03/2011Association 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] 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 Services are available in LETTER hardcopy or electronic format (online access via AAR’s Web page at 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] AAR Web page: http://www.aar.org TTCI Web page: http://www.aar.com MSRP-A1 INDEX The MSRP-A1 Table of Contents is an inclusive index of all MSRP specifications, standards, and recommended practices. It is available online at http://www.aar.com/aar_standards-publications.htm 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] Phone: 719-584-0670 Fax: 719-585-1895 03/2011 G–i AAR Manual of Standards and Recommended Practices Wheels and Axles THIS PAGE LEFT BLANK INTENTIONALLY G–ii 03/2011 . There also are standards and recommended practices for dimensions. Part II—Wheel and Axle (shop) Manual. Part II—Roller Bearing (Shop) Manual • Section H.AAR Manual of Standards and Recommended Practices Wheels and Axles TO THE USER Section G—Wheels and Axles. inspection. wheel mounting. acceptance. the cast steel wheel. • Section G: A generalized subject listing that indicates applicable specifications. Part III—Lubrication Manual • Section J—Specifications for Quality Assurance. normalized. Because of the critical functions of all these components. and manufacturing tolerances. standards (S prefix). A specification included in this volume treats electrochemical metal deposition for restoration of journal surfaces of roller bearing axles. should be used in conjunction with Section G. quenched. and tempered. M-1003 RESPONSIBILITY The coverage of Section G—Wheels and Axles. passenger cars. and recommended practices (RP prefix). and recommended practices. standards (S prefix). the volumes making up this manual. • Table of Contents—Numerical: A numerical listing of the specifications (M prefix). and machining for reuse. followed by overall tempering and controlled cooling. USER’S GUIDE Section G contains three specifications. Wheels subjected to severe service conditions have rims heat-treated and quenched to produce wear-resistant surfaces. covers three main components: the wrought (or forged) steel wheel. Wheels and axles are medium-range carbon steels containing a maximum of less than 1% manganese and minimal levels of phosphorus. wear limits. metallurgy. reclamation. are to be heat-treated. Bearings. sulfur. Axles must always be normalized and. and Recommended Practices: The body of this volume. RELATED SECTIONS Section G—Wheels and Axles. is the responsibility of the AAR Wheels. when used under high-capacity freight cars. and thirteen recommended practices. 03/2011 G–iii . marking. Standards. inspection. and Lubrication Committee. twenty-one standards. and the steel axle. Manual of Standards and Recommended Practices. and recommended practices (RP prefix). • Table of Contents—Alphabetical: An alphabetical listing of the specifications (M prefix). Axles. standards. manufacture. and locomotives. It consists of the following: • Preface: A listing of the subjects covered in the 25 individual sections. exhaustive details are given on design. • Specifications. assembly. gauges. Other sections containing pertinent information are as follows: • Section D—Trucks and Truck Details • Section H—Journal Bearing and Lubrication • Section H. and silicon. This preface is part of each section. condemning limits. Part II—Railway Electronics (5800 Series) • Section K. G–iv 03/2011 . Part II—Roller Bearing (Shop) Manual (700 Series) • Section H. and recommended practices of the Association of American Railroads.com/aar_standards-publications. M-1001 • Section C.g.g. Part III—Lubrication (Shop) Manual (700 Series) • Section I—Intermodal Equipment Manual • Section J—Specification for Quality Assurance. Recommended Practices carry the prefix “RP”( e..aar. Part III—Specifications for Tank Cars. is issued by authority of the Management Committee of the Division and includes all regularly adopted specifications.. Part II—Truck Details and Casting Codes • Section S. M-900). Part II—Electronically Controlled Brake Systems • Section F—Sensors • Section G—Wheels and Axles (600 Series) • Section G. standards. Part II—Wheel and Axle (Shop) Manual (600 Series) • Section H—Journal Bearings and Lubrication (700 Series) • Section H.AAR Manual of Standards and Recommended Practices Wheels and Axles PREFACE The Manual of Standards and Recommended Practices of the Safety and Operations Department. M-1003 • Section K—Railway Electronics (5700 Series) • Section K.htm) • Section A—Table of Contents. Part III—Coupler and Yoke Details Specifications are designated with an “M” prefix (e. S-900). 400.g.com/aar_standards-publications. Association of American Railroads. 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. Fabrication. and Construction of Freight Cars.aar. 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. M-1002 • Section D—Trucks and Truck Details (300 and 3000 Series) • Section E—Brakes and Brake Equipment (300. Part II—Design. Standards are prefixed “S” (e. and 4000 Series) • Section E.htm) • Section B—Couplers and Freight Car Draft Components (100 Series) • Section C—Car Construction—Fundamentals and Details (200 and 2000 Series) • Section C. RP-900). Alphabetical and Numerical Index of Sections B through S inclusive (this is available as a free download at http://www.. S-663. Wheel—Combination Gauge For Wheel Measurements Including Locomotive Flange Limit Of 0. Wheel—Application Drawing For AAR 1B Wheel Gauges S-661 and S-665 Gauge. Steel Wheels Electrochemical Metal Deposition for Repairing Roller Bearing Axle Journals Gauge. Wheel—Combination Gauge For Wheel Measurements Gauge. Wheel—Former Standard 1980 Gauge. Wheel—Minimum Flange Thickness. Wheel—Application for Measuring Condemnable Overheated Wheels Gauge. Height.875 In. Axle—Master Gauge For Verifying Axle Journal and Fillet Gauge S-614 Gauge. and Throat Radii Gauge for AAR-1B Narrow-Flange Steel Wheel Gauge. and Throat Radii Gauge for AAR-1B Wide-Flange Steel Wheels Gauge. Wheel—Application Drawing For Reference Gauge To Verify Wheel Gauges S-661.03/2011 AAR Manual of Standards and Recommended Practices Wheels and Axles TABLE OF CONTENTS—ALPHABETICAL Subject Axle for Passenger Cars (Amfleet) Inboard Roller Bearing— Raised Wheel Seat Axle. Wheel—Maximum Flange Thickness. S-665. S-667. Wheel—Master Gauge For Verifying Wheel Gauges S617 and S-618 Gauge. to 38-in. Height. and Throat Radii Gauge for AAR-1B Narrow-Flange Steel Wheel 03/2011 G–v Standard S-658 Page G[S-658]101 RP-622 M-101 S-649 G[RP-622]157 G[M-101]1 G[S-649]97 S-612 G[S-612]73 S-613 G[S-613]75 M-967 G[M-967]61 RP-613 G[RP-609]145 S-616 G[S-616]81 RP-637 G[RP-637]165 RP-636 G[RP-636]163 RP-638 G[RP-638]167 RP-630 G[RP-630]161 S-627 G[S-627]87 S-628 G[S-628]89 RP-629 G[RP-629]159 S-618 S-617 RP-614 G[S-618]85 G[S-617]83 G[RP-614]151 S-661 G[S-661]109 S-665 G[S-665]117 S-662 G[S-662]111 . Wheel—Application Drawing For AAR 1B Wheel Gauges S-662 and S-667 Gauge. S-662. Wheel—Former Standard 1976 Gauge. Raised Wheel Seat Axles. Gauge. Height. Axle—Reference Gauge For Verifying Axle Journal and Fillet Gauge S-614 Gauge. S-664. S666. Steel Wheels Circumference Measure (Tape) for 38-in. Carbon Steel. and S-668 Gauge. Heat-Treated Axles—Manufacturing Facility Inspection By Technical Services Circumference Measure (Tape) for 27-in. Weight—Machined Finish. to 52-in. Wheel—Maximum Flange Thickness. Wheel—for Measuring Condemnable Overheated Wheels Gauge. Passenger Car (Amfleet) Wheels. Wheel—Reference Gauge For Verifying Combination Wheel Gauge S-627 Gauge. Height. Wheel—Reference Limit Gauge For Verifying AAR 1B Narrow Flange Wheel Gauge S-662 Gauge. Wheel—Reference Master Disk For Verifying Wheel Circumference Gauges S-612 and S-613 Gauge.AAR Manual of Standards and Recommended Practices Wheels and Axles Subject Gauge. Carbon Steel Wheels—Manufacturing Facility Inspection By Technical Services Wheels—Measuring Wheel Circumference (Tape) Using Wheel Gauges S-612 and S-613 G–vi Standard S-667 Page G[S-667]121 S-629 G[S-629]91 S-663 G[S-663]113 S-664 G[S-664]115 S-666 G[S-666]119 S-668 G[S-668]123 S-669 RP-608 G[S-669]125 G[RP-608]143 RP-615 S-630 RP-609 RP-612 G[RP-615]153 G[S-630]95 G[RP-609]145 G[RP-612]147 RP-619 S-614 S-615 S-660 G[RP-619]155 G[S-614]77 G[S-615]79 G[S-660]103 S-657 G[S-657]99 M-107/M-208 G[M-107/M-208]21 S-601 G[S-601]69 S-611 G[S-611]71 03/2011 . Locomotive and Freight Car—Analytic Evaluation Wheel. Wheel—Reference Limit Gauge For Verifying AAR 1B Wide Flange Wheel Gauge S-667 Analytic Evaluation of Locomotive Wheel Designs Gauge. and Throat Radii Gauge for AAR-1B Wide-Flange Steel Wheels Gauge. Wheel—Reference Limit Gauge For Verifying AAR 1B Wide Flange Wheel Gauge S-665 Gauge. Wheel—Minimum Flange Thickness. Wheel—Reference Limit Gauge For Verifying AAR 1B Narrow Flange Wheel Gauge S-661 Gauge. Wheel—Simplified Gauge. Wheel—Standard Inspection Stand for Use with Master Disks Mounting Pressures for Wrought and Cast Steel Wheels on Gear-Driven and Idler Axles of Locomotives Other than Steam Reference Groove for Multiple-Wear Diesel Wheels Wheel Defect—Worn Journal Collar and Journal Fillet Gauge Wheel Defect—Worn Journal Collar and Journal Fillet Gauge Wheel Designs. Height. Wheel—Former Standard 1976 S-627 Gauge. Wheel—Maximum Flange Thickness. to 38-in. Wheel—Reference Gauge For Verifying Combination Wheel Gauge S-627 S-630 Gauge. Heat-Treated M-107/M-208 Wheels. Axle—Reference Gauge For Verifying Axle Journal and Fillet Gauge S-614 S-617 Gauge. Steel Wheels S-614 Wheel Defect—Worn Journal Collar and Journal Fillet Gauge S-615 Wheel Defect—Worn Journal Collar and Journal Fillet Gauge S-616 Gauge. and Throat Radii Gauge for AAR-1B Narrow-Flange Steel Wheel S-662 Gauge. Carbon Steel M-967 Electrochemical Metal Deposition for Repairing Roller Bearing Axle Journals S-601 Wheels—Manufacturing Facility Inspection By Technical Services S-611 Wheels—Measuring Wheel Circumference (Tape) Using Wheel Gauges S-612 and S-613 S-612 Circumference Measure (Tape) for 27-in. Carbon Steel. Wheel—Combination Gauge For Wheel Measurements Including Locomotive Flange Limit Of 0. Wheel—Reference Limit Gauge For Verifying AAR 1B Narrow Flange Wheel Gauge S-662 03/2011 G–vii Page G[M-101]1 G[M-107/M-208]21 G[M-967]61 G[S-601]69 G[S-611]71 G[S-612]73 G[S-613]75 G[S-614]77 G[S-615]79 G[S-616]81 G[S-617]83 G[S-618]85 G[S-627]87 G[S-628]89 G[S-629]91 G[S-630]95 G[S-649]97 G[S-657]99 G[S-658]101 G[S-660]103 G[S-661]109 G[S-662]111 G[S-663]113 G[S-664]115 . Passenger Car (Amfleet) S-658 Axle for Passenger Cars (Amfleet) Inboard Roller Bearing— Raised Wheel Seat S-660 Wheel Designs. and Throat Radii Gauge for AAR-1B Narrow-Flange Steel Wheel S-663 Gauge. S-629 Gauge. Wheel—Standard S-649 Axles—Manufacturing Facility Inspection By Technical Services S-657 Wheel. Wheel—Reference Limit Gauge For Verifying AAR 1B Narrow Flange Wheel Gauge S-661 S-664 Gauge. Wheel—Combination Gauge For Wheel Measurements S-628 Gauge. Wheel—Minimum Flange Thickness. Locomotive and Freight Car—Analytic Evaluation S-661 Gauge. Height.875 In. to 52-in.AAR Manual of Standards and Recommended Practices Wheels and Axles TABLE OF CONTENTS—NUMERICAL Standard Subject M-101 Axles. Wheel—Former Standard 1980 S-618 Gauge. Steel Wheels S-613 Circumference Measure (Tape) for 38-in. and S-668 G–viii Page G[S-665]117 G[S-666]119 G[S-667]121 G[S-668]123 G[S-669]125 G[RP-608]143 G[RP-609]145 G[RP-612]147 G[RP-609]145 G[RP-614]151 G[RP-615]153 G[RP-619]155 G[RP-622]157 G[RP-629]159 G[RP-630]161 G[RP-636]163 G[RP-637]165 G[RP-638]167 03/2011 . S-663. Wheel—Reference Limit Gauge For Verifying AAR 1B Wide Flange Wheel Gauge S-667 Analytic Evaluation of Locomotive Wheel Designs Gauge.AAR Manual of Standards and Recommended Practices Wheels and Axles Standard S-665 S-666 S-667 S-668 S-669 RP-608 RP-609 RP-612 RP-613 RP-614 RP-615 RP-619 RP-622 RP-629 RP-630 RP-636 RP-637 RP-638 Subject Gauge. S-662. Weight—Machined Finish. Wheel—for Measuring Condemnable Overheated Wheels Gauge. Wheel—Application Drawing For AAR 1B Wheel Gauges S-661 and S-665 Gauge. Wheel—Simplified Reference Groove for Multiple-Wear Diesel Wheels Axle. Height. S-667. Wheel—Application Drawing For AAR 1B Wheel Gauges S-662 and S-667 Gauge. and Throat Radii Gauge for AAR-1B Wide-Flange Steel Wheels Gauge. Wheel—Minimum Flange Thickness. Wheel—Master Gauge For Verifying Wheel Gauges S617 and S-618 Gauge. and Throat Radii Gauge for AAR-1B Wide-Flange Steel Wheels Gauge. Axle—Master Gauge For Verifying Axle Journal and Fillet Gauge S-614 Gauge. Raised Wheel Seat Gauge. S-665. S666. Height. Wheel—Application Drawing For Reference Gauge To Verify Wheel Gauges S-661. Wheel—Maximum Flange Thickness. Wheel—Reference Master Disk For Verifying Wheel Circumference Gauges S-612 and S-613 Inspection Stand for Use with Master Disks Mounting Pressures for Wrought and Cast Steel Wheels on Gear-Driven and Idler Axles of Locomotives Other than Steam Gauge. Wheel—Application for Measuring Condemnable Overheated Wheels Gauge. S-664. Wheel—Reference Limit Gauge For Verifying AAR 1B Wide Flange Wheel Gauge S-665 Gauge. All manufacturers of wheels and/or axles are urged to exceed the intent of these requirements as much as possible. Normally. These periodic inspections will include wheel mounting facilities. the out-of-pocket expenses involved to conduct such required inspections will be paid by the company offering such products for this service. When inspection of manufacturing processes or facilities of companies manufacturing wheels and/ or axles for use on cars in interchange service involve travel. working with the appropriate technical committee(s). 03/2011 G–ix . periodic inspections of manufacturers’ facilities will be conducted by AAR personnel approximately every year. where applicable. Expenses will be prorated when more than one facility is visited in the same geographic area.AAR Manual of Standards and Recommended Practices Wheels and Axles REQUIREMENTS FOR WHEELS AND AXLES MANUFACTURED TO AAR SPECIFICATIONS The requirements of these standards. 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. These specifications have been developed on the basis of extensive field experience and tests. recommended practices. and specifications represent the minimum acceptable requirements. AAR Manual of Standards and Recommended Practices Wheels and Axles THIS PAGE LEFT BLANK INTENTIONALLY G–x 03/2011 . quenched.) Grade G—Quenched and tempered. and tempered. G. they shall be slow-cooled following the final heat treatment. or in hoods. If axles (Grades F.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. Grade H—Normalized. These specifications also cover heat-treated locomotive axles. electric furnace. HEAT-TREATED Specification M-101 Adopted: 1914. “Specification for Quality Assurance. nominal diameter at center shall be Grade F.3 Reduction Practice The axles may be made directly from the ingot or from blooms.3 After reduction. cars.0 SCOPE These specifications cover heat-treated axles of all sizes for passenger cars and freight cars to designs shown in Section G. axles shall be slow-cooled in closed containers. covered conveyors. 3. (All freight axles over 6 1/2 in. 03/2011 G [M-101] 1 . 2. Axle manufacturers must meet the requirements of the AAR Manual of Standards and Recommended Practices.0 COOLING AND HEATING 4. Qualification is effective until revoked for cause by the Committee. 4. Grades F. 3. Section J. unless otherwise specified. they shall be slow-cooled in closed containers.” 3. The total reduction from ingot or strand-cast bloom to forging or rolling shall be not less than 3 to 1. and H—Axles are used in heavy duty service on locomotives. Specification M-1003.03/2011 M-101 AAR Manual of Standards and Recommended Practices Wheels and Axles AXLES. Note: The process for manufacturing strand-cast blooms shall be designed to ensure freedom from center porosity and undue segregation. G. Last Revised: 20 1. Approval of a new material or process may include meeting the requirements stated in Appendix C. or furnaces. 4. Failure to maintain reasonable quality standards in manufacturing is an example of cause.2 Discard A sufficient discard shall be made from each ingot to ensure freedom from piping and undue segregation.1 Process The steel shall be made by any of the following processes: open hearth. 4.0 MANUFACTURE 3. or basic oxygen. hoods. and other equipment.1 After axle blooms are produced. The grades of carbon steel axles are as follows: Grade F—Double normalized and tempered.2 Blooms shall be reheated for working in a manner that will prevent internal bursts and overheating. and H) are heat-treated directly from reduction. Proposed changes to material or manufacturing processes must be submitted to the AAR for consideration. CARBON STEEL. 5. 4. and 2) must not be permitted to cool below 500 °F without slow-cooling as defined in paragraph 4.2 Normalizing After being heated to a suitable temperature.3 Double Normalizing The procedure shall consist of two separate normalizing treatments.1.5 When properly vacuum-degassed steel is used. 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. the axles shall be quenched in a suitable medium under reasonably uniform conditions. the axles shall be withdrawn from the furnace and allowed to cool uniformly in air.000 °F before any reheating operation. hoods. the slow-cooling requirements of paragraphs 4.0 STRAIGHTENING Straightening shall be done before machining and preferably at a temperature not lower than 950 °F. 4. A furnace charge thus treated is termed a normalizing charge.4 may be accomplished by piling and covering the piled blooms or axles with insulating materials in lieu of using closed containers. Covered piles must be capable of providing effective cooling rates in accordance with the manufacturer’s procedure or specification. Cooling may be accelerated by increased air circulation. A furnace charge thus treated is termed a quenching charge. and item 2 of paragraph 4. and covered conveyors. 5.1.6 The slow-cooling requirements of paragraphs 4. 5. which must be controlled to provide reasonably uniform cooling.6 Heat treatment may be performed in either batch-type furnaces or continuous furnaces. and item 2 of paragraph 4. 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. Cooling may be accelerated by increased air circulation.03/2011 AAR Manual of Standards and Recommended Practices Wheels and Axles M-101 4.5 Tempering Axles shall be reheated gradually to. and held at. 4. Straightening performed at temperatures lower than 950 °F shall be followed by stress relieving or an applicable heat treatment. 5. G.3.0 HEAT TREATMENT 5. Note: As the temperature of the axles approaches the minimum of 500 °F. 4. 6. furnaces. 5. a supplemental heat source may be necessary to ensure an effective slow-cooling cycle. A furnace charge thus treated is termed a double normalizing charge. The second treatment shall be performed at a lower temperature than the first treatment. 5. but axle blooms must then be pile cooled.3. G [M-101] 2 03/2011 .3. and H) that are heat-treated directly from reduction 1) shall be cooled below the transformation temperature or to approximately 1.1 Axles for heat treatment shall be reheated gradually and uniformly to a suitable temperature to refine the grain structure.4 Quenching After being heated to a suitable temperature.4 Axles (Grades F.4 may be omitted. 03/2011 M-101 AAR Manual of Standards and Recommended Practices Wheels and Axles 7.0 CHEMICAL COMPOSITION The steel shall conform to the requirements for chemical composition shown in Table 7.1. Table 7.1 Chemical composition Grade F Carbon, percentage Manganese, percentage Phosphorus, percentage Sulphur, percentage Silicon, percentage Min. 0.45 0.60 — — 0.15 Grades G and H Heat-Treated Max. Min. 0.59 — 0.90 0.60 0.045 — 0.050 — — 0.15 Max — 0.90 0.045 0.050 — 8.0 LADLE ANALYSIS 8.1 An analysis of each heat of steel shall be made by the manufacturer to determine the percentage 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 paragraph 7.0. 8.2 Identification of Heats in Consecutive Strand 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 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 CHECK ANALYSIS Analysis may be made by the purchaser from one axle representing each heat. The chemical composition thus determined shall conform to the requirements of paragraph 7.0, subject to tolerances included in Table 9.1. 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 9.1 Permissible variations for check analysis Elements Manganese Phosphorus Sulphur Silicon 03/2011 Permissible Variations, Over the Maximum Limit or Under the Minimum Limit Percentage 0.030 0.008 0.008 0.020 G [M-101] 3 03/2011 AAR Manual of Standards and Recommended Practices Wheels and Axles M-101 10.0 TENSION TESTS 10.1 Grades F, G, and H axles shall conform to the requirements in Table 10.1. Table 10.1 Tensile requirements for carbon steel heat-treated axles Grade F (Double Normalized and Tempered) G (Quenched and Tempered) H (Normalized, Quenched, and Tempered) Size (Solid Diameter or Thickness) (in.) Over Not Over — 8 Tensile Strength (psi) Min. 88,000 Yield Strength (psi) Min. 50,000 Elongation in 2 in. (percentage) Min. 22 Reduction of Area (percentage) Min. 37 — 4 7 4 7 10 90,000 85,000 85,000 55,000 50,000 50,000 20 20 19 39 39 37 — 7 7 10 115,000 105,000 75,000 65,000 16 18 35 35 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. 10.4 The tensile properties for all grades listed in Table 10.1 shall be determined by the 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 shall 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 TENSION TEST SPECIMENS 11.1 Tension test specimens shall be taken from the test prolongation or an axle in accordance with the provisions of paragraph 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. 11.3 Tension test specimens shall conform to dimensions shown in Fig. C.1. 11.4 Tension tests from the prolongations shall have minimum tensile strength and yield point values 5% greater than shown in Table 10.1. 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 between the surface and 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 between the surface and center, with the gauge dimension parallel to the axis of the axle. G [M-101] 4 03/2011 03/2011 M-101 AAR Manual of Standards and Recommended Practices Wheels and Axles 12.0 PROLONGATION FOR TEST 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. 12.3 Test reports shall state prolongation sizing prior to test or the use of axles for test. 13.0 MICROSCOPIC TEST FOR HEAT-TREATED AXLES (GRADES F, G, AND 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 specimen. 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. 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 NUMBER OF TESTS 14.1 Unless otherwise specified by the purchaser, mechanical tests for grades and sizes shown in Table 10.1 shall be made from heat-treated axles as covered in 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 paragraph 15.2 of this specification. 14.3 If any test specimen fails because of mechanical condition of the testing apparatus, it may be 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 10.0. 03/2011 G [M-101] 5 0 ULTRASONIC TESTING (NEW AXLES ONLY—RADIAL AND AXIAL) 16.3.4.1 Scope 16. latest edition.2 16. Multiple transducer arrays must be capable of monitoring individual transducers.1. but before drilling cap screw holes.2 Time of Inspection 16. 16. 