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This standard is developed in accordance with the rules given in GB/T 1.1-2009.
This standard replaces TB/T 2817-1997 Technical conditions of solid forged and rolled wheels for railway applications. In addition to editorial changes, the following technical changes have been made with respect to TB/T 2817-1997:
——the scope of the standard is modified (see Clause 1; Clause 1 in Edition 1997);
——the overall geometrical tolerance and the dimension limit deviation of the wheels are modified (see Table 1; Table 1 in Edition 1997);
——the requirement for hydrogen content in molten steel is added (see 4.1.1.1);
——the wheel steel designations, CL65 and CL70, are added (see Table 2);
——the plain disc tensile performance and fatigue performance of wheels are added (see 4.3.1 and 4.3.4);
——the re-inspection rules are deleted (see 6.4 in Edition 1997);
——the normative annex "Testing of hydrogen content in steel for solid wheels” (see Annex A);
——the normative annex "Fatigue test" is added (see Annex B);
This standard was proposed by and is under the jurisdiction of Standards and Metrology Research Institute of China Academy of Railway Sciences Corporation Limited.
The previous edition of the standard replaced by this standard is as follows: TB/T 2817-1997.
Solid forged and rolled wheels for railway wagon applications
1 Scope
This standard specifies the dimension limit deviation and geometrical tolerance, technical requirements and test methods, inspection rules, marking, packaging and protection, and quality certificate of solid forged and rolled wheels for railway wagon applications.
This standard is applicable to the solid forged and rolled wheels for railway wagon applications where the maximum speed is less than or equal to 120km/h. This standard may serve as a reference for solid forged and rolled wheels for fast wagons.
2 Normative references
The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.
GB/T 223 Methods for chemical analysis of iron, steel and alloy
GB/T 228.1 Metallic materials - Tensile testing - Part 1: Method of test at room temperature
GB/T 229 Metallic materials - Charpy pendulum impact test method
GB/T 231.1 Metallic materials - Brinell hardness test - Part 1: Test method
GB/T 1182 Geometrical product specifications(GPS) - Geometrical tolerancing - Tolerances of form orientation location and run-out
GB/T 4336 Carbon and low-alloy steel - Determination of multi-element contents - Spark discharge atomic emission spectrometric method (routine method)
GB/T 6394 Determination of estimating the average grain size of metal
GB/T 9445 Non-destructive testing- Qualification and certification of personnel
GB/T 10561-2005 Steel - Determination of content of nonmetallic inclusions - Micrographic method using standards diagrams
GB/T 13298 Inspection methods of microstructure for metals
GB/T 15822.2 Non-destructive testing - Magnetic particle testing - Part 2: Detection media
GB/T 15822.3 Non-destructive testing - Magnetic particle testing - Part 3:Equipment
GB/T 18838.3 Preparation of steel substrates before application of paints and related products - Specifications for metallic blast-cleaning abrasives - Part 3: High-carbon cast-steel shot and grit
GB/T 18838.4 Preparation of steel substrates before application of paints and related products - Specifications for metallic blast-cleaning abrasives - Part 4: Low-carbon cast-steel shot
GB/T 20066 Steel and iron - Sampling and preparation of specimen for the determination of chemical composition
GB/T 20123 Steel and iron - Determination of total carbon and sulfur content - Infrared absorption method after combustion in an induction furnace (routine method)
GB/T 20125 Low-alloy steel - Determination of multi-element contents - Inductively coupled plasma atomic emission spectrometric method
GB/T 27664.1-2011 Non-destructive testing - Characterization and verification of ultrasonic test equipment - Part 1: Instruments
GB/T 27664.2-2011 Non-destructive testing - Characterization and verification of ultrasonic test equipment - Part 2: Probes
GB/T 27664.3-2012 Non-destructive testing - Characterization and verification of ultrasonic test equipment - Part 3: Combined equipment
JB/T 10174-2008 Methods of quality inspection on shot-peening for steel-iron parts
TB/T 3031-2002 Evaluation of macrostructure defect in radial cross-section of rolled solid wheels for railway
IS0 6933:1986 Railway rolling stock material - Magnetic particle acceptance testing
3 Dimension limit deviation and geometric tolerance of the wheel model
3.1 The wheel manufacturer shall produce and inspect in accordance with the drawings approved through the specified procedures. See Figure 1 for the schematic diagram for wheel model and the symbols of overall dimension.
