Item Name: Steel Axels for Carriages and Wagon.
1. RDSO is reviewing the specification/STR to cater to the latest
technological developments
in the field, modify clauses not relevant in the present context
and making them more
enabling with focus on functional requirements.
2. It is requested that your comments / suggestions with regard to
improvements /
modifications in specification / STR of this item may be submitted
in the following format
alongwith the justification for the changes required.
Part A: Basic Information
5 Address for Correspondence
6 Contact No.
7 Email ID
8 In case of Firm / Individual: Manufacturing experience of item
(or similar Item) on which comments are offered
9 Where relevant: Whether any technical document to support
suggested changes is available / enclosed for better
appreciation
Part B: Comments / suggestions on the specification
SN Clause No. of RDSO STR / Spec
Clause, as exists in RDSO STR / Spec
Clause , as it should read after incorporation of comments /
suggestions in the RDSO Spec / STR
Justification for changes
Joint Director/VDG/Carriage
Manak Nagar, Lucknow – 226011
(RAILWAY BOARD)
Thi::, ~-peci f icat.ion to specifications with their latest
amendments -
J. IS:::228
Method fer Charpy Impact Test fof· metals.
( U-·rmt.c h)
Method for tensile testing o·f steel preodt.u:: t::.,
Reaciy mi)~ed paint~ air drying, red o>:ide zinc chrom~,
priming.
Me·thod of determining austenitic g~ain ~ .. ize of stl?el.
Assessment of surface roughr1ess.
1noulding a1~d e>:trusion.
Ready mj.>:ed paint, brushing~ bituminous~
black~ lead tree, acid, alkali~ water and chlorine resisting.
1..
2.
2 .. 1
2 .. 2
INDIAN RAIUJAY STANDARD SPECIFICATION FOR STEEL AXLES FOR CARRIAGES
AND ~IAGONS
(APPLICABLE TO ALL GAUGES)
IRS:R-'16/9'5
This standard cover·s the technical of steel a>:les for
Carriages and Wagons trailer cc3aches o·f all gatlgesM
t-r:-qui remeni.:s l.ncludin9 EMU
Process of Manufacturing Steel
(i) The axles shall be manufactured from steel made by Electrj.c,
Basic D>:ygen clr by any othe~ process as r:1greE·d to by t.he
Purc:ha£~er-,. The steel sh€·d 1 be of killed quality.
(ii.) The hydrogen content in the liquid shall not e:>:ceed 3
ppm.. I·f it e->:ceeds, then p! ... oper antifl~kirlg treat1nent
shall be carried OIJt a·fter whicl""t the hyd1 ... ogen content
shall be measur-ed and the same shall not exceed 3 ppm.
Chem~cal Composition
Ladle Analysis
The ladle 8nalysis of steel~ when carried out by the met~1od
specified j.n the relevant para of !5:228 or .any other est.ctbl j_
sh~;.:d instt-umented/chemical method.\ ~=-h~ 11 be as per Table !w
In case of any dispute, the procedure given in the relev~nt para of
15:228 sh~ll be the referee method. However, if the method is not
given in any para of IS:228~ the referee method shall bE as agreed
to between the Purchaser and the Manufi-~cturer.
Table-1 Chemical Compo~ition
Ladle An~lysis (Percentage)
c (l .37 m<.~,·~t Ni (l . 30 mc1·:: . Mn 1 12 m.:..:>: . Mo
(1. 05 ma:-: Si 0 1::'· to 0. 46 Cu 0.30 IT!Cl}:
p 0 .04 m~>~ . v 0 .0~1 m,=.;,">~
s 0.04 m~l>: . P+S 0 .07 ma:.·: c..- (1 .. 30 ma::-: .
1
IRS:R-16/95
Product Analysis
~t~e pr·odt]ct analy~is shall tJe carried out on the finished
pr·oduct~ Perlni.ssib1.e variation in case of such pr·oduct
analysis from tt)e ladle analysis ~s
obtained shall be as follows:-
Element "..'ariation Percent
Discard
Suff).c:tent disciilt ... rl sh~ll be made from either E·nd c:·f
e2•.ch ingot t.n ensure fre-:edDm "frorn piping and
h~.rmft:t-1
o::.egreg.a·tic>n ..
Manufacturing Practice
The forged ,a):le·s s-he.ll bt":' mz,nufactt.tred frc.m steel
ingot~;:.. t-c~11et..1 ol"- icn-~\ed dcs\•}n t<"..:-1 bloom -::
... i:::\?. but sh~ll t\e finally shaped to profiles ~y forging
only under a harrrml::r c.t- ?.1 press. ihe pt-of:i1P sha11
gr..::-nera1ly f()lJ.ovJ the contour of ,~ough machined axles as
given. in re1 e··~"'Etnt. dra1,·J:i.n~IS \.·~i. t.h adeqt.121te mac
hi.ning c.tll ov1anc.e.
The l <?SEo
the than a): le.
minim1.lm crt:!SS:· sect:ion of thE: ingc~t.s ~.hall not be than
twice t~le ma~:imum cross section of blool1l end minimL\m cross
section of blc.nm £:.hall not be less
t.\.•Jir::e- ·the fis?.):iiT!LHH c:rc.rs.$ st='r~t.ic.•n of t.he
forged
~
·-'"
3.1
4 ..