16.4.3 Each manufacturer must employ the services of an individual who is prequalified to NDT Level 3. at a minimum.1 Axial Transducers Frequency Size/shape 1.3.4 Personnel 16. in accordance with ASNT. Records must be accessible within 4 hours upon request by any AAR representative.75–1.4. at a minimum. • 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. Recommended Practice SNT TC-1A.50–1.2.5 Records Each facility must maintain the following records for the duration indicated.1 Axial—anytime during production following axle end facing and center drilling. in accordance with American Society for Nondestructive Testing (ASNT).3 Test Equipment Type Quantity Couplant Machine Calibration Pulse-echo-type broadband pass amplifier One or more. diameter or 1. in accordance with ASNT. including individual heat.2 16.00 in.2.00 in. Same couplant to be used for test and calibration. 16. A couplant must be used between the face of the transducer and the test surface. Recommended Practice SNT TC-1A.1 All personnel performing ultrasonic inspection operations must be prequalified to non-destructive testing (NDT) Level 1.03/2011 AAR Manual of Standards and Recommended Practices Wheels and Axles M-101 16. axle serial number. 2009. and date of inspection (10 years from date of manufacture) G [M-101] 6 03/2011 . 16. latest edition.1.00 in. at a minimum.2 This paragraph applies to all new axles.00 in.0– 2. Recommended Practice SNT TC-1A.25 MHz 0. latest edition.1 This paragraph becomes effective July 1. diameter or 1.2 All personnel setting up ultrasonic inspection systems must be prequalified to NDT Level 2. 16.2 Radial—anytime during production following initial rough turn (forged surfaces cannot be effectively radial UT-tested).2 Radial Transducers Frequency Range Size/shape 1. 16. 16.0–5.0 MHz 0. 16. At least annually and each time the system receives maintenance that affects system performance. 1 Calibration and System Tests The ultrasonic inspection system must be validated initially upon installation and at least once every year after initial installation.1.1 Periodic tests shall be made during production testing against the 16-in.1.1.1. latest edition. set up at 20% full-screen height using 16-in. in accordance with ASNT. Example: the following alternates provide equivalent sensitivity: • 1-in.3 Tests must be made every time there is an equipment malfunction or upon powering on.1.6. provided the output from the alternate standard is cross-referenced with the reference block and axle of paragraph 16.6. 16.1.1.3 Reference standards must be inspected and certified semiannually for surface finish on the inspection face(s) of 80 microinch to 125 microinch.1.1. flat-bottom hole 3/8-in.6.1 Personnel certifications for UT testing must be. 16.2 Reference block semiannual validation record. flat-bottom hole 1/4-in.5. All contact surfaces must be smooth with a surface roughness better than 125 microinch for axial test and 500 microinch for the radial test. to 46 in.1. detectable in reference axle 16.1.1.2 Tests must be made every time there is a change of transducers.5 Continuous 16. depth. flat-bottom hole at 15-in. It also should be free from dirt and grit.6.1.5.5. cables. indication from an ASTM E-127 block #1-0300 16.5. 16.2 Detection Capabilities 1/8-in.2 Periodic tests must be made at least once every 4 hours of use.6. and adjustments shall be made to instrument controls to ensure compliance with the specifications. Each certification must be endorsed by a responsible official of that facility and the verifying level III (10 years).1.1 Tests must be made every time there is a change of system operators.1.1 Axial 16.03/2011 M-101 AAR Manual of Standards and Recommended Practices Wheels and Axles 16. to 15 in.-long reference block described above.1. to 30 in. depth. or any other system hardware or accessories.6. flat-bottom hole From 2 in.4 Periodic 16. 03/2011 G [M-101] 7 .6. revalidation date. Recommended Practice SNT TC-1A.1.4.6.6.6.1 Unscheduled system tests shall be made during production testing against the 16-in.6 Validation Validation (system testing) must be performed using the same couplant used during axle testing. 16. 16. 16. 16. (10 years) 16.6.4. including the inspector’s name/ID.5.6. and measured surface finish of the reference block. and adjustments shall be made to instrument controls to ensure compliance with the specifications. 16. detectable in reference axle From 15 in.1.2 Alternate reference standards may be used to calibrate or test system sensitivity.5.1. 16. at a minimum. detectable in reference axle From 30 in.6.-long reference block manufactured from a Grade F axle forging. 16.-long reference block described above.1 Calibration—1/8-in.1. indication from a #1 series “A” Alcoa block • 1 1/2-in. depth. depth.1.6.6. 2. the axle is rejected. 16. an additional 6 dB shall be added to the reference or sensitivity level for scanning purposes.3 Radial 16.3 During the axial discontinuity inspection test and the radial loss of back face reflection test. 16.1 The ultrasonic inspection system must be validated initially upon installation and at least once every year after initial installation.7. 16.7.6.8 Marking All axles that are to be tested radially must have the character “R” immediately following the axle grade marking. the axle is rejected.2.2.2 The same couplant must be used for calibration and examination.3.1.6. 16.2 Scan the entire length of the axle radially through the diameter along one line only.7. 16.6. These expected indications must be recognized and are not cause for rejection.2.7. 16.7.1 If the amplitude of any indication exceeds the DAC curves as defined in Appendix B. 16. paragraph 2.1 Inspection surfaces must be free of all dirt and grit prior to the start of testing. the axle surface must be rough-turned with a surface finish of 500 microinch or better.6.1.3. At a minimum. unless the loss is attributed to geometry. 16.2 The variation in cross-section of the axle may produce spurious indications.3 Both end faces of the axle must be scanned to the full extent of the surfaces (100% area coverage). 16.7.1 The amplitude of the ultrasonic indication must be considered in relation to its distance from the testing surface to evaluate its significance.6.2.2.3.3 Tests must be made every time there is an equipment malfunction or upon powering on. 16. 16. the system set-up must be reverified. This can be accomplished by an electronic device or by distance amplitude curves that are described in Appendix B. 16.3.7.7.7.1.7 Inspection 16.3 The axle will be rejected for a location if a loss of back reflection of 80% or greater is experienced.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).7. The axle end faces must be prepared with a surface finish of 125 microinch or better. 16. These expected indications must be recognized and are not cause for rejection.7.1.2. Discontinuity evaluation shall be performed at the original recorded sensitivity level prior to final disposition.7.3.6.2.1 General 16.1. transducer. or coaxial cable occurs. operator.2 Radial 16. G [M-101] 8 03/2011 .2 If any backface reflection does not exceed 40% of screen height.0.7. All axles failing the radial test must be immediately identified and segregated for scrapping.7. 16.2 Axial 16. 16.1 Calibration and System Tests 16.03/2011 AAR Manual of Standards and Recommended Practices Wheels and Axles M-101 16.2.1 The variation in cross-section of the axle may produce spurious indications.4 When a change to the equipment power source.1.2. C. If in this inspection defects are found that the manufacturer can remedy. 17.” 19. Section G. to 1/4 in.3 For all axles ordered for finished end facing by the purchaser. free of charge.1 For other than the standard freight and passenger car axles referenced in this specification.2 The purchaser may make tests to cover the acceptance or rejection of the material in purchaser’s own laboratory or elsewhere.5.3 The interpretation of injurious defects in axles shall comply with Appendix A.3 The inspector shall examine each axle in each heat for workmanship. 19.4 Rough machined journals and wheel seats shall be 1/8 in. at all times while the work on the contract of the purchaser is being performed. The machining shall be done in a workmanlike manner. C.5 The smooth machined body shall be to the specified size. over the finished diameters and longitudinally 1/8 in. if not specified in axle drawings provided by the purchaser. and wheel seats of axles supplied in finished form will comply with applicable provisions of the AAR Manual of Standards and Recommended Practices. dust guard seats.0 INSPECTION 21. 21. Such tests shall be made at the expense of the purchaser. 21. to all parts of the manufacturer’s works that concern the manufacture of the material ordered.1 Axles shall be machined to a smooth machined finish between the wheel seats.3. to 1/4 in. over the specified minimum length. manufacturer may correct such defects. to 1/4 in. with no more than 1/8 in. Part II. C. defects. 21.2 Finish The axles shall be free from injurious defects. standard tolerances and allowances will apply. unless specified otherwise in Fig. 19. and conformity to the dimensions given on the order or drawing. 17. “Wheel and Axle Manual. “Interpretation of Defects Considered Injurious in Axles.2.0 MARKING Axles shall be legibly cold stamped with characters not less than 1/4 in. The manufacturer shall afford the inspector. The wheel seats and journals shall be rough machined. all reasonable facilities and necessary assistance to satisfy the inspector that the material is being furnished in accordance with these specifications. 17. high in accordance with the AAR standard marking requirements shown in Fig. Tests and inspection for acceptance shall be made at the place of manufacture.0 WEIGHT The approximate weights of the passenger and freight car axles covered by this specification are shown in Specification M-101. 18.0 WORKMANSHIP AND FINISH 19. Journals.” 20.03/2011 M-101 AAR Manual of Standards and Recommended Practices Wheels and Axles 17. 17. allowance longitudinally at each change of cross section. the overall length shall range from 1/8 in. over on the diameters and shall have no more than 1/8 in.1 The inspector representing the purchaser shall have free entry. 03/2011 G [M-101] 9 .0 DIMENSIONS AND TOLERANCES 17. of metal shall be allowed at each change of cross section for finish machining. the rough machining shall be free from objectionable ridges and chatter marks.2 Axle centers shall conform to Fig. together with a report of the test results. 23.1 Any axle that fails to meet the requirements of these specifications will be rejected.0 REJECTION 22. 25.2 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. 26. 22. and Forgings. larger than those shown under dimension “I” in Fig. Details shall be agreed upon by the manufacturer and the purchaser. Figs.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. Billets. 24. “Standard Method of Macroetch Testing Steel Bars.03/2011 AAR Manual of Standards and Recommended Practices Wheels and Axles M-101 22. G [M-101] 10 03/2011 . Blooms.0 CERTIFICATION Upon request of the purchaser in the contract or order. C. and Specification M-101.5. shall be furnished at the time of shipment. a manufacturer’s certification that the material was manufactured and tested in accordance with this specification.0 This specification includes Appendices A.” 25. B.0 The following supplementary requirements shall apply only when specified by the purchaser. C. In case of dissatisfaction with the results of the tests.1 through C.2 The purchaser may specify axle wheel seat diameters 1/8 in. 25.3. Reference shall be made to Specification ASTM E381. C.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. the manufacturer may request a hearing within that time. 2. 03/2011 G [M-101] 11 .3 Total length of such imperfections over 1/4 in. variously described as actual seams. 3.0 The interpretation of injurious defects as enumerated below is not to be considered as precluding other unforeseen or objectionable conditions not specifically listed. It is therefore advisable to describe these conditions in more detail. variously termed hairline.1 Roller Bearing Axles Fine longitudinal discontinuities on the finished (burnished or ground) surfaces variously termed hairlines. in any one end of axle. are considered to be injurious and are cause for rejection without further machining.2 Must not be over 3/4 in.1. 7. long individually in the dust guard seat.0 Any transverse or circumferential seams. or other similar discolorations. 7. ghost lines. stringers.03/2011 M-101 AAR Manual of Standards and Recommended Practices Wheels and Axles APPENDIX A APPENDIX A INTERPRETATION OF DEFECTS CONSIDERED INJURIOUS IN AXLES 1.1.0 JOURNALS AND DUST GUARDS 6. etc. or fine seams are not considered injurious if they meet the following conditions: 6. hairlines. stringers. long must not exceed 2 in. 5.3 Total length of such imperfections. in machined fillets is considered to be injurious and is cause for rejection without further conditioning. 7. long individually in the journal or 1/2 in.2 Must not be over 2 in. in any one end of axle.0 The conditions that have been most difficult for inspectors to evaluate are light lines visible to the normal unaided eye. or laps of indeterminate depth on the axle surfaces other than the discolorations listed in paragraph 4. that appear after the axles have been finish-machined and burnished or ground.1 Must not extend into the dust guard or body fillets.0 WHEEL AND GEAR SEATS 7. shadow seams. to 2 in. must not exceed 4 in. visible to the normal unaided eye that are not actual separations in the metal are not considered injurious.0. 6. stringer.1. 1/4 in.0 Any longitudinal discontinuity. 6. long. shadow marks. or fine seam.1. long individually. 6.1 Must not extend into fillets. 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. 4.0 Ghost lines.. regardless of location. regardless of their location.1. cracks.1.1 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. tight seams.1. variously termed hairlines.03/2011 APPENDIX A AAR Manual of Standards and Recommended Practices Wheels and Axles M-101 7.3 above may be reconditioned by grinding or machining. to 1/2 in.1 Must not extend into fillets adjacent to wheel or gear seat. variously termed hairlines.2.1.2 Must not be over 1/2 in. long individually.2 Must not be over 1/2 in. etc. must not exceed 1 1/2 in.0 AREAS BETWEEN WHEEL (AND GEAR) SEATS (BODY) 8. provided the diameter is not reduced below the specified limit. G [M-101] 12 03/2011 . 7.2. must not exceed 3 in.2 All Other Axles Longitudinal discontinuities on the finished machined surface of wheel and gear seats.1 Must not extend within 1 1/2 in. long.2. or fine seams..3 Total length of such imperfections. 8. long individually. are not considered injurious if they meet the following conditions: 7.1. long. of either end of wheel or gear seat. 8.1. in any one end of axle. fine seams.1 Machined Bodies Longitudinal discontinuities on the finished surfaces. stringers.1. 8. in any 12 in. of body length. 1/4 in. surface imperfections. are not considered injurious if they meet the following conditions: 8. stringers.3 Total length of such imperfections. 1/4 in.2 and 8.1.4 Axles containing longitudinal discontinuities in the body in excess of those described in paragraphs 8. 8. to 1/2 in. 7. These must be recognized and are not reason for rejection. B.0 SPURIOUS ULTRASONIC INDICATIONS FROM CONTOUR VARIATIONS Because an axle varies in cross-section. In the case of heat-treated axles. Fig. Type UM using a 1 1/8-in. this is approximately 1 in. 4. indication from an ASTM E-127 block #1-0300.1. It is not practical to define these indications in the specification.2 Typical distance-amplitude curve for heat-treated axle (as determined with a Sperry reflectoscope.0 NEAR-FIELD RESOLUTION It should be recognized that detection of discontinuities near the test surface is limited by the ultrasonic test frequency. The relationship can be established by an electronic device or by curves.1 Showing location of reference holes in axles Fig. a distance-amplitude relationship is employed. 3. 2. Because the distance-amplitude relationship is influenced primarily by the ultrasonic transducer and instrument.1. For example.0 DISTANCE-AMPLITUDE CORRECTION The amplitude of an ultrasonic indication from a given discontinuity size varies with its distance from the test surface. Appropriate distance-amplitude curves shall be developed.-diameter.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 16.03/2011 M-101 AAR Manual of Standards and Recommended Practices Wheels and Axles APPENDIX B APPENDIX B DISTANCE AMPLITUDE CORRECTION 1. To compensate for this effect.25 MHz quartz transducer) 03/2011 G [M-101] 13 . but the competent operator or technician will recognize these spurious indications as responses from axle contours. indication from a #1 series “A” Alcoa block. particularly at changes of cross-section. and 2) a 1 1/2-in.1. B. 2. B. A typical example is shown in Fig. from the test surface. the following are alternate references for heat-treated axles that give equivalent sensitivity: 1) a 1-in. B. it is possible to produce spurious indications.6.1. it is necessary to relate this factor to the specific equipment used.2 as related to the axle in Fig. 03/2011 APPENDIX C AAR Manual of Standards and Recommended Practices Wheels and Axles M-101 APPENDIX C QUALIFICATION OF MANUFACTURER’S PLANT AS A PRODUCER OF AXLES FOR AAR INTERCHANGE 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. 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 marks to be stamped on the axle end face will be 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. 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, 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 and with MSRP Section J, Specification M-1003. Critical records must be kept up to date with production and be maintained in English. G [M-101] 14 03/2011 03/2011 M-101 AAR Manual of Standards and Recommended Practices Wheels and Axles 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 round tension test specimen with 2-in. gauge length Paragraph 11.3 03/2011 G [M-101] 15 APPENDIX C 03/2011 APPENDIX C AAR Manual of Standards and Recommended Practices Wheels and Axles STAMP HERE NOTE 4 NOTE 6 11-66 66 A001 L ROLLER BRG. PASSENGER CARS ONLY NOTE 1 00000 M-101 NOTE 5 F R NOTE 7 USS-H NOTE 2 NOTE 3 CIRCUMFERENTIAL DEVELOPMENT OF AXLE END NOTE 6 NOTE 1 ROLLER BRG. FREIGHT CARS ONLY NOTE 2 NOTE 7 NOTE 5 NOTE 4 NOTE 3 AAR STANDARD AXLE MARKINGS NOTES: 1. LABORATORY ACCEPTANCE STAMP—FOR USE BY PURCHASER TO SIGNIFY ACCEPTANCE OF AXLES SO MARKED PRIOR TO SHIPMENT BY PRODUCER 2. SERIAL NUMBER. 3. MANUFACTURER’S NAME OR BRAND (SEE TABLE BELOW) 4. MONTH AND YEAR MADE 5. GRADE OF AXLE F =Double Normalized and Tempered G =Quenched and Tempered H =Normalized, Quenched and Tempered GENERAL NOTES: • REFER TO THE LATEST MECHANICAL DIVISION CIRCULAR LETTER LISTING OF AAR-APPROVED AXLE MANUFACTURERS FOR CURRENT APPROVAL STATUS. • ALL MARKS WILL BE DEEPLY AND LEGIBLY STAMPED WITH CHARACTERS NOT LESS THAN 1/4 IN. HIGH. • ALL MARKS FOR FREIGHT CAR ROLLER BEARING AXLES MUST BE LOCATED ADJACENT TO THE PERIPHERY OF THE CENTERING HOLE. • MANUFACTURERS MUST FINISH ONE END OF THE AXLE FOR STAMPING. • THE ABOVE ARE THE MINIMUM MARKING REQUIREMENTS, BUT THE LOCATIONS ON INDIVIDUAL ITEMS MAY VARY FROM THAT ILLUSTRATED. 6. HEAT IDENTIFICATION NUMBER 7. IF AXLE IS RADIALLY UT’D, THEN STAMP IMMEDIATELY FOLLOWING AXLE GRADE = R. Manufacturer’s Name or Brand AXIS BF BSa/ CAF CBa/ CCC CF CHB CHT DDAP DSS HM JAW KWa/ L LCKZ LP MKa/ MRF MW AXIS LLC Bumar-Fablock S.A. Bethlehem Steel Corporation Construcciones y Auxiliar de Ferrocarriles (CAF) Cobrasma CNR Changchun Railway Vehicle Facilities Co.,Ltd. Valdunes (formerly Creusot-Loire) Baotou Paragould AR Chrzanow. Poland Johnstown, PA Beasain, Spain Brazil Jilin Province, China Dunkerque, France Baotou Inner Mongolia PRC Jinxi Axle Company LTD. (Formerly Norinco Jinxi) Taiyuan, Shanxi Province, P.R.C DDAP/RAX Dneprderzhinsk, Ukraine JSC Dneprospetsstal, Zaporozhye (DSS) Zaporozhye, Ukraine Huta Gliwice-Osie Sp. zo.o Gliwice, Poland Standard Forged Products Johnstown, PA Klockner West Germany Lucchini Sidermeccanica SpA (Formerly Temi) Lovere, Italy LugCentroKuZ Lugansk, Ukraine Huta L. W. (Formerly Lucchini Poland) Warsaw, Poland Makrotek Mexico Standard Forged Products McKees Rocks, Pennsylvania MWL Rodas & Eixos LTDA (Formerly Mafersa) Cacapavz, Sao Paulo, Brazil QRSS RW SCOTa/ SFC or Sa/ SMI SPTa/ Qiqihar Railway Rolling Stock Ltd. S. C. SMR S.A. Scot Forge Standard Forgings Sumitomo Metal Industries LTD. British Steel SSD Standard Steel LLC. SW SWASAP Works Ta/ British Steel THM or TZ Taiyuan Heavy Industries Company LTD. TW plus a/ UF USS-Fa/ USS-Ga/ USS-Ha/ V Hawker Siddeley Ural Forge United States Steel Corp. United States Steel Corp. United States Steel Corp. Valdunes (formerly Creusot-Loire) WAP Rail Wheel Factory Indian Railways (Formerly Wheel and Axle Plant) Bonatrans a.s. (Formerly ZAD) ZB Qiqihar, P.R.C. Bals, Romania Clinton, Wisconsin Osaka, Japan Templebourough Works, England Burnham, Pennsylvania Germiston, South Africa Trafford Park Works, England Taiyuan, Shanxi Province, P.R.C Trenton Canada Chebarkul, Russia Fairfield Works Gary Works Homestead Works Valenciennes, France Yelahanka, Bagalore, India Bohumin, Czech Republic a/ No Longer in Production Fig. C.2 AAR standard marking requirements Paragraph 20.0 G [M-101] 16 03/2011 4. 9.2 03/2011 G [M-101] 17 L* 3" ENLARGED SECTION SHOWING OPTIONAL RADIUS WHEN USING CONTOUR GRINDER 1" + 0 1" 4 4 ( * L)3'11 J C OVER SIZE DIA.N. “I” DIMENSION TOLERANCE IS +0. THE TURNED FINISH MUST NOT EXCEED 125 ΜIN. MACHINE CHAMFER TO 250 µin. ± 1" OVERALL LENGTH BREAK SHARP CORNER 1"R 1 2 V +0 1" 16 O N 1"R + 01" 1 2 16 16 CL TO CL OF JOURNAL 3"R E E K I D W AXLES SHALL BE MACHINED TO 250 µin.008" TOTAL DIAL INDICATOR. IF GROUND OR TURNED ONLY. MUST NOT EXCEED .001 INCH AND THERE SHALL BE NO ABRUPT CHANGES OR STEPS OVER THE LENGTH OF THE JOURNAL. DEPTH OF DRILLED HOLE MUST EQUAL V DIMENSION PLUS 7" MAXIMUM.006" TOTAL DIAL INDICATOR. 5. G Y H R J ° 120 120 ° APPENDIX C . Revised 1984. * THE L DIMENSION NEED NOT BE CORRECTED FOR LENGTH EACH TIME THE WHEEL SEATS ARE TURNED ON NEW AXLES MACHINE 3 in. Effective March 1.AAR Manual of Standards and Recommended Practices Wheels and Axles 03/2011 M-101 NOTE: V DIMENSION DESIGNATES MINIMUM LENGTH OF FULL THREAD. FIG. MIN.C. MAX. WORN DIA.2B TAP 3-HOLES COUNTERSINK 1/8" LARGER THAN BOLT DIA. Fig. MAX. NEW DIA. RADIUS AT SPECIFIED DIMENSION L FOR ANY WHEEL SEAT DIA. MAXIMUM ALLOWABLE RUNOUT BETWEEN “G” AND “H” IS . MAXIMUM ALLOWABLE RUNOUT BETWEEN “G” AND “I” IS . TO 8 R. MAXIMUM WHEN TOLERANCED. 8.015" TOTAL DIAL INDICATOR. Fig. NOTES: 1. 5.015. RP-634. IF TURNED AND ROLLED. 1985 Paragraph 17. FOR 7" × 12" JOURNALS.3 Axle for freight car roller bearing—raised wheel seat (page 1 of 2) Standard 1963. WHEN ROTATED ON CENTERS. C.27. RUNOUT ON JOURNAL SURFACE “G”.. JOURNAL FINISH MUST NOT EXCEED 63 ΜIN. 7. 2. BOLT DIA. 5. FINISH TO 125 ΜIN. MAXIMUM PERMISSIBLE VARIATION IN JOURNAL DIAMETER AT ANY PLACE MUST NOT EXCEED .. 6. 3. BETWEEN WHEEL SEATS 2" U ±161" M ±161" MATERIAL AAR SPECIFICATION M101 1" 1" 16 R. 1998. END CHAMFER IS 4° 15' 5/8" ±1/8". MAX.5 and Paragraph 25. 