2019 03 AS-7514-Wheels PC-Draft
2019 03 AS-7514-Wheels PC-Draft
2019 03 AS-7514-Wheels PC-Draft
Wheels
Any questions in relation to this document or RISSB’s accredited development process should be referred to RISSB.
RISSB Office
This Australian Standard® AS 7514 Wheels was prepared by a Rail Industry Safety and Standards Board (RISSB)
Development Group consisting of representatives from the following organisations:
ARTC Downer EDI John Holland Group
Queensland Rail Pacific National Rail Corp
V/Line Trans Adelaide Amsted Rail
KiwiRail Metro Trains Aurizon
Varley Group
The Standard was approved by the Development Group and the Rolling Stock Standing Committee in Select SC
approval date. On Select Board approval date the RISSB Board approved the Standard for release.
Choose the type of review
t
8
Development of the Standard was undertaken in accordance with RISSB’s accredited process. As part of the
en
approval process, the Standing Committee verified that proper process was followed in developing the Standard.
1
RISSB wishes to acknowledge the positive contribution of subject matter experts in the development of this Standard.
Their efforts ranged from membership of the Development Group through to individuals providing comment on a draft
ub e 0
of the Standard during the open review.
m
2
I commend this Standard to the Australasian rail industry as it represents industry good practice and has been
developed through a rigorous process.
om
r P h 4:
s
fo W 1
l
C
75
e
lic
Paul Daly
Chief Executive Officer
AS
RISSB welcomes suggestions for improvements, and asks readers to notify us immediately of any apparent
ra
inaccuracies or ambiguities. Members are encouraged to use the change request feature of the RISSB website at:
http://www.rissb.com.au/products/. Otherwise, please contact us via email at [email protected] or write to Rail
Industry Safety and Standards Board, PO Box 518 Spring Hill Qld 4004, Australia.
D
AS 7514:2018
Wheels
t
8
en
1
Document details
ub e 0
First published as: Enter first publication identifier (AS XXXX:yyyy)
m
ISBN Enter ISBN.
2
om
r P h 4:
Published by SAI Global Limited under licence from the Rail Industry Safety and Standards Board,
PO Box 518 Spring Hill Qld 4004, Australia
s
fo W 1
l
C
75
Copyright
e
© RISSB
All rights are reserved. No part of this work may be reproduced or copied in any form or by any means, electronic or
lic
mechanical, including photocopying, without the written permission of RISSB, unless otherwise permitted under the
AS
Notice to users
This RISSB product has been developed using input from rail experts from across the rail industry and represents
good practice for the industry. The reliance upon or manner of use of this RISSB product is the sole responsibility of
the user who is to assess whether it meets their organisation’s operational environment and risk profile.
ft
ra
D
Document control
Document identification
Designation / Title
AS 7514:2018 Wheels
Document history
Publication Version Effective Date Reason for and Extent of Change(s)
t
8
en
AS 7514:2018 Select Board approval date
1
AS 7514:2010 (Parts 1,2,3,4) 18/03/2010 Aged review - superseded by 2018 edition
ub e 0
m
2
om
r P h 4:
Draft history s
Version Date Change(s)
fo W 1
l
30/05/2018 Public consultation draft
C
75
e
lic
AS
Approval
Name Date
Rail Industry Safety and Standards Board Select Board approval date
ft
ra
D
Contents
1 Introduction................................................................................................................... 6
1.1 Purpose .......................................................................................................... 6
1.2 Scope ............................................................................................................. 6
1.3 Compliance ..................................................................................................... 6
1.4 Referenced documents ................................................................................... 7
1.4.1 Normative references...................................................................................... 7
1.4.2 Informative references .................................................................................... 7
t
1.5 Definitions ....................................................................................................... 8
en
2 Wheel design.............................................................................................................. 11
1
3 Geometrical assessment ............................................................................................ 11
3.1 ub e 0
Rim width ...................................................................................................... 11
m
2
3.2 Wheel diameter............................................................................................. 12
3.3 Wheel web shape ......................................................................................... 13
om
r P h 4:
3.4 Hub axle interface ......................................................................................... 13
3.5
s
Maintenance requirements............................................................................ 13
fo W 1
l
4 Mechanical assessment ............................................................................................. 15
C
75
Appendix Contents
Appendix A Wheel profiles ............................................................................................... 27
t
8
en
Appendix B Wheel profile co-ordinates ............................................................................ 34
1
ub e 0
m
2
om
r P h 4:
s
fo W 1
l
C
75
e
lic
AS
ft
ra
D
1 Introduction
1.1 Purpose
This document describes requirements for Rolling Stock Wheels.
The main purpose of the requirements is to reduce the risk of derailment arising from wheel
failure or damage to infrastructure caused by wheel defects.
1.2 Scope
This document covers the design, construction and maintenance of rolling stock wheels. It
applies to:
t
8
New locomotive, freight, passenger and infrastructure rolling stock wheels, going into service
en
after the date of publication.
