Professional Documents
Culture Documents
MANUAL OF STANDARDS
AND
RECOMMENDED PRACTICES
SECTION G
Compiled under the direction of the Committees responsible for the subjects shown herein.
Published by
Printed in U.S.A.
03/2011
All rights reserved, including the right to reproduce this book in any form. It is the AARs intention that this publica-
tion 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 pur-
chaser 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 net-
work 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:
CIRCULAR Subscriptions to Circular Letters of the AAR Safety and Operations Technical Services are available in
LETTER hardcopy or electronic format (online access via AARs 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: pubs@aar.com
AAR Web page: http://www.aar.org
TTCI Web page: http://www.aar.com
MSRP-A1 The MSRP-A1 Table of Contents is an inclusive index of all MSRP specifications, standards, and
INDEX 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 For technical questions regarding this manual, contact the following:
QUESTIONS Technical Committee Coordinator
Transportation Technology Center, Inc.
P.O. Box 11130
55500 DOT Road
Pueblo, CO 81001
Email: wabl@aar.com
Phone: 719-584-0670
Fax: 719-585-1895
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TO THE USER
Section GWheels and Axles, Manual of Standards and Recommended Practices, covers three
main components: the wrought (or forged) steel wheel, the cast steel wheel, and the steel axle. Be-
cause of the critical functions of all these components, exhaustive details are given on design, met-
allurgy, manufacture, inspection, acceptance, assembly, wear limits, reclamation, and machining
for reuse. Wheels and axles are medium-range carbon steels containing a maximum of less than 1%
manganese and minimal levels of phosphorus, sulfur, and silicon. Wheels subjected to severe ser-
vice conditions have rims heat-treated and quenched to produce wear-resistant surfaces, followed
by overall tempering and controlled cooling. Axles must always be normalized and, when used un-
der high-capacity freight cars, passenger cars, and locomotives, are to be heat-treated, normalized,
quenched, and tempered. A specification included in this volume treats electrochemical metal dep-
osition for restoration of journal surfaces of roller bearing axles. There also are standards and rec-
ommended practices for dimensions, marking, inspection, gauges, condemning limits, wheel
mounting, and manufacturing tolerances.
USERS GUIDE
Section G contains three specifications, twenty-one standards, and thirteen recommended practic-
es. It consists of the following:
Preface: A listing of the subjects covered in the 25 individual sections, the volumes mak-
ing up this manual. This preface is part of each section.
Table of ContentsAlphabetical: An alphabetical listing of the specifications (M pre-
fix), standards (S prefix), and recommended practices (RP prefix).
Table of ContentsNumerical: A numerical listing of the specifications (M prefix),
standards (S prefix), and recommended practices (RP prefix).
Section G: A generalized subject listing that indicates applicable specifications, stan-
dards, and recommended practices.
Specifications, Standards, and Recommended Practices: The body of this volume.
RELATED SECTIONS
Section GWheels and Axles, should be used in conjunction with Section G, Part IIWheel and
Axle (shop) Manual. Other sections containing pertinent information are as follows:
Section DTrucks and Truck Details
Section HJournal Bearing and Lubrication
Section H, Part IIRoller Bearing (Shop) Manual
Section H, Part IIILubrication Manual
Section JSpecifications for Quality Assurance, M-1003
RESPONSIBILITY
The coverage of Section GWheels and Axles, is the responsibility of the AAR Wheels, Axles, Bear-
ings, and Lubrication Committee.
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PREFACE
The Manual of Standards and Recommended Practices of the Safety and Operations Depart-
ment, Association of American Railroads, is issued by authority of the Management Committee of
the Division and includes all regularly adopted specifications, standards, and recommended prac-
tices of the Association of American Railroads.