IRS:R-16/95
In case the a>:les are manufactured direct from ingots by
fnrging undF2'r- c.:( h~tmmt':r ot- t~ pt-es:,s!'l tt·.e ml.nimum
cros:E: section of the ingot shall not be less than three times
the ma):imum cross section cf the axle5.
Cooling
When hot bloo1ns are to be coal~d, the same shall be allowed to
cool uniformly an~ shall not be permitted to come in contact ~lit,~
water or drait oi air. Forged a>:les shall normally be allowed
to cool in a furnace~
All a}:les shall be normalised or heat tr·eated bv other Jnethod as
agreed to between the Purchase~ t1~.nu"'fe..ctt.\re~-.
QUALITY OF MATERIAL
r:o.nd
The a>:l!?s sh,all be sound t.r-n,...~.:~ugt-,out and
lt'd.·t!-Jout crack.::::!' inclusion, burrs, l~ck of metal~ laps or
any other defect det.riment:al t.o their- end u~-P 2.nd .~,h.;-•.
11 be supplied to the prescribed dirn~nsions and toler2nces.
BRANDING
Brar1ding shall be:-: as s.hov~n on the dra~·-ling NCJ. Sk .92114
and such other marks as may be specified by the Purchaser~ shall be
stamped hot on both ends (not on body) cf the <:<:>:l~;sc.
All the follm•ing details shall be restamped cold in 4 to 6 mm
letters of scroll type on the ends after the same are machine
faced
.1
• 2
Manufacturer's code name (in 3 digits PUJ'""cr-,~,s·er·~ .. pr·iol
... ;: ... pprov~~l).
Year of manufacture (in 2 digits i.e . 1995 shall be indicated as
95) .
. 3 Cas·t No.(in 5 digits,first digj.t being an alphabet) .
. 4 Individu~l ser·ial numbe~ (in 5 digits)~
.6 Inspector's ~pproval stamp.
Note~- CEtst drc<.\.·~ir1g
3
6 .. 1
SELECTION FOR ~
A>:les sh~11 be subn\itted iri identifi.able batche5 of
m~>:iml)ffi 1()0 r1os" and each batch should contain axles iron~
only one cast. The selection of B>:les for testir~g
as :.pecified in clauS:.e 6 s..ha.ll be at th{? \'·ate of orH::
c.~)~le per bcttch c.•r par·t t.herec:.-f.
If fewer than 15 a>:les are made from one cast~ the f"1¢.rn ..
\f~-<.{:turt.;..t- could led\·'•.? c•n eE~ch i:<.~·:le 2<.
}.".<ieee eof t.he.> same dia1neter as the forged end of the
axle to enable t!1e Purchaser or his Ir\spectir~g Authority to
select one such piece from ~~hich test pieces may be cut for tt1e
t~:.~s.t.£.:. ~,p~?cj.i:i.E·d in cl~tl...\Se 6 ..
The Purchaser or his Irlspecting Authority shall select C.:•.rrd
t.es.t =:.1 .. JLh Wf the ~0: ll~S:. i::<.S t-·1e me:.:..·~··
think py·oper· t.o the e>:tent o·f the number =..pecifie·d
o3.bove. To en~~l..\re t.he proper a)~les bei~'g tested
~_distinguishing numb~r shall be =;.tt:<~mpe-0 Dl'"" c.ii\s.t on
ever·-/ ingot made from E·Etch c.:a!2-t .• F.\nd f~\n.:-ry billet
~tnd a)~le must be mc:1.ri-:.ecJ ~ .. 1it.h ·the number of the
ingot from which it was taken. Th~ ~xles
tested shall be held to represent the average qtAality c..d the
a-,.tle~ of the lo·t presented from the ca~~rt irc~m
~thict1 they ~~ere select~dM Each s~lect~d t~st a>:le or e~le
end piece shall comply with the following tests \'lithecut
iu.r-t.het- rehe.::~t.j.ng or any c~theT m~nipulation
whatsoever~ either of the a>:le/axle end piece selected for
testing o~ the protion thereof selected for ma~ing
t.he tes.t pieces ...
Extra a>:les ftlr testing in the manner described cl~'IL's'e b
=-hall be provided by the Manufacturer c:c.t Dl.l'-1n e ;.; pen
s'2· •
TESTlN£
Ten:pile Test
in his
T•..?nsilt? ·test: she-(11 be carried ot.\"t in accordi::.-..nce
v~ith
IS~ 16(\8. Methe<d ior tensile testir,g oi steF:-1 pl'""CH:iuc
ts other th21.n sheet.!'- strip:o \.'.,"!) .. re and tube t.u:d.ng
the st?ndard proportional round tensile test piece having a ge:1uge
le-ngth equi:!l t.o ::,.6!:' ~ wht·re A is t.he eros'::.;
se:·ctic,nal are~~ of the test piece~ cc( ld mr:~c hi ned
lc:.,ngit\.\dinally irDm t.fH:· whee-l sea·t Cti the tn):lt?
