet the requirements of paragraph 10.0 may be retreated and tested in accordance with paragraph 11.0. 13.0 MATING
Wheels shall be measured and marked to the lower tape number until the next graduation is reached. Wheels shall be shipped in pairs of the same measured tape size. 14.0 GAUGES
The gauges and tapes shall conform to and be used as required by the standards of the AAR Technical Services Division Alternate tape gauging will meet or exceed the AAR measurement standard for taping wheels. The repeatability and reproducibility of all alternate gauges must be demonstrated. 15.0 PERMISSIBLE VARIATIONS
The wheels shall conform to the dimensions with tolerances as specified in Figs. B.8, B.9, B.11, and B.12 for freight car wheels and in Figs. B.8 and B.10 for locomotive wheels. 15.1
Where Figs. B.9 and B.10 allow a certain percentage of the wheels to vary from standard dimensions for tape size by a given amount, the percentage of such wheels shipped by any manufacturer shall not exceed this percentage during a calendar year. No individual purchaser may receive more than this percentage of his daily shipments of such wheels except by agreement with the manufacturer. 15.2
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16.0 FINISH
Wheels shall be rough bored and shall not have black spots in the rough bore. Front hub face of wheels (1-W, 2-W, and MW) shall be parallel to the plane of the vertical reference line and may be smooth forged, cast, or machined. The back hub face may be smooth forged, cast, or machined. 16.1
The contour of tread and flange shall be as shown in Figs. B.11, B.12, or B.13 as applicable. Wrought steel wheels must be machined and finished smooth without excessive tool chatters. Cast steel wheels shall be as cast, machined, or ground, at the option of the manufacturer. Minimum and maximum flange thickness, height, and throat radii gauges shown in Standards S-661 and S-662 shall be used to check proper profile. Wheels that do not meet the criteria must be scrapped or recontoured. 16.2
Wheels must be free of all condemnable in-service defects. As-produced surfaces must be free from abrupt changes in surface contours. Spot grinding or machining to remove surface defects must not exceed a depth of 1/8 in. (0.125 in.; 3.2 mm). Sectional properties must meet all dimensional requirements following repair of surface defects. Repaired surfaces must have a maximum surface roughness of 500 µin. prior to final shot peening. Repaired surfaces must provide a uniform transition to the as-produced surfaces. 16.3
16.4
Wheels shall not be covered with any substance to such an extent as to hide defects.
Wheel profile is to be checked using wide flange profile gauge shown in Fig. B.14. There will be no more than 1/32-in. variation from the profile. 16.5
17.0 MARKING
Identification markings shall be legibly stamped as shown in Figs. B.4 or B.5. Wheels for freight service must be hot stamped or cold stamped on the back hub face. If any stamped characters are missing or illegible, these shall be replaced by cold stamping in the proper place in the marking sequence. Passenger car wheels may be hot stamped or cold stamped on front or back (as specified by purchaser) hub face. When ordered, locomotive wheels may be hot or cold stamped on the back rim face; or hot or cold stamped on the front hub face; or hot or cold stamped on the back hub face providing finish machining will completely remove the markings on the back hub face. Locomotive wheels that are to receive final hub machining by the purchaser may be ordered with markings paint stenciled on the wheel plate. After final machining, the purchaser will cold stamp the markings on the front hub face. For wheels having raised cast-on markings, the markings shall be legible characters and be as shown in Fig. B.7. For all wheels, stamping should be centered approximately on the hub. No wheel manufactured after May 1, 2009, may be bored and applied with any portion of the wheel manufacturer’s hub stamp closer than 1/8 in. from the inner hub diameter and no closer than 1/8 in. from the outer hub diameter. No wheel manufactured before May 1, 2009, may be bored and applied with any portion of the wheel manufacturer’s hub stamp breaking over the edge of the inner or outer hub diameter. 17.1
The tape size of all wheels shall be paint stencilled on back plates in characters at least 1 in. high. An “H” shall also be paint stencilled on the front plate at least 1 in. in height on those wheels of curved plate, heat-treated configuration. Stencil paint must be white and have a minimum ser vice life of 1 year. 17.2
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18.0 INSPECTION
The inspector representing the purchaser shall have free entry, at all times while the work on the purchaser’s contract is being performed, to all parts of the manufacturer’s works that concern the manufacture of wheels ordered. The manufacturer shall afford the inspector, free of charge, all reasonable facilities and necessary assistance to satisfy the inspector that the wheels are being furnished in accordance with these specifications. Internal defects are usually detected by ultrasonic testing. Such test shall be used in the manufacture of all wheels. The method to be followed and the equipment to be used shall comply with the requirements as shown in paragraph 18.4. Tests and inspection shall be made at the place of manufacture prior to shipment, unless otherwise specified. 18.1
The purchaser may make tests to govern the acceptance or rejection of the wheels in purchaser’s own laboratory or elsewhere. Such tests shall be made at the expense of the purchaser. 18.2
All tests and inspections shall be so conducted so as not to interfere unnecessarily with the operation of the works. 18.3
18.4 Ultrasonic Inspection
For detecting internal discontinuities in the rim of all steel wheels, ultrasonic inspection shall be made by following either the procedures shown below or an AAR-approved equivalent. Equipment used in these procedures shall comply with the following requirements. Each manufacturer shall maintain a documented test method and procedures for ultrasonic inspection of all railroad wheels manufactured under this specification. 18.4.1 Equipment
The instrument shall have a pulse echo receiver and shall operate at frequencies of 2 to 5 MHz required for the test method and type of equipment used. 18.4.1.1
The transducers shall be of the type whose composition and dimensions are appropriate for the test method used. 18.4.1.2
The ultrasonic inspection shall be performed with an automated scanning system. An automatic flaw alarm system shall be used in conjunction with the ultrasonic instrumentation. 18.4.1.3
A suitable couplant shall be used between the test surface and the transducer. The couplant shall be free of air bubbles. Rust inhibitors, softeners, and wetting agents may be added to the couplant. 18.4.1.4
18.4.2 Time of Inspection
Inspection shall be performed after final thermal processing.
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18.4.3 Calibration
Calibration shall be conducted using a reference standard of a wheel or portion of a wheel rim containing simulated defects or other AAR-approved procedure. The instrument sensitivity level should be adjusted to produce an approximate full-scale reflection from the reference standards of paragraphs 18.4.3.2, 18.4.3.3, 18.4.3.4, and 18.4.3.5. 18.4.3.1
For axial testing of all wheels, the reference standard shall be a 1/8-in.-diameter flat-bottom hole generated perpendicular to the rim face and to a depth of 1 1/2 in. (±1/16 in.) at the mid-thickness of the rim. See Fig. B.1 18.4.3.2
For radial testing, the reference standard shall be a 1/8-in.-diameter flat-bottom hole generated from the inside diameter of the rim perpendicular to the tread surface, and shall be a minimum of 1 1/4 in. from the tread surface. See Fig. B.2. 18.4.3.3
A distance amplitude correction (DAC) shall be used for axial and radial testing of wheels. To ensure detection, the DAC will be generated for each testing direction in the following manner. Holes shall not be located close to each other so as to impede the response from each hole individually. 18.4.3.4
18.4.3.4.1 Axial
As a minimum, two additional 1/8-in.-diameter flat-bottom holes shall be generated at whatever depth the manufacturer chooses. The creation of the DAC shall be accomplished using the reference standard and the response(s) from additional holes. Typical depths for the three holes could be 1 1/2, 2 1/2, and 3 1/2 in. All holes should be generated from the front or back rim face. See Fig. B.1. Individual depth standards shall be permitted. 18.4.3.4.2 Radial
To facilitate creation of a DAC, as a minimum, one additional 1/8-in.-diameter flat-bottom hole shall be generated in one-wear and two-wear wheels, and, as a minimum, two additional 1/8-in.-diameter flat-bottom holes shall be generated in multi-wear wheels. Calibration shall be accomplished using the reference standard, and the response(s) from the additional holes shall be used to create the DAC. Table B.1 shows the depth of reference standard holes for the different wheel types. See Fig. B.2. Individual depth standards shall be permitted. Alternate calibration standards may be used when authorized by the AAR WABL Committee. Manufacturer shall document and demonstrate the correlation between the 1/8-in.-diameter flat-bottom hole and the proposed alternate standard. 18.4.3.5
An alternate method for axial testing of cast steel wheels is to use loss of back reflection. The reference standard shall be a 3/8-in.-diameter concave bottom hole generated to a depth of 1/8 in. at the front rim face. See Fig. B.3. 18.4.3.6
Reference standards for the inspection of wheels shall be made from rim-treated wheel steel made by the same process as the wheels being inspected, i.e., wrought or cast. Reference standard need not be the same AAR design as the wheels being inspected. 18.4.3.7
18.4.3.8 Recalibration
Conduct ultrasonic calibration to ensure system conformance to required specifications. Check the ultrasonic system and calibration of the instrument per documented procedures using a calibration standard when any of the following occurs: • Damage to any part of the ultrasonic system • Change in transducers, cables, and other accessories • Loss of power or equipment malfunction • Whenever ultrasonic instrumentation is first turned on 03/2011
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18.4.3.9 System Verification and Test Results Validation 18.4.3.9.1
fications.
Conduct ultrasonic calibration checks to ensure system conformance to required speci-
System calibration shall be verified per documented procedures using a calibration standard at least every 8 hours of operation. If the results from system verification are outside of system tolerance, assessment of previous inspections must be made and appropriate action taken. Action taken shall be supported by wheel reinspection data. 18.4.3.9.2
18.4.3.9.3
Records shall be maintained of system calibration and system verification.
18.4.4 Scanning
Wheels shall be inspected axially from either the front or back rim face and radially from the tread surface. 18.4.4.1
One or more transducers shall be designed and located to give maximum volumetric coverage of the rim cross-section both radially and axially. Each manufacturer shall ensure optimum volumetric coverage for the test method and manufacturing process. Optimization of coverage is verified by using supplemental reference standard holes located in different areas of the rim, as shown in Figs. B.3.1 and B.3.2. 18.4.4.2
18.4.4.3
Scanning speed shall permit detection of reference standards at calibration level.
18.4.5 Rejection
Any wheel with a flaw indication equal to or larger than 25% of the reference standard at the estimated discontinuity depth shall be cause for rejection. 18.4.5.1
Any indication from discontinuity giving a loss of back reflection equal to or greater than the reference standard (covered in paragraph 18.4.3.6) during axial scanning shall be cause for rejection.
18.4.5.2
Ultrasonic indications that result from wheel geometry or spurious electrical signals shall not be valid cause for rejection. 18.4.5.3
The final disposition of rejectable wheel may be determined by manual testing of questioned areas. Wheel records and test results shall be maintained for wheels found to be conforming under this paragraph. 18.4.5.4
18.5 Magnetic Particle Inspection 18.5.1 Purpose
To supplement visual inspection of the surface of new wheels by detecting discontinuities that may be harmful to wheel service. 18.5.2 Scope
This test method covers the wet fluorescent magnetic particle inspection of the plates of wheels ordered to this specification.
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18.5.3 Equipment 18.5.3.1 Magnetizing Apparatus
The magnetizing apparatus shall be capable of inducing suitable magnetic fields within the entire plate area of the wheel to facilitate the disclosure of both circumferentially and radially oriented discontinuities. The magnetizing currents used shall be large enough to induce magnetic fields of sufficient intensity to disclose surface discontinuities 1/4 in. long. The use of prod-type contacts is prohibited. 18.5.3.2 Lighting Apparatus
The inspection shall be performed in a darkened booth with the area of the wheel to be inspected illuminated with properly filtered black light. The black light shall have a predominant wavelength of 4000 Å to 3400 Å, and the intensity of the black light, measured at the surface to be inspected, shall be a minimum of 75 footcandle at point of inspection. 18.5.3.3 Inspection Medium
The bath or solution should be prepared using a suitable carrier fluid and fluorescent magnetic particles and renewed monthly or more often if contamination is noted in weekly tests. Each time the bath is renewed, the bath container should be cleaned out and the agitation and circulation system should be flushed with 1 or 2 gal of clean carrier. Filtering screens should be removed and cleaned by blowing with air. In preparing the new bath, only recommended materials should be used. The amount of powder should be carefully weighed out in accordance with the material manufacturer’s recommendation and be added directly to the bath containing the correct amount of carrier. It is recommended that powder be added directly over the sump so that it will be drawn quickly into the pump and circulated. The amount of carrier and powder used and the date of preparation should be recorded on a regular form set up for this purpose, as outlined in paragraph 18.5.3.3.6. 18.5.3.3.1
Concentration and contamination of the bath solution should be tested weekly as follows: pump and agitation system should be operated for 20 minutes and then the solution should be run through a hose and nozzle for 30 seconds. Using a regular 100-mL centrifuge tube, fill the centrifuge tube with 100 mL of the solution. Allow the bath solution to settle for the time recommended by the manufacturer of the type of powder used, making sure that the tube is not sub jected to excessive vibration during the settling period. Each horizontal division represents 0.1 mL, and a correct reading in volume of particles must be as stipulated by the powder manufacturer. The check also should note contamination caused by dirt, chips, or other foreign matter settling with the powder. Contamination also is indicated when the carrier appears to acquire more than usual fluorescence or when the magnetic particles appear to have lost fluorescent qualities. This condition can be readily observed when the settling tube is exposed to ultraviolet light. The readings obtained are to be shown on the regular report form as outlined in paragraph 18.5.3.3.6. 18.5.3.3.2
The ultraviolet light should be tested weekly using a light meter, such as a type having 75-footcandle scale with a 10× multiplying disc or equivalent or a meter that responds specifically to the ultraviolet range of 3650 Å (365 nm). The latter type meters are calibrated in microwatts per square centimeter. The meter should be held a fixed distance of 15 in. from the light source (from the black light filter surface to the meter-sensing element) and should have a minimum meter reading of 525 µW/cm 2. 18.5.3.3.3
The conversion factor from footcandles (for light meters) to microwatts per square centimeter is 5.7 times the footcandle reading (at 15 in. distance). 18.5.3.3.4
The maximum allowable footcandles will be left to the discretion of the user dependent on the degree of brilliance desired to obtain satisfactory inspection conditions. Before taking readings, it should be known that the glass black light filters are clean. Reports of this test are to be shown on regular form as outlined in paragraph 18.5.3.3.6. 18.5.3.3.5
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A regular form should be prepared embodying the information to be shown on monthly and weekly tests as outlined above, and this form should be on hand at the wheel shop and available to AAR inspectors. 18.5.3.3.6
Prepackaged, self-contained solutions, including aerosol sprays, may be used provided that the following conditions are met: 18.5.3.3.7
18.5.3.3.7.1
tion.
The solution is agitated frequently to ensure that magnetic particles remain in solu-
A detectability test is performed daily on each package in use and a record is kept per paragraph 18.5.3.3.6. The test consists of inspection of a test wheel with a known crack of at least 1/4 in. long or an equipment manufacturer’s approved test piece that will indicate and verify the following: • Proper brilliance of ultraviolet light • Proper concentration of bath solutions • Proper magnetic power source and operation of equipment Note: Test wheel or test piece must be thoroughly cleaned of the last test indicators before testing. This must be verified by ultraviolet light before the test is started. 18.5.3.3.7.2
18.5.4 Preparation for Inspection
The surface shall be scale free before magnetic particle inspection. 18.5.5 Detection of Discontinuities
This inspection shall be performed to detect discontinuities whose axes may be in any direction. Continuous or residual magnetization shall be used with adequate coverage by the inspection medium. 18.5.6 Time of Inspection
The magnetic particle inspection shall be performed following final machining or grinding on wheel plate. 18.5.7 Rejection
Rejection of magnetic particle discontinuity indications must take place if any plate surface indication is 1/4 in. in length or longer in any direction. Discontinuities may be removed by machining or grinding where sufficient stock remains. Such wheels shall be retested by magnetic particle inspection. 18.6 Personnel Requirements for Ultrasonic Inspection
All personnel engaged in ultrasonic operations will be qualified to NDT Level I according to the qualification requirements as defined by the American Society for Nondestructive Testing, Recommended Practice SNT-TC-1A, latest edition. 18.6.1
All personnel conducting inspection setups and machinery setups will be trained and qualified to meet the criteria for NDT Level II for ultrasonic testing as defined by the American Society for Nondestructive Testing, Recommended Practice SNT-TC-1A, latest edition. 18.6.2
Each manufacturer will employ the services of an individual who will be trained and qualified to meet the criteria for NDT Level III for ultrasonic testing as defined by the American Society for Nondestructive Testing, Recommended Practice SNT-TC-1A, latest edition. 18.6.3
19.0 CERTIFICATION
At the purchaser’s request, a certification shall be made the basis of acceptance of the material. This shall consist of a copy of the manufacturer’s test report that the material has been sampled, tested, and inspected in accordance with the provisions of the specification. Each certificate so furnished shall be signed by an authorized agent of the supplier or manufacturer.