The manual is composed of the following sections:
Section ASAdministrative Supplement serves as a suplement to all MSRP sections (this
is available as a free download at http://www.aar.com/aar_standards-publications.htm)
Section ATable of Contents, Alphabetical and Numerical Index of Sections B through S
inclusive (this is available as a free download at http://www.aar.com/aar_standards-publications.htm)
Section BCouplers and Freight Car Draft Components (100 Series)
Section CCar ConstructionFundamentals and Details (200 and 2000 Series)
Section C, Part IIDesign, Fabrication, and Construction of Freight Cars, M-1001
Section C, Part IIISpecifications for Tank Cars, M-1002
Section DTrucks and Truck Details (300 and 3000 Series)
Section EBrakes and Brake Equipment (300, 400, and 4000 Series)
Section E, Part IIElectronically Controlled Brake Systems
Section FSensors
Section GWheels and Axles (600 Series)
Section G, Part IIWheel and Axle (Shop) Manual (600 Series)
Section HJournal Bearings and Lubrication (700 Series)
Section H, Part IIRoller Bearing (Shop) Manual (700 Series)
Section H, Part IIILubrication (Shop) Manual (700 Series)
Section IIntermodal Equipment Manual
Section JSpecification for Quality Assurance, M-1003
Section KRailway Electronics (5700 Series)
Section K, Part IIRailway Electronics (5800 Series)
Section K, Part IIIRailway Electronics (5900 Series)
Section LLettering and Marking of Cars (900 Series)
Section MLocomotives and Locomotive Interchange Equipment
Section NMulti-Level Manual
Section SCasting Details
Section S, Part IITruck Details and Casting Codes
Section S, Part IIICoupler and Yoke Details
Specifications are designated with an M prefix (e.g., M-900). Standards are prefixed S (e.g.,
S-900). Recommended Practices carry the prefix RP( e.g., RP-900).
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TABLE OF CONTENTSALPHABETICAL
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TABLE OF CONTENTSNUMERICAL
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Specification
M-101
Grade FDouble normalized and tempered. (All freight axles over 6 1/2 in. nominal di-
ameter at center shall be Grade F.)
Grade GQuenched and tempered.
Grade HNormalized, quenched, and tempered.
Grades F, G, and HAxles are used in heavy duty service on locomotives, cars, and other equip-
ment.
2.0 QUALIFICATION AS MANUFACTURER
Qualification as a manufacturer of axles for use in AAR interchange service must be in accordance
with Appendix C of this specification. Qualification is effective until revoked for cause by the Com-
mittee. Failure to maintain reasonable quality standards in manufacturing is an example of cause.
Axle manufacturers must meet the requirements of the AAR Manual of Standards and Recom-
mended Practices, Section J, Specification M-1003, Specification for Quality Assurance.
3.0 MANUFACTURE
3.1 Process
The steel shall be made by any of the following processes: open hearth, electric furnace, or basic
oxygen. Proposed changes to material or manufacturing processes must be submitted to the AAR
for consideration. Approval of a new material or process may include meeting the requirements
stated in Appendix C.
3.2 Discard
A sufficient discard shall be made from each ingot to ensure freedom from piping and undue segre-
gation.
3.3 Reduction Practice
The axles may be made directly from the ingot or from blooms. The total reduction from ingot or
strand-cast bloom to forging or rolling shall be not less than 3 to 1, unless otherwise specified.
Note: The process for manufacturing strand-cast blooms shall be designed to ensure freedom from
center porosity and undue segregation.
4.0 COOLING AND HEATING
4.1 After axle blooms are produced, they shall be slow-cooled in closed containers, hoods, or fur-
naces.
4.2 Blooms shall be reheated for working in a manner that will prevent internal bursts and over-
heating.
4.3 After reduction, axles shall be slow-cooled in closed containers, covered conveyors, or in
hoods. If axles (Grades F, G, and H) are heat-treated directly from reduction, they shall be
slow-cooled following the final heat treatment.
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4.4 Axles (Grades F, G, and H) that are heat-treated directly from reduction 1) shall be cooled
below the transformation temperature or to approximately 1,000 F before any reheating opera-
tion; and 2) must not be permitted to cool below 500 F without slow-cooling as defined in
paragraph 4.3.
Note: As the temperature of the axles approaches the minimum of 500 F, a supplemental heat
source may be necessary to ensure an effective slow-cooling cycle.
4.5 When properly vacuum-degassed steel is used, the slow-cooling requirements of paragraphs
4.1, 4.3, and item 2 of paragraph 4.4 may be omitted, but axle blooms must then be pile cooled.
4.6 The slow-cooling requirements of paragraphs 4.1, 4.3, and item 2 of paragraph 4.4 may be
accomplished by piling and covering the piled blooms or axles with insulating materials in lieu of
using closed containers, hoods, furnaces, and covered conveyors. Covered piles must be capable of
providing effective cooling rates in accordance with the manufacturers procedure or specification.