~~~~e1c:•cted in 8ccordance with clause 5~ The ~>:is of the test
piece shall be helf way alonq the radius of the wheel seat.
4
6.L3
6 ~,
6.2.1
6.::-'..2
IRS:R-16/95
When the a~le end test piece is selected in with clause 5.2 the
test piece shall be longitudinally from the piece left on se 1 ec
·t~"?rJ.
accordr3nce machined
yield strength and percentage ·from the test piece shall be
Ncrmalised Qul?nched 8< T~•rrrper·erJ
Ulti1nate tensile str·ength 550-650 (N/mm2 min.)
Yil:-ld str·eng·th (N/mm2 min.)
Elonq8tiDf1 percent(1nin~l
Impact Test {U-notch)
24
40
The impact test shall be carried out in accordance with t.he
requit-ements o·f IS:-1499. The L=t)d.s cr·f t.hf-.: test piece
shall be half way along the radius of the wheel sea·tM The minimum
i1npa~t strertgth C)b·tairled shall be 25 J at 20 deg. C for
normalised steel and 40 J at 20 deg. C for quer1ct1ed ar1d
te11~pered steel.
Hetallographic analysis
Micro E>:amination ;_.-
The n)icro e>camir1~tior1 shall be taken front the ter)sile test
specimen~ which is drawn from tt·1e standard location of the w~Jeel
seat of the a>tle. The structure of normaliselj or quenched and
te1npered axle shall be unj.fornl and typical of tt1e heat
tr·eatmen·t given. Tt1e sampling frequency shall be one test per
cast per heat treatmen·t bt.~tr.:h.
Tt1e sa1nples shall be drawn from the satJle locatior1 of the
tensile tes·t specimen. Tt1e grain size~ c1ete~mined
as per r·equj.re1Der1ts of IS: 2853~ may not be coar·ser· than 5.
Tt1e sa1npling frequency sf1all be one ·t·2s·t per cr.1~s.t p•:::-r
hr-.:·c:~t tre~1.t.ment bE~t.c:h~
IRS:R-16/9!:•
7 ..
8.
8.1
8.3
£-2>:t;ll"!in2t.:i..on ::.hzt11 be t.;;\\::r::-n cin tJ··,s:.::
r~(d:i.al
the wh2el sea·t areaR A·fter polishir1g~ the ~:-t.lt·f~·-'.::e c•n
E'-,'~~.,min;;.,tieon v,:it.h a m-=:,9ni·fj_ct!l.tinn
fr::•.c:tt-)t- :~~ en less must not r~veal any discon·tinuties~
The sa1nplirlg fr·equency s~~all be one t~st ~)er cas·t per t1eat
tr·eatllient bc,t.ch. Chemical Analysis
Tt1e Manufact~1rer shall SlJppl·i a complete c~lemj_cal
analysis of each cast of ttle steel when required to cio so by the
Purct12ser or the lnspectj.ng Autt1ori.ty.1·t1e Pur-chaser or the
Inspecting AlJthority shall also taJ~e
th-r~ ~;;,ampli..::s fr·om DnE.\ a)~lt.:- 1't-om E'VE::Ol,...'l
b-:.{tch for- 2nr.:~ 1 Y=·i s ..
Th-=: F'urcf·s~~E .. er C<t- +_he J.nspec·tir·rg Author:i..ty
:~h~1ll "'j_n c~:,s;p
of reasonable doubts~ resoJ~t to other forms of testirlg suc~l as
magr1etic particle test, micro examination test etc.~ as mutually
agreed to between the Purchaser or lnsp~cting Authority and the
Manuf~cturer to satisfy tha·t the a>:les are free from defects
of any kir~d.
RETESTS
Should a test piece fail to meet ttre requir&!llerlts of ~ny
test and should the Purchaser or the Inspecting Authorj_ty consider
t~lat t~le test piece does not fairly represent the quality of tt1e
batch~ two further test pieces shall be taken for- repeating the
test under which iailt;re had occured. Before taking these test
pieces the batctl of a>~les"' together with ·tt1e test
~-ample.·.=.!( fTli:1."y' vJith the Ct£W.E•ement c•f the
Purch~st:.•r c.<r In~-pecting t;uthorit·y·, bt:: r·er·~ea·t
·trt::t:1ted.
Should either retest piece fail to meet the r-equire ments~ ·tt1e
batch o·f a>:les~ tc)gettler with the test samples~ may with the
2greement of the Purchaser or Inspectir1g Authority, be reheat
treated again and twa further test pieces taken for- repeating the
test under which failure had occurec1~ Should either of the test
pieces fail to fulfil the conditions of the test, the b;..tch of
·the E1:>~le r·epr~:sentecl :-hC~ll tH? rejected.
In case of a>:les reheat treated to meet tt1e r-E·qu.iremf::nt.s
o-f ultri..:.:s=~c·nic test ( lnn~1i tt.tdin.;:--~;} penetr2tion)
as stipulated in Appendix ~A' clause A- 6-l.-3~ they st1all be
resubJnitted for testing in acco!~dance with clause 6~ e?:cept
chemical analysis.