1
Existing locomotive, freight, passenger and infrastructure rollingstock wheels, going into service
after modification. ub e 0
m
2
Operation of rolling stock is not covered.
om
r P h 4:
Rolling stock used on light rail, cane railway and monorail networks are not covered.
s
Requirements for the assembly of wheels onto wheelsets and geometric tolerances of wheels
fitted on wheelsets are not covered. These are covered in AS 7517.
fo W 1
l
Infrastructure maintenance rolling stock used for transportation of goods and material should be
C
75
1.3 Compliance
lic
There are two types of control contained within Australian Standards developed by RISSB:
AS
(a) Requirements.
(b) Recommendations.
Requirements – it is mandatory to follow all requirements to claim full compliance with the
Standard.
Requirements are identified within the text by the term ‘shall’.
Recommendations – do not mention or exclude other possibilities but do offer the one that is
preferred.
Recommendations are identified within the text by the term ‘should’.
Recommendations recognise that there could be limitations to the universal application of the
ft
control, i.e. the identified control cannot be able to be applied or other controls can be
appropriate / better.
ra
For compliance purposes, where a recommended control is not applied as written in the
standard it could be incumbent on the adopter of the standard to demonstrate their actual
D
method of controlling the risk as part of their WHS or Rail Safety National Law obligations.
Similarly, it could also be incumbent on an adopter of the standard to demonstrate their method
of controlling the risk to contracting entities, or interfacing organisations where the risk may be
shared.
Controls in RISSB standards address known railway hazards as included in an appendix.
t
8
en
and trailing stock - technical delivery conditions.
1
(g) ISO 1005/8 Railway Rolling Stock material - Part 8: Solid wheels for tractive
and trailing stock - dimensional and balancing requirements.
ub e 0
m
(h) UIC 812-2 Solid wheels for tractive and trailing stock - Tolerances.
2
(i) UIC 812-3 Technical specification for the supply of solid wheels in rolled non-
om
r P h 4:
alloy steel for tractive and trailing stock.
s
(j) Australian Government Australian Design Rules for road vehicles.
fo W 1
l
(k) RISSB Guideline for the Safe Operation of Road-Rail.
C
75
(j) ISO 1005-1 Railway Rolling Stock Material - Part 1: Rough-rolled tyres for
tractive and trailing stock - Technical delivery conditions.
D
(k) ISO 1005/2 Railway Rolling Stock material - Part 2: Tyres, wheel centres and
tyred wheels for tractive and trailing stock - dimensional, balancing and
assembly requirements.
(l) ISO 1005/4 Railway Rolling Stock material - Part 4: Rolled or forged wheel
centres for tyred wheels for tractive and trailing stock - quality requirements.
(m) UIC 810-1 Technical specification for the supply of rough rolled non-alloy steel
tyres for tractive and trailing stock.
(n) UIC 810-3 Technical specification for the supply of non-alloy flat and sectional
steel for tyre retention spring rings.
(o) UIC 812-1 Technical specification for the supply of rolled or forged steel wheel
centres for tractive and trailing stock - quality requirements.
(p) UIC 812-4 Technical specification for the supply of tyred wheels for tractive
and trailing stock - Tyre fitting and tolerances.
(q) UIC 812-5 Technical specification for the supply of rolled or forged steel wheel
centres for tractive and trailing stock - Tolerances and surface roughness
t
8
en
1.5 Definitions
1
AAR: Association of American Railroads.
ub e 0
m
ARTC network: Interstate standard gauge network, plus New South Wales regional standard
2
gauge network.
Aurizon Network: Narrow gauge network operated by Aurizon in Queensland.
om
r P h 4:
AustralAsia network: Tarcoola to Darwin standard gauge network.
s
fo W 1
Back: The back face or side of a wheel is on the flange side, see Figure 1:1.
l
C
Batch: Wheels produced by a manufacture within the same heat.
75
e
Cane railway network: A railway system dedicated to hauling harvested sugar cane from farms
to a raw sugar factory. Typically, 610 mm gauge. Conventional wheelset: A wheelset having two
lic
wheels and two outboard bearings.
AS
Conventional wheelset: A wheelset having two wheels and two outboard bearings.
EN: European Standards.
Front: The front face or side of a wheel is on the non-flange side, see Figure 1:1.
Freight rolling stock: Hauled Rolling Stock used to transport goods, materials etc.
Gross mass: Nominal total mass of Rolling Stock including maximum payload, provisioning,
maximum service capacity of crew and passengers.
Hub: The centre portion of a wheel that interfaces with the axle, see Figure 1:1.
Infrastructure maintenance rolling stock: Track machines and road-rail vehicle. Also, known
as on track vehicle.
ft
Light rail network: A passenger-carrying railway system operating with trams or other similar
shorter length, lower speed and lower axle-load self-propelled vehicles. Typically used in urban
ra
Operator: The person or body responsible by reason of ownership, control or management, for
the provision, maintenance or operation of trains, or a combination of these, or a person or body
acting on its behalf.
Passenger Rolling stock: Rollingstock carrying people and facilities for these people.
Excludes dedicated motive power units containing only a driving crew (i.e. locomotives).
PTA of WA narrow gauge network: Public Transport Authority of Western Australia narrow
gauge Perth metropolitan network.
QR narrow gauge network: Queensland narrow gauge network operated by Queensland Rail.