5.0 HEAT TREATMENT
5.1 Axles for heat treatment shall be reheated gradually and uniformly to a suitable temperature
to refine the grain structure.
5.2 Normalizing
After being heated to a suitable temperature, the axles shall be withdrawn from the furnace and
allowed to cool uniformly in air. A furnace charge thus treated is termed a normalizing charge.
Cooling may be accelerated by increased air circulation, which must be controlled to provide rea-
sonably uniform cooling.
5.3 Double Normalizing
The procedure shall consist of two separate normalizing treatments. The second treatment shall
be performed at a lower temperature than the first treatment. A furnace charge thus treated is
termed a double normalizing charge. Cooling may be accelerated by increased air circulation,
which must be controlled to provide reasonably uniform cooling.
Note: A single normalizing treatment shall be permitted when all other requirements for Grade F
can be met.
5.4 Quenching
After being heated to a suitable temperature, the axles shall be quenched in a suitable medium
under reasonably uniform conditions. A furnace charge thus treated is termed a quenching charge.
5.5 Tempering
Axles shall be reheated gradually to, and held at, a suitable temperature below the critical range
and shall then be allowed to cool under suitable conditions. A furnace charge thus treated is
termed a tempering charge.
5.6 Heat treatment may be performed in either batch-type furnaces or continuous furnaces.
6.0 STRAIGHTENING
Straightening shall be done before machining and preferably at a temperature not lower than
950 F. Straightening performed at temperatures lower than 950 F shall be followed by stress
relieving or an applicable heat treatment.
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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 prolon-
gations 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.
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16.4 Personnel
16.4.1 All personnel performing ultrasonic inspection operations must be prequalified to
non-destructive testing (NDT) Level 1, at a minimum, in accordance with American Society for
Nondestructive Testing (ASNT), Recommended Practice SNT TC-1A, latest edition.
16.4.2 All personnel setting up ultrasonic inspection systems must be prequalified to NDT Level 2,
at a minimum, in accordance with ASNT, Recommended Practice SNT TC-1A, latest edition.
16.4.3 Each manufacturer must employ the services of an individual who is prequalified to NDT
Level 3, at a minimum, in accordance with ASNT, Recommended Practice SNT TC-1A, latest edition.
16.5 Records
Each facility must maintain the following records for the duration indicated. Records must be
accessible within 4 hours upon request by any AAR representative.
A procedural specification for each validated UT process (current revision)
A posted controlled copy of each UT specification in each UT testing equipment area(s)
(current revision)
All individual axle test results in printable form, including individual heat, axle serial
number, and date of inspection (10 years from date of manufacture)
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16.5.1 Personnel certifications for UT testing must be, at a minimum, in accordance with ASNT,
Recommended Practice SNT TC-1A, latest edition. Each certification must be endorsed by a
responsible official of that facility and the verifying level III (10 years).
16.5.2 Reference block semiannual validation record, including the inspectors name/ID, revalida-
tion date, and measured surface finish of the reference block. (10 years)
16.6 Validation
Validation (system testing) must be performed using the same couplant used during axle testing.
All contact surfaces must be smooth with a surface roughness better than 125 microinch for axial
test and 500 microinch for the radial test. It also should be free from dirt and grit.
16.6.1 Axial
16.6.1.1 Calibration and System Tests
The ultrasonic inspection system must be validated initially upon installation and at least once
every year after initial installation.
16.6.1.1.1 Calibration1/8-in. flat-bottom hole at 15-in. depth, set up at 20% full-screen height
using 16-in.-long reference block manufactured from a Grade F axle forging.
16.6.1.1.2 Detection Capabilities
1/8-in. flat-bottom hole From 2 in. to 15 in. depth, detectable in reference axle
1/4-in. flat-bottom hole From 15 in. to 30 in. depth, detectable in reference axle
3/8-in. flat-bottom hole From 30 in. to 46 in. depth, detectable in reference axle
16.6.1.2 Alternate reference standards may be used to calibrate or test system sensitivity, pro-
vided the output from the alternate standard is cross-referenced with the reference block and axle
of paragraph 16.6.1.1.1.
Example: the following alternates provide equivalent sensitivity:
1-in. indication from a #1 series A Alcoa block
1 1/2-in. indication from an ASTM E-127 block #1-0300
16.6.1.3 Reference standards must be inspected and certified semiannually for surface finish on
the inspection face(s) of 80 microinch to 125 microinch.