6
8.4
9.1
10.
10.1.
10.2
10. ::;
11.
12.1.
.12.2
IRS:R-16/95
The a~les shall not be reheat treated more than over and above ttle
original heat treatment.
twice
ULTRASONIC TEST
All axles coniorn\j.r)g to all the ~foresaid tests shall be
SLlbjected to ultrasonic test and only those passing this test
shall be accepted. The method of test and acceptanc~ standard shall
be ~s given in Appendix A.
MACHINING OF AXLES
Axles sh2ll be delivered rough turned or machined to drawings as
required ~y the Purchaser. The rough turned/machined portion shall
be concentric with the lathe centres of the a~les. The a):les shall
be free from injt!rious tool marks. The surface finj.sh on the
rc~ugh turned or machined a}:les shall be as shi.JY)n an the
drt:iltl}r·HJ.
F'E-riT1anent machined ac-:le.
lathe centres stlall be sn,ooth~ accurately and trul·y in line with
the centres of the
Un 1 ~;2ss rc .. ugh
otherwise specified~ the wheel tur-ned Yli th an allow,:tnce
c•f
finished diameter.
SAMPLE AXLE
sec.~ts
b("-:"
the
A sample axle of each kind, finished complete as per contract
drawing shall be approved by the Purchaser or the Inspecting
Authority before the general execution of the order is proceeded
with. The quality of wor~manship on all other· axles should be
similar to the i-<PPTD\.'P-d samplP-.
INSPECTION
The Inspect.ing Aut.hority or the Pu.rct-~~~ser ~.hi;~l J have free
access to the works of the Manufacturer .~t all r·F:;;n=..on2ble
t.imr:::s. He sh~ill be c..t libt::t-t.y to inspect. the
manufacttJre at an·y stage, ?nd ·to reject any material that does
not conform to the ·te~nls of this specification. The Inspecting
Autt1ority or the Pur-chaser shall have tl1e power to 1nark or
de·f~ce j_n sotne easily distir1guishable manner all rejected
axles~
but shall not be marked or defaced in Stlch a mar1ner so as to
render them unsaleable to other parties~
Power s\1all be r·eser·~ed wi.th the Purchaser or the ln5pecting
Authority to be present ~t, and ·take SL!Ch part, as he thinks
fi·t, in c-.11 t-:inaJ.·y'or,i~~. .:-;nO
phys.icc"'"l/chem.icr.ll/met.-:,llt.\1-gic.:<.l
e>:amination~;. v1hich the
7
J.RS.:R-lb/95
i. __ .... ~
14~
14.2
M~rjLtfRctl~r-er n)2y ur~der·t2\\e for t)j_s own put-pc.~=::-e:--;.
or unc\er "th<.:: tt~l~fil~-':: cd thi~, s-pr::ci·f:i.c~tion:-
both o·f "t_he ~)~J~s ar1d/or thej.r m?te~ials. ir1 all rr12"1fJU.i
·3C ture ..
TESTING FACILITIES
r equ. .:i. l' ed sl1all stlp~~ly iree o·f
for testi.ng 2nd ~-h~ll
C h.:;'·~""'~IE' the ;:,t h.i:::
cost, furnis~l ar1d prepar·e tt1e rlecessary test pieces~
~nd supply labour and ~ppliances for such test_ing 2s
r0~·; be carried out on t·,j_s ow~ prelnises :lr\ accord21~ce
~~j.th this specific~tion~ Faili119 iacilities 3t his owr1 vJor\'_s
far carryj_r)g out the prescribed tests~ ·the ~~ar·1ufacturer sh2ll
bear the cost of carrying ttle tests ~-;} ::~.e~-ihEt'"T:O'.
PROTECTION §;_ PACKING
Journd}.:;
After ir~spection and accep·tar)ce the jourr1als st~all be
c2refully protected with three coats of Ready ~;i>~ed
F'~iJ.nt ~ br-ushing bit.u.nt5 .. n 1~\..t.;:. b] ack to 1',3;9862
C.)l \·~i th i:~ny
other equivalent ~·n·ti-rust con1pOL!nd appro·ved by ·the
Pt\rct~aser~ allowing sufficient dryi_ng time between each coat.