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20.0 REJECTION
Wheels represented by samples that fail to conform to the requirements of these specifications will be rejected. 20.1
Wheels that show injurious defects subsequent to original inspection and acceptance at the manufacturer’s works, or elsewhere, will be rejected, and the manufacturer shall be notified. 20.2
21.0 REHEARING
Samples tested in accordance with this specification that represent rejected wheels shall be held for a period of 14 days from date of the test report. In case of dissatisfaction with the results of the tests, the manufacturer may make claim for a rehearing within that time. 22.0
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This specification includes Appendices A and B; and Figs. B.1 through B.14.
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APPENDIX A
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APPENDIX A AUTHORIZATION FOR DELIVERY OF WHEELS FOR AAR INTERCHANGE SERVICE
Each manufacturer must obtain an authorization for delivery of wheels for AAR interchange use from the Committee prior to delivery. 1.0
The manufacturer applying for delivery authorization must provide the AAR with an electronic copy of the following documentation. 2.0
A descriptive drawing of the wheel type as it will be produced. The descriptive drawing will provide the following information: 2.1
A full-scale drawing showing the wheel cross-section from center of the hub to top of the flange. The drawing may show either a single profile with tolerances or, preferably, two profiles, with one depicting the minimum inner tolerances and the other the maximum outer tolerances in such a way that a wheel section laid on the drawing would fall between the two profiles. This would allow analysis of wheels produced to this drawing. 2.1.1
2.1.2
A notation of the wheel type and heat-treatment classes of the wheels to be produced.
A brief description of the design analysis method and the results of the analysis. The preferred analytic procedure is that covered in S-660. If there is no design analysis, a statement should be made to this effect along with a summarization of the design considerations. If the applicant would like the AAR to perform the S-660 design analysis on a contract basis, the applicant should request details from the AAR. 2.2
A statement advising the specific areas in which the wheel design may not be compatible with normal shop machinery and handling equipment, standard storage facilities, and wheel t ransport cars in general use. 2.3
Authorization for the delivery of a wheel type will be approved by the Committee if deemed suitable for interchange service based on a review of wheel data submitted by the manufacturer. The initial authorization will be for the delivery of 32,000 wheels. If the manufacturer requests additional delivery authorizations, the second will be for 20,000 wheels (52,000 total) and the third will be for 20,000 wheels (72,000 total). Additional allotments or unconditional approval for unlimited quantities will be given after that, provided all required conditions are met. 3.0
A new wheel type (such as CH-36, CJ-36, or J-33) that is made for the first time by the requesting manufacturer will require the following prior to being granted unconditional approval. If necessary, WABL will designate a sponsor railroad to assist the manufacturer in meeting these requirements. 3.1
A minimum of 5,000 wheels installed from the first allotment will have been tracked to provide mileage and will have achieved 200,000 miles in service. 3.1.1
Ultrasonic testing to wheelshop requirements for turned wheels will be performed for 30 or more wheels with at least 200,000 miles of service and with sufficient rim metal to be reapplied. Provided all other criteria are met, upon successful completion of ultrasonic testing, conditional approval, unlimited quantity will be granted. The 30 wheels will then be placed in service and tracked. Ultrasonic testing to wheelshop requirements of turned wheels will be performed for 10 of the 30 wheels reapplied after 100,000 miles additional service. Provided all other criteria are met, upon successful completion of the ultrasonic testing, unconditional approval will be granted. Test costs will be paid by the proponent, and data provided in the form of C-scans will be captured with an AAR observer present and provided to WABL. 3.1.2
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APPENDIX A
At least one out of every 1,000 wheels produced in the initial allotment will be tested for microcleanliness according to paragraph 9.0 of this specification. Results will be reported to the Wheels, Axles, Bearings, and Lubrication Committee Manager within 90 calendar days. Electronic reporting is preferred. Send results to 3.1.3
Email:
[email protected] Facsimile: 719-585-1895 Mail: AAR WABL Committee Manager Transportation Technology Center Inc. P.O. Box 11130 Pueblo, Colorado 81001
Each authorization after the initial authorization will be granted only after satisfactory performance is indicated by a review of service data submitted on the wheel by the manufacturer as well as service data from AAR records. Authorization may be withdrawn if service performance so dictates. 3.2
Changes to any wheel design by the producer must be reviewed by the Committee before delivery authorization may be granted. 4.0
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APPENDIX B QUALIFICATION OF MANUFACTURER’S PLANT AS A PRODUCER OF WHEELS FOR AAR INTERCHANGE SERVICE
Applications for approval are to be submitted to the AAR. Applications shall be provided in electronic file format and must provide a general description of the facility and the equipment to be used in the production of wheels. In the event it is desired to deliver mounted wheel sets, information indicating that equipment is available to comply with the wheel mounting requirements of the AAR Manual of Standards and Recommended Practices , Section G, Part II, “Wheel and Axle Manual” should be included. 1.0
After review of the data submitted with the application, the Committee will authorize the applicant to contact the AAR for information concerning product testing. Normally this will consist of the applicant furnishing three wheels, at applicant’s expense, for testing by the AAR. All costs are to be paid by the applicant upon notification of the testing charges. 2.0
Subsequent to the satisfactory completion of the tests and approval by the Committee of test results, the AAR will inspect the plant where the wheels are to be produced for proper equipment and, if mounted wheels are to be provided, an AAR inspection will be arranged for the wheel shop. These inspections will require that all out-of-pocket expenses be borne by the applicant. These inspections can be arranged concurrently with the test program if the applicant so requests. 3.0
All plants desiring to maintain their status as an AAR-approved manufacturer of wheels for use in AAR interchange service must be inspected yearly with costs of inspection to be borne by the wheel producer. Every effort will be made to inspect all plants in a given area at one time to minimize costs, which will be prorated among the companies inspected. 4.0
In the event that a facility ceases production for less than 1 year and has not received its scheduled annual inspection, an inspection of the facility is required prior to the delivery of any items for use in interchange service. In the event a plant ceases production of wheels for AAR interchange service for more than 60 days and less than 1 year, the AAR must be notified no later than 2 weeks prior to reopening. In the event a plant ceases production of wheels for AAR interchange service for more than 1 year, requalification will be required prior to delivery of any items for use in AAR interchange service. An AAR inspection of the plant will be required, and normally, the provisions of Appendix A will apply for all wheel designs that have been given an authorization in accordance with the procedure outlined in paragraph 2.0 and subparagraphs. The Committee may elect to require testing of wheels in accordance with Appendix B, paragraph 2.0. 5.0
6.0 In addition to the foregoing, wheel manufacturers must meet the requirements of the AAR Manual of Standards and Recommended Practices , Section J, Specification M-1003, “Specification
for Quality Assurance.”
All plants desiring to maintain their status as an AAR-approved manufacturer of wheels for use in AAR interchange service must also have their steel suppliers, shot peening, and heat-treating subcontractors inspected if they do not use their own facility. These inspections will be made in conjunction with the facility inspection, and the cost will be borne by the applicant. 7.0
Wheel manufacturers using a native language other than English are responsible for the accurate communication of all applicable AAR and customer requirements within the plant. 8.0
Plant practices and the final product must conform to the English language versions of any applicable standards or specifications. 8.1
Critical records are defined as the standards, internal procedures, and forms necessary to demonstrate compliance with this Specification M-107/M-208 and with MSRP Section J, Specification M-1003. Critical records must be kept up to date with production and be maintained in English. 8.2
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Fig. B.1 Typical reference standard for rim face ultrasonic test Paragraphs 18.4.3.2 and 18.4.3.4 Hole #1 reference hole Holes #2 and #3 used for distance amplitude correction (DAC)
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Fig. B.1.1 Axial rim test Paragraphs 18.4.3.2 and 18.4.3.4.1 Alternate configuration for distance amplitude correction
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APPENDIX B
Table B.1 Distance below Tread Surface Wheel Design
Reference Hole #1
Hole #2
One-wear two holes
1 1/4 in.
3/4 in.
Two-wear two holes
1 1/4 in.
3/4 in.
Multi-wear three holes
1 1/4 in.
3/4 in.
Fig. B.2 Typical reference standard for rim tread ultrasonic test Paragraphs 18.4.3.3 and 18.4.3.4.2 Hole #1 reference hole Hole #2 and #3 used for distance amplitude correction (see Table B.1)
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Hole #3
2 1/4 in.
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Fig. B.3 Axial rim test Paragraph 18.4.3.6
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Fig. B.3.1 Tread rim test Paragraph 18.4.4.2
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Fig. B.3.2 Axial rim test Paragraph 18.4.4.2
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APPENDIX B
Note 1
Note 2 Note 3 Note 4 Note 5
Stamping is to consist of manufacturer’s serial number, date of manufacture, manufacturer’s identification, and class of heat treatment. Stamping is limited to 14 characters, and the design designation shall be stencilled on the back plate with paint using characters at least 1 in. in height. Stamping is to be spaced a minimum of 1/8 in. between characters and 1 3/8 in. between groups. The stamping shall be located not less than 1/4 in. from the inner edge of the rim. Dies used to produce characters shall be not less than 3/8 in. in nominal height at crest, and hot stamping shall be nominally 3/32 in. in depth. Italicized characters (sloping upward to right) shall be used. All wheels will be marked for class using letters L, A, B, C, or D, as appropriate. All stamped characters must be stamped with a low-stress die design to a minimum depth of 0.015 in. or an AAR-approved alternative. Fig. B.4 Marking of locomotive wheels rim stamping Paragraph 17.1
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APPENDIX B
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Note 1 Note 2
Note 3
Note 4 Note 5 Note 6 Note 7
When ordered, locomotive wheels and wheels for passenger service may be ordered stamped on the front or back hub face. Wheels for freight service are stamped on the back hub face. Stamping is to consist of manufacturer’s serial number, date of manufacture, manufacturer’s identification, class of heat treatment, and design designation in the order shown above. The hub stamping of locomotive wheels may be applied by the purchaser after final machining of the hub. Wheels that are to be marked by the purchaser should be furnished with all marking stencilled on the front plate with paint using characters at least 1 in. in height. Stamping is to be spaced a minimum of 1/8 in. between characters and a minimum of 1 3/8 in. between groups and located approximately central of the hub face. No wheel manufactured after May 1, 2009, may be bored and applied with any portion of the wheel manufacturer’s hub stamp closer than 1/8 in. from the inner hub diameter and no closer than 1/8 in. from the outer hub diameter. No wheel manufactured before May 1, 2009, may be bored and applied with any portion of the wheel manufacturer’s hub s tamp breaking over the edge of the inner or outer hub diameter. Stamps used to produce characters shall be not less than 3/8 in. in height and shall not have sharp edges. All wheels will be marked for class using letters L, A, B, C, or D, as appropriate. The three groups (1) design; (2) serial number; and (3) date of manufacture, manufacturer, and class will be spaced approximately equidistantly around the hub face. All stamped characters must be stamped with a low-stress die design to a minimum depth of 0.015 in. or an AAR-approved alternative. Fig. B.5 Marking of carbon steel wheels hub stamping Paragraph 17.1
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Manufacturer’s Identification TW A BV BW DW P ZW QW FW EW KW LW HW MW NW CS RW SW JW TY or TZ
(TY not used after 10/ 06)
CW G VW
Manufacturer Adtranz Armco B.V.V. (Formerly VSG) Bethlehem Bonatrans a.s. (Formerly ZDB) British Steel Canadian Steel Wheel Construcciones y Auxiliar de Ferrocarriles (CAF) Creusot-Loire Edgewater Steel LTD Klockner Lucchini Sidermeccanica SpA (Formerly Gruppo Lucchini) Maanshan Iron and Steel Co. LTD MWL (Formerly Mafersa) Niznedneprovssky Tube Rolling Plant (NTRP) OneSteel Rail and Forge S. C. SMR S.A (Formerly SMR/MECANO) Standard Steel LLC Sumitomo Metal Industries LTD Taiyuan Heavy Industries Company LTD
APPENDIX B
Location UK Bochum, Germany Bohumin, Czech Republic UK Canada Beasain, Spain France Oakmont, Pennsylvania Germany Lovere, Italy Anhui, Province, P.R.C. Cacapavz, Sao Paulo, Brazil Dnepropetrovsk, Ukraine Waratah NSW, Australia Bals, Romania Burnham, Pennsylvania Osaka, Japan Taiyuan, Shanxi Province, PRC
U.S. Steel U.S. Steel Valdunes
Cast or No Longer Wrought in Production W X W X W W X W W X W X W W X W X W X W W W W W W W W W
Pittsburg, Pennsylvania W Gary, Indiana W Dunkerque & W Valenciennes, France VK Vyksa Steel Works Nizhegorodsky Region, Russia W SO ABC Rail (formerly Abex) Calera, Alabama C C Abex Rail ** Calera, Alabama C S Abex ** St. Louis, Missouri C SJ Abex Johnstown, Pensylvania C T Abex ** Toledo, Ohio C CZ Amsted Maxion (Formerly Iochpe-maxion S.A.) Cruzeiro, Brazil C Datong, Shanxi Province, China CO Datong ABC Castings Company LTD C FM FM Fundiciones de Hierro y Acero Mexico C GB Griffin Wheel Company Bensenville, Illinois C GC Griffin Wheel Company Columbus, Ohio C GI Griffin Wheel Company Kansas City, Kansas C GK Griffin Wheel Company Keokuk, Iowa C GL Griffin Wheel Company Colton, CA C GS Griffin Wheel Company Bessimer, Alabama C GT Griffin Wheel Company Winnipeg, Canada C GY Griffin Wheel Company St. Hyacinthe, Canada C WI Rail Wheel Factory (Formerly Wheel and Axle Plant) Yelahanka, Bagalore, India C AW Scaw Metals Germiston, South Africa C Ruzhou, Henan Province, PRC RZ Tianrui Group Foundry Co. Ltd C TA Tonghe Wheel Company Xinyang City, Henan C Province, PRC ** The letters C, S, or T directly precede the wheel serial number for wheels manufactured prior to about April 1978 Fig. B.6 AAR-approved manufacturers 03/2011
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X X
X X X X X
X X
X X X
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APPENDIX B
M-107/M-208
Note 1. Characters to be cast on the back plate of wheels shall, at least, show the manufacturer’s serial number, date of manufacture, manufacturer’s identification, class, and design designation. Note 2. Cast markings shall be legible characters, at least 1 in. high and so spaced to allow related characters to be readily distinguished as a group. Note 3 All wheels shall be marked for class using letters L, A, B, C, or D, as appropriate. Note 4 The three groups (1) design; (2) serial number; and (3) date of manufacture, manufacturer, and class must be clearly separate. Fig. B.7 Raised markings on cast carbon steel wheels Paragraph 17.1
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Standard Wide Flange Dimensions and Tolerances A
1
B
1 3 ⁄ 8
L
5 23 ⁄ 32
+ 1 ⁄ 16 – 0 + 1 ⁄ 32 – 3 ⁄ 32 ± 1 ⁄ 8
APPENDIX B
Standard Narrow Flange Dimensions and Tolerances 1 1 5 ⁄ 32 5 23 ⁄ 32
+ 1 ⁄ 16 –0 + 1 ⁄ 16 – 0 ± 1 ⁄ 8
(5 1 ⁄ 2 ± 1 ⁄ 8 alternate) Pa/
7 ± 1 ⁄ 4
See Note
R2
2 1 ⁄ 2 ± 1 ⁄ 8
See Note
K a/
0.0865
0.0663
Except A-28 = 7 ± 1 ⁄ 8
Fig. B.8 Standard dimensions and tolerances and permissible variations Paragraphs 2.1 and 15.1 Note: For standard wheel types and for dimensions and other data not
through B.14.
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shown above, see Figs. B.9
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APPENDIX B
Wheels and Axles
M-107/M-208
9.0 PERMISSIBLE VARIATIONS IN DIMENSIONS NOT SHOWN BY TOLERANCES ON FIGS. B.9 THROUGH B.14 9.1 Inside Diameter—Front Face of Rim
The inside diameter of the rim at the front face of the wheel shall not differ from that at the back face of the wheel by more than 1/4 in. 9.2 Thickness of Rim
In any wheel, the radial thickness of the rim shall not vary more than 1/8 in. around the wheel. 9.3 Corner at Inside Diameter of Back Face
A sharp corner is preferable to facilitate measurement. In any case, the radius of the corner shall not exceed 1/8 in. 9.4 Plane of Back Face
When wheels are gauged with a straight edge applied to the back face of the rim, no point on the back face of narrow-flange wheels more than 1 1/4 in. from the inside ed ge of the rim shall be more than 1/32 in. from the straight edge. For wide-flange wheels, no point on the back face of the rim shall be more than 1/32 in. from the straight edge. For narrow- and wide-flange wheels, the back face of the rim measured on the circumference at a distance 1 1/4 in. inward from the apex of the flange must be in plane within 0.040 in. Total Indicator Reading (TIR) with respect to the plane of the front face of the rim. 9.5 Hub Wall Thickness
The thickness of the hub wall in any one wheel measured at any two points equidistant from the face of the hub shall not vary by more than 3/8 in. if the hub is not machined, nor by more than 1/8 in. if the hub is machined. 9.6 Rotundity
Tread when gauged with a ring gauge must not have an opening between tread and gauge at any point over .022 in. 9.7 Diameter of Bore
The diameter of rough bore shall not vary more than 1/16 in. over nor more than 1/16 in. under the dimensions specified by the purchaser. 9.8 Eccentricity of Bore
Eccentricity between the rough bore and tread, measured in the plane of the taping line, shall not exceed .0625 in. TIR, except that no more than 5% of wheels delivered may be over .0625 in. TIR and these must not exceed .09375 in. TIR.