16.6.1.4 Periodic
16.6.1.4.1 Periodic tests shall be made during production testing against the 16-in.-long refer-
ence block described above, and adjustments shall be made to instrument controls to ensure com-
pliance with the specifications.
16.6.1.4.2 Periodic tests must be made at least once every 4 hours of use.
16.6.1.5 Continuous
16.6.1.5.1 Unscheduled system tests shall be made during production testing against the
16-in.-long reference block described above, and adjustments shall be made to instrument controls
to ensure compliance with the specifications.
16.6.1.5.1.1 Tests must be made every time there is a change of system operators.
16.6.1.5.1.2 Tests must be made every time there is a change of transducers, cables, or any other
system hardware or accessories.
16.6.1.5.1.3 Tests must be made every time there is an equipment malfunction or upon powering
on.
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16.6.2 Radial
16.6.2.1 Calibration and System Tests
16.6.2.1.1 The ultrasonic inspection system must be validated initially upon installation and at
least once every year after initial installation.
16.6.2.1.2 CalibrationThe system must be calibrated to exhibit an 80% full-screen-height indi-
cation from the backface reflection in the thickest part of the production axle section (wheel seat).
16.6.2.1.3 Tests must be made every time there is an equipment malfunction or upon powering
on.
16.6.2.1.4 When a change to the equipment power source, transducer, operator, or coaxial cable
occurs, the system set-up must be reverified.
16.7 Inspection
16.7.1 General
16.7.1.1 Inspection surfaces must be free of all dirt and grit prior to the start of testing.
16.7.1.2 The same couplant must be used for calibration and examination.
16.7.1.3 During the axial discontinuity inspection test and the radial loss of back face reflection
test, an additional 6 dB shall be added to the reference or sensitivity level for scanning purposes.
Discontinuity evaluation shall be performed at the original recorded sensitivity level prior to final
disposition.
16.7.2 Axial
16.7.2.1 The amplitude of the ultrasonic indication must be considered in relation to its distance
from the testing surface to evaluate its significance. This can be accomplished by an electronic
device or by distance amplitude curves that are described in Appendix B, paragraph 2.0.
16.7.2.2 The variation in cross-section of the axle may produce spurious indications. These
expected indications must be recognized and are not cause for rejection.
16.7.2.3 Both end faces of the axle must be scanned to the full extent of the surfaces (100% area
coverage). The axle end faces must be prepared with a surface finish of 125 microinch or better.
16.7.2.3.1 If the amplitude of any indication exceeds the DAC curves as defined in Appendix B,
the axle is rejected.
16.7.2.3.2 If any backface reflection does not exceed 40% of screen height, the axle is rejected.
16.7.3 Radial
16.7.3.1 The variation in cross-section of the axle may produce spurious indications. These
expected indications must be recognized and are not cause for rejection.
16.7.3.2 Scan the entire length of the axle radially through the diameter along one line only. At a
minimum, the axle surface must be rough-turned with a surface finish of 500 microinch or better.
16.7.3.3 The axle will be rejected for a location if a loss of back reflection of 80% or greater is
experienced, unless the loss is attributed to geometry.
16.8 Marking
All axles that are to be tested radially must have the character R immediately following the axle
grade marking. All axles failing the radial test must be immediately identified and segregated for
scrapping.
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22.0 REJECTION
22.1 Any axle that fails to meet the requirements of these specifications will be rejected.
22.2 Axles that show injurious defects subsequent to their original inspection and acceptance at
the manufacturers works or elsewhere will be rejected and the manufacturer shall be notified.
23.0 REHEARING
Samples of axles tested in accordance with these specifications that represent rejected material
shall be held for 14 days from date of the test report. In case of dissatisfaction with the results of
the tests, the manufacturer may request a hearing within that time.
24.0 CERTIFICATION
Upon request of the purchaser in the contract or order, a manufacturers certification that the
material was manufactured and tested in accordance with this specification, together with a
report of the test results, shall be furnished at the time of shipment.
25.0 The following supplementary requirements shall apply only when specified by the
purchaser. Details shall be agreed upon by the manufacturer and the purchaser.