8 CHECK LOCATION WITH GAUGE SHOWN ON MSRP SECTION G-II RP-634. DIMENSIONS “B” AND “N” ARE CONSIDERED ENGINEERING DATA FOR TRUCK DESIGN AND DO NOT NECESSARILY AGREE WITH AXLE MANUFACTURING TOLERANCES. THE "W" DIMENSION CANNOT EXCEED THE TOLERANCE LIMITS OF THE GAUGE SHOWN IN MSRP SECTION G-II. 2" ENLARGED VIEW SHOWING CONDITION AT FILLET JOINING BODY PORTION OF AXLE TO INSIDE EDGE OF WHEEL SEAT.015 –0. B X 0 1" + 8 120° STAMP IDENTIFICATION MARKS ON THIS SURFACE. REQUIRED FOR PRESS FIT OF ROLLER BEARING BACKING RING WHERE THE “H” DIAMETER IS TOLERANCED.8 T U. T REMOVE SHARP CORNERS. AND THE ROLLED FINISH MUST NOT EXCEED 16 ΜIN. 1915 7.1905 7.20 5/8" ± 1/8 1 1/4" + 0/.207" 8.1/4 1 1/4" + 0/.532 min.6915 7.397" max 7.5040 7.156" 62 1/2" 79" 89 1/4" 62 1/2" 79" 89 5/8" 7 5/16" 6 7/16" 62 1/2" 78" 7 7/8" 8 9/16" 7 7/8" O 62 1/2" 77" 86 1/8" M 7 5/16" 6 7/16" 62 1/2" 78" 6 3/4" J 2 1/8" 1 15/16" 2 1/8" 2 5/16" 2 1/8" 1 15/16" 1 3/4" R 66 1/8" 66" U 2" 1 7/8" V 69.5" 62 1/2" 79" 87.030 7 5/8" 3" max 6. 6. 7.032 min.1915 6 3/8" 7 9/16" min.086" 2" 69.457 4.530 2 5/16" I 7 5/8" 3" max 5.1/4 X — — 10° 4°15" 2°8" 2°8" 2°8" Y 03/2011 CLASSIFICATION OF AXLE APPENDIX C AAR Manual of Standards and Recommended Practices Wheels and Axles M-101 03/2011 . 6.6915 7.1905 D 5 15/16" 1 13/16" 7 5/8" 3" max 5.032 min. 5.002 8.532 min.293 3.004 min.500" 85.3 Axle for freight car roller bearing—raised wheel seat (page 2 of 2) 7 5/8" 3" max 6.500 3.030 5 1/2" B DIMENSIONS 9. 6.6905 7.000 9 1/2" 8 1/4" 8 3/4" 9 1/2" 8 3/4" 8 1/4" 5 7/8" K N 7 3/8" 8" 7 3/8" 8 9/16" 8" 88" 62 1/2" 79" 87.294" 2 1/8" 67 1/8" 2 1/4" 1 1/8" – 7 69.931" 11 1/16" 11 3/4" 10 15/16" 10 1/16" W — — .5030 7. 5.530 7 5/8" 3" 1 13/16" 7 5/8" 3" max 6.530 7 5/8" 3" max 5.1905 7.853" 5 15/16" 6 7/16" 3.1915 7.532 min.1/4 1 1/4" + 0/. 5.250" ± 0.003 8.SIZE OF JOURNAL 5 1/2 × 10 6 × 11 6 1/2 × 12 7 × 12 6 1/2 × 9 6×8 7×9 D E F G K L M 1 3/4" C E G H G [M-101] 18 4.500" 2 1/8" 1" – 8 1 1/8"–7 1 1/4" –7 1 1/8" – 7 66 1/8" 2 1/8" 1" – 8 7/8" – 9 T Fig.6905 7. C.000" 8.750 4. 625 D E F 5 1/2 × 10 6 × 11 6 1/2 × 12 3.749 .195 6 11/16 5.) 3. BREAK SHARP CORNERS. UNLESS OTHERWISE SPECIFIED.080 .955 .740 .) C 6 3/16 5.03/2011 M-101 AAR Manual of Standards and Recommended Practices Wheels and Axles Class D E F G K L M Size (in.5000 3.749 MATERIAL: ASTM A-576.636 .2500 4.695 7 3/16 6.2500 3. PARTS TO BE HARDENED AND SURFACES MARKED “G” ARE TO BE GROUND. Revised 1982.) 2 3/8 2 5/8 2 7/8 3 1/2 2 7/8 2 5/8 2 7/8 E .007 7 1/2 6.8750 4.507 7 6. 1998 03/2011 G [M-101] 19 .8750 Freight Car Axles B (in.507 APPENDIX C D (in.955 1.850 . TOLERANCE ON ALL DIMENSIONS TO BE 1/64 IN.850 0.) 5 1/2 × 10 6 × 11 6 1/2 × 12 7 × 12 6 1/2 × 9 6×8 7×9 A (in. C.6250 4.195 8 7.508 Amtrak Passenger Car Axles 6 1/2 5.4 Pin-type gauge for cap screw holes in ends of roller bearing axles Standard 1979.695 7 3/16 6.195 6 11/16 5.0000 3.008 7 3/16 6. GRADE 1045 OR EQUIVALENT.955 1 7/8 2 3/8 2 5/8 . Fig.5000 3.8750 4. 5 Axle centering and gauge for axle center and lathe center Adopted 1944. 1979 Paragraph 17.APPENDIX C AAR Manual of Standards and Recommended Practices Wheels and Axles M-101 FINISHED DIMENSIONS AXLE SIZES 3 A 3 4" × 7" 1 B 4 4" × 8" C 5" × 9" 1 D 5 2" × 10" 1 16" FREIGHT ROLLER BEARING AND ALL PLAIN BEARINGS AXLE SIZES E 6" × 11" 1 F 6 2" × 12" G 7" × 12" 1 K 6 2" × 9" L 6" × 8" M 7" × 9" FOR AXLE WITH SPLINE BUSHING THICK STEEL HARDENED LATHE CENTER NOTE: DEPTH OF COUNTERBORE IN ROUGH AXLE SHALL BE INCREASED FROM THAT SHOWN TO COMPENSATE FOR STOCK ALLOWED TO FACE AXLE. C. WHEN SECONDHAND AXLES ARE RECENTERED. DIAMETER AND DEPTH MAY BE INCREASED SUFFICIENTLY TO PRODUCE AN ACCURATE 60º CENTER.2 G [M-101] 20 03/2011 . Fig. Revised 1966. 03/2011 M-107/M-208 AAR Manual of Standards and Recommended Practices 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, or D wheels must be used for freight cars in interchange service. 1.2 Class B, 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 service with severe braking conditions, but with moderate wheel loads. Class B—High-speed service with severe braking conditions and heavier wheel loads. Class 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 2.1 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. B.8 through 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 Committee (hereinafter referred to as the “Committee”) for review. 2.2 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. 3.0 Authorization for delivery for interchange use of any AAR wheel type must be obtained from the AAR as described in Appendix A. 4.0 Qualification as a manufacturer of wheels for use in AAR interchange service must be in accordance with Appendix B. Qualification is effective until revoked for cause by the Committee. Failure to maintain reasonable quality standards in manufacturing is an example of cause. 03/2011 G [M-107/M-208] 21 03/2011 AAR Manual of Standards and Recommended Practices Wheels and Axles M-107/M-208 5.0 MANUFACTURE 5.1 Discard A sufficient discard shall be made from the steel used for the manufacture of all steel wheels to ensure freedom from piping and undue segregation. 5.2 Temperature Control During manufacture of all wheels, necessary care in the regulation of temperature gradients shall be exercised to prevent the development of internal defects or injurious stresses. 6.0 HEAT TREATMENT 6.1 All wheels must be rim-quenched and tempered. 6.2 Rim-Quenching Treatment 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 10.0 and subsequently cooled under controlled conditions. 7.0 SHOT PEENING 7.1 Scope This section covers shot peening of steel wheels to provide improvement in plate fatigue strength. 7.2 Requirements 7.2.1 Shot The shot shall be SAE No. 550 or larger hardened steel as specified in SAE J827. 7.2.2 Shot Size Control 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. 7.2.3 Peening Intensity 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 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. 7.2.3.1 Arc Height Measurement Measurements of arc height shall be made in accordance with SAE Standards J442 or SAE Recommended Practice J443. 7.2.4 Coverage 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 7.2.5 Sequence Shot peening will be performed on all wheels and after any corrective surface preparation on the plate area. Plate area is defined in paragraph 7.2.3. Peening may be performed prior to inspection. G [M-107/M-208] 22 03/2011 03/2011 M-107/M-208 AAR Manual of Standards and Recommended Practices Wheels and Axles 7.2.6 Portable Peeners A portable peening device may be used to re-peen small reconditioned 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 Quality Assurance Provisions 7.3.1 Wheel Surface Condition The peened appearance of rim and hub shall not be cause for rejection. 7.3.2 Frequency of Test 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. 7.3.4 Repeening When test values fail to meet the provisions of paragraph 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 or 0.007, the last half of the wheels peened 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. 03/2011 G [M-107/M-208] 23 Oxygen.a/ 0.040 0. and Cobalt Alloys. The chemical composition thus determined.77 0.25 max.040 max.3.15–1.030 max.2 An analysis of each heat of steel shall be made by the manufacturer to determine the percentage of the elements specified in paragraph 8. 8.1 Test Method 1 The carbon determinations should be one of the following test methods: 8.05 max.10 max. Oxygen.60–0.0 LADLE ANALYSIS 8. 0.a/ .1 Total carbon by the combustion gravimetric method.” G [M-107/M-208] 24 03/2011 .00 Class C 0. chromium. the following formula must be met: 930 – [570 × % carbon] – [80 × % manganese] – [20 × % silicon] – 50 × % chromium] – [30 × % nickel] – [20 × % molybdenum + % vanadium] > 390 8. and Cobalt Alloys.3. shall be reported to the purchaser or purchaser’s representative and shall conform to the requirements specified in paragraph 8.10 max. 0. 0. 0.57 0.00 Residual Elements 0. 8. molybdenum.005–0.25 max.005–0. 0.a/ 0.00 Nickel Chromium Molybdenum Vanadium Copper Aluminum Titanium Colunbium (niobium) 0.a/ .05 max.25 max. ASTM E-1019 “Standard Test Methods for Determination of Carbon.040 0.15–1.60–0.25 max. If the manufacturer chooses to vary from the above limits for nickel. and Hydrogen in Steel and in Iron. Sulfur.1. 0.a/ 0.a/ 0. 0.00 0. 0.2 Total carbon by the combustion thermal conductivity method.25 max.67–0.” 8.1.15–1.a/ 0. Nitrogen. Nitrogen.60–0. a/ Class A 0.67 0.a/ 0.25 max.47–0.030 max. 0. 0.3. and vanadium.35 max.060 max.a/ 0. All analyses should note which method is used for the carbon and/or chemical determinations. Ingot Iron.1 Chemical requirements Element Carbon Manganese Phosphorous Sulfur Silicon Class L 0.a/ 0.030 max. Ladle Analysis (%) Class B 0. ASTM E-1019 “Standard Test Methods for Determination of Carbon.a/ 0.03 max. 0.1.” 8.005–0. 0.03 max.03 max.060 max. Silicon Electrical Steel.35 max.005–0. and Wrought Iron. This analysis shall be made on a test specimen taken during the pouring of the heat.1. 0.03/2011 AAR Manual of Standards and Recommended Practices Wheels and Axles M-107/M-208 8.040 0.060 max.15–1. Low-Alloy Steel. 0.10 max.060 max. and Hydrogen in Steel and in Iron.a/ .10 max.a/ 0.040 max.040 0.35 max.a/ 0.a/ 0. Nickel.05 max.57–0.1.3.a/ . Sulfur. 0.90 0.03 max.47 max.90 0.040 max. followed by quantitative infrared analysis.05 max. Nickel.60–0.030 max.90 0. 0.3 Total carbon by combustion. ASTM E-350 “Standard Test Methods for Chemical Analysis of Carbon Steel.3 Chemical Analysis Chemical analysis of each heat of steel shall be made by one of the test methods listed below.1 The steel shall conform to the following chemical requirements: Table 8.25 max.90 0. together with such identifying records as may be desired. 0.35 max.25 max. 0.040 max. 3. 9. test at least two wheels from a heat specially produced to AAR specifications for the scheduled facility certification continuation inspection once a year.” Then use either ASTM E-350. below the wheel tread and 2 1/2 in. at a minimum. the laboratory conducting the chemical analysis shall follow a standard sampling method. long in the circumferential direction (the rolling direction).3 for chemical analysis of the sample. from a wheel block. E-1019. Dimension tolerances are ±1/8 in.4. wheels shall test two wheels of different heats quarterly.03/2011 M-107/M-208 AAR Manual of Standards and Recommended Practices Wheels and Axles 8. A minimum of one 33-in. and 1/2 in. and other foreign substances. Samples from wheel blocks must be drilled from the end of the block midway between the center and outside. • Facilities that produce only 33-in. When a finished wheel is used. 03/2011 G [M-107/M-208] 25 . wheel and one 36-in.” 8. wide in the axial direction (the rim width). or ASTM E-415 as specified in paragraph 8.1 Sampling Method When wheel blocks or whole wheels are not available for chemical analysis. The purchaser reserves the right to more frequent testing should it be deemed necessary by mutual agreement between the purchaser and producer. “Standard Practice for Sampling Steel and Iron for Determination of Chemical Composition.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. from the back rim face. wheel of different heats produced quarterly per facility shall be tested. thick in the radial direction (the rim thickness). • Facilities not producing wheels to AAR specifications during four successive quarters shall. or 36-in. or from finished wheels selected by the purchaser from each heat in question.0 INTERIOR CONDITION/MICROCLEANLINESS STANDARDS 9.2 Test Method II ASTM E-415 “Standard Test Method for Optical Emission Vacuum Spectrometric Analysis of Carbon and Low-Alloy Steel. to 3 1/4 in. No drilling of the finished wheel plate is permitted. scale. Each sample must be thoroughly mixed together and must be clean and free of oil. 3/4 in. the sample must be obtained from the rim face or the hub in a manner that will not impair the usefulness of the wheel.1 Sample Frequency The metallurgical cleanliness of the wheel steel shall be determined from samples taken from randomly selected finished wheels representing the heat. This standard method of sampling shall be ASTM E-1806.4 Check Analysis An analysis may be made by the purchaser from a sample furnished by the manufacturer that represents the heats. The circumferential surface for microcleanliness evaluation shall be located 1/2 in. Each sample shall be 7/8 in. 8. • Facilities producing different size wheels to AAR specifications during a quarter shall test at least two wheels of different heats during the subject quarter. 9. or 0.3. The WABL Committee must approve alternates to this method.4 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. G [M-107/M-208] 26 03/2011 . paragraph 5. Standard S-060. or the worst field area percentage of any one sample is more than 0.750% sulfides. The surface of the wheel rim shall be properly prepared to permit accurate determination of hardness. Before making the impression. sample shall be carefully prepared and evaluated to ASTM Standard Practice E1245. 10. × 3/4 in. If AAR is advised in two successive quarters. In such cases. The flicker method shall be used to establish the correct setting of the gray-level threshold limits. Inspection results will be available for review by the AAR or other interested parties. any decarburized metal shall be removed from the front face of the rim at the point chosen for measurement.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.1 The hardness of the rim.3 Sample Preparation and Evaluation 9.3.2. voids.100% oxide plus voids.1 Brinell hardness of rim Class L A B C D Minimum Hardness 197 BHN 255 BHN 302 BHN 321 BHN 341 BHN Maximum Hardness 277 BHN 321 BHN 341 BHN 363 BHN 415 BHN Note: Class D alloy steel wheels must meet all chemical requirements for Class C wheels and have approval of the AAR WABL Committee.3.2 or 161 mm2. from the radius joining face and tread. AAR or other interested parties may have the test samples evaluated by other accredited laboratories at their expense.3 Effective January 1. average and worst field area percentage oxides. All inclusions greater than 2. 2008.03/2011 AAR Manual of Standards and Recommended Practices Wheels and Axles M-107/M-208 9. shall show the following values: Table 10.5 µm shall be counted.3. when measured in accordance with the requirements of paragraph 10. 9. 9. and sulfides will be recorded.750% oxide plus voids. The AAR shall be advised quarterly when the six samples representative of the heat tested average more than 0. Administrative Standards.0 BRINELL HARDNESS 10. a special facility inspection may be required to demonstrate that the root cause has been identified and addressed. 10.2 The total area evaluated for each sample shall be not less than 1/4 in. 9.3.1 Each 7/8 in. shall apply. × 1/2 in. the provisions of AAR Manual of Standards and Recommended Practices. Records of test results shall be kept for 10 years after the wheels are shipped. For either heat-treatment process. one on each side of the point first measured and each approximately 1 in.0. All five wheels must meet the requirements in Table 11. The hardness shall be taken per Fig. and those meeting the requirements of paragraph 10. If this wheel fails to meet the requirements in Table 11. For batch-type heat-treating.1. Only one reheat treatment shall be allowed.1.1 Acceptable hardness ranges Class B C D Minimum 285 HB 28 Rc 301 HB 30 Rc 321 HB 32 Rc Maximum 341 HB 40 Rc 363 HB 42 Rc 415 HB 44 Rc If values do not meet the requirements in Table 11. and those meeting the requirements of paragraph 10. and on a minimum of 2 wheels in a heat or heat-treatment lot of 11 to 20. hardness gradient tests shall be performed on a minimum of one wheel from each of the first five heats of steel produced. the wheel shall be considered to have met the requirements of paragraph 10. Where batch heat-treating furnaces are used. all of the wheels represented shall be accepted.0.1.1.2 If all the wheels tested meet the requirements of paragraph 10. 11.0 NUMBER OF TESTS 11. the manufacturer may test all of the wheels in the heat-treatment lot for individual hardness measurement. testing per paragraph 11. should any of the wheels tested fail on check test to meet the requirements of paragraph 10.1 Where continuous heat-treating furnaces are used.5 On new wheel designs or existing designs to which process changes are made.03/2011 M-107/M-208 AAR Manual of Standards and Recommended Practices Wheels and Axles 11. BHN measurements shall be made on 10% of the wheels from each heat. at least one wheel from each heat in the heat-treatment lot must be tested. an additional five wheels from five heats shall be tested.1 utilizing an approved hardness test machine. all wheels from the heat shall be scrapped.1.0. 11. 03/2011 G [M-107/M-208] 27 .1 shall be reheat-treated. should any of the wheels tested fail on check test to meet the requirements of paragraph 10. 11.0. the manufacturer may test for individual hardness measurements all of the wheels of that heat in the lot submitted for inspection. Table 11. Where batch-type heat-treating furnaces are used. and one wheel from the heat shall be tested. 11. 11. from that point. BHN measurements must be made on a minimum of one wheel in a heat or heat-treatment lot of 10 or less.4 When continuous heat-treating furnaces are used. All wheels from heats that have a test wheel that failed to meet the requirements in Table 11.3 If any wheel tested fails to meet the requirements of paragraph 10.5 shall be repeated after a process and/or design change is made. it shall be checked by making two additional hardness measurements. If both of these check measurements meet the requirements of paragraph 10.0. If one or more wheels fail to meet the requirements in Table 11.0 shall be accepted.0 shall be accepted.0. BHN measurements shall be made on 10% of the wheels from each heat-treatment lot. Values shall meet the requirements as shown in Table 11. 0 may be retreated and tested in accordance with paragraph 11. the percentage of such wheels shipped by any manufacturer shall not exceed this percentage during a calendar year.0.0 PERMISSIBLE VARIATIONS 15.11.12 for freight car wheels and in Figs. B.10 for locomotive wheels.0 MATING Wheels shall be measured and marked to the lower tape number until the next graduation is reached. 15.10 allow a certain percentage of the wheels to vary from standard dimensions for tape size by a given amount.0 RETREATMENT Any wheel failing to meet the requirements of paragraph 10.03/2011 AAR Manual of Standards and Recommended Practices Wheels and Axles M-107/M-208 Fig.2 Where Figs. B. B. The repeatability and reproducibility of all alternate gauges must be demonstrated. Wheels shall be shipped in pairs of the same measured tape size.8. 11. 13. 14. No individual purchaser may receive more than this percentage of his daily shipments of such wheels except by agreement with the manufacturer. B.8 and B.1 Hardness mapping locations 12.9. B.1 The wheels shall conform to the dimensions with tolerances as specified in Figs. and B.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.9 and B. 15. G [M-107/M-208] 28 03/2011 . Spot grinding or machining to remove surface defects must not exceed a depth of 1/8 in.. 03/2011 G [M-107/M-208] 29 . As-produced surfaces must be free from abrupt changes in surface contours.4 Wheels shall not be covered with any substance to such an extent as to hide defects. or machined. The back hub face may be smooth forged. 17. may be bored and applied with any portion of the wheel manufacturer’s hub stamp closer than 1/8 in. B. After final machining.2 mm). When ordered.11. B. the purchaser will cold stamp the markings on the front hub face. No wheel manufactured after May 1. B. 3. There will be no more than 1/32-in. Front hub face of wheels (1-W.5 Wheel profile is to be checked using wide flange profile gauge shown in Fig. 2009. and throat radii gauges shown in Standards S-661 and S-662 shall be used to check proper profile. stamping should be centered approximately on the hub. 2-W. or machined. heat-treated configuration.1 Wheels shall be rough bored and shall not have black spots in the rough bore. For all wheels. in height on those wheels of curved plate.7.125 in. B.1 Identification markings shall be legibly stamped as shown in Figs.12.2 The tape size of all wheels shall be paint stencilled on back plates in characters at least 1 in. Repaired surfaces must provide a uniform transition to the as-produced surfaces. 16. variation from the profile. at the option of the manufacturer. 2009. the markings shall be legible characters and be as shown in Fig. B. No wheel manufactured before May 1. 16. 16.13 as applicable. Cast steel wheels shall be as cast. high. For wheels having raised cast-on markings. If any stamped characters are missing or illegible. Minimum and maximum flange thickness. or hot or cold stamped on the front hub face. cast. or hot or cold stamped on the back hub face providing finish machining will completely remove the markings on the back hub face. (0. An “H” shall also be paint stencilled on the front plate at least 1 in. 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. and MW) shall be parallel to the plane of the vertical reference line and may be smooth forged. Wrought steel wheels must be machined and finished smooth without excessive tool chatters. machined.0 MARKING 17. these shall be replaced by cold stamping in the proper place in the marking sequence. height. from the outer hub diameter.4 or B.3 Wheels must be free of all condemnable in-service defects. Wheels for freight service must be hot stamped or cold stamped on the back hub face. Stencil paint must be white and have a minimum service life of 1 year. or ground.03/2011 M-107/M-208 AAR Manual of Standards and Recommended Practices Wheels and Axles 16. cast. Sectional properties must meet all dimensional requirements following repair of surface defects. Locomotive wheels that are to receive final hub machining by the purchaser may be ordered with markings paint stenciled on the wheel plate. Wheels that do not meet the criteria must be scrapped or recontoured. 16.5. 17.0 FINISH 16.14. locomotive wheels may be hot or cold stamped on the back rim face. or B. Passenger car wheels may be hot stamped or cold stamped on front or back (as specified by purchaser) hub face. from the inner hub diameter and no closer than 1/8 in. Repaired surfaces must have a maximum surface roughness of 500 µin.2 The contour of tread and flange shall be as shown in Figs. prior to final shot peening. Each manufacturer shall maintain a documented test method and procedures for ultrasonic inspection of all railroad wheels manufactured under this specification.1 Equipment 18.4.4 A suitable couplant shall be used between the test surface and the transducer.1. 18.2 The transducers shall be of the type whose composition and dimensions are appropriate for the test method used. softeners. An automatic flaw alarm system shall be used in conjunction with the ultrasonic instrumentation.3 All tests and inspections shall be so conducted so as not to interfere unnecessarily with the operation of the works. 18.1 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.4.4.4. G [M-107/M-208] 30 03/2011 .0 INSPECTION 18. to all parts of the manufacturer’s works that concern the manufacture of wheels ordered.1. The manufacturer shall afford the inspector. all reasonable facilities and necessary assistance to satisfy the inspector that the wheels are being furnished in accordance with these specifications. 18.2 Time of Inspection Inspection shall be performed after final thermal processing. Rust inhibitors.4. Equipment used in these procedures shall comply with the following requirements.2 The purchaser may make tests to govern the acceptance or rejection of the wheels in purchaser’s own laboratory or elsewhere.4. ultrasonic inspection shall be made by following either the procedures shown below or an AAR-approved equivalent. free of charge.1 The inspector representing the purchaser shall have free entry. 