QR standard gauge network: QLD/NSW border to Brisbane standard gauge network.
t
RailCorp network: Sydney metropolitan standard gauge network.
en
Regulator: A government body responsible for ensuring compliance with particular laws, acts,
1
regulations, etc., eg. rail safety regulator.
ub e 0
Rail Infrastructure Manager (RIM): Person or organisation who has effective control and
m
management of the rail infrastructure. The RIM either owns the rail infrastructure or has a
2
statutory/contractual right to use the rail infrastructure or control, provide or access to it.
om
r P h 4:
Rail traffic crew: Competent Workers responsible for the operation of rail traffic.
s
Rim: The outer portion of a wheel that interfaces with the rail, see Figure 1:1.
fo W 1
l
Rim thickness: Distance from the underside of the wheel rim (back or front) to the running
surface (tread). C
75
e
Rim Width: Distance between the faces of the rim, see Figure 1:1.
Road-Rail Vehicle: A vehicle that can travel on a road and can also travel on rail by use of a
lic
rail wheel guidance system.
AS
RSO: a person who has effective control and management of the operation or movement of
rolling stock on rail infrastructure for a railway but does not include a person by reason only that
the person drives the rolling stock or controls the network or the network signals.
Tasmanian network: Tasmanian regional narrow-gauge network.
Track Machine: A flange wheeled vehicle used for infrastructure maintenance, construction
and inspections. Separate to freight Rolling Stock (eg. wagons used for carrying rail, sleepers,
spoil, ballast etc) and Road-Rail Vehicles.
TransAdelaide network: Adelaide metropolitan broad-gauge network.
UIC: International Union of Railways.
Victorian broad-gauge network: Victorian regional and Melbourne metropolitan broad-gauge
ft
networks.
ra
Victorian standard gauge network: Victorian regional non-interstate standard gauge network.
Web: The section of a wheel between the hub and the rim, see Figure 1:1.
D
WestNet Rail network: West Australian regional narrow and standard gauge network.
Wheelset: An assembly consisting of axle, wheels and bearings, and where applicable brake
discs, traction gears, traction motor support bearings or gearbox.
t
8
en
1
ub e 0
m
2
Figure 1:1- Definitions
om
r P h 4:
s
fo W 1
l
C
75
e
lic
AS
ft
ra
D
2 Wheel design
The design process of a new wheel design comprises the following four aspects:
(a) Geometrical aspect - to assure compatibility with track and interchangeability
of different solutions.
(b) Mechanical aspect - to ensure that no fatigue cracks will occur.
(c) Thermo-mechanical aspect - to manage wheel deformations and to ensure
that braking will not cause wheel fracture.
(d) Acoustical aspect - to ensure that the solution chosen does not generate more
noise than can be accepted for the application in question.
t
8
en
1
3 Geometrical assessment
ub e 0
m
3.1 Rim width
2
The rim width requirements given in Table 3:1 shall be met, unless otherwise approved by the
om
r P h 4:
relevant Rail Infrastructure Manager (RIM).
s
Network Criteria Rim width (mm)
fo W 1
l
ARTC 25 t axle load 127 to 140
C
75
Recommended rim width dimension for new wheel designs are 127 to 130 or 138 to 140 mm.
Infrastructure rolling stock with axle loads <10t are permitted a smaller rim width than given in
Table 3:1, subject to Table 3:2, and provided the design is proven in similar service and
t
application.
en
Infrastructure rolling stock that are to be detectable by wayside axle counters shall have a rim
1
width compliant with that network's criterion shown in Table 3:2.
ub e 0
m
Network Rim width (mm)
2
QR narrow gauge ≥ 115
om
r P h 4:
Table 3:2 - Rim width for axle counters
s
fo W 1
l
3.2 Wheel diameter
C
75
The RSO shall verify with the prevalent RIM as to the correct wheel diameter. See Table 3:3 for
examples.
lic
AS
The wheel design should allow for a minimum worn rim thickness (t) of at least 20 mm for axle
loads ≤ 25 tonnes and at least 22 mm for axle loads > 25 tonnes.
Rim thickness (t) is defined in Figure 5.2.
The P/D limits for wheel diameter are given in AS 7508.
For infrastructure rolling stock with axle loads < 5 tonnes, smaller worn rim thicknesses are
allowed provided the design is proven in similar service and application.
Infrastructure rolling stock that are to be detectable by wayside axle counters and are to operate
in a network listed below shall have a wheel diameter shown in table 4:1.
Network Wheel diameter (mm)
≥ 350
ra
QR narrow gauge
D
t
8
Figure 3:1 - Conventional wheel web shapes
en
1
The shape of the wheel web should be of curved web design except for those wheels to which
brake discs or quill tubes are attached or where other restrictions may preclude the use of such
ub e 0
m
a design.
2
A design proposal examples of a low stress wheel is shown in Appendix C.
om
r P h 4:
Straight webbed wheels should be avoided if the vehicle is equipped with tread brakes.
s
Low stress wheels (S-shaped web or Parabolic web) should be preferred for all rolling stock
fo W 1
excess of 20 tonnes gross the shape of the web should be of curved web design except for
e
those wheels to which brake discs are attached or where other restrictions may preclude the
use of such a design.
lic
AS
a definitive limit on the final turned diameter of the wheel; or it could be used as a means of
locating a gauge to assess remaining tread thickness.
ra
An example wear groove shape for new wheels is shown in Figure 5.2.