25.1 Macroscopic Tests
The prolongation from the largest axle in each heat shall be sawed normal to the axis of the axle
and shall then be split longitudinally. The transverse and the longitudinal face shall be etched for
microscopic examination. Reference shall be made to Specification ASTM E381, Standard Method
of Macroetch Testing Steel Bars, Billets, Blooms, and Forgings.
25.2 The purchaser may specify axle wheel seat diameters 1/8 in. larger than those shown under
dimension I in Fig. C.3.
26.0 This specification includes Appendices A, B, C, Figs. C.1 through C.5, and Specification M-101.
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APPENDIX A
INTERPRETATION OF DEFECTS CONSIDERED INJURIOUS IN AXLES
1.0 The conditions that have been most difficult for inspectors to evaluate are light lines visible to
the normal unaided eye, variously described as actual seams, hairlines, stringers, shadow seams,
ghost lines, etc., that appear after the axles have been finish-machined and burnished or ground. It
is therefore advisable to describe these conditions in more detail.
2.0 The interpretation of injurious defects as enumerated below is not to be considered as
precluding other unforeseen or objectionable conditions not specifically listed. The right of the
purchaser is reserved to reject temporarily such axles and make final settlement on the basis of
further negotiations between representatives of the manufacturer and the purchaser who are
especially qualified to decide such questions.
3.0 Any transverse or circumferential seams, cracks, or laps of indeterminate depth on the axle
surfaces other than the discolorations listed in paragraph 4.0, regardless of their location, are
considered to be injurious and are cause for rejection without further machining.
4.0 Ghost lines, shadow marks, or other similar discolorations, visible to the normal unaided eye
that are not actual separations in the metal are not considered injurious, regardless of location.
5.0 Any longitudinal discontinuity, variously termed hairline, stringer, or fine seam, in machined
fillets is considered to be injurious and is cause for rejection without further conditioning.
6.0 JOURNALS AND DUST GUARDS
6.1 Roller Bearing Axles
Fine longitudinal discontinuities on the finished (burnished or ground) surfaces variously termed
hairlines, stringers, or fine seams are not considered injurious if they meet the following condi-
tions:
6.1.1 Must not extend into fillets.
6.1.2 Must not be over 3/4 in. long individually in the journal or 1/2 in. long individually in the
dust guard seat.
6.1.3 Total length of such imperfections over 1/4 in. long must not exceed 2 in. in any one end of
axle.
7.0 WHEEL AND GEAR SEATS
7.1 Freight Car Axles (Roller Bearing)
Longitudinal seams in wheel seats of freight car axles are not considered injurious if they meet the
following conditions:
7.1.1 Must not extend into the dust guard or body fillets.
7.1.2 Must not be over 2 in. long individually.
7.1.3 Total length of such imperfections, 1/4 in. to 2 in. long, must not exceed 4 in. in any one end
of axle.
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APPENDIX B
DISTANCE AMPLITUDE CORRECTION
1.0 ALTERNATE REFERENCE STANDARDS
Alternate references may be used to establish the test sensitivity if they are cross-referenced with
the reference test block described in paragraph 16.6.1.1.1. For example, the following are alternate
references for heat-treated axles that give equivalent sensitivity: 1) a 1-in. indication from a #1
series A Alcoa block; and 2) a 1 1/2-in. indication from an ASTM E-127 block #1-0300.
2.0 DISTANCE-AMPLITUDE CORRECTION
The amplitude of an ultrasonic indication from a given discontinuity size varies with its distance
from the test surface. To compensate for this effect, a distance-amplitude relationship is employed.
The relationship can be established by an electronic device or by curves. Because the dis-
tance-amplitude relationship is influenced primarily by the ultrasonic transducer and instrument,
it is necessary to relate this factor to the specific equipment used. Appropriate distance-amplitude
curves shall be developed. A typical example is shown in Fig. B.2 as related to the axle in Fig. B.1.
3.0 SPURIOUS ULTRASONIC INDICATIONS FROM CONTOUR VARIATIONS
Because an axle varies in cross-section, it is possible to produce spurious indications, particularly
at changes of cross-section. These must be recognized and are not reason for rejection. It is not
practical to define these indications in the specification, but the competent operator or technician
will recognize these spurious indications as responses from axle contours.