3.2 See Table 1 for the overall geometrical tolerance and the dimension limit deviation of the wheels.
Figure 1 The schematic diagram for wheel model and the symbols of overall dimension.
Note 1: the distance h from the inner side surface of the rim to the wheel rolling is in accordance with that specified in product sample.
Note 2: Фd01 is the hub bore diameter of the wheel to be assembled.
Table 1 Overall geometric tolerance and dimension limit deviation of wheel In: mm
Item Symbols (see Figure 1) Geometric tolerance / dimensional limit deviation
Dimension Geometrical shapea
Rim Outer diameter (the diameter of the rolling circle) D — +6
0
Inner diameter (inner side) D1 — 0
-4
Inner diameter (outer side) D2 — 0
-4
Width H — +5
+2
Thickness difference of the rims on the same sidec ?B1, ?B2 — ≤0.4
Shapes of flange and treadb — V1 ≤0.5
Roundness of the rolling circle — y ≤0.2
Rim End face runout of inner side surface — n ≤0.3
Outer diameter (inner side) D31 — +4
0
Outer diameter (outer side) D32 — +4
0
Length L — ±2
Distance between inner rim and hub F — +2
0
Inner diameter of wheel hub bore ?B1, ?B2 — 0
-4
Inner diameter cylindricity of the wheel hub bore — x ≤1.0
Runout of wheel hub bore diameter — m ≤1.0
Wall thickness difference of wheel hubs on the same side ?C1, ?C2 — ≤2
Plain disc Thickness of the junction between plain disc and rim S1 — +3
0
Thickness of the junction between plain disc and hub S2 — +3
0
Plain disc outline — V2 ≤4
a See GB/T 1182 for details.
b Inspect with a template, extending from the top of the flange to the local clearance at the outer chamfer.
c Take at least 3 values according to the designated positions B1 and B2 in the Figure , and calculate the maximum difference.
c Take at least 3 values according to the designated positions C1 and C2 in the Figure, and calculate the maximum difference.
4 Technical requirements and inspection methods
4.1 Wheel billet
4.1.1 Requirements.
4.1.1.1 The wheel steel shall be treated by secondary refining and vacuum degassing. The billet may be manufactured by continuous casting or die casting. The static ignot shall be casted from the bottom. Hydrogen content of molten steel shall be no greater than 2.0×10-6, and the analysis of hydrogen content of molten steel shall be conducted in accordance with any methods specified in Annex A.
4.1.1.2 There shall be no defects affecting the rolling quality of the wheels on the billet surface. If the static ignot is used to make the wheel, the steel ingot shall be cropped, and the amount of cropping shall be sufficient to eliminate the harmful parts on both ends of the steel ingot that affect the quality of the wheel.
4.1.1.3 See Table 2 for the designation, code and chemical composition of wheel steel (smelting analysis).
Table 2 Designation, code and chemical composition of wheel steel (smelting analysis)
Steel designation Steel code Mass fraction %
C Si Mn P S Cr Cu Mo Ni V Cr+Mo+Ni
CL60 II 0.55~0.65 0.17~0.37 0.50~0.80 ≤0.025 ≤0.025 ≤0.25 ≤0.25 ≤0.08 ≤0.25 ≤0.06 ≤0.50
CL65 III 0.57~0.67 ≤1.00 ≤1.20 ≤0.025 ≤0.025 ≤0.30 ≤0.30 ≤0.06 ≤0.25 ≤0.08 ≤0.50
CL70 IV 0.67~0.77 ≤1.00 ≤1.20 ≤0.025 ≤0.025 ≤0.30 ≤0.30 ≤0.06 ≤0.25 ≤0.08 ≤0.50
4.1.2 Test method
For the smelting chemical analysis of wheel steel, at least one specimen shall be taken for each furnace. The sampling and analysis test are carried out according to the methods specified in GB/T 20066 and GB/T 223 or GB/T 4336.