D
t
8
en
1
ub e 0
m
2
Figure 3:2 - Example wear groove shape
om
r P h 4:
All new wheels which are required to be re-profiled in a portal lathe shall have a clamping
s
surface for chucking of minimum 13 mm according to Figure 3:3.
fo W 1
l
C
75
e
lic
AS
Wheel hubs may include provision for the oil injection method of removal from axles, with an
example oil injection hole shown in Figure 3:4.
ra
D
t
8
en
1
ub e 0
m
2
om
r P h 4:
s
fo W 1
l
C
75
e
lic
Figure 3:4 - Example oil injection hole
AS
Oil injection grooves in wheel hubs, where fitted, shall have well rounded edges.
Where an oil injection port is featured, it shall also include a removable galvanised steel plug to
prevent the entry of dirt and moisture that could lead to unintended axle damage at the time of
wheel de-mounting.
4 Mechanical assessment
A formal design analysis shall be conducted for wheels produced to a shape or design not
proven in similar service.
The formal design analysis of a wheel should be in accordance with EN 13979-1, or AAR
ft
For infrastructure rolling stock able to travel at speeds greater than 60 km/h or weighing in
excess of 20 tonnes gross the formal design analysis of a wheel should be in accordance with
EN 13979-1, or AAR standard S-660, or another equivalent standard.
D
If the forces on the wheel are likely to deviate substantially from the standardized load cases
given in a standard, then the load cases can be derived from track force measurements.
5 Thermo-mechanical assessment
A thermo-mechanical assessment of new wheel designs shall be conducted where any of the
following apply:
(a) Where tread brakes are used as service brakes.
(b) Where tread brakes are used as park brakes.
(c) Where there is a risk that the heat transferred from wheel mounted brake
discs can overheat the wheel.
The thermo-mechanical assessment of a wheel should be in accordance with EN 13979-1, AAR
standard S-660 or another equivalent standard.
t
8
en
1
6 Acoustical assessment
ub e 0
m
For operations where wheel-to-rail noise emissions, particularly wheel squeal, are known to be
2
a problem, then a wheel design that attenuates noise emissions should be considered.
om
r P h 4:
Methods of attenuating noise at the wheel include ring damping, tuned dampers, constrained
layer damping and resiliently-mounted treads.
s
fo W 1
When it comes to deciding on noise reducing measures, note that track and vehicle are an
l
integrated system and the most appropriate and cost-effective solution could be treating the
C
75
Flanged wheel profiles should comply with Table 7:1. RSO are to verify the appropriate wheel
profile and surface with the RIM.
ANZR-1,
ARTC WPR 2000 – used for coal operations. Not recommended for fright operations
>80km/h.
AustralAsia ANZR-1.
ANZR-1 (allowable and mandatory for vehicles sensitive to hunting due to higher
initial conicity of WPR 2000).
Tasmania ANZR-1,
WPR 2000 (not recommended for freight
operations > 80 km/h).
t
8
en
WR2.
1
WestNet Rail narrow gauge ANZR-1,
ub e 0WR1.
m
2
Aurizon LW3
om
r P h 4:
s Table 7:1 - Acceptable wheel profiles
l
Operators shall gain the approval of the appropriate RIM for use of a rolling stock wheel profile
C
75
not compliant with Table 7:1, including infrastructure maintenance rolling stock able to travel at
e
8 Manufacturing process
Wheels shall be manufactured in accordance with the processes described in AAR
specifications M 107/M 208, or EN 13262, or UIC 812-3, or another equivalent industry
standard.
9 Material
Infrastructure maintenance Rolling Stock that are to be detectable by wayside axle counters and
ft
are to operate in a network listed in Table 9:1 shall have a wheel material compliant with that
network's criterion shown in Table 9:1.
ra
t
8
Cast Wheels Wrought Wheels Cast Wheels Wrought Wheels
en
1
UTS Min. 1100 MPa Min. 1100 MPa Min. 1170 MPa Min. 1170 MPa
0.2% Proof ub e 0
Min. 700 MPa Min. 700 MPa Min. 760 MPa Min. 760 MPa
m
Strength
2
Elongation N/A Min. 10% N/A Min. 10%
om
r P h 4:
Reduction Area N/A Min. 30% N/A Min. 30%
s
fo W 1
l
Fracture Min. 35 ksi sq rt inch N/A Min. 35 ksi sq rt inch N/A
Toughness
C
75
Ultrasonic testing of the rim shall be performed either to the AAR M-107/M-208 criteria or with a
reference block reflector Ø 1mm FBH (as per EN 13262:2004 Category 1).
Known vulnerabilities involving heavy tread braking and braking frequency cycles can be
identified when using AAR Class C wheels without adequate train operation and maintenance
controls in place.
Surface hardness, wear properties, sensitivity to shelling, fatigue and impact strength are the
main properties that affect selection of the wheel material.