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APPENDIX B
STANDARD AAR WHEEL TYPES—WIDE-FLANGE CONTOUR—FOR FREIGHT CAR SERVICE—CARBON STEEL AAR TYPE
A-28 CA-28
E-28 CA-28
A-30 CA-30
J-33 CJ-33
M-33 CM-33
P-33 CP-33
H-36 CH-36
J-36 CJ-36
K-36 CK-36
B-38 CB-38
C-38 CC-38
D-38 CD-38
STATUS DATE
STND 1952
STND 1985
STND 1946
STND 1956
STND 1961
STND 1984
STND 1962
STND 1962
STND 1962
STND 1964
STND 1964
EFFECTIVE DATE
1971
7/1/85
1971
1968
1968
3/1/85
10/1/72
1968
1968
9/1/73
1968
TREAD TYPE
M-W
1-W
M-W
1-W
2-W
M-W
1-W
2-W
M-W
1-W
2-W
M-W
INTENDED AXLE CLASS
F, K
E
F, K
D, E
D, E
D, E, F, G
F
F
F
G
G
G
MAX. CAP. PER WHEEL (LB)
32,875
24,375
32,875
27,500
27,500
32,875
35,750
35,750
35,750
39,375
39,375
39,375
DIMENSION AND TOLERANCES—ALL ENTRIES IN INCHES, EXCEPT TAPES D
28 + 14 TAPES (5%–5)
28 + 14 TAPES (5%–5)
30 + 14 TAPES (5%–5)
33 + 14 TAPES (5%–5)
33 + 14 TAPES (5%–5)
33 + 14 TAPES (5%–5)
36 + 14 TAPES (5%–5)
36 + 14 TAPES (5%–5)
36 + 14 TAPES (5%–5)
38 + 14 TAPES (5%–5)
38 + 14 TAPES (5%–5)
38 + 14 TAPES (5%–5)
G (MIN)
21/2
11/2
21/2
11/4
2
21/2
11/2
2
21/2
11/2
2
21/2
N (MIN)
3/4
5/8
3/4
5/8
5/8
3/4
3/4
3/4
3/4
7/8
7/8
7/8
01
+1 111/8 –0
+1 105/8 –0
+1 111/8 –0
+1 105/8 –0
+1 105/8 –0
+1 117/8 –0
+1 111/8 –0
+1 111/8 –0
+1 111/8 –0
+1 121/8 –0
+1 121/8 –0
+1 121/8 –0
02
+1 111/8 –0
+1 105/8 –0
+1 111/8 –0
+1 105/8 –0
+1 105/8 –0
+1 117/8 –0
+1 111/8 –0
+1 111/8 –0
+1 111/8 –0
+1 121/8 –0
+1 121/8 –0
+1 121/8 –0
MAX FINISH BORE
87/8
83/8
87/8
83/8
83/8
95/8
87/8
87/8
87/8
95/8
95/8
95/8
MIN HUB WALL
11/8
11/8
11/8
11/8
11/8
11/8
11/8
11/8
11/8
11/4
11/4
11/4
P1
7±1/8
7±1/4
7±1/4
7±1/4
7±1/4
7±1/4
7±1/4
7±1/4
7±1/4
7±1/4
7±1/4
7±1/4
R
21/2 ±1/8
21/2 ±1/8
21/2 ±1/8
21/2 ±1/8
21/2 ±1/8
21/2 ±1/8
21/2 ±1/8
21/2 ±1/8
21/2 ±1/8
21/2 ±1/8
21/2 ±1/8
21/2 ±1/8
NOTES: 1. HUB LENGTH TOLERANCE IS BASED ON FINISHED DIMENSION. 2. 5 1/2 × 10 AXLE ALSO STANDARD FOR J-33 AND M-33; 5 1/2 × 10, 6 × 11, AND 6 1/2 × 12 AXLES ALSO STANDARD FOR P-33
Fig. B.9 Standard AAR wheel types—wide-flange contour—for freight car service Paragraphs 2.1, 15.1, and 15.2 03/2011
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APPENDIX B
M-107/M-208
STANDARD AAR WHEEL TYPES—NARROW-FLANGE CONTOUR—FOR DIESEL LOCOMOTIVE AAR TYPE
F-36 CF-36
A-38 CA-38
E-40 CE-40
A-41 CA-41
A-42 CA-42
A-43 CA-43
C-42 CC-42
D-42 CD-42
E-42 CE-42
STATUS DATE
STND 1946
STND 1947
STND 1982
STND 1997
STND 1946
STND 1997
STND 1946
STND 1997
STND 1997
EFFECTIVE DATE
8/1/46
1947
3/1/83
1997
8/1/46
1997
1947
1997
1997
TREAD TYPE
M-W
M-W
M-W*
M-W*
M-W*
M-W*
M-W*
M-W
M-W
DIMENSION AND TOLERANCES—ALL ENTRIES IN INCHES, EXCEPT TAPES, SEE Fig. B.8 FOR DIMENSIONS A, B, C, and L FOR ALL NARROW-FLANGE WHEEL TYPES D
36" TAPES + 14 0
38" TAPES + 14 0
40" TAPES + 14 0
41" TAPES + 14 0
42" TAPES + 14 0
43" TAPES + 14 0
42" TAPES + 14 0
42" TAPES + 14 –0
42" TAPES + 14 –0
G (MIN)
21/2
21/2
21/2
3
3
3
21/2
21/2
31/2
N (MIN)
3/4
7/8
1
1
1
1
1
1
1
01
+1 13 –0
+1 103/4 –0
121/2± 1/8
121/2± 1/8
+1 111/2 –0
121/2± 1/8
+1 131/2 –0
121/2± 1/8
121/2± 1/8
02
+1 13 –0
+1 103/4 –0
131/4± 1/8
131/4± 1/8
+1 111/2 –0
131/4± 1/8
+1 131/2 –0
131/4± 1/8
131/4± 1/8
P
61/2 ±1/8
7±1/8
61/2 ±1/8
61/2 ±1/8
7±1/8
61/2 ±1/8
61/2 ±1/8
61/2 ±1/8
61/2 ±1/8
R1
413/16 ±1/8
55/16 ±1/8
413/16 ±1/8
413/16 ±1/8
45/16 ±1/8
413/16 ±1/8
413/16 +1/8
413/16 ±1/8
413/16 ±1/8
R2
111/16 f
111/16 f
111/16 f
111/16 f
211/16 ±1/8
111/16 f
111/16 f
111/16 f
111/16 f
MAX FINISH BORE
101/4
81/2
915/16
915/16
91/4
915/16
103/4
915/16
915/16
MIN HUB WALL
13/8
11/8
** 11/8
11/8
11/8
11/8
13/8
11/8
11/8
NOTES: 1. WHERE DIMENSION R2 IS MARKED F, EXTRA STOCK OF 1/16 IN. TO 3/16 IN. OVER SPECIFIED DIMENSION MAY BE LEFT FOR MACHINING OF EACH FINISHED SURFACE OR WHEEL MAY BE FURNISHED FINISHED TO EXACT DIMENSION SHOWN. HUB LENGTH TOLERANCE IS BASED ON FINISHED DIMENSION.
* **
REFERENCE GROOVE REQUIRED—SEE RP-619 HUB WALL THICKNESS MAY BE REDUCED AS NECESSARY FOR APPLICATION OF ROLLER BEARING WATER GUARD.
Fig. B.10 Standard wheel types f or locomotive service Paragraphs 2.1, 15.1, and 15.2
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APPENDIX B
AAR-1B WIDE PROFILE CENTERS OF RADII RELATIVE TO GAUGE POINT POINT A B C D E F
X –1.196896 0.589000 0.589000 0.362211 –0.580300 –1.060300
AAR-1B WIDE PROFILE INTERSECTION OF POINTS RELATIVE TO GAUGE POINT POINT 1 2 3 4 5 6 7 8 9
X 1.375000 1.147435 0.589000 0.091706 0.000000 –0.035442 –0.291159 –0.631437 –0.989517
Y –0.624585 0.031070 0.375400 0.162616 0.000000 –0.132273 –0.474998 –0.624585 –0.685529
Detail A
Fig. B.11 AAR-1B wide-flange contour for freight car wheels Paragraphs 2.1, 15.1, and 16.2
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Y –1.149921 –0.249600 –0.312100 –0.097100 0.007500 0.812800
AAR Manual of Standards and Recommended Practices Wheels and Axles
APPENDIX B
M-107/M-208
AAR-1B NARROW PROFILE CENTERS OF RADII RELATIVE TO GAUGE POINT POINT A B C D E F
X –0.204400 0.562500 0.562500 0.370581 –0.571971 –1.052000
Y –0.641800 –0.312500 0.000000 –0.065876 0.038692 0.844000
AAR-1B NARROW PROFILE INTERSECTION OF POINTS RELATIVE TO GAUGE POINT POINT 1 2 3 4 5 6 7 8 9
X 1.156300 0.853075 0.562500 0.140565 0.008400 –0.028575 –0.278542 –0.748621 –0.977100
Y –444011 0.237046 0.375000 0.230296 0.031335 –0.106659 –0.441210 –0.625000 –0.654129
Detail A
Fig. B.12 AAR-1B narrow-flange contour for freight car wheels Paragraphs 2.1, 15.1, and 16.2
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APPENDIX B
NOTE: WHEN WHEEL RIMS ARE REDUCED IN THICKNESS TO SUCH AN EXTENT THAT LATHE DOGS INTERFERE WITH THE 5/8-IN. RADIUS AT THE OUTER RIM FACE, THIS RADIUS MAY BE REDUCED AS NECESSARY OR A CHAMFER USED. FREIGHT LOCOMOTIVE WHEEL RIMS SHALL BE MACHINED WITH A MAXIMUM RADIUS OF 5/8 IN. ON THE OUTER RIM FACE. A CHAMFER IS ALLOWED TO EXTEND PAST THE RADIUS AT 45°, BUT MUST BE NO LONGER THAN 0.4375 IN. MEASURED ALONG ITS LENGTH.
Fig. B.13 Cylindrical tread contour for narrow-flange wheels Paragraphs 2.1 and 16.2
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APPENDIX B
M-107/M-208
Fig. B.14 Tread contour gauge for AAR-1B wheels Paragraph 16.5
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APPENDIX C
APPENDIX C AUTHORIZATION FOR CLASS D WHEEL TEST ALLOTMENT
Each manufacturer must obtain an authorization for Class D test wheels from the Committee prior to delivery. All requirements of the M-107/M-208 wheel specification and associated appendixes apply to Class D wheels. 1.0
The intent of Class D is to provide wheel materials with superior resistance to tread damage when compared to Class C wheels, without compromising any other safety performance characteristics. 1.1
Class D wheel applicants must submit results from laboratory material tests as described in paragraph 3.0 of this appendix, “Material Testing.” Upon acceptance of the laboratory test results, the WABL Committee will authorize a test allotment of 5,000 wheels for field service testing in interchange service. 2.0
3.0 MATERIAL TESTING
The following material testing is required. The applicant must contact the WABL Committee to schedule an AAR observer. Three sample wheels must be tested. Unless otherwise approved by WABL, an AAR observer is required. All costs for the tests and the observer are to be paid by the applicant. Wheel materials should meet the minimum properties listed in Table 3.1. 3.1
Tension testing shall be conducted on two specimens at ambient temperature and two specimens at 1,000 °F. Specimens shall be taken from as close to the tread as possible (at least 1/8 in. of the original wheel tread must remain visible at the ends of the test specimen) in the circumferential direction. Ultimate tensile strength, 0.2% offset yield strength, percentage elongation, and percentage reduction of area shall be determined. Tests must be conducted per ASTM E21 (1,000 °F) and ASTM A370 (ambient temperature), latest edition. 3.1.1
The microstructure shall be classified in the report and should be free of martensite. Six microstructural specimens (1/2 in.2 section) shall be taken in the radial plane direction adjacent to the microcleanliness specimens and must include the tread surface. The intent is to classify all microstructures in the specimen, to include the tread surface. The report should contain sufficient photographic evidence to support the conclusions. 3.1.2
Absence of tensile hoop stress shall be documented by a radial saw cut made to a depth at least 1 in. deeper than the rim inner diameter. No opening of the cut shall be present at the conclusion of the cut. 3.1.3
Hardness mapping of the test wheels shall be performed per M-107/M-208, Section 11.5. In addition, Brinell hardness measurements shall also be taken along the centerline of the plate to the hub inner diameter at approximately 1/2 in. spacing and reported for reference only. 3.1.4
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APPENDIX C
M-107/M-208
Fracture toughness type testing shall be determined for two samples per test wheel at 70 °F to 75 °F according to ASTM E 399, latest edition. The sample shall be taken as shown in Fig. 3.1. If a valid K IC is not obtained, then report the K Q value. 3.1.5
2.4" MIN NI M " 1
2 .5 " M I N
Fig. 3.1 Fracture toughness test sample
The manufacturer must provide lab data demonstrating the relative wear and shelling performance as compared to Class C. The manufacturer must specify the test methods used for the comparison. The following test conditions are recommended. Testing protocols may be changed if better methods can be demonstrated. 3.1.6
To demonstrate performance no worse than Class C, comparative accelerated rolling load wear tests shall be conducted. Tests shall be performed using two discs constructed of the proposed wheel material. 3.1.6.1
Test conditions shall be as follows: • Contact pressure = 319,500 psi • 0.75% slip • Duration = 500,000 cycles
3.1.6.1.1
3.1.6.1.2
The result must be calculated wear rates for Classes C and D.
To demonstrate performance superior to Class C, an accelerated rolling load shelling test shall be conducted using two discs. 3.1.6.2
Test conditions shall be as follows: • Contact pressure = 159,750 • 0.3% slip • Duration = onset of shelling as determined using a vibration sensor
3.1.6.2.1
3.1.6.2.2
The result must compare cycles to shelling onset for Classes C and D. Table 3.1 Minimum material properties Ambient (65 °F–80 °F) 1,000 °F Hardness
341 HB–415 HB
NA
UTS (psi)
>157,000
>70,000
Yield (psi) (0.2% offset method)
>110,000
>50,000
% Elongation in 2 in.
>14
>20
Reduction of Area (%)
>15
>40
Fracture toughness (KIc or Kq)
>35 ksi sq root in.
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APPENDIX C
4.0 FIELD SERVICE TEST ALLOTMENT
Upon Committee review of the laboratory test program, an allotment of 5,000 wheels shall be granted. The manufacturer shall inspect all wheels in service and report to the Committee the cause for any removals. Manufacturer shall select a service that is expected to accumulate at least 50,000 miles per year. 4.1
5.0 FIELD SERVICE TESTING
It is the responsibility of the manufacturer to monitor the performance of the test wheels in service and report results to the WABL Committee. Reduction of removals for tread damage (as compared to Class C) must be demonstrated. The field service test shall include the following: • Monitoring a minimum of 1,000 wheels in 286k service • Documenting car numbers and location of all test wheels • 100% tracking—for removal causes • Visual inspections and sample wear monitoring (30% of test wheels) at the following inter vals: • At least 25,000 miles • At least 50,000 miles • At least 100,000 miles • At least 300,000 miles • 400,000 miles 5.1
5.2
The field service report shall include the following: • Removal causes • Reduction of tread defect removals compared to Class C in the same service • Percentage of test wheels remaining in service after 300,000 miles
6.0 ADDITIONAL ALLOTMENTS 6.1
A second test allotment of 5,000 wheels may be applied for after the 300,000-mile report.