18. The method to be followed and the equipment to be used shall comply with the requirements as shown in paragraph 18. Internal defects are usually detected by ultrasonic testing. at all times while the work on the purchaser’s contract is being performed. The couplant shall be free of air bubbles.4.4 Ultrasonic Inspection For detecting internal discontinuities in the rim of all steel wheels. 18.1. Tests and inspection shall be made at the place of manufacture prior to shipment. Such tests shall be made at the expense of the purchaser.3 The ultrasonic inspection shall be performed with an automated scanning system. and wetting agents may be added to the couplant. 18.1. 18. unless otherwise specified.03/2011 AAR Manual of Standards and Recommended Practices Wheels and Axles M-107/M-208 18. Such test shall be used in the manufacture of all wheels. 18. 3 For radial testing. the DAC will be generated for each testing direction in the following manner. Reference standard need not be the same AAR design as the wheels being inspected. and the response(s) from the additional holes shall be used to create the DAC.1 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.-diameter flat-bottom holes shall be generated at whatever depth the manufacturer chooses. and 3 1/2 in.4. two additional 1/8-in.4.2.e.1 Axial As a minimum. (±1/16 in.3. i. 18. 18. the reference standard shall be a 1/8-in.4. and. See Fig.-diameter flat-bottom hole and the proposed alternate standard.1.4.) at the mid-thickness of the rim. 2 1/2. 18. The creation of the DAC shall be accomplished using the reference standard and the response(s) from additional holes.3. B.7 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.-diameter flat-bottom hole shall be generated in one-wear and two-wear wheels.03/2011 M-107/M-208 AAR Manual of Standards and Recommended Practices Wheels and Axles 18. Check the ultrasonic system and calibration of the instrument per documented procedures using a calibration standard when any of the following occurs: • • • • 03/2011 Damage to any part of the ultrasonic system Change in transducers. All holes should be generated from the front or back rim face. wrought or cast. See Fig.3. 18.4. as a minimum.3 Calibration 18.6 An alternate method for axial testing of cast steel wheels is to use loss of back reflection. Typical depths for the three holes could be 1 1/2. and other accessories Loss of power or equipment malfunction Whenever ultrasonic instrumentation is first turned on G [M-107/M-208] 31 . 18. 18.-diameter concave bottom hole generated to a depth of 1/8 in. 18.4.-diameter flat-bottom holes shall be generated in multi-wear wheels. Manufacturer shall document and demonstrate the correlation between the 1/8-in. Holes shall not be located close to each other so as to impede the response from each hole individually.4 A distance amplitude correction (DAC) shall be used for axial and radial testing of wheels.3. 18.3.3. To ensure detection.3.4.3.4. two additional 1/8-in.1 18.5.2. one additional 1/8-in.3..4.-diameter flat-bottom hole generated from the inside diameter of the rim perpendicular to the tread surface. as a minimum.3.4.4. Individual depth standards shall be permitted.3. B.4. 18. Calibration shall be accomplished using the reference standard.3. B. from the tread surface.3. B.1 shows the depth of reference standard holes for the different wheel types. See Fig. The instrument sensitivity level should be adjusted to produce an approximate full-scale reflection from the reference standards of paragraphs 18. B. and 18.4. Table B. See Fig. See Fig.-diameter flat-bottom hole generated perpendicular to the rim face and to a depth of 1 1/2 in. The reference standard shall be a 3/8-in.3.4. at the front rim face.2 Radial To facilitate creation of a DAC. Individual depth standards shall be permitted.5 Alternate calibration standards may be used when authorized by the AAR WABL Committee. the reference standard shall be a 1/8-in.3.3.8 Recalibration Conduct ultrasonic calibration to ensure system conformance to required specifications.4.4.2 For axial testing of all wheels. cables.4.4. and shall be a minimum of 1 1/4 in.2. 18. 5 Magnetic Particle Inspection 18.5 Rejection 18.9.3. If the results from system verification are outside of system tolerance. 18. 18.5.3.4 Scanning 18. 18.4.4.9.4.4.3 Scanning speed shall permit detection of reference standards at calibration level.1 Conduct ultrasonic calibration checks to ensure system conformance to required specifications.4. 18.4. as shown in Figs.5.2 Any indication from discontinuity giving a loss of back reflection equal to or greater than the reference standard (covered in paragraph 18. G [M-107/M-208] 32 03/2011 .4.1 Wheels shall be inspected axially from either the front or back rim face and radially from the tread surface. 18.3. Each manufacturer shall ensure optimum volumetric coverage for the test method and manufacturing process.3.5.3 Ultrasonic indications that result from wheel geometry or spurious electrical signals shall not be valid cause for rejection.5.2.1 Purpose To supplement visual inspection of the surface of new wheels by detecting discontinuities that may be harmful to wheel service.4. Optimization of coverage is verified by using supplemental reference standard holes located in different areas of the rim. 18.5.4.9 System Verification and Test Results Validation 18.4.03/2011 AAR Manual of Standards and Recommended Practices Wheels and Axles M-107/M-208 18. Action taken shall be supported by wheel reinspection data.1 and B.4.4.5. B. 18. Wheel records and test results shall be maintained for wheels found to be conforming under this paragraph.2 System calibration shall be verified per documented procedures using a calibration standard at least every 8 hours of operation.4.2 One or more transducers shall be designed and located to give maximum volumetric coverage of the rim cross-section both radially and axially.3. 18. 18.3 Records shall be maintained of system calibration and system verification.3.4. assessment of previous inspections must be made and appropriate action taken. 18.2 Scope This test method covers the wet fluorescent magnetic particle inspection of the plates of wheels ordered to this specification. 18.4.1 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.4 The final disposition of rejectable wheel may be determined by manual testing of questioned areas.4.6) during axial scanning shall be cause for rejection.9.4.3. 5. The use of prod-type contacts is prohibited. making sure that the tube is not subjected to excessive vibration during the settling period.3. 18. 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/cm2. Reports of this test are to be shown on regular form as outlined in paragraph 18. 18.3.3 Inspection Medium 18. The magnetizing currents used shall be large enough to induce magnetic fields of sufficient intensity to disclose surface discontinuities 1/4 in.3. long.5.3.3.3.7 times the footcandle reading (at 15 in.5. 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.1 mL.3. chips. Each time the bath is renewed.3 The ultraviolet light should be tested weekly using a light meter.03/2011 M-107/M-208 AAR Manual of Standards and Recommended Practices Wheels and Axles 18. The black light shall have a predominant wavelength of 4000 Å to 3400 Å. It is recommended that powder be added directly over the sump so that it will be drawn quickly into the pump and circulated. distance). 18.5.3. In preparing the new bath. 18.5.3. fill the centrifuge tube with 100 mL of the solution.3.5. Using a regular 100-mL centrifuge tube.5.3. only recommended materials should be used.3 Equipment 18.3.6.3. Allow the bath solution to settle for the time recommended by the manufacturer of the type of powder used. The readings obtained are to be shown on the regular report form as outlined in paragraph 18.3.3. and the intensity of the black light.5. Before taking readings. or other foreign matter settling with the powder.5 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. as outlined in paragraph 18. measured at the surface to be inspected.4 The conversion factor from footcandles (for light meters) to microwatts per square centimeter is 5.1 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.3.5. 18. 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. 18. This condition can be readily observed when the settling tube is exposed to ultraviolet light. shall be a minimum of 75 footcandle at point of inspection.3. it should be known that the glass black light filters are clean. the bath container should be cleaned out and the agitation and circulation system should be flushed with 1 or 2 gal of clean carrier. and a correct reading in volume of particles must be as stipulated by the powder manufacturer.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.3.3. The latter type meters are calibrated in microwatts per square centimeter. Each horizontal division represents 0.5. The amount of carrier and powder used and the date of preparation should be recorded on a regular form set up for this purpose. The check also should note contamination caused by dirt.6. 03/2011 G [M-107/M-208] 33 .6.1 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. The meter should be held a fixed distance of 15 in.5.2 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. 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). Filtering screens should be removed and cleaned by blowing with air.5. a certification shall be made the basis of acceptance of the material.5.6.6 Personnel Requirements for Ultrasonic Inspection 18.7. and inspected in accordance with the provisions of the specification.6.3.6. 18. Each certificate so furnished shall be signed by an authorized agent of the supplier or manufacturer.5.3. tested.5.7 Rejection Rejection of magnetic particle discontinuity indications must take place if any plate surface indication is 1/4 in.5.3.7 Prepackaged. 18.6 Time of Inspection The magnetic particle inspection shall be performed following final machining or grinding on wheel plate. This shall consist of a copy of the manufacturer’s test report that the material has been sampled. and this form should be on hand at the wheel shop and available to AAR inspectors.0 CERTIFICATION At the purchaser’s request.6.5.3. 18. Recommended Practice SNT-TC-1A.3 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.1 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.3. G [M-107/M-208] 34 03/2011 . including aerosol sprays.5. Discontinuities may be removed by machining or grinding where sufficient stock remains. 18.03/2011 AAR Manual of Standards and Recommended Practices Wheels and Axles M-107/M-208 18.5. 18. 18. in length or longer in any direction.3.5. 18.3.1 The solution is agitated frequently to ensure that magnetic particles remain in solution.2 A detectability test is performed daily on each package in use and a record is kept per paragraph 18. The test consists of inspection of a test wheel with a known crack of at least 1/4 in. 18. Recommended Practice SNT-TC-1A.4 Preparation for Inspection The surface shall be scale free before magnetic particle inspection. Such wheels shall be retested by magnetic particle inspection.6 A regular form should be prepared embodying the information to be shown on monthly and weekly tests as outlined above. 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. 19. Recommended Practice SNT-TC-1A.2 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.3. may be used provided that the following conditions are met: 18.3. latest edition. 18. Continuous or residual magnetization shall be used with adequate coverage by the inspection medium.5 Detection of Discontinuities This inspection shall be performed to detect discontinuities whose axes may be in any direction.7. self-contained solutions. latest edition. latest edition. This must be verified by ultraviolet light before the test is started.3.5. 22.0 REJECTION 20. will be rejected. the manufacturer may make claim for a rehearing within that time. 21. or elsewhere.14.2 Wheels that show injurious defects subsequent to original inspection and acceptance at the manufacturer’s works.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.1 through B. B.0 This specification includes Appendices A and B.03/2011 M-107/M-208 AAR Manual of Standards and Recommended Practices Wheels and Axles 20. and the manufacturer shall be notified.1 Wheels represented by samples that fail to conform to the requirements of these specifications will be rejected. and Figs. 03/2011 G [M-107/M-208] 35 . 20. In case of dissatisfaction with the results of the tests. 000 miles of service and with sufficient rim metal to be reapplied. the second will be for 20.03/2011 APPENDIX A AAR Manual of Standards and Recommended Practices Wheels and Axles M-107/M-208 APPENDIX A AUTHORIZATION FOR DELIVERY OF WHEELS FOR AAR INTERCHANGE SERVICE 1. This would allow analysis of wheels produced to this drawing. Additional allotments or unconditional approval for unlimited quantities will be given after that.000 wheels installed from the first allotment will have been tracked to provide mileage and will have achieved 200. conditional approval.2 Ultrasonic testing to wheelshop requirements for turned wheels will be performed for 30 or more wheels with at least 200.0 The manufacturer applying for delivery authorization must provide the AAR with an electronic copy of the following documentation. 3. If necessary. G [M-107/M-208] 36 03/2011 . The descriptive drawing will provide the following information: 2. two profiles. The 30 wheels will then be placed in service and tracked.1 A new wheel type (such as CH-36. the applicant should request details from the AAR. provided all required conditions are met.0 Each manufacturer must obtain an authorization for delivery of wheels for AAR interchange use from the Committee prior to delivery. Provided all other criteria are met. a statement should be made to this effect along with a summarization of the design considerations. preferably. unlimited quantity will be granted. The initial authorization will be for the delivery of 32. 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. The preferred analytic procedure is that covered in S-660. unconditional approval will be granted. upon successful completion of ultrasonic testing. 2.000 total). 3.000 wheels (52.000 total) and the third will be for 20. 2.1 A full-scale drawing showing the wheel cross-section from center of the hub to top of the flange. Provided all other criteria are met.000 miles additional service. If there is no design analysis. 3. 2. WABL will designate a sponsor railroad to assist the manufacturer in meeting these requirements. or J-33) that is made for the first time by the requesting manufacturer will require the following prior to being granted unconditional approval.3 A statement advising the specific areas in which the wheel design may not be compatible with normal shop machinery and handling equipment. and wheel transport cars in general use. and data provided in the form of C-scans will be captured with an AAR observer present and provided to WABL. If the applicant would like the AAR to perform the S-660 design analysis on a contract basis. 2.000 wheels.1 A descriptive drawing of the wheel type as it will be produced. CJ-36.1. 3. Ultrasonic testing to wheelshop requirements of turned wheels will be performed for 10 of the 30 wheels reapplied after 100.1. standard storage facilities. Test costs will be paid by the proponent.1.1.0 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.1 A minimum of 5.000 wheels (72.2 A brief description of the design analysis method and the results of the analysis. If the manufacturer requests additional delivery authorizations. 2.2 A notation of the wheel type and heat-treatment classes of the wheels to be produced. upon successful completion of the ultrasonic testing.000 miles in service. The drawing may show either a single profile with tolerances or. Results will be reported to the Wheels.2 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.O.03/2011 M-107/M-208 AAR Manual of Standards and Recommended Practices Wheels and Axles APPENDIX A 3. Box 11130 Pueblo. and Lubrication Committee Manager within 90 calendar days.0 of this specification. 4.1. P. Send results to Email: wabl@aar. Electronic reporting is preferred.3 At least one out of every 1.0 Changes to any wheel design by the producer must be reviewed by the Committee before delivery authorization may be granted. 03/2011 G [M-107/M-208] 37 . Colorado 81001 3. Authorization may be withdrawn if service performance so dictates.com Facsimile: 719-585-1895 Mail: AAR WABL Committee Manager Transportation Technology Center Inc. Bearings.000 wheels produced in the initial allotment will be tested for microcleanliness according to paragraph 9. Axles. and heat-treating subcontractors inspected if they do not use their own facility. Specification M-1003. at applicant’s expense. and forms necessary to demonstrate compliance with this Specification M-107/M-208 and with MSRP Section J. Every effort will be made to inspect all plants in a given area at one time to minimize costs. if mounted wheels are to be provided. Specification M-1003. Critical records must be kept up to date with production and be maintained in English. 5.0 Subsequent to the satisfactory completion of the tests and approval by the Committee of test results. and normally. These inspections can be arranged concurrently with the test program if the applicant so requests. information indicating that equipment is available to comply with the wheel mounting requirements of the AAR Manual of Standards and Recommended Practices. for testing by the AAR. An AAR inspection of the plant will be required. In the event a plant ceases production of wheels for AAR interchange service for more than 1 year. Normally this will consist of the applicant furnishing three wheels. 8.0 In addition to the foregoing. Section G. In the event it is desired to deliver mounted wheel sets.0 Applications for approval are to be submitted to the AAR. 6. G [M-107/M-208] 38 03/2011 . requalification will be required prior to delivery of any items for use in AAR interchange service.” 7. Part II. shot peening. These inspections will require that all out-of-pocket expenses be borne by the applicant. “Specification for Quality Assurance. These inspections will be made in conjunction with the facility inspection. the AAR must be notified no later than 2 weeks prior to reopening. the AAR will inspect the plant where the wheels are to be produced for proper equipment and. internal procedures.0 After review of the data submitted with the application.0 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. 2. Section J. 4.0. In the event a plant ceases production of wheels for AAR interchange service for more than 60 days and less than 1 year. All costs are to be paid by the applicant upon notification of the testing charges.03/2011 APPENDIX B AAR Manual of Standards and Recommended Practices Wheels and Axles M-107/M-208 APPENDIX B QUALIFICATION OF MANUFACTURER’S PLANT AS A PRODUCER OF WHEELS FOR AAR INTERCHANGE SERVICE 1. which will be prorated among the companies inspected. 8. 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.2 Critical records are defined as the standards. paragraph 2. and the cost will be borne by the applicant. The Committee may elect to require testing of wheels in accordance with Appendix B. 3. wheel manufacturers must meet the requirements of the AAR Manual of Standards and Recommended Practices. 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 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. an inspection of the facility is required prior to the delivery of any items for use in interchange service. an AAR inspection will be arranged for the wheel shop. 8.0 In the event that a facility ceases production for less than 1 year and has not received its scheduled annual inspection. the Committee will authorize the applicant to contact the AAR for information concerning product testing.0 and subparagraphs.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.1 Plant practices and the final product must conform to the English language versions of any applicable standards or specifications. “Wheel and Axle Manual” should be included. 03/2011 M-107/M-208 AAR Manual of Standards and Recommended Practices Wheels and Axles Fig.4.1 Typical reference standard for rim face ultrasonic test Paragraphs 18.2 and 18.4 Hole #1 reference hole Holes #2 and #3 used for distance amplitude correction (DAC) 03/2011 G [M-107/M-208] 39 APPENDIX B . B.3.4.3. 1 Axial rim test Paragraphs 18.03/2011 APPENDIX B AAR Manual of Standards and Recommended Practices Wheels and Axles M-107/M-208 Fig.1 Alternate configuration for distance amplitude correction G [M-107/M-208] 40 03/2011 .1.3.4.2 and 18.4.3. B.4. 03/2011 M-107/M-208 AAR Manual of Standards and Recommended Practices Wheels and Axles APPENDIX B Table B.3 and 18. 1 1/4 in.4.1 Wheel Design One-wear two holes Two-wear two holes Multi-wear three holes Reference Hole #1 1 1/4 in. .2 Typical reference standard for rim tread ultrasonic test Paragraphs 18. B. Fig. 3/4 in.3.4.4.3. 1 1/4 in.2 Hole #1 reference hole Hole #2 and #3 used for distance amplitude correction (see Table B.1) 03/2011 G [M-107/M-208] 41 Hole #3 2 1/4 in. Distance below Tread Surface Hole #2 3/4 in. 3/4 in. B.3 Axial rim test Paragraph 18.4.6 G [M-107/M-208] 42 03/2011 .03/2011 APPENDIX B AAR Manual of Standards and Recommended Practices Wheels and Axles M-107/M-208 Fig.3. 2 03/2011 G [M-107/M-208] 43 APPENDIX B .4.4. B.3.1 Tread rim test Paragraph 18.03/2011 M-107/M-208 AAR Manual of Standards and Recommended Practices Wheels and Axles Fig. 4.03/2011 APPENDIX B AAR Manual of Standards and Recommended Practices Wheels and Axles M-107/M-208 Fig. B.2 G [M-107/M-208] 44 03/2011 .2 Axial rim test Paragraph 18.3.4. 015 in. in depth. CLASS /8" 1 13/8" 1" MIN. in nominal height at crest. Stamping is limited to 14 characters. All stamped characters must be stamped with a low-stress die design to a minimum depth of 0. Italicized characters (sloping upward to right) shall be used.4 Marking of locomotive wheels rim stamping Paragraph 17. or D. Dies used to produce characters shall be not less than 3/8 in. and the design designation shall be stencilled on the back plate with paint using characters at least 1 in. from the inner edge of the rim. B. TAPE SIZE Note 1 Note 2 Note 3 Note 4 Note 5 Stamping is to consist of manufacturer’s serial number. or an AAR-approved alternative. between characters and 1 3/8 in. and hot stamping shall be nominally 3/32 in. date of manufacture. as appropriate. A. The stamping shall be located not less than 1/4 in. between groups. B. C.1 03/2011 G [M-107/M-208] 45 . manufacturer’s identification. in height. Fig. and class of heat treatment. Stamping is to be spaced a minimum of 1/8 in.03/2011 M-107/M-208 AAR Manual of Standards and Recommended Practices Wheels and Axles APPENDIX B MONTH YEAR SERIAL NUMBER MFGR. All wheels will be marked for class using letters L. may be bored and applied with any portion of the wheel manufacturer’s hub stamp closer than 1/8 in. between characters and a minimum of 1 3/8 in. B. and class will be spaced approximately equidistantly around the hub face. in height and shall not have sharp edges. as appropriate. from the inner hub diameter and no closer than 1/8 in. or D. between groups and located approximately central of the hub face. or an AAR-approved alternative. manufacturer’s identification. 