New wheels prior to fitment on a wheelset should be machined to tolerances and surface finish
as given in AAR specification M-107/M-208, or ISO 1005/8, or EN 13262, or UIC 812-2, or
D
t
8
en
Cast iron - AAR Class A, B or C or equivalent.
1
Table 11:1 – Suggested brake block/wheel combinations
ub e 0
m
2
12 Balancing
om
r P h 4:
Wheels intended for use at a speed greater than 120 km/h shall be statically balanced to less
s
than the value stated in 12:2.
fo W 1
l
Any imbalance shall be corrected by machining.
C
75
e
v ≤ 120 -
lic
120 v ≤ 200
AS
75
200 v ≤ 250 50
v > 250 25
v ≤ 100 -
120 v ≤ 200 75
ft
v > 250 25
D
t
8
en
14 Identification and records
1
14.1 Branding of new wheel designs
ub e 0
m
New wheels shall be branded with the following marks:
2
(a) manufacturer's mark;
om
r P h 4:
(b) cast number, or serial number which can be identified with the specific cast, or
s
both cast and serial number;
fo W 1
(e) for wheels operating at speeds over 100 km/h: position of residual imbalance
and its symbol.
lic
The wheel marking arrangement shall comply with one of the following:
AS
(a) Be marked on the hub-web fillet as shown in Figure 3:3 - Clamping surface
and example position of marking.
(b) Be marked on the hub front or back face according to AAR Specification M-
107/M-208 Figure B.5 or ISO 1005-6.
(c) Be cast on the web as per ISO 1005-6 Figure 16.1.
ft
ra
D
t
8
en
1
Figure 14:1 - Example marking on hub-web fillet
14.2 ub e 0
Branding of existing wheel designs
m
2
Replacement new wheels for existing wheel designs should be clearly branded on the hub or
cast on the web with the following information:
om
r P h 4:
(a) manufacturer’s mark.
s
fo W 1
(b) cast number, or serial number which can be identified with the specific cast, or
l
both cast and serial number.
C
75
14.4 Records
The RSO shall keep or be able to access records of chemical and physical test results for each
batch of steel used in the manufacture of new wheels.
The wheel steel batch records shall be retained until wheel disposal.
ft
The wheel steel batch test results shall be traceable to the cast numbers or the serial numbers
marked on the wheels.
ra
t
8
Figure 15:1 - Wheel types
en
1
Some example standards for tyred wheel components are–
(a) ub e 0
tyre: ISO 1005-1 and ISO 1005/2, or UIC 810-1;
m
2
(b) retaining ring: ISO 1005/2 or UIC 810-3.; wheel centre: ISO 1005/2 and ISO
1005/4, or UIC 812-1 and UIC 812-5.
om
r P h 4:
(c) wheel centre: ISO 1005/2 & ISO 1005/4, or UIC 812-1 & UIC 812-5.
s
Tyred wheels shall be only used on heritage rolling stock where such vehicles were originally
fo W 1
l
equipped with tyred wheels.
C
75
Tyred wheels shall be assembled so that all components remain in place for the service life of
e
the wheel.
lic
Some example procedures for tyred wheel assembly are described within ISO 1005/2 and UIC
812-4.
AS
The tyre and the rim of the wheel centre should have two adjacent punch marks, as a tyre-rim
displacement indicator.
Tyred rail wheels should only be used on vehicles if the wheels have been manufactured to a
design which has been proven in a similar service and application.
Re-tread tyres shall not be fitted to road wheels that are used in rail mode.
ra
For road wheels that provide traction or braking when in rail mode the tread surface shall
completely cover the railhead always.
D
Refer to AS 7507 for Rolling Stock outline requirements for road wheels.
Road wheels should be maintained in accordance with the guidelines checklist rail road vehicles
and AS 7502 Rail Road Vehicles.
16 Inspection- General
Operators shall develop and comply with criteria that define when and how wheels shall be
routinely inspected.
The training of wheel inspectors should involve:
(a) recognition and assessment of wheel profile wear, tread damage, wheel
overheating and cracking;
(b) the proficient use of measuring instruments and go no-go gauges.
The staff performing the inspections shall have written documentation and be trained on the
inspection procedure and the action to be taken when defects are found.
t
8
en
Wheel inspections performed as part of normal train inspection and during changes of brake
1
blocks/ brake pads in terminals and sidings may not generally cover the full wheel because of
practical limitations on the access to all parts of the wheels.
ub e 0
m
If any defects are identified during the initial inspection, the whole wheel shall be closely
2
examined.
om
r P h 4:
Wheel inspections where the wheelsets are not fitted under a vehicle should include the full
circumference and total surface of the wheels on both sides of the wheelset.
s
Refer to the RISSB Wheel Defect Manual
fo W 1
l
C
75
e
17 Inspection schedule
lic
Wheel inspections should be carried out as follows:
AS
18 Dimensional limits
Operators shall develop and comply with criteria that define when a vehicle has to be removed
from service due to wheel wear or exceeded dimensional limits.
ft
Refer to the RISSB Wheel Defect Manual for suitable wheel wear and dimensional limits.
ra
The equipment required to measure wheel dimensions shall be nominated in the wheel
inspection procedures.