After the 400,000-mile test report is accepted by the WABL Committee, additional allotments may be approved per Appendix A . 6.2
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APPENDIX C
Wheels and Axles
M-107/M-208
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M-967
AAR Manual of Standards and Recommended Practices Wheels and Axles
ELECTROCHEMICAL METAL DEPOSITION FOR REPAIRING ROLLER BEARING AXLE JOURNALS Specification M-967 Adopted: 1980; Last Revised: 2008 1.0 SCOPE This document describes the certification requirements, equipment, materials, personnel requirements, quality control, and utilization of the electrochemical metal deposition process for repairing roller bearing axle journals. 2.0 PROCESS DESCRIPTION The electrochemical metal deposition process is an electrochemical metallizing process in which the high current density technology of arc welding is applied to a concentrated electrolyte solution, thus depositing metal without the use of either heat or immersion tanks. The solution is held in, or pumped through, an absorbent material attached to an inert electrode (anode) that, in turn, is attached to a DC power pack. The cathode lead of the power pack is attached to the workpiece, and a current is passed through the solution. The result is a rapid deposition of metal onto the area contacted by the anode. The process requires neither the pre-machining of base metal nor the subsequent stress relief and embrittlement relief of the metal deposit. A motion between the anode and the workpiece is required to produce high quality, uniform deposits. 3.0 APPLICATIONS The electrochemical metal deposition process can be used effectively on specific surfaces, as listed in the AAR Manual of Standards and Recommended Practices , Section G-II, paragraph 1.2.7, where a metal deposit is required for restoration of original dimensions on roller bearing axle journals and dust guards. 4.0 GENERAL REQUIREMENTS 4.1 Equipment Equipment used with the electrochemical metal deposition process and supplied by the process manufacturer incorporates certain safety features commensurate with handling electrodes and electrolytes. No equipment shall be used that does not have these safety features and that is not certified by the process manufacturer as having been designed specifically for electrochemical metal deposition. 4.1.1 Power Pack 4.1.1.1 The DC output ranges of power packs used for electrochemical metal deposition processes shall be determined by the process manufacturer. The capacity of the power pack is directly related to the size of the surface on which metal is being deposited and the thickness of that deposit.
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M-967
4.1.1.2 The following are features that shall be integral parts of the power pack: • Voltmeter • Dual-range ammeter with automatic switching or dual ammeters
• • • • • •
Digital amp-hour meter Polarity reversing switch Overload protection Infinitely variable voltage control Instantaneous (1/2 cycle) safety cutout switch Controlled ripple
4.1.2 Handles and Anodes Handles for the process are conductive, must be matched to the amperes drawn for a given application, should aid in dissipating heat, and must provide operator protection as well as ease of operation. The anodes must be of a material chemically inert to the electrolyte solution. The only materials considered universally inert to all electrolytes used in the electrochemical metal deposition process are high-density, high-purity graphite or platinum with up to 11% iridium alloy. Other anode materials may be used with a specific compatible solution; however, both the anode and solution must be approved in writing by the process manufacturer. This written approval must also be provided to the AAR. Where graphite anodes are used, graphite shall have less than 1% metallics by volume, of a grade approved, in writing, by the process manufacturer for each electrolyte being used. This written approval must also be submitted to the AAR. 4.2 Solutions 4.2.1 The solutions used in the electrochemical metal deposition process are highly concentrated water base chemicals. These include preparatory solutions for cleaning and activating the surface to be coated, metal deposition solutions for coating, and metal removal solutions for polishing and stripping. All metal deposition solutions must carry a batch number and be traceable to the manufacturer’s control batch and the axle repaired. Note: Although several sources for electrochemical metal deposition solutions may be developed, compatibility of the chemicals in the process is mandatory for process integrity. Therefore, in no case will solutions, either preparatory or metal deposition, of different manufacturers be intermixed or substituted into a buildup procedure. 4.3 A solution certified by the process manufacturer and annually verified by the axle reconditioner as capable of depositing nickel with minimum C50 Rockwell or 500 Knoop hardness tested per ASTM B-578 with a 50-g load must be used when repairing roller bearing axles. Documentation of the hardness test must include the test method and batch number(s) and be kept on record. 5.0 TECHNICAL REQUIREMENTS 5.1 Operator Qualification The electrochemical metal deposition process is operator dependent and, therefore, only certified personnel shall be permitted to process interchange equipment. Certification may be obtained in any of the following manners: 5.1.1 Completion of a manufacturer’s theoretical course of instruction and a demonstrated ability to repair axles consistently to the manufacturer’s process procedures. 5.1.2 Completion of a theoretical course certified by the process manufacturer and a demonstrated ability to repair axles consistently to the manufacturer’s process procedures. 5.1.3 Completion of theoretical and hands-on training under direct supervision of a certified operator for a period as stipulated in the facility’s AAR Manual of Standards and Recommended Practices, Section J, Specification M-1003, “Specification for Quality Assurance,” to include a demonstrated ability to repair axles.
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AAR Manual of Standards and Recommended Practices Wheels and Axles
5.1.4 The course shall provide the operator proficiency in the electrochemical metal deposition process including the following: • Inspection and preparation of metal surfaces for electrochemical metal deposits • Selection of proper tools • Calculation of deposit thickness
• Application of metal deposit • Proper finishing techniques 5.1.5 The demonstration of ability shall consist of properly repairing at least two journals with each of the following defects:
For status code 3A: a. Undersized journal greater than .003 in. below minimum b. Seal wear ring groove greater than .008 in. deep c. Water etch in cone area greater than .001 in. deep d. Undersized journal and ring groove combination e. Undersized journal and water etch combination f. Undersized journal that has been previously rebuilt (nickel deposited to nickel over the entire journal) For status code 3B: a. Undersized journal greater than .003 in. below minimum For status code 3C: a. Undersized dust guard greater than 0.003 in. below minimum 5.1.6 Proper repairing shall be determined by testing 100% of the repaired journals in accordance with paragraphs 5.2.1, 5.2.2, 5.2.3, and 5.2.4, except in the case of dust guard repairs where paragraph 5.2.3 does not apply. 5.1.7 Adequate records to document the above demonstration of operator proficiency for certification shall be maintained. Operator recertification is required annually and shall include the ability to demonstrate qualification by written examination and/or practical application as stipulated in the facility’s quality assurance manual required by AAR Manual of Standards and Recommended Practices , Section J, Specification M-1003, “Specification for Quality Assurance.” 5.2 Inspection Procedure The quality of an electrochemical metal deposition deposit is most readily proven when secondary processing such as machining or grinding is accomplished. However, since the process obtains significant cost reduction when secondary processing is not required and the part is built to size, other inspection procedures are available. 5.2.1 Visual Inspection All deposits shall be smooth, uniform in color, and free of blisters, pits, nodules, porosity, excessive edge build-up, and other defects that would affect the functional use of the axle. The deposit surface of the repaired journal shall be free of burnings and stress concentrations. Burning is defined as rough, coarse grained, or dark deposits caused by localized high current density or arcing. Highly stressed deposits will normally be indicated by cracks or crazing. The above defects are cause for rejection. 5.2.2 Adhesion Test Each axle journal repaired by the electrochemical metal deposition process shall have an adhesion test performed. The adhesion test is accomplished using Scotch #250 tape or an equivalent high-tack-strength, pressure-sensitive tape as approved by the AAR. The adhesion test is accomplished as follows: 03/2011
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5.2.2.1 Thoroughly clean and dry the processed surface with a method that will not adversely affect tape adhesion. 5.2.2.2 Cut a piece of 1-in.-wide unused tape approximately 6 in. longer than the width of the processed area. 5.2.2.3 Stick the tape longitudinally across the width of the processed area of the journal so that approximately 1/2 in. of the base metal on each side is taped to ensure coverage of both edges of the processed area. Tamp the tape down to ensure thorough adhesion. 5.2.2.4 Grip the loose end of the tape and rip rapidly upward (at a right angle to the surface), removing the tape with a single jerk. 5.2.2.5 Inspect the tape and processed surface area. Any deposit nickel adhering to the tape and part of the processed area visually lifted is cause for rejection. 5.2.3 Burnishing 5.2.3.1 The deposit is suspect if moderate burnishing will cause a nonadhering deposit to lift, peel, or flake; therefore, an inspection sampling derived from ANSI/ASQC Z1.9–1993 shall be burnished and retested in accord with paragraphs 5.2.1 and 5.2.2 with a minimum daily inspection of 5%. 5.2.3.2 Each active operator shall have at least one axle inspected for compliance with this paragraph for each week of production. 5.2.3.3 A moderate burnishing shall be that which creates a 0.0001-in. to 0.0002-in. reduction in journal diameter after being burnished. 5.2.4 Surface Finish 5.2.4.1 The deposit surface finish on the repaired journal must not exceed 63 µin. 5.2.4.2 The deposit finish on the repaired dust guard must not exceed 125 µin. 5.2.5 Dimensional Inspection When restoration of the entire length of the journal is required, average journal diameters must be within the prescribed tolerances for new axles except for the restored area of the journal diameter outside the area bounded by the inboard edge of the seal wear ring contact area, to the outboard edge of the outboard cone. The average journal diameter may be used to meet journal diameter requirements for the AAR Manual of Standards and Recommended Practices , Section G-II, Fig. 4.1. The radius of the journal fillet must meet the new axle dimensions. When restoring the dust guard for use in fitted applications, the diameter of the repaired dust guard must be within the prescribed tolerances for new axles. 6.0 GENERAL REQUIREMENTS The requirements of the AAR Manual of Standards and Recommended Practices , Section G, Part II, “Wheel and Axle Manual,” pertaining to axle repairs by this process and to facility certification must be met. In addition to the foregoing, those facilities maintaining or requesting certification in accord with M-967 must meet the requirements of the AAR Manual of Standards and Recommended Practices , Section J, Specification M-1003, “Specification for Quality Assurance.”
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APPENDIX A
APPENDIX A QUALIFICATION OF APPLICANTS’ FACILITY FOR REPAIRING AXLES BY ELECTROCHEMICAL METAL DEPOSITION PROCESS 1.0 The applicant must provide the Technical Services Division with an application for approval, as described in the AAR Manual of Standards and Recommended Practices , Administrative Standards, Standard S-060. Applications shall be provided in electronic file format and must include brochures, material safety data sheets, and any other information that provides a general description of the facility equipment and process to be used in the electrochemical metal deposition repair of axles. 2.0 After determining that the application is consistent with the requirements of this specification, the Committee will authorize the applicant to contact the AAR for information concerning product testing. 3.0 All costs are to be paid upon notification of the testing charges. Product testing shall consist of the applicant’s furnishing a minimum of three axles with journals electrochemically repaired and shall include (as required by the applicable status code number) the following: 3.1 Two journals having had only seal wear ring grooves greater than 0.008 in. repaired. 3.2 Two journals undersize greater than 0.003 in. below minimum with full length of journal restored. 3.3 Two journals with full length of journal restored over repaired water etch greater than 0.001 in. on the outboard cone seat. This must reflect nickel over nickel restoration. 3.4 Two dust guards having the dust guards greater than 0.003 in. below minimum restored. 4.0 The following tests shall be performed at or under the observation of the AAR with the test results being provided to the Committee. 4.1 Microhardness test as per ASTM-B-578, latest revision. Microhardness for electroplating on a minimum 0.002-in. deposit material on a seal wear ring groove. Minimum microhardness should be C50 Rockwell or 500 Knoop tested per ASTM B-578 with a 50-g load. 4.2 Visual inspection as per paragraph 5.2.1. 4.3 Adhesion test as per paragraph 5.2.2. 4.4 All journals and dust guards must be measured and meet dimensional requirements as per paragraph 5.2.5. 4.5 All journals and dust guards must be measured and meet the surface finish requirements per paragraph 5.2.4. 4.6 Mounting and removal of a bearing three times on journals with full length restored with a minimum interference fit of 0.002 in. All journals must meet the requirements of paragraph 5.2.2. 4.7 Journals must meet burnishing and testing specifications per paragraph 5.2.3. Photographic documentation will be developed to confirm compliance with paragraphs 4.1, 4.2, and 4.3 of this appendix. Subsequent to performance of the test referenced in paragraph 4.6 of this appendix, inspection will be performed in accordance with paragraphs 4.2 and 4.3 thereof. 4.8 Mounting and removal of a fitted backing ring three times on restored dust guards.
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APPENDIX A
AAR Manual of Standards and Recommended Practices Wheels and Axles
M-967
5.0 Subsequent to the satisfactory completion of the tests and approval of the test results by the Committee, the AAR Technical Services Division will inspect the facility where the axles are to be repaired for proper procedures and equipment, including a demonstration of the ability to meet the requirements of this specification. These inspections will require a certification fee as per the AAR Field Manual of Interchange Rules , Rule 120. These inspections may be arranged concurrently with the test program. 6.0 It is considered necessary that each qualified applicant have enough axles in AAR interchange service to develop meaningful performance data. Therefore, the applicant will be required to deliver at least 150 axles during the first 2 years after receipt of AAR approval and at least 1500 axles within any consecutive 5-year period for use in AAR interchange service. When data to support the number of deliveries is not available to the AAR, the applicant will be asked to provide this information by listing the required number of axles delivered and to which customers delivery was made. In the event the delivery requirement is not met and upon notification by the AAR, the applicant will be required to requalify. 7.0 Requalification will require at least a current plant inspection by the AAR and a certification by the applicant that repaired axles are of the same process and material, subject to compliance with the latest version of this specification, as previously approved by the Committee. The Committee may elect to require verification of any or all of the provisions of Appendix A of this specification for requalification. 8.0 In the event that a plant ceases production for more than 60 days but no more than 1 year, the AAR must be notified no less than 2 weeks prior to reopening. In the event that a plant ceases production for more than 1 year, requalification will be required prior to delivery of any items for use in AAR interchange service. The Committee may elect to require testing of axles in accordance with paragraph 2.0 of Appendix A .
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APPENDIX B
APPENDIX B AUTHORIZATION FOR DELIVERY OF AXLES REPAIRED BY THE ELECTROCHEMICAL METAL DEPOSITION PROCESS FOR AAR INTERCHANGE SERVICE 1.0 Each applicant must obtain an authorization for delivery of repaired axles for AAR interchange use from the Committee prior to delivery. 2.0 Authorization for delivery of repaired axles will be approved after review of the tests and of the AAR Field Manual of Interchange Rules Rule 120 inspection report required by Appendix A . Authorization may be withdrawn if service performance so dictates.
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S-601
AAR Manual of Standards and Recommended Practices Wheels and Axles
WHEELS—MANUFACTURING FACILITY INSPECTION BY TECHNICAL SERVICES Standard S-601 Adopted: 1964; Last Revised: 2004 1.0 SCOPE 1.1 This document became effective March 1, 1980. 1.2 An AAR Technical Services Division inspector will periodically inspect steel wheel manufacturing facilities to ensure that control practiced by manufacturers is effective in maintaining a constant standard of quality to meet the requirements of AAR specifications and service conditions to which the wheels are subjected. 2.0 GENERAL Current operating conditions on railroads make it imperative that high quality is maintained in all wheels. Processes used by individual manufacturers differ in many details, but all have been developed to produce wheels that will meet the specification requirements. 3.0 DUTIES The following shall be the duties of an inspector: 3.1 To obtain definite information concerning plant facilities and manufacturing processes and obtain a general knowledge of the manufacturing procedure. This should not imply that the inspector should require detailed information of melting practice or of any other processes adopted by a manufacturer. The inspector should determine the following: • If steel is basic or acid • If steel is melted in electric or open-hearth furnaces or by basic oxygen process • Chemical analysis procedures • Pouring practice • If ingots produce individual or several wheels • Method of converting ingots to billets or blocks • Type of heating furnaces • Method of forging, rolling, and casting • Method of cooling and heat treatment • Frequency of furnace instrumentation calibration • Frequency of calibration of furnace temperature monitoring equipment • Type of machines • Operation of shot peening equipment • Inspection procedures, including • Operation of magnetic particle inspection equipment • Operation of ultrasonic inspection equipment • Condition and calibration of equipment for mechanical property determinations and dimensional measurements • Shipping procedures • Adequacy manufacturing records
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S-601
3.2 To inspect typical wheels that the manufacturer has released for shipment. 3.2.1 The inspections shall be in accordance with the requirements outlined in the AAR Manual of Standards and Recommended Practices , Section G, Part II, “Wheel and Axle Manual” and in M-107/M-208 of this manual. 3.2.2 Table 3.1 lists in detail defects that, through past experience, have been found to be detrimental to the performance of wheels in service: Table 3.1 Defects detrimental to wheel performance Defects Inclusions (sand/slag)
Rims Plates Hubs x
Cracks (hot tears/cold shut)
x
x
x
Laps/seams
x
x
x
Deep or numerous pits (insufficient stock)
x
x
x
Deep chuck marks (extending to edge of back rim)
x
Abrupt change in section
x
Poorly blended machine sections Improper stamping
x
x
x
x
3.3 To report to the AAR Technical Services Division and manufacturer on the results of the inspection.
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S-611
AAR Manual of Standards and Recommended Practices Wheels and Axles
WHEELS—MEASURING WHEEL CIRCUMFERENCE (TAPE) USING WHEEL GAUGES S-612 AND S-613 Standard S-611 Adopted: 1893, 1973; Last Revised: 2004 1.0 These wheel circumference measures are used for taping wheels to ensure that wheels mounted on the same axle shall be of the same diameter and that new wheels are within the specification limits. 2.0 The measures are calibrated by 1/8-in. circumference and 1/2 tape sizes interpolated. 3.0 For new wheels, tape 283 (S-612) represents a wheel of exactly 38-in. diameter. 4.0 The tape size of a wheel is considered to be that of the lower graduation until the next graduation is reached. 5.0 The four lugs that contact on the face of the flange are to hold the tape in the center of the treads. These lugs should preferably have ribs pressed into them to reduce a tendency to bend out of shape. 6.0 In use, the tape should lie flat on the treads all the way around, including the handle and lug. Kinks in tape are not tolerated. 7.0 The wheel circumference gauge (S-613) may be used not only for taping new wheels but for taping worn wheels of large diameter. Because this tape is calibrated in increments of 1 in. from a 35-in.-diameter wheel to a 52-in.-diameter wheel, it may be used for checking the worn diameter of any of the intermediate size wheels. 8.0 All wheel tapes should be checked periodically on a master ring of known accuracy.