Tt)e journals shall then be fL~rthel~ p!~otec·ted
with mi.nin1um ~· m1~ thick well fitted Hi.gh Densit-y
f"-'c_,]ye:thyJenE' to l~i!7328 design3tE'd t:~s
Ht>PE---1-4--t-18 C:D\--'12·1'·'=', i.f't tv~o c~nd ·f~·.t.:•.E-
C.ind sur-r-ou.nd.:ing the L.~.>;le End collar~ journal and
shoulder in case of plain t·ype a~1es and with a m3.ni.ITlUm 5 m1n
thic~ well ~~~d one piece High Density Polyethylene
ber:tring f i ·t.t.r.:;-d,.,
~-ur-r-ot.l.nd inq thr? j ;_::,u.r-nE-!.1 e.nd ~-t"!ou.l c\er ~,nd
~-;:.::cu.r-l:-cJ
thl'-et::· P!·JC screlt,<'::::. t_o ~:::,u:;_t ttie ct>'.le-
er1d ~'.S:· gi··,.-'E•n in r-l-::-1EVC\r-~t ~\>:1e-
r:Jr8.\·?:i.ng in c~~=-e of r~c.l1et- bearing
co-v'er VJj __ th
'l.::.he type
The· .;:;·,-: le body c._n\.1 \o·~heE·l ·~;;P-c::~·ts ~-h~·d 1 be
p21.i.ntt-:?d v;i th one co~~.t o·f :::Lnc chr·on1{..1te pt--imer-
to 18:20"714- fol1o\-'~ed bv a ~-econd CC<r:<.t o·f 81i:tCk
.Jttpt~"tr-s to IS:: 34·1~ C1llo~-+ii-J9 suffj_cient tiiile· for
d.ryir1g between ~ach coat.. All pa!~ts must be c1.ean and free
irom r·ust and moisture at the time tt1e coa·ts are appli~d. The
a>:l~ body and wt· 1 e~l sea·t st!all tt1en be ·fulrther
protected with minimum 5 mm thic~t well fitted ~igh Der,si·ty
Polyethyle11e to 18:7328 designated as HDPE-44-MB covering, secured
with s·teel s~traps as shown in Fig.4.
IRS:R-16/95
UL TRASm-IIC URACTION lL
INSPECTION OF NEW AXLES FOR RAILWAY TRAILING) MET~OF TESTING
STANDARDS
The::- fli€..~thCJrJ c·f tt-:c-':-:lt.ir(g anc:'1 -the
?!:::c,.:::p·t_z-:'.nc.~.:- ..:::.·let.nt~~~~,r-cl
s~.::::-1::.
C!Ut he!EUndE:l""" ~-hE~} .l bE: USE·d to E·-·/r2i}U,?,te 2.11
t·'jp•::::o:: ... ~ ()·f
ne~~ axles oi r2il~1B~I rolling stoc~~ (Carriage, W~gc)n
and Et~lu t ... l .... <:<.iler- coacht::·!:-::-) .:: ... ~.
~-t.ipu.lE.1tE·d .ln tJ·~i_r:-}
~~r.:~~::..·ci -rit:.::"<:t.ic.n.
Fo\,...
a>: le ser-··;ice ..
EQUIPMENT
The j_nstru.m• ... ':'lit u.~--·~d mu.~·::.t be o·f pu.1sr:: echD
type:~
be oper~ted at 2.(1 to M~~2 frequency for b\3th p€:n t r ~~-bi l i
t·y discontinui·ty det~·ction.
tu
T~le instruJJler·~t ma·y be used with varj_ous t·ipes of
tr·ar1sd,Jcers n~l!llely~ Bariumtitanate~ PZl-, Le~d
me·tarlit)biate etc. of 2(} to 26 m11l cjia.or equj_valen·t
ar·e2
prot)e. Other t~·pes and si~es o·f transduceys o·f si1nilar
r·E-s-:-pc•n:.~e Lt;c;p?-b:i.1ity ~:.:~, t'nose
<:J~::-cr:.i.b•.::c~ 111.::::-<.\' be u.s,e{.:J
IAi-t\-!
tt)e approval of the Inspecting Authol··i·ty.
STAGE OF INSPECTION
Tht:;- 2:>~.1·:::·::.; ~"h~~ll br:..•
l..IItr-~_'::,e<rliC:ally insp•?ci:.~d -:.:dtt.::r·
t~t·;r_.:::
s·tipul2ted heat t1~e2tment ?nd 1n2chi.ning o·f the Ef)d faces to a
ti.~~ish o·f N8 to 18~3(~73.
JNSTRUMENl" SENS1Tl\l1TY
Thl:.':' .irl:::-tn_\merlt SE-n5-.itivi ty shc.ll be i:..~djust.E'd
with u--1;_-::~
h~lp of a refer·er~ce bloc~ m2nu·factur·ed fiorr1 a~ ~):le
fo1··gir)g in the nor·1nalised condi-tion~ and confol''Jnir,g l:o
tt)1.s speciii.cation. Tt)8 block ~~~~all be 406 m1n lor1g. Tl-18
tY.~o end f~1ce~;;, r::.h,~·-11 be m;.;chint::-d pc:ir~l.lE·.\ to
~
IRS:R-16/9:'•
.A-6--2
A-6-2--2
he <."i i}"''t-t:•ot.tC•ITI 3.2 IT!fl\ d:\~'-• j-·1oJe
clr:cllc·d ;..·,erpendiCL\}i"'lr' 1~o or)e of the end f2ces at
mi_cj-l~adi.us to a depth oi r--~bc\u·t.: ~~:::. rr:•+1 ~:-L<ch
"+..:h;;: .. t th12 ·fJ.;,._t br)ttum c,·f the hole ~.r-~c:~J
l
c~nc!