D
An Operator’s wheel dimensional limit criteria shall be approved by the relevant RIM.
t
8
en
1
ub e 0
m
2
Figure 19:1 - Stages of development of a shattered rim
om
r P h 4:
s
When changes are made to wheel designs or braking systems the RSO should review risk
fo W 1
A typical means of verifying non-destructive wheel tests is by checking the method and
equipment on a wheel or test piece with known defects.
lic
AS
20 In-service defects
RSOs shall develop and comply with criteria that define when a vehicle has to be removed from
service due to wheel defects.
A wheelset shall be inspected if it produces a wayside wheel impact monitoring system alarm.
The following are typical in-service wheel defects that need condemning criteria;
(a) shelling;
(b) spalling;
(c) scaling;
ft
t
8
en
(r) on tyred wheels: Detachment of retaining ring;
1
(s) on tyred wheels: Cracked spokes.
ub e 0
Refer to the RISSB Wheel Defect Manual for suitable in-service wheel defect limits.
m
2
When wheel defects are found action shall be taken to minimise the risk of wheel failure in
service or damage to the track infrastructure.
om
r P h 4:
The form and condition of the wheel flange is important because of the potential for wheel climb
s
and derailment caused by irregular or deformed flanges, such as arises, wear grooves, surface
fo W 1
running surface.
e
An RSO’s condemning limits for the in-service wheel defects that may affect the wheel to rail
lic
contact area shall be approved by the relevant RIM.
AS
Post-derailment wheel checks should involve a detailed inspection for surface damage and
ra
cracking.
Tolerance requirements for the axle bending/distortion check are given in AS 7517.
D
22 Repairs
RSOs shall develop and comply with criteria that define when a wheel should be repaired or
scrapped.
Restoration of the profile and the roundness of the wheel shall be done by turning by a re-
profiling lathe or milling machine.
Machining tolerances for a re-profiled wheel on a wheelset are prescribed in AS 7517.
Witness marks are allowed under the following conditions:
(a) Depth is not greater than 1.2 mm.
(b) Position on the wheel profile is 10 mm or more above the tread line.
(c) Contour is smooth and blend evenly into the wheel profile.
If a full flange profile cannot be achieved, thin flange derivatives should be used.
t
The wheel rim shall not be turned below the last turning groove or a predetermined minimum
en
allowable rim thickness.
1
Wheel turning should remove all marks, cracks and heat-affected material from the surface of
the tread. ub e 0
m
Wheels with damaged coating (e.g. due to overheating or bad flaking) and not scrapped, shall
2
not have their coating full repaired as overheating damage can be cumulative.
om
r P h 4:
Any repairing of the paint should be such that in the event of a second event, it is evident that
the wheel has been subjected to more overheating.
s
fo W 1
Overheating details should be recorded for the wheelset if the wheel disc is not scrapped.
l
C
The RSO shall have in place a process to ensure existing wheels in service have a adequate
75
surface finish. For example, many RSO use 12.5 microns for final surface finish.
e
lic
23 Temporary repairs to wheel skids
AS
The repair of wheel skids by welding is permitted as a temporary measure to allow recovery of a
vehicle or wheelset with severe wheel skids.
All weld metal, including the heat affected zone, shall be removed by turning, and the tread
surface inspected for possible flaws, prior to replacing the wheelset into service.
The wheel should be scrapped if it cannot be guaranteed that the heat affected zone has been
removed and residual compressive stress has not been compromised.
ft
ra
D
A.1 ANZR-1
t
8
en
1
ub e 0
m
Figure A.1:1 - ANZR-1 full profile
2
om
r P h 4:
s
fo W 1
l
C
75
e
lic
AS
A.2 ANZR-1 1 in 40
t
8
en
1