4.2 Wheel manufacturing
4.2.1 Requirements.
4.2.1.1 The wheel shall be subjected to integral forging or rolling forming; upon heating during hot forming, the wheel billet shall be prevented from overheating and overburning.
4.2.1.2 The wheel rim shall be quenched and tempered, and the plain disc shall be prevented from water inflow during quenching.
4.2.1.3 See Table 3 for permissible deviation for chemical composition analysis and smelting analysis of the finished wheel.
Table 3 Permissible deviation for chemical composition analysis
Steel designation Permissible deviation (mass fraction)
%
C Si Mn P S Cr Cu Mo Ni V
CLCL60 +0.03
-0.02 +0.03
-0.02 +0.03
-0.03 +0.005
0 +0.005
0 +0.03
0 +0.03
0 +0.02
0 +0.03
0 +0.01
0
CL65 +0.03
-0.02 +0.03
0 +0.03
0 +0.005
0 +0.005
0 +0.03
0 +0.03
0 +0.02
0 +0.03
0 +0.01
0
CL70 +0.03
-0.02 +0.03
0 +0.03
0 +0.005
0 +0.005
0 +0.03
0 +0.03
0 +0.02
0 +0.03
0 +0.01
0
Permissible deviation for chemical compositions of finished product refers to the deviation of the chemical compositions of finished wheel from those specified in Table 2.
4.2.2 Test methods
For the chemical analysis of the finished wheel, no less than 50g of steel scrap sample shall be taken from 30mm below the tread at the nominal diameter of the rim, and the analysis shall be carried out in accordance with GB/T 223. If spectral analysis is used, the end part of the tensile specimen may be used, and the test is carried out in accordance with the method specified in GB/T 4336. The chemical analysis of finished wheel shall also be carried out in accordance with the methods specified in GB/T 20123, GB/T 20125. Discrepancy, if any, may be subjected to arbitration according to the methods specified in GB/T 233.
4.3 Mechanical property
4.3.1 Tensile property
4.3.1.1 Requirements
See Table 4 for tensile performance of the wheel.
4 Tensile property
Steel designation Rim Plain disc
Upper yield strength ReHa N/mm2
Tensile strength Rm N/mm2 Percentage elongation after fracture A4% Percentage reduction of sectional area Z% Rm reductionb
N/mm2 Percentage elongation after fracture A5%
CL60 ≥580 ≥910 ≥10 ≥14 ≥120 ≥14
CL65 ≥620 ≥1,010 ≥10 ≥14 ≥130 ≥12
CL70 ≥650 ≥1,050 ≥10 ≥14 ≥130 ≥10
a If no apparent yield strength occurs, the stress Rp0.2 shall be determined.
b The reduction value of tensile strength relative to that of the rim on the same wheel.
4.3.1.2 Location of specimens
The specimens shall be taken from the rim and plain disc of the wheel and see Figure 2 for the location.
Keys:
1——the tensile specimen for rim;
2——the tensile specimen for plain disc.
Figure 2 Location of tensile specimens
4.3.1.3 Test method
It shall be carried out with the methods specified in GB/T 228.1. The inner diameter of the parallel length of tensile specimen for plain disc is 10 mm, and the original gauge length is 5 times its diameter. The inner diameter of the parallel length of tensile specimen for the rim is 15mm, and the original gauge length is 4 times its diameter.
4.3.2 Impact resistance
4.3.2.1 Requirements
See Table 5 for the average of impact test. Take the average of the results of 3 specimens as the test result, and the minimum value of the single specimen shall be no less than 70% of the values specified in Table 5. The test temperature is +20 °C, and a U-shaped notch specimen with a depth of 2mm shall be used.