1Jo:::<1ng t.ht? E•Li U i p.IT:E·n t C•f C<.bC•U.t
the -==.en:::.i t:<..._.J :!. ty t.o CJi··.'E 2.n
E'r_.:hc_,
Di thl;;· ,:;!mp.l 'L t,ude
the spposite end ·face.
or-~ a semple piece o·f 2):le ln~teri.~l ~~lth p0r~pe>:
c,r-, t1-lE pr-c:rt.e::'
f.ittE·ci
With tt)e ~-ensiti·vity setting, ~s descri.t)ed in clBuse A ... •
t-'.,bC!V£'~_. ~>:}ES \"i"hP.n SC~\l""lnFI_-j
/11C.::-,r·IU.i::<.ll·y" Dl'" by ~:<~U.ttJ!liC:t'tE•d
ir1spection techniq~Jes fJ-oiD one end face shall produce a
rr~lrtJ._frl1 .. \t'fJ <:<i 2~( ITI!r~ bo:1ck.
,-o::-·f1r:ctj_nn ft-Dill tr·~e oppoo::.;,:i+..:r-:-- f_:.nd
fr::~.ce~
A>:les wt1ich del no·t r~eet the above requiretnents s~~811 be
,~ejected. H0~1ever·~ tt1e Manufacturer 1nay~ by muttJal agreen\ent
~;ith the Pt1rct1~ser ar lnspectj_ng Author·j_ty~
J~ehe~t treat the a>:les and resubmit ior his test. Reheat
tr·ea·ted 3):1es shall conform to t.he stj_pt~lations
of ''Retests'' clause 8 .
DISCONTINUITY DETECTION
~Jith the sensiti.·vity settir)g as described ir1 clause A- ~,-~
the ~i.:·~~-t.-n_lfif•.::n-t.: ~::-h?,11 br.:- c_c:q·.•;..:,_ble
c,·f detecting j_n reierer)ce a>:le piecGs~ flat bottom holes
o·f sizes and c:1t cii':':.tE<.r,cc:-s :i_nc!ic.?-tt::-d .:i.n
th~:::- fc·lJe<._.~j_ng l-..:r::1bJe:
3.2
The depth range of the ir)strument st~~ll be set to more tt1an
t1ali the length o·f a>:le und~r test. Tt~e a)tles shall be
scanned alternati·vely from both the end iace co·~erir)g th2
ma~imu!J) en~ face area possible wt1et~1er· by rn~tnual or
automated inspEction techniques.
10
A-6-2-4
IRS,R-16/9:"·
The aj:les shall not show any discontinuity ir)dication E):ceeding
tt~e levels obtainecl fron\ refer·ence flat bottom holes of size
for· the various ~ones as indicated belov~ -
F'erm:i_e.~.ible Si2e of D::i.::,continui t.y (Mi:(ii.
Zone: II III
F .B.Hole (di;:,) 3~2 mm 6 .A r;,m 9 .~, mm
Please see Fig~l (a) for identification o·f zones.
The a1nolitude oi all discontinuity j.ndJ.cation s\)all be
evaluated with respect to distance from the test suriace by
utilising ei·ther· an in-built Dis·tance Amplitude Correction
device if provided in th~
instrutne11t or by es·tablj.sing Dis·tance Amplitude Curves (DAC)
for the specific instrutnent and transducer as described in clause
A-7 below~
ThE! gain/ a.-t tenuator contl-ol set t.ing shall be the
se<.ii"fl2 as used for the respective zone for establishirlg
DAC.
A-6-2-5 A>:les under test shall be rejected if the aJnplitude oi
ec.nv disccJntj_nuity indic;;~tiolt l?)~ceecls the levels indicated
in clause A-6-2-3~ read with the corr·esponding _DAC ior the
r·espective zor)e.
A-b-3 LONGITUDINAL DISCONTINUITY DETECTION
A-6-3-1 With tt1e ser1sitivity setting as described in Clause A- 5
8bove~ a):les when scanr1ed m3nually or by atAtc)!lla·ted
inspection technique by pl~cirlg the normal pl-obe~
fittecj with perspex piece \)aving diamet&r o1 Cllrvatur~
to 1natch the diameter of ~xle on the bod·y o·f tt1e
A·-7
ti;·:le!:·.!' ~.:::.hs:J. J. not producli~~ by
int.t?.~-fiiL~di_<:~tE~ ~;i~.:Jr-.a1 in between initj_atl and
back sign~l obtained fro!n tt1e other end o·f the diameter· o·f the
a~le, suggestiv~ of longitudinal ciiscontinuity. The axle shall be
tested t.ht-ou.~~hou.t tr·,E· leng"t.h d.nd c2l ibr;;.~t:1.ern
sh~-<11 be m;.:~de ~t
:z~oo mm de·pth range
A):le which do r1ot ll)eet the ~bove requir·ecJJetlt~ s~iall be
r·ejected.
DISTANCE AMPLITUDE CORRECTION !DAC)
The amplitude d j_scontinui ·ty tx·st. sur-f<<ce.
of ultrasonic indication for size var·ie5 with the dj.~tance
It is~ therefore, necessar·y
l1
IRS:R-16/95
A-8
A-8-1
A-8-2
A-8-'l
A-9
eithel .. an in-b\.\:i.lt di':·t~nc~· ;:"\rrtplituOe cor·rec:·tieon
dt:-··.Jicr.;o \:)r' t-st~-~.blis.h pp,c r:ur~·.,·e ic1 .. the
particulcd"'" t·)"pe of F.t~·:le~
tlec:c:tu.= .. e -t.he d:\.s.·t~tr1ce 2tmp1 itud~::·?