Figure A.2:1 - ANZR-1 1 in 40 profiles
ub e 0
m
A.3 WPR 2000
2
om
r P h 4:
s
fo W 1
l
C
75
e
lic
AS
A.4 LW3
t
8
en
1
ub e 0
m
2
om
r P h 4:
A.5 WR1
s
fo W 1
l
C
75
e
lic
AS
t
8
en
1
Figure A.5.2 - WR1 profile Z section cut out
ub e 0
m
A.6 WR2
2
om
r P h 4:
s
fo W 1
l
C
75
e
lic
AS
A.7 2M-40
t
8
en
1
ub e 0
m
2
om
r P h 4:
Figure A.7:1 – 2M-40 profile
s
fo W 1
l
A.8 2M-41
C
75
e
lic
AS
t
8
en
1
ub e 0
m
2
om
r P h 4:
A.10 MP1
s
fo W 1
l
C
75
e
lic
AS
A.11 MP2
ft
ra
D
A.12 HRS1
t
8
en
1
ub e 0
m
2
om
r P h 4:
s
fo W 1
l
A.13 Square flange RRV
C
75
e
lic
AS
ft
ra
D
t
8
en
5 1.700 15.380 85 29.750 17.034 165 49.750 27.007
1
6 2.200 13.211 86 30.000 17.489 166 50.000 27.041
7 2.700 ub e 0
11.287 87 30.250 17.910 167 50.250 27.075
m
2
8 3.200 9.544 88 30.500 18.302 168 50.500 27.108
om
r P h 4:
9 3.700 7.961 s 89 30.750 18.669 169 51.000 27.172
l
11 4.700 5.843 91 31.250 19.339 171 52.000 27.292
C
75
t
8
36 17.200 0.203 116 37.500 24.044 196 64.500 28.470
en
1
37 17.700 0.308 117 37.750 24.156 197 65.000 28.506
m
39 18.700 0.585 119 38.250 24.372 199 66.000 28.575
2
40 19.200 0.759 120 38.500 24.476 200 66.500 28.609
om
r P h 4:
41 19.700 0.959 121 38.750 24.576 201 67.000 28.642
s
fo W 1
t
8
67 27.500 11.258 147 45.250 26.281 227 95.000 30.079
en
1
68 27.600 11.533 148 45.500 26.327 228 97.500 30.204
m
70 27.800 12.082 150 46.000 26.417 230 102.500 30.454
2
71 27.900 12.357 151 46.250 26.461 231 105.000 30.579
om
r P h 4:
72 28.000 12.632 152 46.500 26.504 232 110.000 31.079
s
fo W 1
t
8
6 2.200 13.211 86 30.000 17.489 166 50.000 27.041
en
7 2.700 11.287 87 30.250 17.910 167 50.250 27.075
1
8 3.200 9.544 88 30.500 18.302 168 50.500 27.108
ub e 0
m
9 3.700 7.961 89 30.750 18.669 169 51.000 27.172
2
10 4.200 6.769 90 31.000 19.014 170 51.500 27.233
om
r P h 4:
11 4.700 5.843 91 31.250 19.339 171 52.000 27.292
s
fo W 1
t
8
37 17.700 0.308 117 37.750 24.156 197 65.000 28.506
en
1
38 18.200 0.435 118 38.000 24.266 198 65.500 28.541
m
40 19.200 0.759 120 38.500 24.476 200 66.500 28.609
2
41 19.700 0.959 121 38.750 24.576 201 67.000 28.642
om
r P h 4:
42 20.200 1.185 122 39.000 24.673 202 67.500 28.674
s
fo W 1
t
8
68 27.600 11.533 148 45.500 26.327 228 97.500 30.204
en
1
69 27.700 11.807 149 45.750 26.372 229 100.000 30.329
m
71 27.900 12.357 151 46.250 26.461 231 105.000 30.579
2
72 28.000 12.632 152 46.500 26.504 232 110.000 31.079
om
r P h 4:
73 28.100 12.906 153 46.750 26.547 233 115.000 31.579
s
fo W 1
t
8
6 2.200 13.211 86 28.250 19.764 166 49.500 27.234
en
7 2.700 11.287 87 28.500 20.042 167 50.000 27.290
1
8 3.200 9.544 88 28.750 20.306 168 50.500 27.346
ub e 0
m
9 3.700 7.961 89 29.000 20.558 169 51.000 27.400
2
10 4.200 6.769 90 29.250 20.798 170 51.500 27.454
om
r P h 4:
11 4.700 5.843 91 29.500 21.027 171 52.000 27.507
s
fo W 1
t
8
37 17.700 1.460 117 36.000 24.683 197 65.000 28.561
en
1
38 18.200 1.780 118 36.250 24.771 198 65.500 28.591
m
40 19.200 2.580 120 36.750 24.939 200 66.500 28.648
2
41 19.700 3.064 121 37.000 25.019 201 67.000 28.676
om
r P h 4:
42 20.200 3.560 122 37.250 25.096 202 67.500 28.703
s
fo W 1
t
8
68 24.800 13.281 148 43.750 26.455 228 115.000 31.579
en
1
69 24.900 13.556 149 44.000 26.496 229 120.000 32.079
m
71 25.100 14.105 151 44.500 26.575 231 130.000 33.079
2
72 25.200 14.380 152 44.750 26.614 232 134.000 33.479
om
r P h 4:
73 25.300 14.655 153 45.000 26.652 233 136.000 35.479
s
fo W 1
t
8
en
6 2.200 13.211 86 28.250 19.764 166 49.500 27.234
1
7 2.700 11.287 87 28.500 20.042 167 50.000 27.290
ub e 0
m
2
8 3.200 9.544 88 28.750 20.306 168 50.500 27.346
om
r P h 4:
9 3.700 7.961 s 89 29.000 20.558 169 51.000 27.400
l
11 4.700 5.843 91 29.500 21.027 171 52.000 27.507
C
75
e
t
8
33 15.700 0.470 113 35.000 24.301 193 63.000 28.434
en
1
34 16.200 0.660 114 35.250 24.401 194 63.500 28.467
m
36 17.200 1.130 116 35.750 24.592 196 64.500 28.530
2
37 17.700 1.460 117 36.000 24.683 197 65.000 28.561