2009. YEAR M-107/M-208 160 TAPE SIZE 1' MIN. The hub stamping of locomotive wheels may be applied by the purchaser after final machining of the hub. and design designation in the order shown above. All stamped characters must be stamped with a low-stress die design to a minimum depth of 0. Fig.1 G [M-107/M-208] 46 03/2011 . No wheel manufactured before May 1.5 Marking of carbon steel wheels hub stamping Paragraph 17. and (3) date of manufacture. (2) serial number. 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. 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. from the outer hub diameter. locomotive wheels and wheels for passenger service may be ordered stamped on the front or back hub face. Stamping is to be spaced a minimum of 1/8 in. Stamps used to produce characters shall be not less than 3/8 in. DESIGN When ordered. class of heat treatment.3 MONTH 12 77 GK /" 38 1 3/8 " /8" CLASS 3 MFGR. B. date of manufacture. /8" 03/2011 APPENDIX B AAR Manual of Standards and Recommended Practices Wheels and Axles B MI Note 2 Note 3 Note 4 Note 5 Note 6 Note 7 MIN . in height. The three groups (1) design. A. No wheel manufactured after May 1. All wheels will be marked for class using letters L. /18" 18 Note 1 89 SERIAL NUMBER J33 54 N. Wheels for freight service are stamped on the back hub face. manufacturer. 2009. Stamping is to consist of manufacturer’s serial number.015 in. C. s. Czech Republic UK Canada Beasain. Canada C C WI Rail Wheel Factory (Formerly Wheel and Axle Plant) Yelahanka. Australia Bals. Indiana W Dunkerque & W Valenciennes.A (Formerly SMR/MECANO) Standard Steel LLC Sumitomo Metal Industries LTD Taiyuan Heavy Industries Company LTD Location UK Bochum. Missouri C SJ Abex Johnstown. Ohio C CZ Amsted Maxion (Formerly Iochpe-maxion S. Ukraine Waratah NSW. Iowa C GL Griffin Wheel Company Colton. C. P.6 AAR-approved manufacturers 03/2011 U. Japan Taiyuan. Louis. Italy Anhui. Province. Kansas C GK Griffin Wheel Company Keokuk.S. Germany Bohumin.03/2011 M-107/M-208 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 AAR Manual of Standards and Recommended Practices Wheels and Axles Manufacturer Adtranz Armco B. Romania Burnham.R. PRC C RZ Tianrui Group Foundry Co. or T directly precede the wheel serial number for wheels manufactured prior to about April 1978 Fig. Brazil Dnepropetrovsk.C. Henan Province. CA C GS Griffin Wheel Company Bessimer.) Cruzeiro. Cacapavz. Pennsylvania Germany Lovere.V. S. LTD MWL (Formerly Mafersa) Niznedneprovssky Tube Rolling Plant (NTRP) OneSteel Rail and Forge S. Spain France Oakmont. Alabama C GT Griffin Wheel Company Winnipeg.A. Brazil C Datong. PRC 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. China C CO Datong ABC Castings Company LTD FM FM Fundiciones de Hierro y Acero Mexico C GB Griffin Wheel Company Bensenville.S. Bagalore. Steel Valdunes APPENDIX B G [M-107/M-208] 47 X X X X X X X X X X X X . Shanxi Province. South Africa C Ruzhou. Alabama C S Abex ** St. B. Ltd TA Tonghe Wheel Company Xinyang City. PRC ** The letters C. Sao Paulo. France Nizhegorodsky Region. Shanxi Province. Steel U. SMR S. Henan C Province. Ohio C GI Griffin Wheel Company Kansas City. Russia W VK Vyksa Steel Works SO ABC Rail (formerly Abex) Calera. India AW Scaw Metals Germiston. (Formerly VSG) Bethlehem Bonatrans a.V. Illinois C GC Griffin Wheel Company Columbus. (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. Hyacinthe. Pensylvania C T Abex ** Toledo. Alabama C C Abex Rail ** Calera. Pennsylvania Osaka. Pennsylvania W Gary. Canada C GY Griffin Wheel Company St. Characters to be cast on the back plate of wheels shall. A. Cast markings shall be legible characters. Note 3 All wheels shall be marked for class using letters L. at least. Note 2.7 Raised markings on cast carbon steel wheels Paragraph 17. high and so spaced to allow related characters to be readily distinguished as a group. B. and class must be clearly separate. show the manufacturer’s serial number. Note 4 The three groups (1) design.1 G [M-107/M-208] 48 03/2011 . C. (2) serial number. CLASS TRADEMARK Note 1. date of manufacture. class. manufacturer’s identification. B. Fig. as appropriate.03/2011 APPENDIX B AAR Manual of Standards and Recommended Practices Wheels and Axles M-107/M-208 SERIAL NUMBER 09 7511 CJ-33 78 S0 C 08 DESIGN MONTH YEAR MFGR. or D. and design designation. and (3) date of manufacture. at least 1 in. manufacturer. B.0663 Except A-28 = 7 ± 1⁄8 Fig.9 through B. 03/2011 G [M-107/M-208] 49 . see Figs.1 Note: For standard wheel types and for dimensions and other data not shown above.14.8 Standard dimensions and tolerances and permissible variations Paragraphs 2.1 and 15. B.03/2011 M-107/M-208 AAR Manual of Standards and Recommended Practices Wheels and Axles A B L Pa/ R2 K a/ Standard Wide Flange Dimensions and Tolerances 1 1 + ⁄16 –0 1 1 3⁄8 + ⁄32 3 – ⁄32 5 23⁄32 ± 1⁄8 7 ± 1⁄4 2 1⁄2 ± 1⁄8 0.0865 APPENDIX B Standard Narrow Flange Dimensions and Tolerances 1 1 + ⁄16 –0 1⁄16 + 1 5⁄32 –0 5 23⁄32 ± 1⁄8 (5 1⁄2 ± 1⁄8 alternate) See Note See Note 0. For narrow. measured in the plane of the taping line.03/2011 APPENDIX B AAR Manual of Standards and Recommended Practices Wheels and Axles M-107/M-208 9. 9.0625 in. 9. the radial thickness of the rim shall not vary more than 1/8 in. except that no more than 5% of wheels delivered may be over . TIR and these must not exceed . TIR. from the inside edge of the rim shall be more than 1/32 in.6 Rotundity Tread when gauged with a ring gauge must not have an opening between tread and gauge at any point over .and wide-flange wheels.0625 in. 9. nor by more than 1/8 in. no point on the back face of narrow-flange wheels more than 1 1/4 in. shall not exceed .4 Plane of Back Face When wheels are gauged with a straight edge applied to the back face of the rim. under the dimensions specified by the purchaser.3 Corner at Inside Diameter of Back Face A sharp corner is preferable to facilitate measurement. 9.8 Eccentricity of Bore Eccentricity between the rough bore and tread.040 in. from the straight edge. 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. if the hub is not machined.7 Diameter of Bore The diameter of rough bore shall not vary more than 1/16 in. For wide-flange wheels.022 in. over nor more than 1/16 in.09375 in. B. In any case. if the hub is machined. G [M-107/M-208] 50 03/2011 . 9. the radius of the corner shall not exceed 1/8 in.9 THROUGH B.2 Thickness of Rim In any wheel. from the straight edge. the back face of the rim measured on the circumference at a distance 1 1/4 in. TIR. inward from the apex of the flange must be in plane within 0. 9. no point on the back face of the rim shall be more than 1/32 in.14 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. Total Indicator Reading (TIR) with respect to the plane of the front face of the rim. around the wheel.0 PERMISSIBLE VARIATIONS IN DIMENSIONS NOT SHOWN BY TOLERANCES ON FIGS. E D. EXCEPT TAPES 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) 11/4 2 21/2 5/8 5/8 3/4 11/2 2 21/2 11/2 2 21/2 3/4 3/4 3/4 7/8 7/8 7/8 +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 +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 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: 1.875 27. E D. F.875 35.AAR Manual of Standards and Recommended Practices Wheels and Axles 03/2011 M-107/M-208 APPENDIX B L TAPING LINE B A G N R D O1 O2 P C L 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.875 24.750 35.375 39. 6 × 11.500 27. 5 1/2 × 10 AXLE ALSO STANDARD FOR J-33 AND M-33. and 15.500 32. PER WHEEL (LB) 32. B.375 39.750 35.375 D 28 + 14 TAPES (5%–5) 28 + 14 TAPES (5%–5) 30 + 14 TAPES (5%–5) 33 + 14 TAPES (5%–5) 38 + 14 TAPES (5%–5) 38 + 14 TAPES (5%–5) G (MIN) 21/2 11/2 21/2 N (MIN) 3/4 5/8 3/4 01 +1 111/8–0 +1 105/8–0 02 +1 111/8–0 MAX FINISH BORE DIMENSION AND TOLERANCES—ALL ENTRIES IN INCHES.2 03/2011 G [M-107/M-208] 51 .1. K D. AND 6 1/2 × 12 AXLES ALSO STANDARD FOR P-33 Fig. G F F F G G G MAX.375 32. 2. K E F. CAP. E.750 39. HUB LENGTH TOLERANCE IS BASED ON FINISHED DIMENSION. 15.9 Standard AAR wheel types—wide-flange contour—for freight car service Paragraphs 2.1. 5 1/2 × 10. 8 FOR DIMENSIONS A. and 15. 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 1 121/2± 1/8 +1 131/2–0 121/2± 1/8 121/2± 1/8 01 +1 13–0 +1 103/4–0 121/2± 1/8 121/2± 1/8 +1 111/2–0 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: 1.03/2011 APPENDIX B AAR Manual of Standards and Recommended Practices Wheels and Axles M-107/M-208 L TAPING LINE B A G N R D O1 O2 P C L 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. B. EXCEPT TAPES. C. * ** REFERENCE GROOVE REQUIRED—SEE RP-619 HUB WALL THICKNESS MAY BE REDUCED AS NECESSARY FOR APPLICATION OF ROLLER BEARING WATER GUARD.10 Standard wheel types for locomotive service Paragraphs 2. Fig.1. B. TO 3/16 IN. HUB LENGTH TOLERANCE IS BASED ON FINISHED DIMENSION. EXTRA STOCK OF 1/16 IN. OVER SPECIFIED DIMENSION MAY BE LEFT FOR MACHINING OF EACH FINISHED SURFACE OR WHEEL MAY BE FURNISHED FINISHED TO EXACT DIMENSION SHOWN.2 G [M-107/M-208] 52 03/2011 . WHERE DIMENSION R2 IS MARKED F.1. B. 15. SEE Fig. 624585 –0.474998 –0.2 03/2011 G [M-107/M-208] 53 Y –1.685529 Detail A Fig.M-107/M-208 AAR Manual of Standards and Recommended Practices Wheels and Axles APPENDIX B AAR-1B WIDE PROFILE CENTERS OF RADII RELATIVE TO GAUGE POINT POINT A B C D E F X –1.1.11 AAR-1B wide-flange contour for freight car wheels Paragraphs 2.000000 –0.589000 0.097100 0.624585 0.147435 0. B.589000 0.580300 –1.132273 –0.060300 AAR-1B WIDE PROFILE INTERSECTION OF POINTS RELATIVE TO GAUGE POINT POINT 1 2 3 4 5 6 7 8 9 X 1.812800 .291159 –0.149921 –0.989517 Y –0.312100 –0.375000 1.035442 –0.249600 –0.031070 0.375400 0.196896 0.000000 –0.007500 0. and 16.589000 0.362211 –0.091706 0. 15.1.631437 –0.162616 0. 140565 0.000000 –0.038692 0.106659 –0.312500 0.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 –0.008400 –0.12 AAR-1B narrow-flange contour for freight car wheels Paragraphs 2. B.654129 Detail A Fig.031335 –0.156300 0.1.562500 0.977100 Y –444011 0.853075 0.562500 0.370581 –0.028575 –0.748621 –0. 15.441210 –0.562500 0.065876 0.571971 –1.052000 Y –0.2 G [M-107/M-208] 54 03/2011 .1.204400 0.230296 0.237046 0.625000 –0.278542 –0.844000 AAR-1B NARROW PROFILE INTERSECTION OF POINTS RELATIVE TO GAUGE POINT POINT 1 2 3 4 5 6 7 8 9 X 1.375000 0.641800 –0. and 16. 13 Cylindrical tread contour for narrow-flange wheels Paragraphs 2. ON THE OUTER RIM FACE. FREIGHT LOCOMOTIVE WHEEL RIMS SHALL BE MACHINED WITH A MAXIMUM RADIUS OF 5/8 IN.1 and 16.4375 IN. MEASURED ALONG ITS LENGTH. THIS RADIUS MAY BE REDUCED AS NECESSARY OR A CHAMFER USED. B. A CHAMFER IS ALLOWED TO EXTEND PAST THE RADIUS AT 45°. BUT MUST BE NO LONGER THAN 0. Fig.2 03/2011 G [M-107/M-208] 55 .M-107/M-208 AAR Manual of Standards and Recommended Practices Wheels and Axles 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. 987 VERIFY WITH CONTOUR MAPPING MAX MANUFACTURE DEVIATION: . -1. B.14 Tread contour gauge for AAR-1B wheels Paragraph 16.8128) R1.02338.003" MAX RECERTIFICATION DEVIATION: . -0.0841873.0603.4374) 3 (0.AAR Manual of Standards and Recommended Practices Wheels and Axles APPENDIX B M-107/M-208 6.750 Fig.480.4289. -1.5 G [M-107/M-208] 56 03/2011 .5625 1.094 4 3 BASELINE 1 CENTERS OF RADII A (0.950724) 5 (1.49764) 2 (0. -1. 0.469 ؼ " INTERSECTION POINTS 1 (0.000) B 0. -0.005" MATERIAL: STAINLESS STEEL 17-7 1 8 " THICKNESS HARDENED .000 A WHEEL CONTOUR ACCEPTANCE GAUGE FOR AAR 1B NARROW & WIDE FLANGE 2 R.500 5 B 2.000.500 3 3 8 8 " 1.769141.2878) 4 (1.8053) 4.8624° 1. -0. M-107/M-208 AAR Manual of Standards and Recommended Practices Wheels and Axles APPENDIX C APPENDIX C AUTHORIZATION FOR CLASS D WHEEL TEST ALLOTMENT 1. 3.0 MATERIAL TESTING 3. Unless otherwise approved by WABL. All costs for the tests and the observer are to be paid by the applicant. The report should contain sufficient photographic evidence to support the conclusions.000 wheels for field service testing in interchange service.1 The intent of Class D is to provide wheel materials with superior resistance to tread damage when compared to Class C wheels.1 Tension testing shall be conducted on two specimens at ambient temperature and two specimens at 1.5. Tests must be conducted per ASTM E21 (1. The applicant must contact the WABL Committee to schedule an AAR observer.2 The microstructure shall be classified in the report and should be free of martensite.1. 3. In addition. the WABL Committee will authorize a test allotment of 5.2% offset yield strength. 2. 3.1. latest edition. to include the tread surface.1.0 of this appendix. Wheel materials should meet the minimum properties listed in Table 3. 3. of the original wheel tread must remain visible at the ends of the test specimen) in the circumferential direction.” Upon acceptance of the laboratory test results.2 section) shall be taken in the radial plane direction adjacent to the microcleanliness specimens and must include the tread surface.000 °F) and ASTM A370 (ambient temperature). All requirements of the M-107/M-208 wheel specification and associated appendixes apply to Class D wheels. without compromising any other safety performance characteristics.3 Absence of tensile hoop stress shall be documented by a radial saw cut made to a depth at least 1 in. Three sample wheels must be tested. percentage elongation. and percentage reduction of area shall be determined. 1. 03/2011 G [M-107/M-208] 57 .000 °F. Six microstructural specimens (1/2 in.4 Hardness mapping of the test wheels shall be performed per M-107/M-208. 0. Brinell hardness measurements shall also be taken along the centerline of the plate to the hub inner diameter at approximately 1/2 in.0 Class D wheel applicants must submit results from laboratory material tests as described in paragraph 3. The intent is to classify all microstructures in the specimen. No opening of the cut shall be present at the conclusion of the cut. an AAR observer is required. spacing and reported for reference only. 3.0 Each manufacturer must obtain an authorization for Class D test wheels from the Committee prior to delivery.1 The following material testing is required.1.1. Ultimate tensile strength. Section 11. “Material Testing. deeper than the rim inner diameter. Specimens shall be taken from as close to the tread as possible (at least 1/8 in. 1.2. If a valid KIC is not obtained.1 Test conditions shall be as follows: • Contact pressure = 319. 3.1. 3.1.75% slip • Duration = 500.6.6. 1" MIN 2.4" MIN 2.1 To demonstrate performance no worse than Class C.1. 3. >14 >20 Reduction of Area (%) >15 >40 Fracture toughness (KIc or Kq) >35 ksi sq root in. Tests shall be performed using two discs constructed of the proposed wheel material. Table 3. 3. 3. comparative accelerated rolling load wear tests shall be conducted.1 Fracture toughness test sample 3. Testing protocols may be changed if better methods can be demonstrated.2 The result must be calculated wear rates for Classes C and D.6.3% slip • Duration = onset of shelling as determined using a vibration sensor 3. 3.000 Yield (psi) (0.2.APPENDIX C AAR Manual of Standards and Recommended Practices Wheels and Axles M-107/M-208 3. latest edition.2% offset method) >110.750 • 0.000 °F Hardness 341 HB–415 HB NA UTS (psi) >157.1 Test conditions shall be as follows: • Contact pressure = 159.500 psi • 0. The following test conditions are recommended.1.1. G [M-107/M-208] 58 03/2011 .6.1.1.000 >70. then report the KQ value.6.6 The manufacturer must provide lab data demonstrating the relative wear and shelling performance as compared to Class C.1.2 The result must compare cycles to shelling onset for Classes C and D. an accelerated rolling load shelling test shall be conducted using two discs. The sample shall be taken as shown in Fig.1.000 >50.000 cycles 3.1.5 "M IN Fig. The manufacturer must specify the test methods used for the comparison.5 Fracture toughness type testing shall be determined for two samples per test wheel at 70 °F to 75 °F according to ASTM E 399.1 Minimum material properties Ambient (65 °F–80 °F) 1.6.000 % Elongation in 2 in.2 To demonstrate performance superior to Class C. 000-mile test report is accepted by the WABL Committee.0 FIELD SERVICE TESTING 5. 6.M-107/M-208 AAR Manual of Standards and Recommended Practices Wheels and Axles APPENDIX C 4.000 miles • At least 300. 03/2011 G [M-107/M-208] 59 .1 A second test allotment of 5.000-mile report.0 ADDITIONAL ALLOTMENTS 6. an allotment of 5.000 miles • 400. The field service test shall include the following: • Monitoring a minimum of 1.2 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 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 intervals: • At least 25.000 miles 6.1 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.000 miles • At least 50.2 After the 400.1 Upon Committee review of the laboratory test program. additional allotments may be approved per Appendix A.000 miles • At least 100.000 wheels shall be granted.000 miles per year. Manufacturer shall select a service that is expected to accumulate at least 50. 5. The manufacturer shall inspect all wheels in service and report to the Committee the cause for any removals.000 miles 5.000 wheels may be applied for after the 300.0 FIELD SERVICE TEST ALLOTMENT 4. APPENDIX C AAR Manual of Standards and Recommended Practices Wheels and Axles M-107/M-208 THIS PAGE LEFT BLANK INTENTIONALLY G [M-107/M-208] 60 03/2011 . 3. 4.0 GENERAL REQUIREMENTS 4.0 APPLICATIONS The electrochemical metal deposition process can be used effectively on specific surfaces. and a current is passed through the solution. 2. A motion between the anode and the workpiece is required to produce high quality. thus depositing metal without the use of either heat or immersion tanks. in turn. 03/2011 G [M-967] 61 . The result is a rapid deposition of metal onto the area contacted by the anode.7.1 The DC output ranges of power packs used for electrochemical metal deposition processes shall be determined by the process manufacturer. Section G-II. quality control. or pumped through.2. is attached to a DC power pack.0 SCOPE This document describes the certification requirements. uniform deposits. The cathode lead of the power pack is attached to the workpiece. personnel requirements. 4.1 Power Pack 4.03/2011 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: 1980.1.1 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. materials. Last Revised: 2008 1.0 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.1. equipment. 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. an absorbent material attached to an inert electrode (anode) that. 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. The process requires neither the pre-machining of base metal nor the subsequent stress relief and embrittlement relief of the metal deposit. paragraph 1. and utilization of the electrochemical metal deposition process for repairing roller bearing axle journals. The solution is held in. where a metal deposit is required for restoration of original dimensions on roller bearing axle journals and dust guards. as listed in the AAR Manual of Standards and Recommended Practices.1. 2 Handles and Anodes Handles for the process are conductive. of different manufacturers be intermixed or substituted into a buildup procedure. Other anode materials may be used with a specific compatible solution. must be matched to the amperes drawn for a given application. in writing. high-purity graphite or platinum with up to 11% iridium alloy.1.2 Solutions 4. The anodes must be of a material chemically inert to the electrolyte solution. of a grade approved.2 • • • • • • • • AAR Manual of Standards and Recommended Practices Wheels and Axles M-967 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. compatibility of the chemicals in the process is mandatory for process integrity.1. 5.2 Completion of a theoretical course certified by the process manufacturer and a demonstrated ability to repair axles consistently to the manufacturer’s process procedures.1 The solutions used in the electrochemical metal deposition process are highly concentrated water base chemicals. 5.1 Completion of a manufacturer’s theoretical course of instruction and a demonstrated ability to repair axles consistently to the manufacturer’s process procedures.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. either preparatory or metal deposition. therefore. Documentation of the hardness test must include the test method and batch number(s) and be kept on record.1. only certified personnel shall be permitted to process interchange equipment. This written approval must also be provided to the AAR. Specification M-1003. should aid in dissipating heat. Note: Although several sources for electrochemical metal deposition solutions may be developed. All metal deposition solutions must carry a batch number and be traceable to the manufacturer’s control batch and the axle repaired. and metal removal solutions for polishing and stripping.03/2011 4. Certification may be obtained in any of the following manners: 5.1. graphite shall have less than 1% metallics by volume. The only materials considered universally inert to all electrolytes used in the electrochemical metal deposition process are high-density. G [M-967] 62 03/2011 . Where graphite anodes are used. 5.1.1.0 TECHNICAL REQUIREMENTS 5. in no case will solutions. and must provide operator protection as well as ease of operation. Section J.1 Operator Qualification The electrochemical metal deposition process is operator dependent and.” to include a demonstrated ability to repair axles.2. 4. however. 4. These include preparatory solutions for cleaning and activating the surface to be coated.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. Therefore. metal deposition solutions for coating. “Specification for Quality Assurance. both the anode and solution must be approved in writing by the process manufacturer. This written approval must also be submitted to the AAR. by the process manufacturer for each electrolyte being used. 003 in. excessive edge build-up. deep Undersized journal and ring groove combination Undersized journal and water etch combination Undersized journal that has been previously rebuilt (nickel deposited to nickel over the entire journal) For status code 3B: a. 5.008 in.1. and free of blisters. e. pressure-sensitive tape as approved by the AAR.1. deep Water etch in cone area greater than .1. f. Specification M-1003. 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.03/2011 M-967 AAR Manual of Standards and Recommended Practices Wheels and Axles 5. coarse grained.3. porosity.1. below minimum 5. Undersized dust guard greater than 0. “Specification for Quality Assurance. and other defects that would affect the functional use of the axle.2.2 Adhesion Test Each axle journal repaired by the electrochemical metal deposition process shall have an adhesion test performed.2.2.2. except in the case of dust guard repairs where paragraph 5. 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. d. pits. below minimum For status code 3C: a. c.” 5. The deposit surface of the repaired journal shall be free of burnings and stress concentrations.1 Visual Inspection All deposits shall be smooth. 5. Burning is defined as rough.2. Undersized journal greater than . since the process obtains significant cost reduction when secondary processing is not required and the part is built to size. However. b. nodules.1. Highly stressed deposits will normally be indicated by cracks or crazing.6 Proper repairing shall be determined by testing 100% of the repaired journals in accordance with paragraphs 5. or dark deposits caused by localized high current density or arcing.2.001 in.