~-~eJ.ationship it;::,
influenced priJ~ar·iJy by the ultr·asonic equipment ~nd transducer,
it is r1ecessary to establish tt)e DAC for specific equipment and
trar)sducer combinati~) used.
For es·t8blishing DAC for the three zones, indicated in Fig.1 (a),
four or mor·e reference a):le cut pieces for r.~.c.h :-:etne
v-~l.th pl"-ogt-essJ.-../t-:.·ly V~ir·>'·ing lE.·n9tr·,s
t:<.nd VIi th the relevant size of flat-bottom hole drilled
perpendi cu.lat- to Olte of the end faces ecn ec<.ct-1
pi.:::~c:e may be l_t=::-ed 2.nd the diste.nce r.Hnplit.ude
cur·.,·es d1,...C:tV)n iDr ee;ch 'ZC1rte ·fn\- the
):"!2-t-t.i~l_,lB.r" ·t:ype D"f 2.)~1~.: tD bE te=>ted.
Ho~·-1E···1er~
where Jnore than one type of a>:le is to be tested~ a commorl
DAC could be est~bli~hed for axles having close geometr·:l"
An altern~te mett)od would be to star·t wittl an ~):le
piEce equal to half the length of the axle under test ~~ith the
three sj.zes oi fl~t bottom holes~ vi2. 3~2~
6~4 ar1d 9.5 mm dia. respectively~ drilled perpendit~lar to or1e
o·f tt1e erld-faces and mid-radius suitably dis.pr::rs-~ed arc,ursd
the cent, ... e. Scarn-~ ing sh2ll be cr.:·n·tinu.ed ?:fter-
pr-ogressiveJ·:~ s1 icing the c,>: 1 e from the testing end.
From the amplitude indications and the clistctrH.:e the DAC could
be dravin ior each zoone!l C~nt1 for thE· relev·etnt hole~-.
f'--.n e>~t..~fi"~"f~le oi t~ste.":t.bl ishing a ·t-ypic.a1 DAC
e~::. pE·r 8-t•ovr= t;-m rnethods is giv•m in Fig.l (b) , 1 (c)
li< 1(d).·
REJECTION
Foe Pnd---f~ce to end~-i;:\C~?. ·pene-tr·~ibilit:y test.~ ~::~ee
c1al~l.SIZ·
{-1-6-1-1 and clause A-6-1-3.
SpLn- i en_~~.
MARKING
echoes attributable to tt1e geometry of the ground noise of the
instrument shall not be a t-eject.i.on.
Axles that conform to the above ultrasonj.c stipulations shall be
stamped ''UT'> on the end face as indicated in clau::.e-4.
F9/R-l6/9::~
12
TEST
25
II
AXLE WITH OUTSIDE JOURNAL ALL TYPES (PI.AIN/ROU.ER BEARING)
FIG. 1 (a) ZONE DEMARCATION FOR ULJJRASONIC TESTING OF ROUGH TURNED
AXLES
(TO BE READ ALONGWITH THE RELEVANT AXLE DRAWING)
LENGTH
MID LENGTH
3.2 F.B. HOLE 6.4 F.B. HOLE
.£_ .B. HOLE 9.5 F.B. HOLE 9.5 F.B. HOLE 6.4 F.B. HOLE
END VIEW AT 381 mm END VIEW AT 762 mm END VIEW AT 'YY'
~q~qqqqqq
\()~oog~~m~!f NI"') .... U),....IDO.-
AITENUATOR SETTING IX ~ m m m m m m ~ fu -EXAMPLES OF ESTABUSHING
DISTANCE AMPUTUDE
CURVE FOR A TYPICAL AXLE FIG.-1 (d)
TABLE FOR FIG 1 (b)
FlAT BOTTOM HOLE DISTANCE OF FLAT BOTTOM OF THE (mm) HOLES FROM THE
TESTING FACE (mm)l_··
3.2 - 76.2, 152.-4-, 254.0 3.2- "'6.4- 381.0
6.4- 508.0, 635.0
. WHERE' THE: REFERENCE AXLE. WILL BE PROGRESSI'iELY.SUCED 'AND
TESTED,
METHOD ~OF; UlfTRASONIC TESTING, OF:.l~A.~'~ES
L3
FIGURE-2
.--:- r--
f---V
DIMENSIONS TOLERANCE
CORRESPOND!~ DIMENSIONS OF lHE FINISHED
AXLE.
DENSITY POLYETHYLENE TO IS:7328-74 OESIG:'IATED JoS
HOPE-44-MB.
3. PROTECTIVE COVERS SHALL BE ClAMPED WITH
MIN. 20 mm WIDE STEEL STRAPS AT SUITABLE LOCATIONS WITH MINIIAUM
TWO STEEL STRAPS
ON EACH JOURNAL & 1HR£E ON AXLE BODY.