om
r P h 4:
38 18.200 1.780 118 36.250 24.771 198 65.500 28.591
s
fo W 1
t
8
64 24.400 12.182 144 42.750 26.286 224 101.500 30.404
en
1
65 24.500 12.457 145 43.000 26.329 225 103.000 30.479
m
67 24.700 13.006 147 43.500 26.414 227 110.000 31.079
2
68 24.800 13.281 148 43.750 26.455 228 115.000 31.579
om
r P h 4:
69 24.900 13.556 149 44.000 26.496 229 120.000 32.079
s
fo W 1
t
8
E6 48.5331 27.3245
en
E7 41.3056 26.2808
1
E8 34.8653 24.1960
ub e 0
m
E9 28.2593 16.9150
2
E10 25.2160 8.5537
om
r P h 4:
E11 13.0000 0.0000
s
fo W 1
t
8
E6 48.5331 27.3245
en
E7 41.3056 26.2808
1
E8 34.8653 24.1960
ub e 0
m
E9 28.2593 16.9150
2
E10 25.2160 8.5537
om
r P h 4:
E11 13.0000 0.0000
s
fo W 1
t
8
C6 53.3579 -30.9470 E6 34.8181 25.6214
en
C7 73.3289 -219.8944 E7 40.2271 27.6096
1
C8 93.7578 156.5953 E8 47.0512 28.7206
ub e 0
m
C9 107.6219 62.6121 E9 60.8454 29.7936
2
E10 100.0000 31.7513
om
r P h 4:
E11 112.0000 32.9333
s
fo W 1
l
C
75
e
lic
AS
ft
ra
D
t
8
E2 0.000 21.000 46 39.482 24.912 102 90.820 28.740
en
E3 1.773 10.061 47 40.588 25.188 103 91.607 28.768
1
E4 20.255 20.004 48 41.535 25.429 104 92.339 28.794
ub e 0
m
E5 27.210 10.840 49 42.568 25.641 105 93.163 28.823
2
E6 28.711 14.964 50 43.534 25.831 106 94.000 28.844
om
r P h 4:
E7 40.383 25.1633 51 44.549 26.005 107 95.000 28.868
s
fo W 1
t
8
21 18.487 1.033 77 70.000 28.000 133 121.000 29.809
en
1
22 19.383 1.477 78 71.097 28.039 134 122.000 29.876
m
24 21.057 2.569 80 73.151 28.112 136 124.000 30.012
2
25 21.842 3.189 81 74.220 28.150 137 125.000 30.079
om
r P h 4:
26 22.590 3.851 82 75.317 28.189 138 126.000 30.147
s
fo W 1
t
8
C6 103.760 -369.847 40 36.510 22.839 90 85.799 29.755
en
E1 0.000 31.365 41 37.418 23.260 91 86.799 29.805
1
E2 3.562 8.371 42 38.339 23.650 92 87.799 29.855
ub e 0
m
E3 26.276 7.896 43 39.273 24.009 93 88.799 29.905
2
E4 28.860 15.000 44 40.215 24.336 94 89.799 29.955
om
r P h 4:
E5 34.578 21.816 45 41.173 24.633 95 90.799 30.005
s
E6 42.991 25.102 46 42.138 24.897 96 91.799 30.055
fo W 1
l
E7 54.576 27.118C 47 43.111 25.129 97 92.799 30.105
75
e
t
8
22 20.302 1.235 72 67.859 28.539 122 117.780 31.354
en
23 21.179 1.713 73 68.849 28.627 123 118.780 31.404
1
24 22.012 2.262 74 69.845 28.713 124 119.780 31.454
ub e 0
m
25 22.798 2.879 75 70.847 28.797 125 120.780 31.504
2
26 23.530 3.560 76 71.843 28.878 126 121.760 31.553
om
r P h 4:
27 24.203 4.299 77 72.833 28.956 127 122.760 31.603
s
28 25.352 5.931 78 73.829 29.032 128 123.760 31.653
fo W 1
l
29 26.215 7.732
C 79 74.832 29.106 129 124.760 31.703
75
e
t
8
The Standards development process is rigorous and transparent.
en
Authors work with RISSB's Project Managers and Development Groups to ensure that products are acceptable to
1
industry. Standing Committees oversee this work and ensure that proper governance and process is followed. The
products are exposed to the public and industry for comment and validated by an independent validator.
ub e 0
m
Once agreed by the Development Groups, Standing Committees and Validator, the drafts are passed to the RISSB
2
Board for approval.
The same process is used in developing other RISSB products, although Guidelines are not exposed to the public for
om
r P h 4:
comment or validated, given their non-binding nature.
s
fo W 1
The Standards Development and Accreditation Committee audits RISSB annually to ensure that RISSB’s processes
are in accordance with SDAC accreditation requirements.
lic
AS
Brisbane Office
Level 4, 15 Astor Terrace
Brisbane, QLD, 4000
Melbourne Office
Level 4, 580 Collins Street,
Melbourne, Vic 3000
t
8
PO Box 518
en
Spring Hill, QLD, 4004
1
ub e 0
m
T +61 6270 4523
2
F +61 6270 4516
E [email protected]
om
r P h 4:
For information regarding the sale and distribution of Australian
Standards developed by RISSB contact:
s
ISBN Enter ISBN.
fo W 1
l
C
75
e
http://infostore.saiglobal.com/store