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S-612
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CIRCUMFERENCE MEASURE (TAPE) FOR 27-IN. TO 38-IN. STEEL WHEELS Standard S-612 Adopted: 1893; Last Revised: 2004 Note: For master gauge, see RP-608 and RP-609.
NOTE: THE SCALE ON THE WHEEL TAPE CAN HAVE A TOLERANCE OF ±.005 BETWEEN ANY TWO POINTS ON THE SCALE WITH NO ACCUMULATIVE VARIATION. LINEAR DIMENSIONS SHOWN REPRESENT MEASUREMENTS OF ACTUAL CIRCUMFERENCE OF THE WHEEL AND NOT STRAIGHT LENGTH OF THE TAPE. GRADUATIONS ARE TO BE SPACED 1/8 IN. APART WITH THE TAPE LAID FLAT.
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S-613
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Part 1
CIRCUMFERENCE MEASURE (TAPE) FOR 38-IN. TO 52-IN. STEEL WHEELS Standard S-613 Adopted: 1945; Last Revised: 2004
1.0 SCOPE 1.1 This standard became effective July 1, 1980. 1.2 See S-611.
NOTE 1: MARK WHEEL DIAMETERS IN 1/8-IN. FIGURES ON TAPE AS SHOWN ABOVE AND AS INDICATED IN THE FOLLOWING TABLE:
WHEEL DIA. 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 NOTE 2: THE SCALE ON THE WHEEL TAPE CAN HAVE A TOLERANCE OF ±.005 BETWEEN ANY TWO POINTS ON THE SCALE WITH NO ACCUMULATIVE VARIATION. LINEAR DIMENSIONS SHOWN REPRESENT MEASUREMENTS OF ACTUAL CIRCUMFERENCE OF THE WHEEL AND NOT STRAIGHT LENGTH OF THE TAPE. GRADUATIONS ARE TO BE SPACED 1/8 IN. APART WITH THE TAPE LAID FLAT.
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TAPE SIZE 207½ 233 258 283 308 333 358 385½ 409 434 459 484 509 534 559½ 584½ 610 636
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S-614
AAR Manual of Standards and Recommended Practices Wheels and Axles
WHEEL DEFECT—WORN JOURNAL COLLAR AND JOURNAL FILLET GAUGE Standard S-614 Adopted: 1903; Last Revised: 2004 Note: See RP-613 for the master gauge and S-616 for the limiting wear condemning gauge.
MATERIAL: ASTM A-576, Grade 1020 HARDEN AND GROUND ON ALL GAUGING SURFACES. CHROMIUM-PLATED FINISH
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S-615
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WHEEL DEFECT—WORN JOURNAL COLLAR AND JOURNAL FILLET GAUGE Former Standard S-615 Adopted: 1975; Last Revised: 2004 1.0 SCOPE 1.1 This gauge can be used for 7/8-in. or less flange on locomotive wheels. 1.2 This standard became effective April 1, 1981.
Gauge No. 34401A MATERIAL: .093 STAINLESS STEEL UNLESS OTHERWISE STATED, ALL TOLERANCES ARE ±.010 in.
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S-616
AAR Manual of Standards and Recommended Practices Wheels and Axles
GAUGE, AXLE—REFERENCE GAUGE FOR VERIFYING AXLE JOURNAL AND FILLET GAUGE S-614 Former Standard S-616 Adopted: 1938; Last Revised: 2004 1.0 SCOPE This gauge applies to Gauge No. 34401 described in S-614.
MATERIAL: ASTM A-576, Grade 1020
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S-617
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GAUGE, WHEEL—FORMER STANDARD 1980 Former Standard S-617 Adopted: 1923; Last Revised: 1980 Note: For the master gauge, see RP-614.
MATERIAL: ASTM A-576, Grade 1020
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S-618
AAR Manual of Standards and Recommended Practices Wheels and Axles
GAUGE, WHEEL—FORMER STANDARD 1976 Former Standard S-618 Adopted: 1976 Note: “Steel Wheel Gauge—1976” is to be suitably marked on the back side of the gauge in approximately 1/8-in. letters. For the master gauge, see RP-614.
MATERIAL: .093-in. STAINLESS STEEL FOR BODY O F GAUGE AND .050-in. STAINLESS STEEL OF SUITABLE HARDNESS FOR GAUGE FINGER. TOLERANCES ON DECIMAL DIMENSIONS TO BE ±.005 in. AND ON DIMENSIONS IN COMMON FRACTIONS TO BE ±1/64 in. UNLESS OTHERWISE SPECIFIED. REMOVE BURRS AND SHARP EDGES.
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S-627
GAUGE, WHEEL—COMBINATION GAUGE FOR WHEEL MEASUREMENTS Standard S-627 Adopted: 1998 Note: For the limiting wear condemning gauge, see Standard S-629.
Notch Detail A
B
0
3/16
1/4
1/4
1/8
1/8
1/2
1/8
3/16
3/4
1/8
1/8
1
3/16
1/4
1 1/4
1/8
1/8
1 1/2
1/8
3/16
1 3/4
1/8
1/8
2
3/16
1/4
2 1/4
1/8
1/8
2 1/2
1/8
3/16
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Material: Stainless steel 304 Thickness: 3/32
NOTES: 1. UNLESS OTHERWISE SPECIFIED, MANUFACTURE TOLERANCES ARE ±.010. 2. BOXED DIMENSIONS ARE MINIMUM CHARACTERISTICS TO BE VERIFIED FOR RECERTIFICATION. 3. RECERTIFICATION TOLERANCE IS ±.015 IN.
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S-628
GAUGE, WHEEL—COMBINATION GAUGE FOR WHEEL MEASUREMENTS INCLUDING LOCOMOTIVE FLANGE LIMIT OF 0.875 IN. Standard S-628 Adopted: 1998
Notch Detail 0
A 3/16
B 1/4
1/4 1/2 3/4
1/8 1/8 1/8
1/8 3/16 1/8
1 1 1/4 1 1/2
3/16 1/8 1/8
1/4 1/8 3/16
1 3/4 2
1/8 3/16
1/8 1/4
2 1/4
1/8
1/8
2 1/2
1/8
3/16
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Material: Stainless steel 304 Thickness: 3/32
NOTES: 1. UNLESS OTHERWISE SPECIFIED, MANUFACTURE TOLERANCES ARE ±.010. 2. BOXED DIMENSIONS ARE MINIMUM CHARACTERISTICS TO BE VERIFIED FOR RECERTIFICATION. 3. RECERTIFICATION TOLERANCE IS ±.015 IN. 4. THIS GAUGE CAN BE USED FOR 7/8-IN. OR LESS FLANGE ON LOCOMOTIVE WHEELS.
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S-629
AAR Manual of Standards and Recommended Practices Wheels and Axles
GAUGE, WHEEL—REFERENCE GAUGE FOR VERIFYING COMBINATION WHEEL GAUGE S-627 Standard S-629 Adopted: 1998
Verify using contour mapping Maximum manufacture deviation from nominal: .003 in. Maximum recertification deviation from nominal: .005 in.
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Material: Stainless steel 17-7 Thickness: 3/16 in.
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S-629
Application Drawings (page 1 of 2)
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Application Drawings (page 2 of 2)
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S-630
GAUGE, WHEEL—STANDARD Standard S-630 Adopted: 1998 Finger radii Centers 0.3125 0.251A 0.251B 1.3125 0.7656 1.562 0.126 0.5625 0.1875
X
Y
0.00 0.00 –0.755726 0.0536604 –0.29881 0.00 0.00 0.0332779 –1.24331
0.00 0.00 –0.685488 –0.999073 –0.573978 0.00 –1.49899 –0.874367 –0.610423
Wide Flange Markings (Optional)
Material: Rivet and thumb knob: 303 stainless steel Body and finger: stainless steel 17-7 Hardened
Manufacture tolerance: ±.005 Recertification tolerance: ±.010
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0 at 5 0 at 4 0 at 3 0 at 2 0 at 1 0 at 0
A 1.375 1.313 1.250 1.188 1.125 1.063
At 0 2 3 4 5 6 7 8 9
B 1.264 1.210 1.168 1.120 1.070 1.034 0.995 0.951 0.894
S-630
Wide Flange Markings (Optional)
Manufacture tolerance: ±.005 Recertification tolerance: ±.010
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At 0 2 3 4 5 6 7 8 9 10 11
C 1.483 1.408 1.364 1.323 1.283 1.248 1.203 1.142 1.077 0.997 0.896
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S-649
AAR Manual of Standards and Recommended Practices Wheels and Axles
AXLES—MANUFACTURING FACILITY INSPECTION BY TECHNICAL SERVICES Standard S-649 Adopted: 1966; Last Revised: 2004 1.0 OBJECTIVE An AAR Technical Services Division inspector will periodically inspect manufacturing facilities and processes pertaining to production of steel car and locomotive axles. This will include such necessary inspection of the product to ensure that controls practiced by the manufacturers are adequate to minimize defects that might result in service failures. 2.0 GENERAL The procedures followed by the inspector will include a review and written record of practices and facilities starting with the axle bloom immediately after rolling or forging and continuing through the cooling practice of the axles. Heat-treating practices also will be reviewed. Extensive inspection of finished axles will not ordinarily be required. This should not imply that the inspector will require detailed information of processes adopted by a manufacturer. 3.0 DUTIES 3.1 The following are some details of the practices that will be reviewed by the inspector: • Axle bloom handling, including cooling practice immediately after rolling or forging • Axle bloom heating practice, including furnace controls and type of furnace • Reduction practice, including facilities • Straightening practice • Axle cooling practice • Heat-treatment facilities and controls • Quality controls, tensile testing, and records • Ultrasonic testing • Determining if equipment and procedures for machining axles are adequate to meet AAR specifications for the finished product 3.2 The inspections shall be in accordance with the requirements outlined in M-101. 3.3 A report will be made to the AAR Technical Services Division and the manufacturer on the results of the inspection.
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S-657
WHEEL, PASSENGER CAR (AMFLEET) Standard S-657 Adopted: 1980 1.0 SCOPE This standard became effective April 1, 1981.
NOTES: 1. MATERIAL: AAR MANUAL OF STANDARDS AND RECOMMENDED PRACTICES,SECTION G, SPECIFICATION M-107/M-208. CLASS B. 2. DESIGN: AAR STEEL PASSENGER CAR WHEEL M-36 OR CM-36, MULTIWEAR TREAD, NARROW FLANGE CONTOUR. 3. MARKING: MSR P SPECIFICATION M-107/M-208. 4. TREAD: MSRP SPECIFICATIONM-107/M-208 FIG. B.13, EXCEPT 1:40 TAPER. 5. PERMISSIBLE VARIATION IN DIMENSIONS: PER MSRP SPECIFICATION M-107/M-208, FIG. B.8, EXCEPT AS SHOWN. 6. MACHINING: A. MSRP SPECIFICATIONM-107/M-208 AND AS SHOWN. B. INNER FACE OF WHEEL HUB SHALL BE SQUARE WITH CENTERLINE OF FINISHED WHEEL BORE WITHIN .002 TOTAL INDICATOR READING (TIR.) C. WHEEL SHALL BE MACHINED ALL OVER. D. MAXIMUM DYNAMIC UNBALANCE AT THE OUTSIDE DIAMETER OF THE RIM SHALL NOT EXCEED 0.6 LB. STAMP UNBALANCE IN OUNCES ON THE INSIDE FACE OF THE RIM AT THE HEAVIEST POINT. AS AN ALTERNATIVE, IT IS ACCEPTABLE TO MACHINE THE WHEELS ON ALL SURFACES TO WITHIN A DIMENSIONAL TOLERANCE OF ±.005 IN. E. SURFACE FINISH ON ID OF RIMS, WEB, AND OD OF HUB SHALL BE 250 ΜIN. MAXIMUM AND SHALL BE 350 ΜIN. MAXIMUM FINISH ON THE TREAD, FLANGE, AND RIM FACES. 7. WHEEL PLATE AREA, ID OF RIM, AND OD OF HUB SHALL BE SHOT PEENED IN ACCORDANCE WITH MSRP SPECIFICATION M-107/M-208. 8. WHEEL SHALL BE ULTRASONICALLY TESTED AND MAGNETIC PARTICLE INSPECTED AFTER MACHINING IN ACCORDANCE WITH MSRP SPECIFICATION M-107/M-208. 9. THE VENDOR SHALL FURNISH AMTRAK WITH WHEELS IN PAIRS WITH THE SAME TAPE SIZE. IN ADDITION TO MSRP SECTION G, “WHEELS AND AXLES,” TAPE SIZE MARKING REQUIREMENTS, THE TAPE SIZE ALSO SHALL BE STENCILED ON THE WHEEL TREAD IN 1-IN. (MINIMUM HEIGHT) LETTERS. 10. THE WORD “AMTRAK” SHALL BE STENCILED ON THE INSIDE PLATE IN 1-IN. (MINIMUM HEIGHT) LETTERS, COLOR WHITE. 11. WHEELS ARE FOR USE WITH TRUCKS HAVING INSIDE JOURNAL ROLLER BEARINGS.
Dimensions and Tolerances A 1 +1/16 –0
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C
D
G
L
N1
N2
O1
O2
P
R1
R2
1 5/32 +1/16 11/16 ±1/16 36 +14 tapes 2 3/4 min. 5 1/2 ±1/8 in. 3/4 min. 1 min. 10 3/4 +1/4 10 3/4 +1/4 7 ±1/8 8 5/8 ±1/8 –1.625 +.000 –0 –0 tapes –1/8 –1/8 –.028
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S-658
AXLE FOR PASSENGER CARS (AMFLEET) INBOARD ROLLER BEARING—RAISED WHEEL SEAT Standard S-658 Adopted: 1980; Last Revised: 2004 1.0 SCOPE This standard became effective March 1, 1983.
NOTES: 1. MATERIAL: AAR M-101, GRADE F. THE AXLE OTHERWISE MUST BE IN COMPLIANCE WITH AAR MANUAL OF STANDARDS AND RECOMMENDED PRACTICES , SECTION G, M-101, LATEST REVISION. 2. ROUGH MACHINED AXLE IS TO BE SUBCRITICALLY QUENCHED FROM 1000 °F TO 1050 °F IN WATER. ALLOW .187 IN. OVER FINISHED DIAMETERS. RELIEF GROOVES ARE TO BE MACHINED AND COLD-ROLLED AFTER SUBCRITICAL QUENCHING. 3. FINISH MARKS WERE REMOVED IN THE 1982 REVISION.
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LABORATORY ACCEPTANCE, MANUFACTURER’S NAME OR BRAND, MONTH AND YEAR, HEAT NUMBER, SERIAL NUMBER, GRADE OF AXLE, AND PART NUMBER ARE TO BE STAMPED ON ONE END OF THE AXLE TUBE BY THE MANUFACTURER AND TRANSFERRED TO THE FINISH AXLE IN THE PRESENCE OF THE RAILROAD COMPANY INSPECTOR UNLESS WAIVED BY THE RAILROAD COMPANY. DATE OF APPLICATION AND PLACE WHERE MOUNTED ARE TO BE STAMPED ON THE OPPOSITE END OF THE AXLE BY THE BUILDER OR RAILROAD COMPANY.