Table 5 Impact energy In: J
Steel designation Impact absorbed energy KU2 (20℃)
Rim Plain disc
CL60 — ≥16
CL65 ≥20 ≥16
CL70 ≥18 ≥12
4.3.2.2 Test location
See Figure 3 for the location of specimen for impact test
Figure 3 Location of specimens for impact test
4.3.2.3 Test method
It shall be carried out with the methods specified in GB/T 229.
4.3.3 The hardness of section of wheel rim
4.3.3.1 Requirements
The minimum Brinell hardness in the entire wear area of the rim shall be greater than or equal to the value specified in Table 6. Even if the wear depth is not greater than 30 mm, the hardness value specified in Table 6 shall be achieved at a maximum depth of 30 mm under the tread.
If the wear limit is less than 30 mm, the hardness of the rim-plain disc transition (point A, Figure 4) is at least 10HBW smaller than the hardness at 30 mm; if the wear limit is greater than 30 mm, the hardness of the rim-plain disc transition (point A, Figure 4) is at least 10HBW smaller than the hardness at the wear limit.
Table 6 The value of hardness of rim
Steel designation Minimum value of Brinell hardness HBW 10/3000
CL60 265
CL65 280
CL70 300
4.3.3.2 Measuring points
As is shown in Figure 4, measure the hardness at 4 points on the radial section of rim.
Keys:
1—the position with maximum depth of 30mm under the tread or the wear limit;
2—the inner side surface of wheel after processing;
3—the diameter of the rolling circle.
Figure 4 Measuring points for hardness on the radial section of rim
4.3.3.3 Test method
The test shall be carried out in accordance with the methods specified in GB/T 231.1. Diameter of indenter is 10mm.
4.3.4 Fatigue performance
4.3.4.1 Requirements
The wheel shall be free of crack after 107 times rolling under the specified test stress. See Table 7 for radial test stress of plain disc
Table 7 Radial stress
Symmetric loading Machined plain disc
The inspected value of radial stress ±240 N/mm2
4.3.4.2 Test method
See Annex B for the specific requirements for the specimens, methods, and equipment of fatigue test.
4.3.5 The hardness of rim surface
4.3.5.1 Requirements
Test for hardness of rim surface shall be conducted for each wheel after heat treatment; the test can be conducted before machining; and the surface hardness values shall meet the requirements specified in Table 8. The press marks of Brinell hardness can be reserved on the rim surface.
Table 8 Values of rim surface hardness
Steel designation Brinell hardness value
HBW 10/3000
CL60 277~341
CL65 ≥302
CL70 ≥321
4.3.5.2 Measuring points
The press mark for measuring the surface hardness of the rim shall be taken in the area specified in Figure 5.
Keys:
1—the lower edge of the chamfer at the connection of the outer side of the rim and the tread;
2—the Brignell hardness measurement area.
Figure 5 Hardness measurement area on the rim surface
4.3.5.3 Test method
The test method shall be in accordance with that specified in GB/T 231.1. Diameter of pressing ball is 10mm.
4.4 Homogenization of heat treatment
4.4.1 Requirements.
The change in hardness values measured on the rim of the same wheel shall be smaller than 30 HBW.
4.4.2 Measuring points
The hardness shall be measured at three points evenly distributed on the outer side of the rim. The press mark for measuring the surface hardness of the rim shall be taken from the same diameter in the area specified in Figure 5.
4.4.3 Test methods
The test method shall be carried out according to GB/T 231.1.The test method shall be in accordance with that specified in GB/T 231.1. Diameter of pressing ball is 10mm
Foreword
1 Scope
2 Normative references
3 Dimension limit deviation and geometric tolerance of the wheel model
4 Technical requirements and inspection methods
5 Inspection rules
6 Marking
7 Packaging and protection
8 Quality certificate
9 Requirements for use
Annex A (Normative) Testing of hydrogen content in steel for solid wheels
Annex B (Normative) Fatigue test
Annex C (Normative) Ultrasonic testing method
Annex D (Normative) Magnetic particle inspection
Annex E (Normative) Imbalance elimination method