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.003 in. 5. and 5. Section J. uniform in color.7 Adequate records to document the above demonstration of operator proficiency for certification shall be maintained.2. The adhesion test is accomplished using Scotch #250 tape or an equivalent high-tack-strength.003 in. The adhesion test is accomplished as follows: 03/2011 G [M-967] 63 .4. other inspection procedures are available. below minimum Seal wear ring groove greater than . 5. The above defects are cause for rejection.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 5.3 does not apply.2. Undersized journal greater than . 3 Stick the tape longitudinally across the width of the processed area of the journal so that approximately 1/2 in. 5.-wide unused tape approximately 6 in. The average journal diameter may be used to meet journal diameter requirements for the AAR Manual of Standards and Recommended Practices. therefore. “Wheel and Axle Manual.2.0002-in. removing the tape with a single jerk.2. 5. the diameter of the repaired dust guard must be within the prescribed tolerances for new axles.1 The deposit surface finish on the repaired journal must not exceed 63 µin.1 Thoroughly clean and dry the processed surface with a method that will not adversely affect tape adhesion.2.3 Burnishing 5. reduction in journal diameter after being burnished.2. In addition to the foregoing.4.” pertaining to axle repairs by this process and to facility certification must be met. 5. longer than the width of the processed area.03/2011 AAR Manual of Standards and Recommended Practices Wheels and Axles M-967 5.4 Grip the loose end of the tape and rip rapidly upward (at a right angle to the surface). 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.2. Fig.1 The deposit is suspect if moderate burnishing will cause a nonadhering deposit to lift.2. 5.3 A moderate burnishing shall be that which creates a 0. Tamp the tape down to ensure thorough adhesion.1.2. Section J.0 GENERAL REQUIREMENTS The requirements of the AAR Manual of Standards and Recommended Practices.2.2. Section G.0001-in. peel.3. of the base metal on each side is taped to ensure coverage of both edges of the processed area. The radius of the journal fillet must meet the new axle dimensions. Any deposit nickel adhering to the tape and part of the processed area visually lifted is cause for rejection. 5. 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 G-II.3.3.2.2. “Specification for Quality Assurance. 6. Specification M-1003.1 and 5.9–1993 shall be burnished and retested in accord with paragraphs 5. to the outboard edge of the outboard cone.2. 5.2. 5. Part II.4 Surface Finish 5. 4.2.2 Cut a piece of 1-in.5 Inspect the tape and processed surface area.2 with a minimum daily inspection of 5%. 5.2.5 Dimensional Inspection When restoration of the entire length of the journal is required.4.” G [M-967] 64 03/2011 .2.2 The deposit finish on the repaired dust guard must not exceed 125 µin. 5.2. When restoring the dust guard for use in fitted applications.2 Each active operator shall have at least one axle inspected for compliance with this paragraph for each week of production. an inspection sampling derived from ANSI/ASQC Z1.2.2. 5.2. or flake. to 0. repaired. 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. 3.8 Mounting and removal of a fitted backing ring three times on restored dust guards. 3.2. 4.2. 4. 4. latest revision. 3.2 and 4.5. Administrative Standards.003 in. 4.3 of this appendix.003 in.3 Adhesion test as per paragraph 5. 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. 03/2011 G [M-967] 65 .2. inspection will be performed in accordance with paragraphs 4. Subsequent to performance of the test referenced in paragraph 4. Applications shall be provided in electronic file format and must include brochures.03/2011 M-967 AAR Manual of Standards and Recommended Practices Wheels and Axles APPENDIX A APPENDIX A QUALIFICATION OF APPLICANTS’ FACILITY FOR REPAIRING AXLES BY ELECTROCHEMICAL METAL DEPOSITION PROCESS 1. and 4. on the outboard cone seat.002 in. 4. material safety data sheets.2 Visual inspection as per paragraph 5.2. 2.2.7 Journals must meet burnishing and testing specifications per paragraph 5. below minimum restored.001 in.4. Photographic documentation will be developed to confirm compliance with paragraphs 4.6 Mounting and removal of a bearing three times on journals with full length restored with a minimum interference fit of 0. 4.1 Microhardness test as per ASTM-B-578.2.002-in.4 All journals and dust guards must be measured and meet dimensional requirements as per paragraph 5. below minimum with full length of journal restored. Microhardness for electroplating on a minimum 0. Minimum microhardness should be C50 Rockwell or 500 Knoop tested per ASTM B-578 with a 50-g load. This must reflect nickel over nickel restoration.4 Two dust guards having the dust guards greater than 0.1. 3.0 After determining that the application is consistent with the requirements of this specification.1. 4.2. deposit material on a seal wear ring groove. as described in the AAR Manual of Standards and Recommended Practices.6 of this appendix.2 Two journals undersize greater than 0. Standard S-060.3 Two journals with full length of journal restored over repaired water etch greater than 0. All journals must meet the requirements of paragraph 5.2. 4.0 All costs are to be paid upon notification of the testing charges. the Committee will authorize the applicant to contact the AAR for information concerning product testing.3.1 Two journals having had only seal wear ring grooves greater than 0. 4.3 thereof.2. 4.0 The applicant must provide the Technical Services Division with an application for approval.5 All journals and dust guards must be measured and meet the surface finish requirements per paragraph 5.0 The following tests shall be performed at or under the observation of the AAR with the test results being provided to the Committee.008 in. subject to compliance with the latest version of this specification. the AAR Technical Services Division will inspect the facility where the axles are to be repaired for proper procedures and equipment. Therefore. Rule 120. including a demonstration of the ability to meet the requirements of this specification.03/2011 APPENDIX A AAR Manual of Standards and Recommended Practices Wheels and Axles M-967 5. 7. 8. These inspections may be arranged concurrently with the test program. In the event the delivery requirement is not met and upon notification by the AAR.0 It is considered necessary that each qualified applicant have enough axles in AAR interchange service to develop meaningful performance data. The Committee may elect to require testing of axles in accordance with paragraph 2. In the event that a plant ceases production for more than 1 year. The Committee may elect to require verification of any or all of the provisions of Appendix A of this specification for requalification.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. the applicant will be asked to provide this information by listing the required number of axles delivered and to which customers delivery was made. When data to support the number of deliveries is not available to the AAR. requalification will be required prior to delivery of any items for use in AAR interchange service.0 Subsequent to the satisfactory completion of the tests and approval of the test results by the Committee. the applicant will be required to requalify.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. 6. as previously approved by the Committee. 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. G [M-967] 66 03/2011 . These inspections will require a certification fee as per the AAR Field Manual of Interchange Rules.0 of Appendix A. 03/2011 M-967 AAR Manual of Standards and Recommended Practices Wheels and Axles APPENDIX B APPENDIX B AUTHORIZATION FOR DELIVERY OF AXLES REPAIRED BY THE ELECTROCHEMICAL METAL DEPOSITION PROCESS FOR AAR INTERCHANGE SERVICE 1.0 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. 03/2011 G [M-967] 67 .0 Each applicant must obtain an authorization for delivery of repaired axles for AAR interchange use from the Committee prior to delivery. 2. 03/2011 APPENDIX B AAR Manual of Standards and Recommended Practices Wheels and Axles M-967 THIS PAGE LEFT BLANK INTENTIONALLY G [M-967] 68 03/2011 . 0 SCOPE 1. 1.0 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.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. Last Revised: 2004 1. 2. rolling.1 This document became effective March 1. 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. 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. but all have been developed to produce wheels that will meet the specification requirements. Processes used by individual manufacturers differ in many details.03/2011 S-601 AAR Manual of Standards and Recommended Practices Wheels and Axles WHEELS—MANUFACTURING FACILITY INSPECTION BY TECHNICAL SERVICES Standard S-601 Adopted: 1964. 3.0 GENERAL Current operating conditions on railroads make it imperative that high quality is maintained in all wheels. 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 03/2011 G [S-601] 69 . This should not imply that the inspector should require detailed information of melting practice or of any other processes adopted by a manufacturer. 1980. “Wheel and Axle Manual” and in M-107/M-208 of this manual. Section G.1 Defects detrimental to wheel performance Defects Rims Plates Hubs Inclusions (sand/slag) x x x Cracks (hot tears/cold shut) 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 x x x Improper stamping x 3. 3.1 lists in detail defects that.2 Table 3. have been found to be detrimental to the performance of wheels in service: Table 3.3 To report to the AAR Technical Services Division and manufacturer on the results of the inspection.2.03/2011 AAR Manual of Standards and Recommended Practices Wheels and Axles S-601 3. G [S-601] 70 03/2011 .2.1 The inspections shall be in accordance with the requirements outlined in the AAR Manual of Standards and Recommended Practices. through past experience. Part II. 3.2 To inspect typical wheels that the manufacturer has released for shipment. -diameter wheel.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. it may be used for checking the worn diameter of any of the intermediate size wheels. Because this tape is calibrated in increments of 1 in. the tape should lie flat on the treads all the way around.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. 7. 03/2011 G [S-611] 71 .0 All wheel tapes should be checked periodically on a master ring of known accuracy.0 In use.0 The tape size of a wheel is considered to be that of the lower graduation until the next graduation is reached. 2. 5. 6.0 For new wheels. Last Revised: 2004 1. from a 35-in. circumference and 1/2 tape sizes interpolated.0 The measures are calibrated by 1/8-in. tape 283 (S-612) represents a wheel of exactly 38-in. including the handle and lug. Kinks in tape are not tolerated.03/2011 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. diameter.0 The wheel circumference gauge (S-613) may be used not only for taping new wheels but for taping worn wheels of large diameter. 3.-diameter wheel to a 52-in. 4. 1973. 8. AAR Manual of Standards and Recommended Practices Wheels and Axles S-611 THIS PAGE LEFT BLANK INTENTIONALLY G [S-611] 72 03/2011 . STEEL WHEELS Standard S-612 Adopted: 1893. TO 38-IN.03/2011 S-612 AAR Manual of Standards and Recommended Practices Wheels and Axles CIRCUMFERENCE MEASURE (TAPE) FOR 27-IN. APART WITH THE TAPE LAID FLAT. see RP-608 and RP-609.005 BETWEEN ANY TWO POINTS ON THE SCALE WITH NO ACCUMULATIVE VARIATION. 03/2011 G [S-612] 73 . NOTE: THE SCALE ON THE WHEEL TAPE CAN HAVE A TOLERANCE OF ±. Last Revised: 2004 Note: For master gauge. GRADUATIONS ARE TO BE SPACED 1/8 IN. LINEAR DIMENSIONS SHOWN REPRESENT MEASUREMENTS OF ACTUAL CIRCUMFERENCE OF THE WHEEL AND NOT STRAIGHT LENGTH OF THE TAPE. AAR Manual of Standards and Recommended Practices Wheels and Axles S-612 THIS PAGE LEFT BLANK INTENTIONALLY G [S-612] 74 03/2011 . 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 ±. STEEL WHEELS Standard S-613 Adopted: 1945. APART WITH THE TAPE LAID FLAT. LINEAR DIMENSIONS SHOWN REPRESENT MEASUREMENTS OF ACTUAL CIRCUMFERENCE OF THE WHEEL AND NOT STRAIGHT LENGTH OF THE TAPE.2 See S-611.03/2011 S-613 AAR Manual of Standards and Recommended Practices Wheels and Axles Part 1 CIRCUMFERENCE MEASURE (TAPE) FOR 38-IN.0 SCOPE 1. 1980. NOTE 1: MARK WHEEL DIAMETERS IN 1/8-IN.1 This standard became effective July 1. TO 52-IN. GRADUATIONS ARE TO BE SPACED 1/8 IN. 03/2011 G [S-613] 75 TAPE SIZE 207½ 233 258 283 308 333 358 385½ 409 434 459 484 509 534 559½ 584½ 610 636 .005 BETWEEN ANY TWO POINTS ON THE SCALE WITH NO ACCUMULATIVE VARIATION. 1. Last Revised: 2004 1. AAR Manual of Standards and Recommended Practices Wheels and Axles S-613 THIS PAGE LEFT BLANK INTENTIONALLY G [S-613] 76 03/2011 . Grade 1020 HARDEN AND GROUND ON ALL GAUGING SURFACES. Last Revised: 2004 Note: See RP-613 for the master gauge and S-616 for the limiting wear condemning gauge. MATERIAL: ASTM A-576. CHROMIUM-PLATED FINISH 03/2011 G [S-614] 77 .03/2011 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. AAR Manual of Standards and Recommended Practices Wheels and Axles S-614 THIS PAGE LEFT BLANK INTENTIONALLY G [S-614] 78 03/2011 . 010 in. 34401A MATERIAL: .03/2011 S-615 AAR Manual of Standards and Recommended Practices Wheels and Axles WHEEL DEFECT—WORN JOURNAL COLLAR AND JOURNAL FILLET GAUGE Former Standard S-615 Adopted: 1975. ALL TOLERANCES ARE ±. 1. Last Revised: 2004 1. or less flange on locomotive wheels. 1981.0 SCOPE 1.1 This gauge can be used for 7/8-in. 03/2011 G [S-615] 79 .2 This standard became effective April 1. Gauge No.093 STAINLESS STEEL UNLESS OTHERWISE STATED. AAR Manual of Standards and Recommended Practices Wheels and Axles S-615 THIS PAGE LEFT BLANK INTENTIONALLY G [S-615] 80 03/2011 . MATERIAL: ASTM A-576.0 SCOPE This gauge applies to Gauge No. AXLE—REFERENCE GAUGE FOR VERIFYING AXLE JOURNAL AND FILLET GAUGE S-614 Former Standard S-616 Adopted: 1938. 34401 described in S-614. Last Revised: 2004 1.03/2011 S-616 AAR Manual of Standards and Recommended Practices Wheels and Axles GAUGE. Grade 1020 03/2011 G [S-616] 81 . AAR Manual of Standards and Recommended Practices Wheels and Axles S-616 THIS PAGE LEFT BLANK INTENTIONALLY G [S-616] 82 03/2011 . WHEEL—FORMER STANDARD 1980 Former Standard S-617 Adopted: 1923.03/2011 S-617 AAR Manual of Standards and Recommended Practices Wheels and Axles GAUGE. see RP-614. Grade 1020 03/2011 G [S-617] 83 . MATERIAL: ASTM A-576. Last Revised: 1980 Note: For the master gauge. AAR Manual of Standards and Recommended Practices Wheels and Axles S-617 THIS PAGE LEFT BLANK INTENTIONALLY G [S-617] 84 03/2011 . letters. 03/2011 G [S-618] 85 . TOLERANCES ON DECIMAL DIMENSIONS TO BE ±. AND ON DIMENSIONS IN COMMON FRACTIONS TO BE ±1/64 in. For the master gauge.050-in. REMOVE BURRS AND SHARP EDGES.005 in. see RP-614. STAINLESS STEEL OF SUITABLE HARDNESS FOR GAUGE FINGER.03/2011 S-618 AAR Manual of Standards and Recommended Practices Wheels and Axles GAUGE. UNLESS OTHERWISE SPECIFIED. MATERIAL: . STAINLESS STEEL FOR BODY OF GAUGE AND . 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.093-in. AAR Manual of Standards and Recommended Practices Wheels and Axles S-618 THIS PAGE LEFT BLANK INTENTIONALLY G [S-618] 86 03/2011 . G [S-627] 87 .AAR Manual of Standards and Recommended Practices Wheels and Axles 03/2011 S-627 GAUGE. RECERTIFICATION TOLERANCE IS ±. UNLESS OTHERWISE SPECIFIED. 3. WHEEL—COMBINATION GAUGE FOR WHEEL MEASUREMENTS Standard S-627 Adopted: 1998 Note: For the limiting wear condemning gauge. Notch Detail 0 1/4 1/2 3/4 1 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2 03/2011 A 3/16 1/8 1/8 1/8 3/16 1/8 1/8 1/8 3/16 1/8 1/8 B 1/4 1/8 3/16 1/8 1/4 1/8 3/16 1/8 1/4 1/8 3/16 Material: Stainless steel 304 Thickness: 3/32 NOTES: 1. see Standard S-629. 2. BOXED DIMENSIONS ARE MINIMUM CHARACTERISTICS TO BE VERIFIED FOR RECERTIFICATION.015 IN. MANUFACTURE TOLERANCES ARE ±.010. AAR Manual of Standards and Recommended Practices Wheels and Axles S-627 THIS PAGE LEFT BLANK INTENTIONALLY G [S-627] 88 03/2011 . 010. G [S-628] 89 . RECERTIFICATION TOLERANCE IS ±. THIS GAUGE CAN BE USED FOR 7/8-IN. 3.AAR Manual of Standards and Recommended Practices Wheels and Axles 03/2011 S-628 GAUGE. WHEEL—COMBINATION GAUGE FOR WHEEL MEASUREMENTS INCLUDING LOCOMOTIVE FLANGE LIMIT OF 0. UNLESS OTHERWISE SPECIFIED. Standard S-628 Adopted: 1998 Notch Detail 0 1/4 1/2 3/4 1 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2 03/2011 A 3/16 1/8 1/8 1/8 3/16 1/8 1/8 1/8 3/16 1/8 1/8 B 1/4 1/8 3/16 1/8 1/4 1/8 3/16 1/8 1/4 1/8 3/16 Material: Stainless steel 304 Thickness: 3/32 NOTES: 1. BOXED DIMENSIONS ARE MINIMUM CHARACTERISTICS TO BE VERIFIED FOR RECERTIFICATION. 4. MANUFACTURE TOLERANCES ARE ±.875 IN. 2.015 IN. OR LESS FLANGE ON LOCOMOTIVE WHEELS. AAR Manual of Standards and Recommended Practices Wheels and Axles S-628 THIS PAGE LEFT BLANK INTENTIONALLY G [S-628] 90 03/2011 . 005 in. WHEEL—REFERENCE GAUGE FOR VERIFYING COMBINATION WHEEL GAUGE S-627 Standard S-629 Adopted: 1998 Verify using contour mapping Maximum manufacture deviation from nominal: . 03/2011 G [S-629] 91 Material: Stainless steel 17-7 Thickness: 3/16 in.03/2011 S-629 AAR Manual of Standards and Recommended Practices Wheels and Axles GAUGE.003 in. . Maximum recertification deviation from nominal: . 03/2011 AAR Manual of Standards and Recommended Practices Wheels and Axles S-629 Application Drawings (page 1 of 2) G [S-629] 92 03/2011 . 03/2011 S-629 AAR Manual of Standards and Recommended Practices Wheels and Axles Application Drawings (page 2 of 2) 03/2011 G [S-629] 93 . AAR Manual of Standards and Recommended Practices Wheels and Axles S-629 THIS PAGE LEFT BLANK INTENTIONALLY G [S-629] 94 03/2011 . 573978 0.00 –0.3125 0.49899 –0.24331 0.29881 0.685488 –0.251A 0.755726 0.1875 X Y 0.00 –1.0536604 –0.AAR Manual of Standards and Recommended Practices Wheels and Axles 03/2011 S-630 GAUGE.3125 0.5625 0.010 03/2011 G [S-630] 95 .999073 –0.00 0.126 0. WHEEL—STANDARD Standard S-630 Adopted: 1998 Finger radii Centers 0.00 –0.0332779 –1.874367 –0.00 0.562 0.7656 1.005 Recertification tolerance: ±.251B 1.00 0.00 0.610423 Wide Flange Markings (Optional) Material: Rivet and thumb knob: 303 stainless steel Body and finger: stainless steel 17-7 Hardened Manufacture tolerance: ±. 375 1.323 1.03/2011 AAR Manual of Standards and Recommended Practices Wheels and Axles 0 at 5 0 at 4 0 at 3 0 at 2 0 at 1 0 at 0 A 1.894 S-630 Wide Flange Markings (Optional) Manufacture tolerance: ±.483 1.283 1.188 1.210 1.896 03/2011 .063 At 0 2 3 4 5 6 7 8 9 B 1.125 1.034 0.168 1.010 G [S-630] 96 At 0 2 3 4 5 6 7 8 9 10 11 C 1.313 1.995 0.070 1.264 1.005 Recertification tolerance: ±.364 1.077 0.951 0.203 1.120 1.250 1.408 1.248 1.997 0.142 1. including cooling practice immediately after rolling or forging • Axle bloom heating practice. This should not imply that the inspector will require detailed information of processes adopted by a manufacturer. 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. including facilities • Straightening practice • Axle cooling practice • Heat-treatment facilities and controls • Quality controls. Last Revised: 2004 1.03/2011 S-649 AAR Manual of Standards and Recommended Practices Wheels and Axles AXLES—MANUFACTURING FACILITY INSPECTION BY TECHNICAL SERVICES Standard S-649 Adopted: 1966. Heat-treating practices also will be reviewed. Extensive inspection of finished axles will not ordinarily be required.1 The following are some details of the practices that will be reviewed by the inspector: • Axle bloom handling.0 OBJECTIVE An AAR Technical Services Division inspector will periodically inspect manufacturing facilities and processes pertaining to production of steel car and locomotive axles. including furnace controls and type of furnace • Reduction practice. tensile testing.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.3 A report will be made to the AAR Technical Services Division and the manufacturer on the results of the inspection.2 The inspections shall be in accordance with the requirements outlined in M-101. 3. 03/2011 G [S-649] 97 . and records • Ultrasonic testing • Determining if equipment and procedures for machining axles are adequate to meet AAR specifications for the finished product 3. 3.0 DUTIES 3. AAR Manual of Standards and Recommended Practices Wheels and Axles S-649 THIS PAGE LEFT BLANK INTENTIONALLY G [S-649] 98 03/2011 . AND RIM FACES. (MINIMUM HEIGHT) LETTERS. MACHINING: A. CLASS B. (MINIMUM HEIGHT) LETTERS. SURFACE FINISH ON ID OF RIMS.SECTION G. 7. 1 min. WHEEL SHALL BE ULTRASONICALLY TESTED AND MAGNETIC PARTICLE INSPECTED AFTER MACHINING IN ACCORDANCE WITH MSRP SPECIFICATION M-107/M-208. MULTIWEAR TREAD. MATERIAL: AAR MANUAL OF STANDARDS AND RECOMMENDED PRACTICES. DESIGN: AAR STEEL PASSENGER CAR WHEEL M-36 OR CM-36. AND OD OF HUB SHALL BE 250 ΜIN. THE WORD “AMTRAK” SHALL BE STENCILED ON THE INSIDE PLATE IN 1-IN. NOTES: 1.005 IN. MSRP SPECIFICATION M-107/M-208 AND AS SHOWN.028 G [S-657] 99 . WHEEL PLATE AREA. NARROW FLANGE CONTOUR. Dimensions and Tolerances A 1 +1/16 –0 03/2011 B 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. ID OF RIM. IT IS ACCEPTABLE TO MACHINE THE WHEELS ON ALL SURFACES TO WITHIN A DIMENSIONAL TOLERANCE OF ±.002 TOTAL INDICATOR READING (TIR. MAXIMUM AND SHALL BE 350 ΜIN.) C. 1981. SPECIFICATION M-107/M-208. MAXIMUM FINISH ON THE TREAD.625 +. IN ADDITION TO MSRP SECTION G.6 LB. WEB. PERMISSIBLE VARIATION IN DIMENSIONS: PER MSRP SPECIFICATION M-107/M-208. THE VENDOR SHALL FURNISH AMTRAK WITH WHEELS IN PAIRS WITH THE SAME TAPE SIZE. THE TAPE SIZE ALSO SHALL BE STENCILED ON THE WHEEL TREAD IN 1-IN. 9. B. 3. WHEELS ARE FOR USE WITH TRUCKS HAVING INSIDE JOURNAL ROLLER BEARINGS. FLANGE. AS AN ALTERNATIVE.13. 10 3/4 +1/4 10 3/4 +1/4 7 ±1/8 8 5/8 ±1/8 –1. MARKING: MSRP SPECIFICATION M-107/M-208.0 SCOPE This standard became effective April 1.AAR Manual of Standards and Recommended Practices Wheels and Axles 03/2011 S-657 WHEEL. AND OD OF HUB SHALL BE SHOT PEENED IN ACCORDANCE WITH MSRP SPECIFICATION M-107/M-208. “WHEELS AND AXLES. STAMP UNBALANCE IN OUNCES ON THE INSIDE FACE OF THE RIM AT THE HEAVIEST POINT. 2. EXCEPT 1:40 TAPER. MAXIMUM DYNAMIC UNBALANCE AT THE OUTSIDE DIAMETER OF THE RIM SHALL NOT EXCEED 0. WHEEL SHALL BE MACHINED ALL OVER.000 –0 –0 tapes –1/8 –1/8 –. 11. INNER FACE OF WHEEL HUB SHALL BE SQUARE WITH CENTERLINE OF FINISHED WHEEL BORE WITHIN . 6. 3/4 min. 8.8. 4. TREAD: MSRP SPECIFICATION M-107/M-208 FIG. COLOR WHITE. EXCEPT AS SHOWN. PASSENGER CAR (AMFLEET) Standard S-657 Adopted: 1980 1. B. E. 5 1/2 ±1/8 in. D.” TAPE SIZE MARKING REQUIREMENTS. 10. B. 5. FIG. AAR Manual of Standards and Recommended Practices Wheels and Axles S-657 THIS PAGE LEFT BLANK INTENTIONALLY G [S-657] 100 03/2011 . 03 TYP A 5.69 ±. MFG.95 46.81 ±. TAPER NOT TO EXCEED .38 TYP 7. 5.500 DIA.06 .052 . SERIAL NUMBER.63 DIA.0 SCOPE This standard became effective March 1. NAME OR BRAND MO.25 17. MONTH AND YEAR.75 ±. .19 .046 5° .19 R 5. USE 1200 POUNDS ROLLER PRESSURE. (TYPICAL) AXLE CL ±. DETAIL A END FACES MUST BE SQUARE WITH O.D.50 C 1. 6.19 LABORATORY ACCEPTANCE STAMP PART NO.00 DIA.00 +.90 3.81 DIA. ROLL DOWN GROOVE AND OVERLAP AT BOTTOM.19 RADIUS.25 4. (TYP) BEARING SEAT TO BE UNIFORM DIAMETER THROUGHOUT. GRADE OF AXLE. ROUGH MACHINED AXLE IS TO BE SUBCRITICALLY QUENCHED FROM 1000 °F TO 1050 °F IN WATER. RELIEF GROOVES ARE TO BE MACHINED AND COLD-ROLLED AFTER SUBCRITICAL QUENCHING.25 +. MANUFACTURER’S NAME OR BRAND. 4. THE AXLE OTHERWISE MUST BE IN COMPLIANCE WITH AAR MANUAL OF STANDARDS AND RECOMMENDED PRACTICES. MATERIAL: AAR M-101. 