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S-660
WHEEL DESIGNS, LOCOMOTIVE AND FREIGHT CAR—ANALYTIC EVALUATION Standard S-660 Adopted: 1981; Last Revised: 2009 1.0 OBJECTIVE 1.1 The ultimate objective of this procedure is to provide an additional method to help evaluate a given wheel design to perform satisfactorily under normal railroad operating service conditions. This objective will be attained by comparing the results of stress analyses of different wheel designs. The database contains wheel designs demonstrating either satisfactory field performance or unsatisfactory service with high failure rates. 1.2 The first step is to ensure that the computations will be of sufficient accuracy and reproducibility, regardless of where and by whom they are made. This procedure permits the use of all calculational techniques that can be demonstrated to provide accurate results and that permit the analyses to be made under a standard set of assumptions (i.e., material property data and loading conditions). 1.3 This procedure shall be operative under M-107/M-208, Appendix A , paragraph 2.2. 2.0 BACKGROUND 2.1 Several computer codes can calculate wheel stresses, and these results can help in the evaluation of the suitability of the wheel design. If stress comparisons are to be made among wheels of different design, however, the magnitude and manner of design load application to the wheel must be specified, as well as the accuracy requirements for the computational technique, if consistent results are to be obtained. 2.2 The designated mechanical and thermal loads are not intended to indicate the maximum possible loads that might occur under service conditions, nor are they necessarily representative of specific service conditions. The values selected represent levels that would be expected to be exceeded only a very small percentage of the time. Load levels above these values may occur under certain special conditions and would not necessarily lead to failure of the wheel. 3.0 LIMITATIONS Stress calculations are limited to elastic analyses. The results of an elastic analysis will give some indication of the quality of the wheel design. The thermal input (as subsequently defined) is limited, which permits the use of simpler equations to describe the mechanical and physical properties. 4.0 RESULTS 4.1 The results of the temperature calculation shall be displayed on a contour plot. The maximum temperature shall be indicated. Isotherms at even 100 ºF intervals are required. 4.2 The results of the stress calculation will be expressed in terms of effective stresses. The effective, or von Mises, stress is calculated from the principal stresses by the following equation:
σeff
1 = ------2
( σ 1 – σ 2 )
2
+
( σ 2 – σ 3 )
2
+
( σ 3 – σ 1 )
2
where σ1, σ2, and σ3 are the principal stresses.
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4.3 While it is recognized that the thermal load cannot exist alone, it will not be advisable to include combined mechanical (vertical and/or lateral) and thermal loads in the rim stress calculation because there are analytic complexities in calculating stresses close to the point of load application. This leads to the following set of desired information: 4.3.1 A maximum effective stress on the surface of the plate, resulting from the individual or combined action of vertical, lateral, and thermal loads. 4.3.2 Maximum effective stresses at designated points on the surface of the rim, resulting from only a thermal load.
The maximum stress shall be found, regardless of wheel orientation. If the maximum stress occurs at an orientation other than 0º, the orientation must be specified in the tabulation of the results. Data shall be provided in both tabular and graphical (contour) form. Constant stress contours shall be labeled, and their spacing shall be chosen for clarity. 5.0 WHEEL LOADS Load magnitudes should be a function of the maximum static rail load. The mechanical load magnitudes are currently twice the maximum static rail load for a vertical load and the maximum static rail load for a lateral load. The thermal loads also are proportional to the maximum static rail load. Examples of currently approved loads are given in Table 5.1. Table 5.1 Wheel load parameters Vertical Load (lb)
Lateral Load (lb)
Thermal Load (HP for 20 min., 100% into wheel)
125 ton: 38-in. diameter
78,750
39,375
41.92
110 ton: 36-in. diameter
71,500
35,750
38.00
100 ton: 28-, 30-, 33-in. diameter
65,750
32,875
35.00
70 ton: 33-in. diameter
55,000
27,500
29.28
One Wear 28-in. diameter
48,750
24,375
25.95
Locomotive: 40-in. diameter and over
70,000
35,000
37.00
Wheel Types
Note: Mechanical loads shall be introduced at several alternative locations. 5.1 Vertical (e.g., 71,500 lb for 36-in.-diameter wheel) Two different positions for the line of action of the vertical load shall be considered. A load V1 shall be imposed in the flange throat, such that the line of action of the load passes through a point 1/8 in. horizontally removed from the gauging point on the flange. (This requirement becomes 1 1/2 in. from the back rim face for wide-flange wheels and 1 9/32 in. for narrow-flange wheels.) An edge load, V2, shall have a line action 1 in. from the front rim face. 5.2 Lateral (e.g., 35,750 lb for 36-in.-diameter wheel) The line of action of the lateral load, L1, shall be imposed at the same point of action as V1, described in paragraph 5.1 (see Fig. 11.1). 5.3 Thermal (e.g., 38.0 hp for 20 minutes for 36-in.-diameter wheel) The thermal load, Th, shall be introduced axisymmetrically around the tread of the wheel. The load shall be applied evenly over the area 1 11/16 in. on either side of a line centered 3 7/16 in. from the back face of the rim for wide-flange wheels and 1 11/16 in. on either side of a line centered 3 7/32 in. for narrow-flange wheels, as shown in Fig. 11.1. Simultaneously the convective load shall be applied to each of the elements in the above area.
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AAR Manual of Standards and Recommended Practices Wheels and Axles
6.0 LOAD COMBINATIONS Possible load combinations are given for the separate consideration of plate and rim stresses. One must limit the number of load combinations in order to keep the total calculation time within reasonable limits. Experience will show what combinations lead to the most critical stresses. 6.1 Plate Stress Results Calculate maximum effective surface stress under the following combinations:
Vertical Load V1 + Lateral Load L1, Vertical Load V2, Thermal Load Th, V2 + Th, and V1 + L1 + Th. 6.2 Rim Stress Results—Thermal Only Calculate the maximum effective surface stresses at the tread, back and front rim faces (including corners), and the flange. These shall be shown on the contour plot. 7.0 WHEEL CONFIGURATION 7.1 New Condition 7.1.1 The wheel configuration used in the analysis shall conform to the requirements listed in M-107/M-208. The minimum rim thickness and the normal rim width given in the AAR specifications for new wheels shall be used. If necessary, it shall be obtained by translating the new wheel tread and flange geometry radially inward to bring the taping line position to the minimum rim thickness position. The original plate and rim fillet contours and locations shall be retained. 7.1.2 The calculation shall be made at the mean of the envelope dimensions required by M-107/M-208, Appendix A , paragraph 2.1.1. 7.1.3 In the data summary, the source of the wheel profile (drawing or wheel measurement) shall be stated. The plate thickness (N) shall be stated. The exact diameter at the taping line before and after translation and the amount of translation of the tread-flange geometry (to bring the taping line to the minimum specified rim thickness position) also shall be stated if it is necessary to reduce the rim thickness for the purpose of the calculation. 7.2 Condemning Limit Rim Thickness 7.2.1 The wheel configuration (at the condemning limit) is quite sensitive to the development of large thermal stresses. The assumed worn wheel configuration shall be obtained by translating the new wheel tread-flange geometry radially inward to bring the tape line position to the rim thickness designated as the thin rim condemning limit (AAR Field Manual of Interchange Rules , Rule 41, Section A.1.h). The original plate and rim fillet contours and locations shall be retained. 7.2.2 Calculations shall be made for the Th and V2 + Th cases; all data required in paragraph 6.2 also shall be furnished. The exact diameter at the taping line before and after translation, and the amount of translation of the tread-flange geometry (to bring the taping line to the thin rim condemning limit), also shall be stated.
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8.0 MATERIAL PROPERTIES AND BOUNDARY CONDITIONS Material properties and boundary conditions are specified so that the results of various calculational techniques are comparable. 8.1 Data Required for Temperature Calculations Initial Temperature:
Assume 75 °F
Density:
Assume 0.283 lb/in.3
Specific Heat:
Assume the linear function:CP= 0.102 + 0.000052 × T (BTU/lb·ºF)
Thermal Conductivity:
Assume the linear function:K= 28.1 – 0.0060 × T (BTU/h·ft·ºF)
Convection Coefficient:
Assume a constant:
Emissivity:
None required. The effect of radiated heat transport from the surface of the wheel is to be neglected in these calculations.
h = 4 BTU/h·ft2·ºF
8.2 Data Required for Stress Calculations Modulus of Elasticity:
Assume 29,000,000 psi
Poisson’s Ratio:
Assume 0.30
Coefficient of Thermal Expansion:Assume the linear function:alpha = [6.0 + 0.002 × (T-75) ] µin./in.·ºF 8.3 Boundary Conditions: Fix all hub bore nodes in the radial and axial directions at a radius of 1 in. 9.0 ACCURACY OF CALCULATIONAL TECHNIQUE Any candidate analytical procedure for stress calculations must be shown to provide accurate results. The results must be both accurate and convergent. Accuracy can be defined with respect to a standard set of calculated results. Convergence must be examined to ensure that the use of smaller element sizes or more terms in the series representations will not appreciably change the results of the calculations. 9.1 Qualification of Code Qualification of an analytical procedure shall include a demonstration that the results of the finite element analyses are convergent. 9.2 Comparison with Standard Solution The code shall be used to calculate wheel stresses for a standard problem. A specific wheel configuration with a given set of loads shall be defined. Stress and temperature predictions must fall within a specified tolerance. 10.0 REQUIRED DATA In addition to the data required in paragraphs 6.0 and 7.0, all data necessary to permit a knowledgeable individual to repeat the calculation must be reported. Reference to this procedure for the loads and mechanical/physical properties is sufficient. The intent is to permit one program user to check the results of another user. 11.0 RESPONSIBILITY 11.1 Once an analytical procedure has been qualified, it shall be the responsibility of the vendor to inform the AAR if he deviates from the conditions under which he qualified. The vendor must then demonstrate that the new code still qualifies. 11.2 In auditing the analyses done by vendors, the AAR may, at its discretion, require any vendor to rerun the standard solution in its entirety or in part. Failure on the part of the vendor to comply shall be grounds for disqualification.
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Fig. 11.1 Locations of assumed loadings for wide-flange, steel, freight car wheels (not to scale) Paragraphs 5.2 and 5.3
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AAR Manual of Standards and Recommended Practices Wheels and Axles
GAUGE, WHEEL—MAXIMUM FLANGE THICKNESS, HEIGHT, AND THROAT RADII GAUGE FOR AAR-1B NARROW-FLANGE STEEL WHEEL Standard S-661 Adopted: 1991 1.0 SCOPE 1.1 This standard became effective March 29, 1991. 1.2 This standard supersedes MSRP S-602.
Notes:
1. Unless noted, all other tolerances are ±0.0250. 2. Hanging holes optional. 3. Minimum 0.120-in. steel with minimum 55 RC hardness.
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AAR Manual of Standards and Recommended Practices Wheels and Axles
GAUGE, WHEEL—MINIMUM FLANGE THICKNESS, HEIGHT, AND THROAT RADII GAUGE FOR AAR-1B NARROW-FLANGE STEEL WHEEL Standard S-662 Adopted: 1991 1.0 SCOPE 1.1 This standard became effective March 29, 1991. 1.2 This standard supersedes MSRP S-603.
Notes:
1. Unless noted, all other tolerances are ±0.0250. 2. Hanging holes optional. 3. Minimum 0.120-in. steel with minimum 55 RC hardness.
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AAR Manual of Standards and Recommended Practices Wheels and Axles
GAUGE, WHEEL—REFERENCE LIMIT GAUGE FOR VERIFYING AAR 1B NARROW FLANGE WHEEL GAUGE S-661 Standard S-663 Adopted: 1991 1.0 SCOPE 1.1 This standard became effective March 29, 1991. 1.2 This standard supersedes MSRP S-604.
Notes:
1. Unless noted, all other tolerances are ±0.0250. 2. Hanging holes optional. 3. Minimum 0.120-in. steel with minimum 55 RC hardness.
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AAR Manual of Standards and Recommended Practices Wheels and Axles
GAUGE, WHEEL—REFERENCE LIMIT GAUGE FOR VERIFYING AAR 1B NARROW FLANGE WHEEL GAUGE S-662 Standard S-664 Adopted: 1991 1.0 SCOPE 1.1 This standard became effective March 29, 1991. 1.2 This standard supersedes MSRP S-604.
Notes:
1. Unless noted, all other tolerances are ±0.0250. 2. Hanging holes optional. 3. Minimum 0.120-in. steel with minimum 55 RC hardness.
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AAR Manual of Standards and Recommended Practices Wheels and Axles
GAUGE, WHEEL—MAXIMUM FLANGE THICKNESS, HEIGHT, AND THROAT RADII GAUGE FOR AAR-1B WIDE-FLANGE STEEL WHEELS Standard S-665 Adopted: 1991 1.0 SCOPE 1.1 This standard became effective March 29, 1991. 1.2 This standard supersedes MSRP S-605.
Notes:
1. Unless noted, all other tolerances are ±0.0250. 2. Hanging holes optional. 3. Minimum 0.120-in. steel with minimum 55 RC hardness.
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AAR Manual of Standards and Recommended Practices Wheels and Axles
GAUGE, WHEEL—REFERENCE LIMIT GAUGE FOR VERIFYING AAR 1B WIDE FLANGE WHEEL GAUGE S-665 Standard S-666 Adopted: 1991 1.0 SCOPE 1.1 This standard became effective March 29, 1991. 1.2 This standard supersedes MSRP S-606.
Notes:
1. Unless noted, all other tolerances are ±0.0250. 2. Hanging holes optional. 3. Minimum 0.120-in. steel with minimum 55 RC hardness.
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AAR Manual of Standards and Recommended Practices Wheels and Axles
GAUGE, WHEEL—MINIMUM FLANGE THICKNESS, HEIGHT, AND THROAT RADII GAUGE FOR AAR-1B WIDE-FLANGE STEEL WHEELS Standard S-667 Adopted: 1991 1.0 SCOPE 1.1 This standard became effective March 29, 1991. 1.2 This standard supersedes MSRP S-607.
Notes:
1. Unless noted, all other tolerances are ±0.0250. 2. Hanging holes optional. 3. Minimum 0.120-in. steel with minimum 55 RC hardness.
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AAR Manual of Standards and Recommended Practices Wheels and Axles
GAUGE, WHEEL—REFERENCE LIMIT GAUGE FOR VERIFYING AAR 1B WIDE FLANGE WHEEL GAUGE S-667 Standard S-668 Adopted: 1991 1.0 SCOPE 1.1 This standard became effective March 29, 1991. 1.2 This standard supersedes MSRP S-608.
Notes:
1. Unless noted, all other tolerances are ±0.0250. 2. Hanging holes optional. 3. Minimum 0.120-in. steel with minimum 55 RC hardness.
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S-669
AAR Manual of Standards and Recommended Practices Wheels and Axles
ANALYTIC ANALYTIC EVALUATION EVALUATION OF LOCOMOTIVE LOCOMOTIVE WHEEL WHEEL DESIGNS DESIGNS Standard S-669 Adopted: 2011 1.0 OBJEC JECTIVE
The objective of this procedure is to provide a method, using the AAR Manual of Standards and S-660 as a basis, to evaluate the performance of a proposed loco Recommended Practices Standard S-660 as motive wheel design under normal railroad operating service conditions. The objective will be achieved by comparing the results obtained from the application of this procedure to a fatigue criterion and prescribed vibration performance limits. The first step is to ensure that the computations will be of sufficient accuracy and reproducibility where and by whom they are made. This procedure permits the use of all computational techniques that can be demonstrated to provide accurate results and that permit the analysis to be performed under a standard set of assumptions (i.e., material property data and loading conditions). This procedure shall be operative under MSRP Specification M-107/M-208, M-107/M-208 , Appendix A , paragr paragraph aph 2.2 2.2.. This standard applies to new wheel designs that have not yet received approval for use in service pursuant to the requirements of Standard S-660. S-660 . 2.0 BACKGROU ROUND
Computational finite element methods may be applied to obtain the results required by this standard. These results form the basis of the AAR evaluation of the wheel design. Because the evaluation process consists of comparisons of results for wheels of different designs, the magnitude and manner of design load application to the wheel as well as the accuracy requirements for the computational technique must be specified if consistent, comparable results are to be obtained. 3.0 ANALYST ANALYST AND CODE CODE QUAL QUALIFI IFICAT CATION ION
To ensure accuracy and consistency of the results of an analysis, analysts and software must be qualified by the AAR. Qualification shall be obtained by performing a benchmark analysis of a prescribed wheel design and heat-treatment schedule (identifying the initial temperature, quench duration, quenched region, and annealing temperature and duration) that shall be obtained from the committee coordinator of the Wheels, Axles, Bearings, and Lubrication (WABL) Committee. The analysis shall be conducted using the procedures and material properties provided herein, and a report of the results res ults obtained shall be submitted to the committee coordinator. 4.0 RESULTS
Specific results reporting requirements are described below. Stress results must be reported in pounds per square inch (psi) at each nodal location.