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
to
(Applicable to all gauges)
Serial No. R 16-95
1. Substitute the following against clause 2.1 (i):
"The axles shall be manLifactured from steel made by Electric or
Basic oxyg~n process. The steel shall be of killed quali ty
...
Add the following in second line of clause 2.1 (iii after 3
ppm:
''As per standard procedure.''
~- Add the following clause as clause 2.1 (iii):
"Nitrogen content in the steel shall not e>:ceed 0.007 per
cent."
4. Substitute the following against e><isting clause
2.6:
"Heat Treatment:
All a>:les shall be either normalised or oil hardened and
tempered to achieve the mechanical properties laid down in clause
6.1.3, to guarantee the structural homogenity in the same axle or
axles in the same batch as laid down in clause 6.3.1 and tree from
distortion."
1
5. Delete the e>:isting clause 7 and substitute the follo wing
as clause 7:
"Magnetic Particle Test:
All axles (in rOLigh machined condition or fully machined and heat
treated condition) shall be tested by the magnetic particle method
both in longitudinal and circular magnetisa tion and shall not
reveal any harmful surface defects. The axles revealing harmful
surface defects shall be rejected. All axles shall be demagnetised
after the magnetic particle test."
6. Add the following .s clause as clause 15;
15. Guarantee
1::'·.1 The a>:le. shall be guaranteed by the Supplier for five
years against any defect attributable to the manufacture and not
revealed during acceptance inspection.
15.2 This period shall be calculated from the end of the month
stamped on the axle.
15.3 In case of axles for new vehicles, the delivery date of the
vehicles to which they are fitted shall be regarded as the date of
delivery of axles.
15.4 Axles, which during guarantee period show defects making them
either· unfit for servic2 or· r·E-8i...oC~ng ...
J;o:=..:..:-·
period of service, will be rejected.
*********
TO
(Application to all gauges)
Serial NO. R 16-95
Add the following as clause 2.4.5.
The axles can also be manufactured using concast blooms. When
manufacturing axles from concast blooms a minimum reduction ratio
of 3:1 is to be maintained.
Add the following as clause 7.1, 7.2, 7.3 & 7.4
The acceptance limit of surface/sub-surface defects is given
below:
7.1 Imperfections not acceptable.
Transverse/circumferential seams cracks or laps of any depth
(indeterminate) on axle surface. Longitudinal discontinuity
(hairline, stringer, fine seam) in machined fillests.
7.2 I~prefections considered acceptable.
7.2 Journels:
~ .2.2 Fine lor.gitudinal discontinuity (hairline, fine searr.) on
sc:rface if:
Not extendted on fillets. Less than 19mm individually.
stringer,
~.3 Whee~ seats·
(i) Iii; (iii)
Not extended on fillets Individually not more than Slmm long. Total
length of imperfection (6.Smm to Slmm) exceed lOS mm.
nc= tc
Lon::ritudinal discontinui~ies (hairli:::.e, st:ri:1ger, :ine
seams)
Not extended to fillets of wheels/gear seat. Individual~y not more
~han 38mm. Total length of discontinuity r.ot to exceed 38.::.c,:n
ir. any 305nun.
~e~ete c~ause A-6-3 of Annexure-A and substitute the fc~low ing as
A-6-J .
A-6-3 .kQ.Dg:tudir.o.l discon+-1 nL:.itv detecrion:
A-6-3-l· Depth range ca::..ibration - The ultrasonic flaw
de~ector
is to be calibrated for 250mrn depth range (longit·..:dir.a:. wave}
w:..r.~1 the help of a portlon of approx. 2 OOmrn diamet2r o=:
thlckness ar.d length ::.sorrrrn. A 3. 2mm dia flat bottom hole
sha:.:. be dri:'..led perpendicularly from thickness to a depth of
25.::.2mm. One zero degree probe fitted with perspex block having
c::::1cave cur.rature corresponding to axle diameter shall be used.
.::..dj us:: the depth and delay cont:::ol knob so that on-set o!:
the ba:k re flection from opposite surface s~all appear at 8
horizonto.::. mai:1 scale division. Each main sca:'..e division
thus will rep::2Se!:::. 25mm for longidutinal wave.
(r--.""-,,. \]:-I)
A-6-3-2 Sensitivity setting Place· the zero degree probe ·fitted
with perspex to the diametrically opposite side of the flat bottom
hole. A echo at 7.5 horizontal scale division will appear on the
screen. Adjust the gain level to achieve the echo height to 6 0 ~
of the vertical scale division. This gain level should not be
changed during testing of axle.
A-6-3-3 Acceptance criteria - Any flaw echo having amplitude 60~ or
more and of characteristics indicated below shall be a cause for
rejection.
a) Any longitudinal defect of length 75mm or more located in the
body of the axle or somm or more under wheel seat and journal
region.
b) Minimum distance between two successive isolated defect 200mm or
less.
c) More than 3 isolated defects exist throughout the axle.
* * * * * * *
To
IRS R-16/95
To
(Applicable to All Gauges)
Serial No. IRS R-16/95
Replace clause 15.1 by the following: 15.1 “The axle shall be
guaranteed by the Supplier for six years against any defect