6. 6.44 DETAIL C NOTES: 1.001 PER FOOT ON DIAMETER.31 6. HEAT NUMBER. 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.05R .50 FINISHED AXLE ±. CL 2. MONTH & YEAR STAMPING ONE END OF AXLE WHERE MOUNTED STAMPING OTHER END OF AXLE .90 REF. 6.44 +.06 . 2.265 .6240 6.03 .88 R TYP WHEEL SEAT (TYPICAL) 6.00 R 35.19 . FINISH MARKS WERE REMOVED IN THE 1982 REVISION.00 1.1915 DIA. SECTION G.13 +. .015 .00 DIA. WHEELS MOUNTED .125 1.AAR Manual of Standards and Recommended Practices Wheels and Axles 03/2011 S-658 AXLE FOR PASSENGER CARS (AMFLEET) INBOARD ROLLER BEARING—RAISED WHEEL SEAT Standard S-658 Adopted: 1980. ALLOW .00 DIA. 3. REF. DETAIL B 5.015 15.88 R COLD ROLL RELIEF GROOVES OVER REGION SHOWN WITH ROLLER HAVING CONTOUR OF .1905 .00 JOURNAL CENTERS REF 71.00 .187 IN. OVER FINISHED DIAMETERS. F .015 6.015 B DIA. 6. METHOD OF COLD-ROLLING RELIEF GROOVES GRADE OF AXLE F FOR CHEMISTRY ONLY HEAT NO.19 5. GRADE F.135 DIA.50 R .078 . LATEST REVISION. 03/2011 G [S-658] 101 LABORATORY ACCEPTANCE. 1. Last Revised: 2004 1.94 SYMMETRICAL ABOUT 60° 6. . START ROLLING AT THESE POINTS.502 DIA.25 DIA. & YR.6260 DIA.00 DIA.015 DIA. M-101.00 ±. . 1983. . . AAR Manual of Standards and Recommended Practices Wheels and Axles S-658 THIS PAGE LEFT BLANK INTENTIONALLY G [S-658] 102 03/2011 . If stress comparisons are to be made among wheels of different design. Last Revised: 2009 1. or von Mises. The effective. 4. 1. 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.( σ 1 – σ 2 ) + ( σ 2 – σ 3 ) + ( σ 3 – σ 1 ) 2 where σ1.1 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. stress is calculated from the principal stresses by the following equation: 1 2 2 2 σ eff = ------. and these results can help in the evaluation of the suitability of the wheel design.2. The results of an elastic analysis will give some indication of the quality of the wheel design. 03/2011 G [S-660] 103 . however. regardless of where and by whom they are made. LOCOMOTIVE AND FREIGHT CAR—ANALYTIC EVALUATION Standard S-660 Adopted: 1981. σ2.2 The designated mechanical and thermal loads are not intended to indicate the maximum possible loads that might occur under service conditions. The thermal input (as subsequently defined) is limited.0 LIMITATIONS Stress calculations are limited to elastic analyses.2 The first step is to ensure that the computations will be of sufficient accuracy and reproducibility. as well as the accuracy requirements for the computational technique. Isotherms at even 100 ºF intervals are required. The values selected represent levels that would be expected to be exceeded only a very small percentage of the time. The database contains wheel designs demonstrating either satisfactory field performance or unsatisfactory service with high failure rates. 1. paragraph 2. nor are they necessarily representative of specific service conditions. the magnitude and manner of design load application to the wheel must be specified.0 RESULTS 4. The maximum temperature shall be indicated.e.2 The results of the stress calculation will be expressed in terms of effective stresses. which permits the use of simpler equations to describe the mechanical and physical properties. This objective will be attained by comparing the results of stress analyses of different wheel designs. material property data and loading conditions). 4..1 The results of the temperature calculation shall be displayed on a contour plot. if consistent results are to be obtained. 2. Load levels above these values may occur under certain special conditions and would not necessarily lead to failure of the wheel. 2. 3.3 This procedure shall be operative under M-107/M-208. and σ3 are the principal stresses.0 BACKGROUND 2.1 Several computer codes can calculate wheel stresses.0 OBJECTIVE 1.AAR Manual of Standards and Recommended Practices Wheels and Axles 03/2011 S-660 WHEEL DESIGNS. Appendix A. ) An edge load.500 lb for 36-in.-diameter wheel) The thermal load.750 100 ton: 28-. 38.2 Lateral (e. from the back face of the rim for wide-flange wheels and 1 11/16 in. resulting from the individual or combined action of vertical. 35. diameter 71.000 27.g. on either side of a line centered 3 7/16 in. from the back rim face for wide-flange wheels and 1 9/32 in. as shown in Fig.875 70 ton: 33-in. If the maximum stress occurs at an orientation other than 0º. 4.000 Note: Mechanical loads shall be introduced at several alternative locations. for narrow-flange wheels. Thermal Load (HP for 20 min. Simultaneously the convective load shall be applied to each of the elements in the above area.375 Locomotive: 40-in..g.00 35. 100% into wheel) 41. and their spacing shall be chosen for clarity. shall be imposed at the same point of action as V1. 5. The load shall be applied evenly over the area 1 11/16 in.0 WHEEL LOADS Load magnitudes should be a function of the maximum static rail load. diameter 65. Examples of currently approved loads are given in Table 5. such that the line of action of the load passes through a point 1/8 in. shall have a line action 1 in. described in paragraph 5. This leads to the following set of desired information: 4.00 5.1. The thermal loads also are proportional to the maximum static rail load.g.3.000 35. lateral. 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.2 Maximum effective stresses at designated points on the surface of the rim. shall be introduced axisymmetrically around the tread of the wheel. The maximum stress shall be found.750 32.0 hp for 20 minutes for 36-in.3 While it is recognized that the thermal load cannot exist alone.3.750 39.-diameter wheel) The line of action of the lateral load. Constant stress contours shall be labeled. 71. V2. 5.95 37. and thermal loads. Data shall be provided in both tabular and graphical (contour) form. 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. for narrow-flange wheels.. on either side of a line centered 3 7/32 in.1.1 A maximum effective stress on the surface of the plate.1 (see Fig. 5.750 24.3 Thermal (e.00 29.375 110 ton: 36-in. from the front rim face.. 30-. the orientation must be specified in the tabulation of the results.28 25.1). diameter and over 70. diameter 55. Th. 11.. A load V1 shall be imposed in the flange throat. G [S-660] 104 03/2011 . Table 5. 33-in. 11.1 Wheel load parameters Wheel Types Vertical Load (lb) Lateral Load (lb) 125 ton: 38-in. horizontally removed from the gauging point on the flange.92 38.750 lb for 36-in.1 Vertical (e. (This requirement becomes 1 1/2 in.500 35.03/2011 AAR Manual of Standards and Recommended Practices Wheels and Axles S-660 4. diameter 48. resulting from only a thermal load. diameter 78. L1. regardless of wheel orientation.-diameter wheel) Two different positions for the line of action of the vertical load shall be considered.500 One Wear 28-in. 1. 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. 6. The original plate and rim fillet contours and locations shall be retained. 7.03/2011 S-660 AAR Manual of Standards and Recommended Practices Wheels and Axles 6.1. and the flange.2 Calculations shall be made for the Th and V2 + Th cases.1 The wheel configuration (at the condemning limit) is quite sensitive to the development of large thermal stresses. the source of the wheel profile (drawing or wheel measurement) shall be stated.0 WHEEL CONFIGURATION 7. 7. These shall be shown on the contour plot. If necessary. back and front rim faces (including corners). 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.2 Rim Stress Results—Thermal Only Calculate the maximum effective surface stresses at the tread.2 also shall be furnished. all data required in paragraph 6. The exact diameter at the taping line before and after translation. 7. Appendix A.1. paragraph 2.0 LOAD COMBINATIONS Possible load combinations are given for the separate consideration of plate and rim stresses.2. Rule 41.h). 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.1. Section A. and the amount of translation of the tread-flange geometry (to bring the taping line to the thin rim condemning limit).2. 03/2011 G [S-660] 105 .1 New Condition 7. The original plate and rim fillet contours and locations shall be retained. The plate thickness (N) shall be stated.1.1. and V1 + L1 + Th. V2 + Th.1 Plate Stress Results Calculate maximum effective surface stress under the following combinations: Vertical Load V1 + Lateral Load L1. 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. The minimum rim thickness and the normal rim width given in the AAR specifications for new wheels shall be used. also shall be stated.1 The wheel configuration used in the analysis shall conform to the requirements listed in M-107/M-208. Thermal Load Th. 7. 7.3 In the data summary. 6. Vertical Load V2.2 Condemning Limit Rim Thickness 7.2 The calculation shall be made at the mean of the envelope dimensions required by M-107/M-208. 000052 × T (BTU/lb·ºF) Assume the linear function:K= 28. 9. 10. The intent is to permit one program user to check the results of another user.0 ACCURACY OF CALCULATIONAL TECHNIQUE Any candidate analytical procedure for stress calculations must be shown to provide accurate results. 11.3 Assume the linear function:CP= 0. 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. at its discretion.0 MATERIAL PROPERTIES AND BOUNDARY CONDITIONS Material properties and boundary conditions are specified so that the results of various calculational techniques are comparable. A specific wheel configuration with a given set of loads shall be defined. The effect of radiated heat transport from the surface of the wheel is to be neglected in these calculations.000.0 REQUIRED DATA In addition to the data required in paragraphs 6.2 Data Required for Stress Calculations Modulus of Elasticity: Assume 29. Failure on the part of the vendor to comply shall be grounds for disqualification.000 psi Poisson’s Ratio: Assume 0.30 Coefficient of Thermal Expansion:Assume the linear function:alpha = [6.2 In auditing the analyses done by vendors.2 Comparison with Standard Solution The code shall be used to calculate wheel stresses for a standard problem. all data necessary to permit a knowledgeable individual to repeat the calculation must be reported.0060 × T (BTU/h·ft·ºF) Assume a constant: h = 4 BTU/h·ft2·ºF None required.0 and 7.283 lb/in. Accuracy can be defined with respect to a standard set of calculated results.1 Data Required for Temperature Calculations Initial Temperature: Density: Specific Heat: Thermal Conductivity: Convection Coefficient: Emissivity: Assume 75 °F Assume 0. The results must be both accurate and convergent. 11. G [S-660] 106 03/2011 . 9. require any vendor to rerun the standard solution in its entirety or in part.3 Boundary Conditions: Fix all hub bore nodes in the radial and axial directions at a radius of 1 in.·ºF 8.102 + 0.0 RESPONSIBILITY 11.1 – 0.002 × (T-75) ] µin.03/2011 AAR Manual of Standards and Recommended Practices Wheels and Axles S-660 8. 9.1 Once an analytical procedure has been qualified.0 + 0.1 Qualification of Code Qualification of an analytical procedure shall include a demonstration that the results of the finite element analyses are convergent. Reference to this procedure for the loads and mechanical/physical properties is sufficient.0. 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./in. 8. 8. Stress and temperature predictions must fall within a specified tolerance. the AAR may. steel.3/32" V1 GAUGING POINT 13/8" /8" 1 V2 L1 1" 3 3/8" Th 3 7/16" Fig.2 and 5.AAR Manual of Standards and Recommended Practices Wheels and Axles 03/2011 S-660 5 23/32" ± 1/8" + 1/32" . 11. freight car wheels (not to scale) Paragraphs 5.1 Locations of assumed loadings for wide-flange.3 03/2011 G [S-660] 107 . AAR Manual of Standards and Recommended Practices Wheels and Axles S-660 THIS PAGE LEFT BLANK INTENTIONALLY G [S-660] 108 03/2011 . all other tolerances are ±0. Notes: 1.0250. 3. steel with minimum 55 RC hardness.1 This standard became effective March 29. 2. 1. Hanging holes optional. HEIGHT.03/2011 S-661 AAR Manual of Standards and Recommended Practices Wheels and Axles GAUGE. WHEEL—MAXIMUM FLANGE THICKNESS.0 SCOPE 1.2 This standard supersedes MSRP S-602. AND THROAT RADII GAUGE FOR AAR-1B NARROW-FLANGE STEEL WHEEL Standard S-661 Adopted: 1991 1. 1991. Minimum 0. Unless noted. 03/2011 G [S-661] 109 .120-in. AAR Manual of Standards and Recommended Practices Wheels and Axles S-661 THIS PAGE LEFT BLANK INTENTIONALLY G [S-661] 110 03/2011 . 1991.03/2011 S-662 AAR Manual of Standards and Recommended Practices Wheels and Axles GAUGE. Hanging holes optional. Minimum 0. 03/2011 G [S-662] 111 . 2.0 SCOPE 1. WHEEL—MINIMUM FLANGE THICKNESS. HEIGHT. Unless noted.0250. AND THROAT RADII GAUGE FOR AAR-1B NARROW-FLANGE STEEL WHEEL Standard S-662 Adopted: 1991 1. 3. all other tolerances are ±0.2 This standard supersedes MSRP S-603. Notes: 1. 1. steel with minimum 55 RC hardness.1 This standard became effective March 29.120-in. AAR Manual of Standards and Recommended Practices Wheels and Axles S-662 THIS PAGE LEFT BLANK INTENTIONALLY G [S-662] 112 03/2011 . Minimum 0. 3. 1. steel with minimum 55 RC hardness. all other tolerances are ±0. Hanging holes optional. 2.1 This standard became effective March 29. WHEEL—REFERENCE LIMIT GAUGE FOR VERIFYING AAR 1B NARROW FLANGE WHEEL GAUGE S-661 Standard S-663 Adopted: 1991 1.0250. Notes: 1. Unless noted.2 This standard supersedes MSRP S-604. 1991.0 SCOPE 1.120-in. 03/2011 G [S-663] 113 .03/2011 S-663 AAR Manual of Standards and Recommended Practices Wheels and Axles GAUGE. AAR Manual of Standards and Recommended Practices Wheels and Axles S-663 THIS PAGE LEFT BLANK INTENTIONALLY G [S-663] 114 03/2011 . 0250. 1. 1991.120-in.1 This standard became effective March 29. steel with minimum 55 RC hardness. 2. Hanging holes optional. Unless noted. Minimum 0.03/2011 S-664 AAR Manual of Standards and Recommended Practices Wheels and Axles GAUGE. Notes: 1.2 This standard supersedes MSRP S-604. 03/2011 G [S-664] 115 . all other tolerances are ±0.0 SCOPE 1. 3. WHEEL—REFERENCE LIMIT GAUGE FOR VERIFYING AAR 1B NARROW FLANGE WHEEL GAUGE S-662 Standard S-664 Adopted: 1991 1. AAR Manual of Standards and Recommended Practices Wheels and Axles S-664 THIS PAGE LEFT BLANK INTENTIONALLY G [S-664] 116 03/2011 . HEIGHT.0 SCOPE 1. Notes: 1. all other tolerances are ±0. 3.120-in. Hanging holes optional.1 This standard became effective March 29.0250. AND THROAT RADII GAUGE FOR AAR-1B WIDE-FLANGE STEEL WHEELS Standard S-665 Adopted: 1991 1. 03/2011 G [S-665] 117 .03/2011 S-665 AAR Manual of Standards and Recommended Practices Wheels and Axles GAUGE. 1. 2.2 This standard supersedes MSRP S-605. steel with minimum 55 RC hardness. Unless noted. 1991. Minimum 0. WHEEL—MAXIMUM FLANGE THICKNESS. AAR Manual of Standards and Recommended Practices Wheels and Axles S-665 THIS PAGE LEFT BLANK INTENTIONALLY G [S-665] 118 03/2011 . 0250.120-in.2 This standard supersedes MSRP S-606.0 SCOPE 1. 1. WHEEL—REFERENCE LIMIT GAUGE FOR VERIFYING AAR 1B WIDE FLANGE WHEEL GAUGE S-665 Standard S-666 Adopted: 1991 1. 3. Minimum 0. all other tolerances are ±0. 03/2011 G [S-666] 119 . 2. Unless noted.1 This standard became effective March 29. 1991. Notes: 1. Hanging holes optional. steel with minimum 55 RC hardness.03/2011 S-666 AAR Manual of Standards and Recommended Practices Wheels and Axles GAUGE. AAR Manual of Standards and Recommended Practices Wheels and Axles S-666 THIS PAGE LEFT BLANK INTENTIONALLY G [S-666] 120 03/2011 . HEIGHT. 2. 03/2011 G [S-667] 121 . Notes: 1. Minimum 0.2 This standard supersedes MSRP S-607. WHEEL—MINIMUM FLANGE THICKNESS.0250.0 SCOPE 1.1 This standard became effective March 29. 1991. Hanging holes optional. AND THROAT RADII GAUGE FOR AAR-1B WIDE-FLANGE STEEL WHEELS Standard S-667 Adopted: 1991 1. Unless noted.03/2011 S-667 AAR Manual of Standards and Recommended Practices Wheels and Axles GAUGE.120-in. 1. 3. steel with minimum 55 RC hardness. all other tolerances are ±0. AAR Manual of Standards and Recommended Practices Wheels and Axles S-667 THIS PAGE LEFT BLANK INTENTIONALLY G [S-667] 122 03/2011 . 2. WHEEL—REFERENCE LIMIT GAUGE FOR VERIFYING AAR 1B WIDE FLANGE WHEEL GAUGE S-667 Standard S-668 Adopted: 1991 1. steel with minimum 55 RC hardness.03/2011 S-668 AAR Manual of Standards and Recommended Practices Wheels and Axles GAUGE.0 SCOPE 1. 1. Notes: 1.2 This standard supersedes MSRP S-608.120-in. Hanging holes optional. 3. 1991. 03/2011 G [S-668] 123 . all other tolerances are ±0. Minimum 0.1 This standard became effective March 29.0250. Unless noted. AAR Manual of Standards and Recommended Practices Wheels and Axles S-668 THIS PAGE LEFT BLANK INTENTIONALLY G [S-668] 124 03/2011 . AAR Manual of Standards and Recommended Practices Wheels and Axles 03/2011 S-669 ANALYTIC EVALUATION OF LOCOMOTIVE WHEEL DESIGNS Standard S-669 Adopted: 2011 1.0 OBJECTIVE The objective of this procedure is to provide a method, using the AAR Manual of Standards and Recommended Practices Standard S-660 as a basis, to evaluate the performance of a proposed locomotive 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, Appendix A, paragraph 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. 2.0 BACKGROUND 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 AND CODE QUALIFICATION 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 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. 03/2011 G [S-669] 125 AAR Manual of Standards and Recommended Practices Wheels and Axles S-669 5.0 SOLUTION QUALITY AND REQUIRED ANALYSES 5.1 Solution Quality and Analysis Overview 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 paragraphs 5.2 to 5.6 and paragraphs 7.0 and 8.0. The first analysis is performed according to the current requirements in Standard S-660 (with additions) as described in paragraph 5.2 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 paragraph 5.3 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 in paragraph 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 paragraph 5.4 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 paragraph 5.5. This is accomplished by combining selected results from the three analyses described above according to the procedure outlined in paragraph 7.0. The fifth analysis requires determination of certain vibration characteristics of the proposed wheel design as described in paragraph 5.6 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 paragraph 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. G [S-669] 126 03/2011 S-669 AAR Manual of Standards and Recommended Practices Wheels and Axles 5.2 S-660 Analysis An analysis pursuant to the requirements in Standard S-660 (most recent version) shall be completed. Compliance with this standard expands the requirements of Standard S-660 paragraph 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. 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 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 Heat-Treatment Analysis 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 Interference Fit Analysis 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 Fatigue Analysis 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 this evaluation determines whether the proposed wheel design is likely to experience fatigue failure before its desired lifetime. 03/2011 G [S-669] 127 as shown in Fig. A 360° model of the wheel. Interference pressure between the hollow axle and wheel hub shall be ignored in this analysis.2.6 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. shall be created using solid (brick) elements with a minimum of eight nodes. The use of higher-order solid elements is permitted. The elastic material properties prescribed in Standard S-660 (most recent version) shall be used in the vibration analysis. 5. 5.1 3-D rendering of locomotive wheel identifying angular reference positions (view is of front face of wheel) G [S-669] 128 03/2011 .1.AAR Manual of Standards and Recommended Practices Wheels and Axles S-669 5. that model shall be revolved as described below to generate the three-dimensional model. 90° 180° 0° 270° Fig.4.3. If a two-dimensional (axisymmetric) model is used to perform the analyses described in paragraphs 5. and 5. The portion of the S-660 compliant model that represents the hollow axle shall be retained. 5. 5. The 45° plane is the plane at which the stress results are reported. The 0° plane is the plane on which the specified loads are applied.2. These requirements are illustrated in Fig. Black and white segments represent minimum 5° arc length segments on opposite sides of 45° plane. 5.S-669 AAR Manual of Standards and Recommended Practices Wheels and Axles The elements generated in the hoop direction shall have a maximum angular length of 10° or less.2 Illustration of 3-D model created by revolution of 2-D axisymmetric model (view is of front face of wheel) 03/2011 G [S-669] 129 . 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°. Note: Shaded sectors represent minimum 10° arc length segments. Red arrow indicates direction of tractive load applied to tread surface. Fig. This condition is satisfied when the temperature at all nodes is within the range of ambient temperature plus 5 °F. 6. The analysis ends (t = tn) when the wheel reaches ambient temperature at the end of the cool-down period.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 material is considered to be strain-free at this point in time.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. G [S-669] 130 03/2011 . Fig.2. quench duration and extent. Time begins (t = 0) when the wheel exits the austenizing furnace at a uniform elevated temperature. In a decoupled analysis. the temperature history at each node shall be calculated first using thermal elements. 6.AAR Manual of Standards and Recommended Practices Wheels and Axles S-669 6. Orthogonal (normal) stresses at each node in the region identified in Fig.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 6.1 for each model shall be retained.0. and any dwell time that may exist between any steps in the heat-treatment process. 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. Convective and radiative heat transfer shall be accounted for on all exterior surfaces of the wheel as described in paragraph 10. annealing temperature and duration.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. The schedule identifies initial temperature.0 LOADING CONDITIONS 6. 2. At the conclusion of the heat-treatment simulation. A nominal interference of 0. TyzL.2 Worn Rim Geometry To determine the residual stress distribution in the worn wheel.3 Interference Fit Analysis The interference fit shall be accomplished by inserting a hollow axle stub into the wheel bore. worn rim G [S-669] 131 . TxzL) Orthogonal normal stresses under load (SxL. SyP. Orthogonal (normal) stresses at each node in each model in the region identified in Fig. new (full) rim V1+L1. SzR) Orthogonal normal stresses (SxR. referenced to the diameter is assumed. SzP) Orthogonal normal stresses (SxP. worn rim V2. SyR. worn rim Interference-fit stresses.) may be used. or eight load cases.0 shall be used. SzL. worn rim Heat-treatment residual stresses.1. new (full) rim Interference-fit stresses. TyzL. TxzL) Orthogonal normal stresses under load (SxL. Element removal alters the residual stress distribution. TxyL. SzL. TxzL) Orthogonal normal stresses under load (SxL. as shown in Table 6. Table 6. 6. SyP. SyR. TyzL. and 6. elements are removed from the model described above to arrive at the worn rim geometry. SzL. new (full) rim V2. 6. For convenience.3 yield eight sets of stress results.1 Summary of load cases Load Case 1 2 3 4 5 6 7 8 03/2011 Required Result at Each Node Orthogonal normal stresses under load (SxL. This technique involves modifying the stiffness matrix. new (full) rim Heat-treatment residual stresses. 