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5.0 SOLUTI SOLUTION ON QUALI QUALITY TY AND AND REQUIR REQUIRED ED ANALYS ANALYSES ES 5.1 Solutio Solution n Quality Quality and Anal Analysi ysis s Overvi Overview ew
The analytical procedures applied to produce the results required by this standard must be accurate and convergent. Accuracy can be determined by comparison with a standard set of calculated results. Convergence must be examined to ensure that the choice of finite element size and density or the number of terms in the series representations (if employed) do not appreciably affect the results of the calculations. For the purpose of compliance with the requirements of this standard, convergence is achieved when the maximum von Mises effective stress predicted by the analytical procedure employed is less than 500 lb/in. 2 (psi) for successive complete mesh refinements. Five analyses are required to evaluate the conditions described in this standard as described in paragraph paragraphss 5.2 5.2 to to 5.6 5.6 and and paragr paragraph aphss 7.0 7.0 and and 8.0 8.0.. The first analysis is performed according to the current requirements in Standard S-660 (with S-660 (with additions) as described in paragr paragraph aph 5.2 5.2 and and consists of an elastic analysis of the wheel in the new and worn (to the condemning limit) conditions. This analysis may be performed using a two- or three-dimensional finite element model. The second analysis consists of an elastic-plastic simulation of the wheel heat treating process as described in paragr paragraph aph 5.3 5.3 and and may be performed using a two- or three-dimensional finite element model. This analysis also considers the wheel in the new and worn (to the condemning limit) conditions. Mechanical properties for this analysis are specified s pecified in paragraph paragraph 10.0 10.0.. Because the purpose of this analysis is for comparison of wheel designs only, analysts who wish to extend this analysis to consider conditions not specified here may wish to apply different properties for such analyses. The third analysis involves calculation of the elastic stresses resulting from the wheel-to-axle interference fit as described in paragr paragraph aph 5.4 5.4 and and may be performed using a two- or three-dimensional finite element model. This analysis also considers the wheel in the new and worn (to the condemning limit) conditions. The fourth analysis identifies fatigue-prone locations in the proposed wheel design through application of the Sines criterion as described in paragr paragraph aph 5.5 5.5.. This is accomplished by combining selected results from the three analyses described above according to the procedure outlined in paragr paragraph aph 7.0 7.0.. The fifth analysis requires determination of certain vibration characteristics characteristics of the proposed wheel design as described in paragr paragraph aph 5.6 5.6 A A three-dimensional model of the wheel is necessary to perform this elastic analysis (for the full-thickness rim condition only) according to the procedures outlined in paragr paragraph aph 8.0 8.0.. To simplify the task of manipulating and interpreting the results, the cross-sectional finite element mesh (in the radial-axial plane) of all models used to satisfy the requirements of this standard for a particular wheel design must be identical.
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5.2 5.2 S-66 S-660 0 Ana Analysi lysis s
An analysis pursuant to the requirements in Standard S-660 (most S-660 (most recent version) shall be completed. Compliance with this standard expands the requirements of Standard S-660 paragr paragraph aph 7.2 to include the V1+L1 and V2 load cases for the worn rim condition. Two types of finite element models may be used to perform the Standard S-660 analysis. S-660 analysis. The first model type consists of a mesh of structural or thermal elements as required. The structural element will have three displacement degrees of freedom at each node, and the thermal element will have a single degree of freedom (temperature) at each node. The second model type that may be utilized to perform the Standard S-660 analysis S-660 analysis comprises a mesh composed of harmonic structural or thermal elements. The structural element will have three displacement degrees of freedom at each node, and the thermal element will have a single degree of freedom (temperature) at each node. The difference is, with this type of element, the structural and thermal loads are characterized by Fourier series approximations. Compared with the first model type, run times are faster and file sizes are smaller using harmonic elements. If this technique is employed, a sufficient number of terms must be considered in the Fourier series representation of the loading to obtain an accurate solution. 5.3 5.3 Heat Heat-T -Tre reat atme ment nt Analy Analysi sis s
The state of residual stress in the wheel following wheel rim heat treatment (quenching, tempering, and cool down) shall be determined. The heat-treatment analysis shall be performed independently of all other analyses required by this standard. The complete thermal and stress transient history, beginning at the start of the quench process (assuming a uniform temperature) and ending when the wheel reaches ambient thermal conditions, shall be calculated. Viscoelastic creep effects shall be accounted for in the heat-treatment analysis. Because the fatigue analysis methodology requires combining results from different analyses at particular nodal locations, the same model used to perform the Standard S-660 analysis must be used for the heat-treatment analysis. Results of the heat-treatment analysis shall be presented as four contour plots depicting the axial, radial, circumferential (hoop), and in-plane shear stress components individually for the new and worn rim conditions. 5.4 5.4 Inte Interfe rfere rence nce Fit Fit Anal Analys ysis is
An interference fit of 0.010 in. (referenced to the diameter) between the wheel bore and axle shall be applied. The interference fit analysis shall be performed independently of all other analyses required by this standard. Because the fatigue analysis methodology requires combining results from different analyses at particular nodal locations, the same model and material properties used to perform the Standard S-660 analysis must be used for the interference fit analysis. Results of the interference fit analysis shall be presented as four contour plots depicting the axial, radial, circumferential (hoop), and in-plane shear stress components individually for the new and worn rim conditions. 5.5 5.5 Fatig atigue ue Anal Analys ysis is
The fatigue analysis specified in this standard shall be performed by applying the Sines criterion to the results obtained from the preceding analyses. In the Sines criterion context, the live (alternating and mean) stresses are those that occur as a result of the applied loading, and the as-manufactured residual stresses and the stresses due to interference fit represent the static stresses. The analytically-determined stresses are combined with certain material constants to evaluate the Sines criterion at each node in the model. The outcome of o f this evaluation determines whether the proposed wheel design is likely to experience fatigue failure before its desired lifetime.
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5.6 Vibration Analysis
The objective of this analysis is to evaluate the dynamic performance of the proposed wheel by simulating the dynamic reaction between the wheel and the track. A 360° model of the wheel, as shown in Fig. 5.1, shall be created using solid (brick) elements with a minimum of eight nodes. The use of higher-order solid elements is permitted. If a two-dimensional (axisymmetric) model is used to perform the analyses described in paragraphs 5.2, 5.3, and 5.4, that model shall be revolved as described below to generate the three-dimensional model. The portion of the S-660 compliant model that represents the hollow axle shall be retained. The elastic material properties prescribed in Standard S-660 (most recent version) shall be used in the vibration analysis. Interference pressure between the hollow axle and wheel hub shall be ignored in this analysis. 90°
180°
0°
270°
Fig. 5.1 3-D rendering of locomotive wheel identifying angular reference positions (view is of front face of wheel)
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The elements generated in the hoop direction shall have a maximum angular length of 10° or less. The model shall have a plane of nodes at 45°. The angular length of the elements on either side of the 45° plane shall extend in the hoop direction by no more than 5°. These requirements are illustrated in Fig. 5.2. The 0° plane is the plane on which the specified loads are applied. The 45° plane is the plane at which the stress results are reported.
Note: Shaded sectors represent minimum 10° arc length segments. Black and white segments represent minimum 5° arc length segments on opposite sides of 45° plane. Red arrow indicates direction of tractive load applied to tread surface. Fig. 5.2 Illustration of 3-D model created by revolution of 2-D axisymmetric model (view is of front face of wheel)
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6.0 LOADING CONDITIONS 6.1 Standard S-660 Stress Results
Obtain the orthogonal (normal) stresses for the following loading combinations from the Standard S-660 analysis (using the material properties defined therein) for all nodes in each model (new and worn rim conditions): Vertical Load V1 + Lateral Load L1 Vertical Load V2. Orthogonal (normal) stresses at each node in the region identified in Fig. 6.1 for each model shall be retained.
Fig. 6.1 Portion of model (red regions) in which stresses due to applied loads (L1 + V1 and V2) must be retained for fatigue analysis of the new and worn rim conditions 6.2 Heat-Treatment Residual Stresses
The heat-treatment schedule shall be provided by the AAR WABL Committee for the benchmark analysis to be performed for analyst qualification. The schedule identifies initial temperature, quench duration and extent, annealing temperature and duration, and any dwell time that may exist between any steps in the heat-treatment process. Convective and radiative heat transfer shall be accounted for on all exterior surfaces of the wheel as described in paragraph 10.0. All other submissions to the WABL Committee according to this standard must utilize the heat-treatment schedule proposed for the actual wheel design for which approval is sought. 6.2.1 New Rim Geometry
The purpose of this analysis is to establish the state of residual stress for the new rim geometry due to the heat-treatment process including cool-down to room temperature. In a decoupled analysis, the temperature history at each node shall be calculated first using thermal elements. Time begins (t = 0) when the wheel exits the austenizing furnace at a uniform elevated temperature. The material is considered to be strain-free at this point in time. The analysis ends ( t = tn) when the wheel reaches ambient temperature at the end of the cool-down period. This condition is satisfied when the temperature at all nodes is within the range of ambient temperature plus 5 °F.
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In the second part of the decoupled analysis, the time-dependent nodal temperatures are applied to the structural elements to obtain the residual stresses. The relevant temperature-dependent material property data in paragraph 10.0 shall be used. At the conclusion of the heat-treatment simulation, orthogonal (normal) stresses at each node in the model in the region identified in Fig. 6.1 shall be retained. 6.2.2 Worn Rim Geometry
To determine the residual stress distribution in the worn wheel, elements are removed from the model described above to arrive at the worn rim geometry. Element removal alters the residual stress distribution. This technique involves modifying the stiffness matrix. The relevant temperature-dependent material property data in paragraph 10.0 shall be used. After removal of the rim material, orthogonal (normal) stresses at each node in the model in the region identified in Fig. 6.1 shall be retained. 6.3 Interference Fit Analysis
The interference fit shall be accomplished by inserting a hollow axle stub into the wheel bore. A nominal interference of 0.010 in. referenced to the diameter is assumed. For convenience, the hollow axle geometry shown in Fig. 5.2 (in which the axle bore diameter is 2 in.) may be used. The interference fit stresses shall be determined for the new and worn rim conditions. The element removal technique described above may be used to obtain the interference fit stresses for the worn rim geometry. Material properties for the wheel and axle shall be as defined in Standard S-660 (current version). Orthogonal (normal) stresses at each node in each model in the region identified in Fig. 6.1 shall be retained. 6.4 Required Stress Results
The analyses performed according to paragraphs 6.1, 6.2, and 6.3 yield eight sets of stress results, or eight load cases, as shown in Table 6.1. Table 6.1 Summary of load cases
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Load Case
Required Result at Each Node
Condition
1
Orthogonal normal stresses under load (S x L, Sy L, Sz L, T xy L, Tyz L, T xz L)
V1+L1, new (full) rim
2
Orthogonal normal stresses under load (S x L, Sy L, Sz L, T xy L, Tyz L, T xz L)
V2, new (full) rim
3
Orthogonal normal stresses under load (S x L, Sy L, Sz L, T xy L, Tyz L, T xz L)
V1+L1, worn rim
4
Orthogonal normal stresses under load (S x L, Sy L, Sz L, T xy L, Tyz L, T xz L)
V2, worn rim
5
Orthogonal normal stresses (S x R , Sy R , Sz R )
Heat-treatment residual stresses, new (full) rim
6
Orthogonal normal stresses (S x R , Sy R , Sz R )
Heat-treatment residual stresses, worn rim
7
Orthogonal normal stresses (S x P , Sy P , Sz P )
Interference-fit stresses, new (full) rim
8
Orthogonal normal stresses (S x P, Sy P, Sz P)
Interference-fit stresses, worn rim
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7.0 FATIGUE ANALYSIS ACCORDING TO SINES CRITERION
Combinations of static or residual stress with superimposed alternating stress were examined by Sines [1, 2, 3, 4] and it was found that the permissible alternation of stress is a reasonably linear function of the orthogonal normal static stresses expressed as follows:
J ′ 2 ≤ A – α ( J 1 M + J 1 R + J 1 P )
Equation (1)
in which J' 2 represents the octahedral shear stress and is defined as follows: 1 2 = -- [ ( S x – S y ) + 3
J ′ 2
( S y – S z )
2
+
( S z – S x )
2
2 2 2 + 6 ( T xy + T yz + T xz )]
1 -2
Equation (2)
which, for the purposes of this standard, is characterized by the amplitudes of the stresses due to the applied load as derived from the stress states on the load application plane (at 0°) and on a radial plane located 180° from the load application plane. The amplitude of each nodal stress component ( S , i T ij) in Equation (2) is defined as follows:
S i
1 L = -- [ ( S L i ) 0 ° – ( S i ) 180 ° ] and 2
T ij
1 L = -- [ ( T L ij 0 ° ) – ( T ij 180 ° ) ] 2
Equation (3)
in which the subscripts 0° and 180° denote the value of each stress component on the respective model planes (the regions identified in Fig. 6.1), and the superscript L denotes the stresses due to the applied loads. These stresses are obtained from the analysis performed according to paragraph 6.1. J 1 M is the mean of the sum of the orthogonal (normal) components of the alternating stresses ( Si L) at each node as determined by the analysis performed according to paragraph 6.1 and is defined as follows:
J M 1
1 L + S L + S L ) + = -- [ ( S x y z 0 ° 2
L ) ( S x L + S y L + S z ] 180 °
Equation (4)
in which ( S x L + S y L + S z L)0° are the orthogonal (normal) stress components at the nodes on the radial plane upon which the load is acting (at 0°), and ( S x L + S y L + S z L)180° are the orthogonal (normal) stress components at the nodes on a radial plane 180° away (the regions identified in Fig. 6.1), and J 1 R is the sum of the orthogonal (normal) components of the residual (static) stresses ( Si R) at each node as determined by the analysis performed according to paragraph 6.2 and is defined as follows:
J R 1
=
S x R + S x R + S x R
Equation (5)
and J 1 P is the sum of the orthogonal (normal) components of the interference fit (static) stress ( Si P) at each node as determined by the analysis performed according to paragraph 6.3 and is defined as follows:
J P 1
=
P S x P + S y P + S z
Equation (6)
The values of the constants ( A = 28 ksi and
= 0.16) have been experimentally determined [5, 6].
α
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Equation (1) shall be evaluated at each node in each model in the region identified in Fig. 7.1 for the four combinations of load cases shown in Table 7.1. If, under any load combination, Equation (1) evaluates to false (the alternating stresses are greater than the static stresses) at any node in the model(s), then fatigue is predicted, rendering the design unacceptable.
Note: Area comprises portion of wheel cross-section between red lines that connect inboard and outboard hub outer diameters and inboard and outboard rim inner diameters.
Fig. 7.1 Region in which Sines criterion is applied
Table 7.1 Load combinations to which Equation (1) shall be applied Load Combination
J’ 2
J 1M
J 1R
J 1P
A
Load Case 1
Load Case 1
Load Case 5
Load Case 7
B
Load Case 2
Load Case 2
Load Case 5
Load Case 7
C
Load Case 3
Load Case 3
Load Case 6
Load Case 8
D
Load Case 4
Load Case 4
Load Case 6
Load Case 8
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7.1 Results
The results obtained by application of the Sines criterion for the four load combinations described in paragraph 7.0 shall be presented as four contour plots in the plane of the wheel cross-section on which the mechanical loads act in a format similar to that shown in Fig. 7.2.
Fig. 7.2 Sample contour plot of Sines parameter on portion of wheel cross-section identified in Fig. 7.1 (legend omitted)
For each of these plots, the value to be contoured at each node location is the Sines parameter, SP, which is the difference between the left-hand and right-hand sides of Equation (1), or
SP
=
J ′ 2 – [ A – α ( J 1 M + J 1 R + J 1 P ) ]
Equation (7)
Negative contour data ( SP less than 0) indicate locations at which the Sines criterion is satisfied. Positive contour data ( SP greater than 0) represent fatigue-prone locations at which the Sines criterion is violated. Fatigue-prone locations are unacceptable, and if identified through application of this procedure, the proposed wheel design must be revised and the analysis procedure repeated until no Sines criterion violations remain ( SP < 0 everywhere in the specified plate region). The minimum safety factor and the location in the wheel plate at which it occurs shall be reported for each load combination. The safety factor represents the fatigue margin for the proposed wheel design and is determined in the following way. The analysis described in paragraph 7.0 yields a value for the Sines parameter ( SP) at each node for each of the specified nominal loading conditions. The stresses due to the mechanical loads are recomputed assuming the nominal load (L1, V1, V2) is increased by a load factor n. Because the model is linearly elastic, the stresses due to the mechanical loads (load cases 1 through 8 in Table 6.1) increase proportionally.
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The Sines parameter SP is recomputed for each node for each load combination described in Table 7.1. Each node is now characterized by two values for SP: one due to the nominal load (load factor = 1) and one resulting from the increased load (load factor = n). The safety factor at each node is the multiplier (load factor) on the mechanical load necessary to cause the left-hand and right-hand sides of the Sines criterion to be equal at this location ( SP = 0). This concept is graphically depicted in Fig. 7.3:
Fig. 7.3 Schematic illustrating method for determining safety factor
Table 7.2 Reporting format for fatigue analysis results
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Load Combination
Loading Description
Rim Condition
Maximum SP
Safety Factor
A
V1 + L1
NEW
B
V2
C
V1 + L1
D
V2
WORN
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8.0 VIBRATION ANALYSIS 8.1 Modal Analysis
A modal analysis shall be conducted to determine the vibration characteristics (natural frequencies and mode shapes) in the frequency range of 0 Hz to 500 Hz. The saddle mode of vibration (as shown in Fig. 8.1) is the subject of this analysis. The natural frequency associated with this mode shall be used in a harmonic response analysis to determine the stress field in the wheel. Damping is ignored.
0° - 180° reference plane
Fig. 8.1 Wheel in saddle-mode of vibration with reference plane for applied load 8.1.1 Finite Element Model
The three-dimensional model described in paragraph 5.6 shall be used. 8.1.2 Material Properties
Relevant material properties as defined in Standard S-660 (current version) shall be used. Thermal effects are not considered in this analysis. The modal and harmonic response analyses are performed assuming elastic material behavior. 8.1.3 Boundary Conditions
The outer surface of the hollow axle stub shall be fixed to the inner surface of the wheel hub. Axle bore nodal degrees of freedom are fixed. Interference pressure between the hollow axle and wheel hub is ignored in this analysis. 8.1.4 Modal Analysis Results
The lowest frequency at which the wheel vibrates in the saddle-mode shape as shown in Fig. 8.1 shall be reported to a minimum of three decimal places.
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8.2 Harmonic Response Analysis
A harmonic response analysis shall be conducted for the saddle mode of vibration to predict the sustained dynamic behavior and the steady-state response of the wheel to a tractive load that varies sinusoidally with time. The forcing frequency of the applied load is 0.002% greater than the saddle-mode natural frequency obtained in paragraph 8.1.4 (i.e., f = f n·[1+0.00002] to a minimum of three decimal places). The same model used for the modal analysis shall be used for the harmonic response analysis. Three load cases shall be considered. Tractive loads shall be applied in the rail running direction on the wheel tread surface in the 0° plane identified in Fig. 5.2 at the locations shown in Table 8.1. A force magnitude of 300 lb is sufficient to provide adequate excitation. Damping is ignored. Table 8.1 Load locations for harmonic analysis Load Case
Load Location on Wheel Tread
H1
1 in. from front rim face
H2
3 1/16 in. from the back rim face for wide flange wheels 2 27/32 in. from the back rim face for narrow flange wheels
H3
1 1/2 in. from the back rim face for wide flange wheels 1 9/32 in. from the back rim face for narrow flange wheels
8.3 Harmonic Response Analysis Results
For each load case identified in Table 8.1, provide the following graphical results: • A three-dimensional view of the model depicting the wheel in the saddle mode of vibration as shown in Fig. 8.1 • Two-dimensional contour plots of circumferential (hoop), axial, and radial stresses in the cross-sectional plane located 45° from the 0° plane at which the excitation is applied (as identified in Fig. 5.2) when the amplitude of the forced vibration is maximum For each load case identified in Table 8.1, report the following data as shown in Table 8.2: • The maximum residual circumferential (hoop) tensile stress in the wheel rim resulting from the heat-treatment analysis as identified in Fig. 8.2 (paragraph 6.2) • The circumferential (hoop) stress range due to the forced vibration at the location of maximum residual circumferential (hoop) tensile stress in the wheel rim (in the cross-sectional plane located 45° from the 0° plane at which the excitation is applied as identified in Fig. 5.2) resulting from the heat-treatment analysis (paragraph 6.2) • The maximum circumferential (hoop) tensile stress in the wheel rim (in the cross-sectional plane located 45° from the 0° plane at which the excitation is applied as identified in Fig. 5.2) that occurs during the forced vibration analysis (paragraph 8.3)
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Fig. 8.2 Arrow indicates typical location of maximum residual circumferential (hoop) tensile stress in wheel rim following simulated heat treatment. This is referred to as cross-sectional “Location X” in Table 8.2 (legend omitted)
Table 8.2 Reporting format for stresses due to heat treatment and forced vibration (ksi)
Load Case
Maximum Rim Circumferential (Hoop) Tensile Stress Following Simulated Heat Treatment at Location X (see Fig. 8.2 )
Circumferential (Hoop) Stress Due to Forced Vibration at Location X
Maximum Rim Circumferential (Hoop) Tensile Stress Due to Forced Vibration
H1
H2
H3
9.0 RESPONSIBILITY 9.1 Deviations
Once an analytical procedure has been qualified, it shall be the responsibility of the vendor to inform the AAR if he deviated from the conditions for which he is qualified. The vendor must demonstrate that the new code still qualifies. 9.2 Auditing
In auditing the analysis done by vendors, the AAR may, at its discretion, require any vendor to rerun the standard solution in its entirety or in part. Failure on the part of the vendor to comply shall be grounds for disqualification.
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10.0 MATERIAL PROPERTIES
Material properties are specified so that the results of various computational techniques may be compared. 10.1 Material Properties (Constants) for Heat-Treatment Simulation
Initial temperature (after residual stress calculation): 75 °F Ambient temperature for cool-down portion of residual stress analysis: 75 °F Mass density: 0.283 lbm/in.3 Convection coefficient (wheel to air): H = 9.6450 ×10 -6 BTU/sec-in.2-°F (assume constant) or H = 5.0 BTU/hr-ft2-°F (assume constant) Convection coefficient (wheel to water) [7]: H = 1.0417 ×10 -3 BTU/ sec-in.2-°F (assume constant) or H = 540.0 BTU/hr-ft2-°F (assume constant) Stefan-Boltzmann constant: 3.30632716e-15 BTU/sec-in. 2-R4 Emissivity: 0.80 View factor: 1.0
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10.2 Material Properties (Temperature-Dependent) for Heat-Treatment Simulation Table 10.1 Specific heat [8]
Table 10.2 Thermal conductivity [7]
Temp (°F)
(BTU/lbm-°F)
Temp (°F)
(BTU/sec-in-°F)
0
0.1059
0
0.000672
75
0.1106
75
0.000664
1292
0.1866
392
0.000629
1337
0.4079
1292
0.000403
1382
0.1487
1472
0.000329
1652
0.1309
1800
0.000361
1800
0.1309
10.3 Material Properties (Temperature-Dependent) for Stress Calculations Table 10.3 Modulus of elasticity (E) and hardening modulus (Etan) Temp (°F)
E (kips/in.2)
Etan [9, 10, 11, 12]a/ (kips/in.2)
0
29368
2016
75
29000
2192
100
28955
2250
200
28543
2484
300
28130
2719
400
27718
2953
500
27306
3187
600
26859
3028
700
26407
2804
800
25741
2514
900
24784
2151
1000
23553
1790
1100
20542
1431
1200
17531
1071
1300
14424
726
1400
11698
557
1500
9952
424
1600
9114
384
1700
8577
343
1800
7390
303
a/
Table 10.4 Poisson's ratio [ 9, 11, 13] Temp (°F)
ν
0
0.2820
75
0.2836
514
0.2927
752
0.2980
932
0.3020
1292
0.3200
1472
0.3400
1800
0.3461
Table 10.5 Coefficient of thermal expansion [8]
Temp (°F)
Thermal Expansion Coefficient per °F
0
6.22E-06
75
6.22E-06
212
6.22E-06
400
8.58E-06
1292
8.58E-06
1472
9.61E-06
1800
9.61E-06
Temperature-dependent values for hardening modulus have been interpolated such that they are presented for the same temperatures as the modulus of elasticity.
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Table 10.6 Yield strength
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Table 10.7 Creep strain rate [7]
σy
Temp (°F)
(kips/in.2)
0
80.00
75
80.00
100
79.94
200
79.69
300
79.44
400
79.20
500
78.95
600
77.71
700
76.32
800
67.77
900
54.91
1000
41.95
1100
32.77
1200
23.59
1300
14.63
1400
10.50
1500
8.94
1600
7.79
1700
6.63
1800
5.48
&
ε
– 08
= 4.6410
– 53712 -----------------T + 460
12.5 ( σ ef f ) e
in which
&
ε
=
the creep strain rate (1/°F)
σeff
= von Mises effective stress (ksi)
T
=
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11.0 REFERENCES
1. Sines, G. 1955. Failure of Materials Under Combined Repeated Stresses with Superimposed Static Stresses. NACA Technical Note 3495. 2. Sines, G. 1969. Elasticity and Strength. Needham Heights:Allyn and Bacon. 3. Sines, G., and J.L. Waisman, eds. 1959. Metal Fatigue. London:McGraw-Hill. 4. Stephens, R.I., A. Fatemi, R.R. Stephens, and H.O. Fuchs. 1980. Metal Fatigue in Engineering, Hoboken:Wiley and Sons. 5. McKeigan, P.C., F.J. McMaster, and J.E. Gordon. 2002. Fatigue Performance of AAR Grade B Wheel Steel at Ambient and Elevated Temperatures. ASME Paper IMECE2002-33240. 6. McMaster, F. J., G.P. Robledo. and J.E. Gordon. 2005. Fatigue Performance of AAR Grade A Wheel Steel at Ambient and Elevated Temperatures. ASME Paper IMECE2005-82519. 7. Kuhlman, C., H. Sehitoglu, and M. Gallagher. 1988. The Significance of Material Properties on Stresses Developed During Quenching of Railroad Wheels. Proceedings of the 1988 Joint ASME IEEE Railroad Conference. 8. Metals Handbook. 1948. Vol. 1, 9th edition. Cleveland:American Society for Metals. 9. Slavik, D., and H. Sehitoglu. 1986. Constitutive Models Suitable for Thermal Loading. ASME J. Eng. Mats. Techn. 108:108-312. 10. Lunden, R. 1991. Contact Region Fatigue of Railway Wheels Under Combined Mechanical Rolling Pressure and Thermal Brake Loading. Wear. 144:57-70. 11. Orringer, O., D.E. Gray, and R.J. McCown. 1993. Evaluation of Immediate Actions Taken with Cracking Problems Observed in Wheels of Rail Commuter Cars. DOT-VNTSC-FRA. 93:3. 12. Berg, N. A., and R. Alber. 1972. Tread Braking Versus the Wheel. Proceedings of the 64th Annual Convention of the Air Brake Association . 13. Metals Handbook. 1948. Vol. 1, 10th edition. Cleveland:American Society for Metals.
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RP-608
GAUGE, WHEEL—REFERENCE MASTER DISK FOR VERIFYING WHEEL CIRCUMFERENCE GAUGES S-612 AND S-613 Recommended Practice RP-608 Adopted: 1937; Last Revised: 2004
MATERIAL: ASTM A-47 Grades 32510 or 35018 03/2011
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INSPECTION STAND FOR USE WITH MASTER DISKS Recommended Practice RP-609 Adopted: 1937; Last Revised: 2004
MATERIAL: COLD ROLLED STEEL, CAST IRON
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MOUNTING PRESSURES FOR WROUGHT AND CAST STEEL WHEELS ON GEAR-DRIVEN AND IDLER AXLES OF LOCOMOTIVES OTHER THAN STEAM Recommended Practice RP-612 Adopted: 1951; Last Revised: 2004 Diameter of Wheel Seat (in.)
Minimum
Desired Mounting Pressure (ton)
Maximum
6.000 to 6.346, inclusive
75
80
95
6.347 to 6.730, inclusive
75
85
100
6.731 to 7.115, inclusive
75
90
110
7.116 to 7.499, inclusive
75
95
115
7.500 to 7.884, inclusive
80
100
120
7.885 to 8.269, inclusive
85
105
125
8.270 to 8.653, inclusive
90
110
130
8.654 to 9.038, inclusive
90
115
140
9.039 to 9.423, inclusive
95
120
145
9.424 to 9.807, inclusive
100
125
150
9.808 to 10.192, inclusive
105
130
155
10.193 to 10.576, inclusive
110
135
160
10.577 to 10.961, inclusive
110
140
170
10.962 to 11.346, inclusive
115
145
175
11.347 to 11.730, inclusive
120
150
180
11.731 to 12.115, inclusive
125
155
185
12.116 to 12.499, inclusive
130
160
190
12.500 to 12.884, inclusive
130
165
200
12.885 to 13.269, inclusive
135
170
205
13.270 to 13.653, inclusive
140
175
210
13.654 to 14.000, inclusive
145
180
215
Desired mounting pressures are based on 13 ton/in. of diameter, expressed in the nearest 5 ton with an allowable variation of 20% over and under, except the first three minimum pressures, which are shown as 75 ton, being considered better practice for these sizes.
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RP-613
AAR Manual of Standards and Recommended Practices Wheels and Axles
GAUGE, AXLE—MASTER GAUGE FOR VERIFYING AXLE JOURNAL AND FILLET GAUGE S-614 Recommended Practice RP-613 Adopted: 1937; Last Revised: 2004 1.0 SCOPE This master gauge applies to Gauge No. 34401, described in the AAR Manual of Standards and Recommended Practices , S-614.
MATERIAL: ASTM A-576, Grade 1020
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RP-614
GAUGE, WHEEL—MASTER GAUGE FOR VERIFYING WHEEL GAUGES S-617 AND S-618 Recommended Practice RP-614 Adopted: 1937; Last Revised: 2004 1.0 SCOPE This master gauge applies to the steel wheel gauges described in the AAR Manual of Standards and Recommended Practices , Standards S-617 and S-618.
MARK: MASTER FOR WHEEL GAUGE (3/32-in. STAMPS) MATERIAL: ASTM A-576, Grade 1020 FINISH: CHROMIUM PLATE
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RP-615
AAR Manual of Standards and Recommended Practices Wheels and Axles
GAUGE, WHEEL—SIMPLIFIED Recommended Practice RP-615 Adopted: 1975; Last Revised: 2004 1.0 SCOPE 1.1 This gauge can be used for checking high-flange, thin-rim, and grooved tread for all freight car wheels. 1.2 This recommended practice became effective October 1, 1976.
MATERIAL: .093-in. STAINLESS STEEL. UNLESS OTHERWISE STATED. ALL TOLERANCES ARE ±.010 in. REMOVE BURRS AND SHARP EDGES.
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RP-619
AAR Manual of Standards and Recommended Practices Wheels and Axles
REFERENCE GROOVE FOR MULTIPLE-WEAR DIESEL WHEELS Recommended Practice RP-619 Adopted: 1970; Last Revised: 2004
NOTE: THIS REFERENCE GROOVE IS OPTIONAL AND IS MACHINED AT THE REQUEST OF THE CUSTOMER UNLESS SPECIFIED AS REQUIRED.
DESIGN
“D” (in.)a/
CH 33
29
H 33
29
CA 34
30
A 34
30
CF 36
32
F 36
32
CA 38
34
A 38
34
CE 40
36
E 40
36
CA 42
38
A 42
38
CC 42
38
C 42
38
a/ TOLERANCE = 1/32 IN.
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RP-622
AAR Manual of Standards and Recommended Practices Wheels and Axles
AXLE, WEIGHT—MACHINED FINISH, RAISED WHEEL SEAT Recommended Practice RP-622 Adopted: 1966; Last Revised: 2007 Nominal Weight (lb) Classification of Axles
Roller Bearing
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Size of Journal (in.)
Rough-Turned Journal and Wheel Seats Freight Car
Passenger Car
D
5 1/2 × 10
810
840
E
6 × 11
975
1005
F
6 1/2 × 12
1175
1220
G
7 × 12
1415
—
K
6 1/2 × 9
1168
—
L
6×8
900
—
M
7×9
1325
—
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RP-629
AAR Manual of Standards and Recommended Practices Wheels and Axles
GAUGE, WHEEL—FOR MEASURING CONDEMNABLE OVERHEATED WHEELS Recommended Practice RP-629 Adopted: 1980; Last Revised: 2004 Note: See RP-630 for application.
MATERIAL: 16 GAUGE BLACK STEEL
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RP-630
AAR Manual of Standards and Recommended Practices Wheels and Axles
GAUGE, WHEEL—APPLICATION FOR MEASURING CONDEMNABLE OVERHEATED WHEELS Recommended Practice RP-630 Adopted: 1980; Last Revised: 2004 Note: See RP-629 for gauge drawing.
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RP-636
AAR Manual of Standards and Recommended Practices Wheels and Axles
GAUGE, WHEEL—APPLICATION DRAWING FOR AAR 1B WHEEL GAUGES S-662 AND S-667 Recommended Practice RP-636 Adopted: 1991 1.0 SCOPE This recommended practice can be used when checking with the following gauges: S-667 (wide flange) and S-662 (narrow flange).
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RP-637
AAR Manual of Standards and Recommended Practices Wheels and Axles
GAUGE, WHEEL—APPLICATION DRAWING FOR AAR 1B WHEEL GAUGES S-661 AND S-665 Recommended Practice RP-637 Adopted: 1991 1.0 SCOPE This recommended practice can be used when checking with the following gauges: S-665 (wide flange) and S-661 (narrow flange).
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RP-638
AAR Manual of Standards and Recommended Practices Wheels and Axles
GAUGE, WHEEL—APPLICATION DRAWING FOR REFERENCE GAUGE TO VERIFY WHEEL GAUGES S-661, S-662, S-663, S-664, S-665, S-666, S-667, AND S-668 Recommended Practice RP-638 Adopted: 1991 1.0 SCOPE This recommended practice can be used when checking with the following gauges:
Maximum Flange Thickness, Height and Throat Radii Gauges: Maximum Limit Wear Gauges: Minimum Flange Thickness, Height and Throat Radii Gauges: Minimum Limit Wear Gauges:
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S-665 and S-661 S-663 and S-666 S-667 and S-662 S-664 and S-668
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