5. 6. The interference fit stresses shall be determined for the new and worn rim conditions. SzR) Orthogonal normal stresses (SxP. SzP) Condition V1+L1. After removal of the rim material. TxzL) Orthogonal normal stresses (SxR.4 Required Stress Results The analyses performed according to paragraphs 6.0 shall be used.1 shall be retained. SzL.1. TxyL. SyL. The relevant temperature-dependent material property data in paragraph 10.1 shall be retained. SyL.1 shall be retained. orthogonal (normal) stresses at each node in the model in the region identified in Fig. SyL. 6. TyzL. SyL. The element removal technique described above may be used to obtain the interference fit stresses for the worn rim geometry. TxyL. 6. 6. The relevant temperature-dependent material property data in paragraph 10. the time-dependent nodal temperatures are applied to the structural elements to obtain the residual stresses.2. 6.2 (in which the axle bore diameter is 2 in.AAR Manual of Standards and Recommended Practices Wheels and Axles S-669 In the second part of the decoupled analysis. orthogonal (normal) stresses at each node in the model in the region identified in Fig. TxyL.010 in. Material properties for the wheel and axle shall be as defined in Standard S-660 (current version). the hollow axle geometry shown in Fig. 6. These stresses are obtained from the analysis performed according to paragraph 6.3 and is defined as follows: J 1P = S xP + S yP + S zP Equation (6) The values of the constants (A = 28 ksi and α = 0.[ ( S xL + S yL + S zL ) 0° + ( S xL + S yL + S zL ) 180° ] 2 Equation (4) in which (SxL + SyL + SzL)0° are the orthogonal (normal) stress components at the nodes on the radial plane upon which the load is acting (at 0°). 6]. for the purposes of this standard.[ ( T ijL 0° ) – ( T ijL 180° ) ] 2 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.[ ( S iL ) 0° – ( S iL ) 180° ] and T ij = --.16) have been experimentally determined [5. Tij) in Equation (2) is defined as follows: 1 1 S i = --. 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 1M + J 1R + J 1P ) Equation (1) in which J'2 represents the octahedral shear stress and is defined as follows: 1--- 2 1 2 2 2 2 + T2 + T2 )] J′ 2 = --.2 and is defined as follows: J R 1 = S xR + S xR + S xR Equation (5) and J1P is the sum of the orthogonal (normal) components of the interference fit (static) stress (SiP) at each node as determined by the analysis performed according to paragraph 6. and the superscript L denotes the stresses due to the applied loads. 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. 6.1. 2.AAR Manual of Standards and Recommended Practices Wheels and Axles S-669 7. G [S-669] 132 03/2011 .1). and (SxL + SyL + SzL)180° are the orthogonal (normal) stress components at the nodes on a radial plane 180° away (the regions identified in Fig. The amplitude of each nodal stress component (Si.0 FATIGUE ANALYSIS ACCORDING TO SINES CRITERION Combinations of static or residual stress with superimposed alternating stress were examined by Sines [1. and J1R is the sum of the orthogonal (normal) components of the residual (static) stresses (SiR) at each node as determined by the analysis performed according to paragraph 6.[ ( S x – S y ) + ( S y – S z ) + ( S z – S x ) + 6 ( T xy yz xz 3 Equation (2) which. J1M is the mean of the sum of the orthogonal (normal) components of the alternating stresses (SiL) at each node as determined by the analysis performed according to paragraph 6.1).1 and is defined as follows: 1 J 1M = --. 7.1 Load combinations to which Equation (1) shall be applied Load Combination J’2 J1M J1R J1P 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 03/2011 G [S-669] 133 .1. rendering the design unacceptable.1 Region in which Sines criterion is applied Table 7. 7. If. 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. Fig.AAR Manual of Standards and Recommended Practices Wheels and Axles S-669 Equation (1) shall be evaluated at each node in each model in the region identified in Fig. 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. under any load combination.1 for the four combinations of load cases shown in Table 7. Fig. Positive contour data (SP greater than 0) represent fatigue-prone locations at which the Sines criterion is violated. The safety factor represents the fatigue margin for the proposed wheel design and is determined in the following way. 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). 7. 7.2. V2) is increased by a load factor n. SP. 7. and if identified through application of this procedure. G [S-669] 134 03/2011 . the value to be contoured at each node location is the Sines parameter.1 (legend omitted) For each of these plots.1 Results The results obtained by application of the Sines criterion for the four load combinations described in paragraph 7. or SP = J′ 2 – [ A – α ( J 1M + J 1R + J 1P ) ] Equation (7) Negative contour data (SP less than 0) indicate locations at which the Sines criterion is satisfied.0 yields a value for the Sines parameter (SP) at each node for each of the specified nominal loading conditions.1) increase proportionally.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. Fatigue-prone locations are unacceptable. The stresses due to the mechanical loads are recomputed assuming the nominal load (L1. V1.2 Sample contour plot of Sines parameter on portion of wheel cross-section identified in Fig. which is the difference between the left-hand and right-hand sides of Equation (1). The minimum safety factor and the location in the wheel plate at which it occurs shall be reported for each load combination.AAR Manual of Standards and Recommended Practices Wheels and Axles S-669 7. The analysis described in paragraph 7. Because the model is linearly elastic. the stresses due to the mechanical loads (load cases 1 through 8 in Table 6. 2 Reporting format for fatigue analysis results 03/2011 Load Combination Loading Description Rim Condition Maximum SP Safety Factor A V1 + L1 NEW <value> <value> B V2 <value> <value> C V1 + L1 <value> <value> D V2 <value> <value> WORN G [S-669] 135 .3 Schematic illustrating method for determining safety factor Table 7. 7.3: Fig. This concept is graphically depicted in Fig.1. 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).AAR Manual of Standards and Recommended Practices Wheels and Axles S-669 The Sines parameter SP is recomputed for each node for each load combination described in Table 7. 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). 7. 8.1 shall be reported to a minimum of three decimal places. Axle bore nodal degrees of freedom are fixed. The saddle mode of vibration (as shown in Fig.1) is the subject of this analysis. Damping is ignored.1. 8.2 Material Properties Relevant material properties as defined in Standard S-660 (current version) shall be used.1. 8.1 Finite Element Model The three-dimensional model described in paragraph 5.4 Modal Analysis Results The lowest frequency at which the wheel vibrates in the saddle-mode shape as shown in Fig.1 Wheel in saddle-mode of vibration with reference plane for applied load 8.1. G [S-669] 136 03/2011 . Interference pressure between the hollow axle and wheel hub is ignored in this 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 modal and harmonic response analyses are performed assuming elastic material behavior.1.6 shall be used. 0° .3 Boundary Conditions The outer surface of the hollow axle stub shall be fixed to the inner surface of the wheel hub. 8. Thermal effects are not considered in this analysis.0 VIBRATION ANALYSIS 8.180° reference plane Fig. 8. The natural frequency associated with this mode shall be used in a harmonic response analysis to determine the stress field in the wheel.AAR Manual of Standards and Recommended Practices Wheels and Axles S-669 8. 1.2) when the amplitude of the forced vibration is maximum For each load case identified in Table 8. from the back rim face for wide flange wheels 2 27/32 in. The same model used for the modal analysis shall be used for the harmonic response analysis. 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.2 (paragraph 6.00002] to a minimum of three decimal places). A force magnitude of 300 lb is sufficient to provide adequate excitation. f = fn·[1+0.2: • The maximum residual circumferential (hoop) tensile stress in the wheel rim resulting from the heat-treatment analysis as identified in Fig. from the back rim face for wide flange wheels 1 9/32 in. 5. and radial stresses in the cross-sectional plane located 45° from the 0° plane at which the excitation is applied (as identified in Fig.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.AAR Manual of Standards and Recommended Practices Wheels and Axles S-669 8. 5.1.2) • 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.1 • Two-dimensional contour plots of circumferential (hoop). The forcing frequency of the applied load is 0. Tractive loads shall be applied in the rail running direction on the wheel tread surface in the 0° plane identified in Fig.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.2 at the locations shown in Table 8. axial.1.002% greater than the saddle-mode natural frequency obtained in paragraph 8. Table 8. from the back rim face for narrow flange wheels H3 8.2) resulting from the heat-treatment analysis (paragraph 6. Three load cases shall be considered.. 8.3) 03/2011 G [S-669] 137 .4 (i. 5.3 Harmonic Response Analysis Results For each load case identified in Table 8.1 Load locations for harmonic analysis Load Case Load Location on Wheel Tread H1 1 in.e. from the back rim face for narrow flange wheels 1 1/2 in. 5. from front rim face H2 3 1/16 in.1. report the following data as shown in Table 8. 8.2) that occurs during the forced vibration analysis (paragraph 8. Damping is ignored. This is referred to as cross-sectional “Location X” in Table 8. The vendor must demonstrate that the new code still qualifies.2) Circumferential (Hoop) Stress Due to Forced Vibration at Location X Maximum Rim Circumferential (Hoop) Tensile Stress Due to Forced Vibration H1 <value> <value> <value> H2 <value> <value> H3 <value> <value> 9. at its discretion.1 Deviations Once an analytical procedure has been qualified. 9.2 Arrow indicates typical location of maximum residual circumferential (hoop) tensile stress in wheel rim following simulated heat treatment. Failure on the part of the vendor to comply shall be grounds for disqualification. G [S-669] 138 03/2011 . it shall be the responsibility of the vendor to inform the AAR if he deviated from the conditions for which he is qualified. require any vendor to rerun the standard solution in its entirety or in part.0 RESPONSIBILITY 9.AAR Manual of Standards and Recommended Practices Wheels and Axles S-669 Fig. 8. the AAR may. 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.2 Auditing In auditing the analysis done by vendors.2 (legend omitted) Table 8. 30632716e-15 BTU/sec-in.3 Convection coefficient (wheel to air): H = 9.2-°F (assume constant) or H = 540.0 03/2011 G [S-669] 139 .80 View factor: 1.1 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: 0.2-R4 Emissivity: 0.2-°F (assume constant) or H = 5.0417 ×10-3 BTU/ sec-in.0 MATERIAL PROPERTIES Material properties are specified so that the results of various computational techniques may be compared. 10.S-669 AAR Manual of Standards and Recommended Practices Wheels and Axles 10.283 lbm/in.0 BTU/hr-ft2-°F (assume constant) Convection coefficient (wheel to water) [7]: H = 1.6450 ×10-6 BTU/sec-in.0 BTU/hr-ft2-°F (assume constant) Stefan-Boltzmann constant: 3. 4079 0.3461 Table 10.5 Coefficient of thermal expansion [8] Temp (°F) 0 75 212 400 1292 1472 1800 Thermal Expansion Coefficient per °F 6.2) 0 75 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 29368 29000 28955 28543 28130 27718 27306 26859 26407 25741 24784 23553 20542 17531 14424 11698 9952 9114 8577 7390 a/ Etan [9.22E-06 6.000361 10.58E-06 8. 11.58E-06 9.2836 0. 11.3400 0.2) 2016 2192 2250 2484 2719 2953 3187 3028 2804 2514 2151 1790 1431 1071 726 557 424 384 343 303 Table 10.3200 0.3 Modulus of elasticity (E) and hardening modulus (Etan) Temp (°F) E (kips/in.3 Material Properties (Temperature-Dependent) for Stress Calculations Table 10.2 Material Properties (Temperature-Dependent) for Heat-Treatment Simulation Table 10. G [S-669] 140 03/2011 .3020 0.000329 0.2927 0.1059 0. 10. 13] Temp (°F) 0 75 514 752 932 1292 1472 1800 ν 0.AAR Manual of Standards and Recommended Practices Wheels and Axles S-669 10.000629 0. 12]a/ (kips/in.1487 0.1 Specific heat [8] Temp (°F) 0 75 1292 1337 1382 1652 1800 Table 10.61E-06 9.000664 0.2980 0.2820 0.61E-06 Temperature-dependent values for hardening modulus have been interpolated such that they are presented for the same temperatures as the modulus of elasticity.22E-06 6.1309 0.1309 Temp (°F) 0 75 392 1292 1472 1800 (BTU/sec-in-°F) 0.4 Poisson's ratio [ 9.1106 0.000672 0.2 Thermal conductivity [7] (BTU/lbm-°F) 0.1866 0.22E-06 8.000403 0. 79 6.69 79.91 41.95 77.44 79.50 8.20 78.95 32.59 14.63 5.32 67.94 7.00 79.71 76.S-669 AAR Manual of Standards and Recommended Practices Wheels and Axles Table 10.00 80.77 23.6 Yield strength 03/2011 Temp (°F) σy (kips/in.5 )e ( σ eff – 53712----------------T + 460 in which ε& = the creep strain rate (1/°F) σeff = von Mises effective stress (ksi) T = temperature (°F) G [S-669] 141 .48 Table 10.2) 0 75 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 80.63 10.94 79.7 Creep strain rate [7] ε& = 4.6410 – 08 12.77 54. 10th edition. 12. 1969. and J. 1. McCown. and R.. 2005. Metal Fatigue in Engineering. ASME Paper IMECE2002-33240. G.I. G. O.E. Mats. 6.P. Gallagher. Fatigue Performance of AAR Grade A Wheel Steel at Ambient and Elevated Temperatures. Alber. Evaluation of Immediate Actions Taken with Cracking Problems Observed in Wheels of Rail Commuter Cars. Constitutive Models Suitable for Thermal Loading. Slavik. J. 4. Contact Region Fatigue of Railway Wheels Under Combined Mechanical Rolling Pressure and Thermal Brake Loading. ASME J.R. NACA Technical Note 3495. Proceedings of the 1988 Joint ASME IEEE Railroad Conference. and H. Cleveland:American Society for Metals. D.C. A. 1. 1959. Kuhlman. 1986. eds. and M. Waisman. F.. and H.E. Robledo. 10. P. Sines. 13. Sehitoglu. and J. 1988. Fatemi. Gray. 9. D. The Significance of Material Properties on Stresses Developed During Quenching of Railroad Wheels. and J.. 11.J. 108:108-312. Berg.. Stephens.L.. 1991.AAR Manual of Standards and Recommended Practices Wheels and Axles S-669 11. G. R. Metal Fatigue.. Techn. Tread Braking Versus the Wheel. 3. Metals Handbook. 8. F. 144:57-70. Lunden. Sehitoglu. 1993. Hoboken:Wiley and Sons. 5. McKeigan.0 REFERENCES 1.. Proceedings of the 64th Annual Convention of the Air Brake Association. 93:3. and R.J. N. Eng. H. Fuchs. McMaster. 1972. A.E. Gordon. 2002. R. 1955. R. 1948. C. Fatigue Performance of AAR Grade B Wheel Steel at Ambient and Elevated Temperatures. Metals Handbook. G. Elasticity and Strength. London:McGraw-Hill. Vol. ASME Paper IMECE2005-82519.O. G [S-669] 142 03/2011 . Sines. 2. Orringer. Cleveland:American Society for Metals. 1980.. Stephens. Wear. DOT-VNTSC-FRA. Vol. Sines. McMaster. Gordon. Failure of Materials Under Combined Repeated Stresses with Superimposed Static Stresses. Needham Heights:Allyn and Bacon. 1948. 7. 9th edition. 33" AND 30" DIAMETER (6°-55'-23" APART. WHEEL—REFERENCE MASTER DISK FOR VERIFYING WHEEL CIRCUMFERENCE GAUGES S-612 AND S-613 Recommended Practice RP-608 Adopted: 1937. /16" STAMPS 3 MARK: MASTER DISK FOR CHECKING WHEEL CIRCUMFERENCE MEASURE OF 27" TO 38" DIAMETER WHEELS.002" 37. Last Revised: 2004 49" 1 /4" 29" 1" 21/2" 38.) 11/4" 21/4" 3" 11/4" . 35" 11/4" 13/8" 1 1 + /64" 383/32" -0" SECTION A-A 1"R. 36".AAR Manual of Standards and Recommended Practices Wheels and Axles 03/2011 RP-608 GAUGE. MATERIAL: ASTM A-47 Grades 32510 or 35018 G [RP-608] 143 38 51 52. /2" R.012" 52 3 6 C L A MARK: MASTER DISK FOR CHECKING WHEEL CIRCUMFERENCE MEASURE OF 35" TO 52" DIAMETER WHEELS. 3" A 50° . C L MAKE MARKS AS SHOWN 52" DOWN TO 35" 5 0 31/2" MAKE MARKS AT 38".010" .998" 1 /4" 1 /4" R.002" 51.998" 1 /64" 52 3/32 ± 0 60° ENLARGED VIEW OF MARK 03/2011 31/2" 31/2" 31/2" 31/2" /12" 1"R . AAR Manual of Standards and Recommended Practices Wheels and Axles RP-608 THIS PAGE LEFT BLANK INTENTIONALLY G [RP-608] 144 03/2011 . CAST IRON 03/2011 G [RP-609] 145 .03/2011 RP-609 AAR Manual of Standards and Recommended Practices Wheels and Axles INSPECTION STAND FOR USE WITH MASTER DISKS Recommended Practice RP-609 Adopted: 1937. Last Revised: 2004 MATERIAL: COLD ROLLED STEEL. AAR Manual of Standards and Recommended Practices Wheels and Axles RP-609 THIS PAGE LEFT BLANK INTENTIONALLY G [RP-609] 146 03/2011 . 577 to 10. 03/2011 G [RP-612] 147 .000. inclusive Minimum 75 75 75 75 80 85 90 90 95 100 105 110 110 115 120 125 130 130 135 140 145 Desired Mounting Pressure (ton) 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 Maximum 95 100 110 115 120 125 130 140 145 150 155 160 170 175 180 185 190 200 205 210 215 Desired mounting pressures are based on 13 ton/in.347 to 11.347 to 6.423. inclusive 8. Last Revised: 2004 Diameter of Wheel Seat (in. inclusive 13.500 to 7.039 to 9.499.962 to 11. inclusive 7.038. inclusive 7.424 to 9.731 to 7.807. inclusive 12.115. except the first three minimum pressures.885 to 13.) 6.000 to 6. of diameter.116 to 12.03/2011 RP-612 AAR Manual of Standards and Recommended Practices Wheels and Axles MOUNTING PRESSURES FOR WROUGHT AND CAST STEEL WHEELS ON GEAR-DRIVEN AND IDLER AXLES OF LOCOMOTIVES OTHER THAN STEAM Recommended Practice RP-612 Adopted: 1951.115.576. inclusive 6. inclusive 9. inclusive 10.270 to 8.730. inclusive 10. inclusive 6. inclusive 10. inclusive 12.885 to 8.731 to 12. inclusive 7.193 to 10.192. which are shown as 75 ton.499.730.654 to 9.269. inclusive 12. inclusive 9. being considered better practice for these sizes.808 to 10.653.270 to 13. inclusive 9. inclusive 11.269.346. inclusive 13.961.346.653.884. inclusive 8.654 to 14. inclusive 11. expressed in the nearest 5 ton with an allowable variation of 20% over and under.500 to 12.116 to 7.884. AAR Manual of Standards and Recommended Practices Wheels and Axles RP-612 THIS PAGE LEFT BLANK INTENTIONALLY G [RP-612] 148 03/2011 . AXLE—MASTER GAUGE FOR VERIFYING AXLE JOURNAL AND FILLET GAUGE S-614 Recommended Practice RP-613 Adopted: 1937. Grade 1020 03/2011 G [RP-613] 149 .0 SCOPE This master gauge applies to Gauge No. 34401. Last Revised: 2004 1. S-614. MATERIAL: ASTM A-576. described in the AAR Manual of Standards and Recommended Practices.03/2011 RP-613 AAR Manual of Standards and Recommended Practices Wheels and Axles GAUGE. AAR Manual of Standards and Recommended Practices Wheels and Axles RP-613 THIS PAGE LEFT BLANK INTENTIONALLY G [RP-613] 150 03/2011 . Grade 1020 FINISH: CHROMIUM PLATE 03/2011 G [RP-614] 151 .0 SCOPE This master gauge applies to the steel wheel gauges described in the AAR Manual of Standards and Recommended Practices. Last Revised: 2004 1. WHEEL—MASTER GAUGE FOR VERIFYING WHEEL GAUGES S-617 AND S-618 Recommended Practice RP-614 Adopted: 1937. Standards S-617 and S-618. STAMPS) MATERIAL: ASTM A-576. MARK: MASTER FOR WHEEL GAUGE (3/32-in.03/2011 RP-614 AAR Manual of Standards and Recommended Practices Wheels and Axles GAUGE. AAR Manual of Standards and Recommended Practices Wheels and Axles RP-614 THIS PAGE LEFT BLANK INTENTIONALLY G [RP-614] 152 03/2011 . Last Revised: 2004 1.093-in.0 SCOPE 1. 03/2011 G [RP-615] 153 . REMOVE BURRS AND SHARP EDGES. 1. UNLESS OTHERWISE STATED. and grooved tread for all freight car wheels. DETAIL A (FOR GROOVED TREAD MEASUREMENT) MATERIAL: .03/2011 RP-615 AAR Manual of Standards and Recommended Practices Wheels and Axles GAUGE. 1976. ALL TOLERANCES ARE ±. WHEEL—SIMPLIFIED Recommended Practice RP-615 Adopted: 1975.1 This gauge can be used for checking high-flange.2 This recommended practice became effective October 1.010 in. thin-rim. STAINLESS STEEL. AAR Manual of Standards and Recommended Practices Wheels and Axles RP-615 THIS PAGE LEFT BLANK INTENTIONALLY G [RP-615] 154 03/2011 . 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. Last Revised: 2004 NOTE: THIS REFERENCE GROOVE IS OPTIONAL AND IS MACHINED AT THE REQUEST OF THE CUSTOMER UNLESS SPECIFIED AS REQUIRED.03/2011 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. 03/2011 G [RP-619] 155 . AAR Manual of Standards and Recommended Practices Wheels and Axles RP-619 THIS PAGE LEFT BLANK INTENTIONALLY G [RP-619] 156 03/2011 . ) 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 — G [RP-622] 157 . RAISED WHEEL SEAT Recommended Practice RP-622 Adopted: 1966. WEIGHT—MACHINED FINISH. Last Revised: 2007 Nominal Weight (lb) Classification of Axles Roller Bearing 03/2011 Size of Journal (in.03/2011 RP-622 AAR Manual of Standards and Recommended Practices Wheels and Axles AXLE. AAR Manual of Standards and Recommended Practices Wheels and Axles RP-622 THIS PAGE LEFT BLANK INTENTIONALLY G [RP-622] 158 03/2011 . Last Revised: 2004 Note: See RP-630 for application. MATERIAL: 16 GAUGE BLACK STEEL 03/2011 G [RP-629] 159 . WHEEL—FOR MEASURING CONDEMNABLE OVERHEATED WHEELS Recommended Practice RP-629 Adopted: 1980.03/2011 RP-629 AAR Manual of Standards and Recommended Practices Wheels and Axles GAUGE. AAR Manual of Standards and Recommended Practices Wheels and Axles RP-629 THIS PAGE LEFT BLANK INTENTIONALLY G [RP-629] 160 03/2011 . WHEEL—APPLICATION FOR MEASURING CONDEMNABLE OVERHEATED WHEELS Recommended Practice RP-630 Adopted: 1980.03/2011 RP-630 AAR Manual of Standards and Recommended Practices Wheels and Axles GAUGE. 03/2011 G [RP-630] 161 . Last Revised: 2004 4" Note: See RP-629 for gauge drawing. AAR Manual of Standards and Recommended Practices Wheels and Axles RP-630 THIS PAGE LEFT BLANK INTENTIONALLY G [RP-630] 162 03/2011 . 0 SCOPE This recommended practice can be used when checking with the following gauges: S-667 (wide flange) and S-662 (narrow flange).03/2011 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. CONTACT REQUIRED FLANGE HEIGHT THROAT RADII CONTACT REQUIRED FLANGE THICKNESS 03/2011 G [RP-636] 163 . AAR Manual of Standards and Recommended Practices Wheels and Axles RP-636 THIS PAGE LEFT BLANK INTENTIONALLY G [RP-636] 164 03/2011 . 0 SCOPE This recommended practice can be used when checking with the following gauges: S-665 (wide flange) and S-661 (narrow flange). WHEEL—APPLICATION DRAWING FOR AAR 1B WHEEL GAUGES S-661 AND S-665 Recommended Practice RP-637 Adopted: 1991 1. CONTACT REQUIRED FLANGE HEIGHT THROAT RADII CONTACT REQUIRED FLANGE THICKNESS 03/2011 G [RP-637] 165 .03/2011 RP-637 AAR Manual of Standards and Recommended Practices Wheels and Axles GAUGE. AAR Manual of Standards and Recommended Practices Wheels and Axles RP-637 THIS PAGE LEFT BLANK INTENTIONALLY G [RP-637] 166 03/2011 . S-663. S-662. Height and Throat Radii Gauges: Maximum Limit Wear Gauges: Minimum Flange Thickness. S-665. S-667. WHEEL—APPLICATION DRAWING FOR REFERENCE GAUGE TO VERIFY WHEEL GAUGES S-661.0 SCOPE This recommended practice can be used when checking with the following gauges: Maximum Flange Thickness. AND S-668 Recommended Practice RP-638 Adopted: 1991 1. S-666. Height and Throat Radii Gauges: Minimum Limit Wear Gauges: CONTACT REQUIRED CONTACT REQUIRED FLANGE HEIGHT 03/2011 S-665 and S-661 S-663 and S-666 S-667 and S-662 S-664 and S-668 FLANGE THICKNESS G [RP-638] 167 .03/2011 RP-638 AAR Manual of Standards and Recommended Practices Wheels and Axles GAUGE. S-664. 03/2011 AAR Manual of Standards and Recommended Practices Wheels and Axles RP-638 THIS PAGE LEFT BLANK INTENTIONALLY G [RP-638] 168 03/2011 .