4.0 NEAR-FIELD RESOLUTION
It should be recognized that detection of discontinuities near the test surface is limited by the
ultrasonic test frequency. In the case of heat-treated axles, this is approximately 1 in. from the test
surface.
Fig. B.2 Typical distance-amplitude curve for heat-treated axle (as determined with a Sperry reflectoscope, Type UM
using a 1 1/8-in.-diameter, 2.25 MHz quartz transducer)
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APPENDIX C M-101
APPENDIX C
QUALIFICATION OF MANUFACTURERS 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 applicants 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.
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M-101 APPENDIX C
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
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APPENDIX C M-101
NOTE 6
NOTE 1
ROLLER BRG.
FREIGHT CARS NOTE 2
ONLY NOTE 4
NOTE 7
NOTE 5 NOTE 3
AAR STANDARD AXLE MARKINGS
J
R
K
G
I
AXLES SHALL BE MACHINED TO 250 in.
120 X B C D 2" MAX. BETWEEN WHEEL SEATS
1" + 0
STAMP ( * L)3'11
4 1"
IDENTIFICATION MARKS 161" 4
ON THIS SURFACE. W M
MACHINE CHAMFER TO
U 161"
250 in. MAX. MATERIAL AAR SPECIFICATION
1"
1"
M101
16 R. MIN. TO 8 R. MAX.
ENLARGED SECTION SHOWING OPTIONAL * THE L DIMENSION NEED NOT BE CORRECTED FOR
RADIUS WHEN USING CONTOUR GRINDER LENGTH EACH TIME THE WHEEL SEATS ARE TURNED
NOTES:
1. I DIMENSION TOLERANCE IS +0.015 0.015.
ON NEW AXLES MACHINE 3 in.
RADIUS AT SPECIFIED
2. MAXIMUM ALLOWABLE RUNOUT BETWEEN G AND H IS .006" TOTAL DIAL INDICATOR. DIMENSION L FOR ANY
3. MAXIMUM ALLOWABLE RUNOUT BETWEEN G AND I IS .008" TOTAL DIAL INDICATOR. WHEEL SEAT DIA.
4. FOR 7" 12" JOURNALS, END CHAMFER IS 4 15' 5/8" 1/8".
L*
3"
5. REQUIRED FOR PRESS FIT OF ROLLER BEARING BACKING RING WHERE THE H
DIAMETER IS TOLERANCED. FINISH TO 125 IN. MAXIMUM WHEN TOLERANCED. 2"
6. THE "W" DIMENSION CANNOT EXCEED THE TOLERANCE LIMITS OF THE GAUGE SHOWN IN
MSRP SECTION G-II, RP-634, FIG. 5.27.
OVER SIZE DIA.
7. RUNOUT ON JOURNAL SURFACE G, WHEN ROTATED ON CENTERS, MUST NOT EXCEED
.015" TOTAL DIAL INDICATOR.
WORN DIA.
NEW DIA.
8. DIMENSIONS B AND N ARE CONSIDERED ENGINEERING DATA FOR TRUCK DESIGN AND
1"
+
8
0
DO NOT NECESSARILY AGREE WITH AXLE MANUFACTURING TOLERANCES.
J
9. JOURNAL FINISH MUST NOT EXCEED 63 IN., IF GROUND OR TURNED ONLY. IF TURNED
AND ROLLED, THE TURNED FINISH MUST NOT EXCEED 125 IN., AND THE ROLLED FINISH ENLARGED VIEW SHOWING
MUST NOT EXCEED 16 IN. CONDITION AT FILLET JOINING
BODY PORTION OF AXLE TO
INSIDE EDGE OF WHEEL SEAT.
Fig. C.3 Axle for freight car roller bearingraised wheel seat (page 1 of 2)
Standard 1963; Revised 1984, 1998; Effective March 1, 1985
Paragraph 17.5 and Paragraph 25.2
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APPENDIX C
03/2011
CLASSIFI- DIMENSIONS
CATION SIZE OF
OF AXLE JOURNAL B C D E G H I J K M N O R T U V W X Y
D 5 1/2 10 5 1/2" 1 3/4" 7 5/8" 3" max 5.1915 6 3/8" 7 9/16" 6 3/4" 5 7/8" 62 1/2" 77" 86 1/8" 1 3/4" 7/8" 9 66" 1 7/8" 10 1/16" 1 1/4" 28"
min. 5.1905 + 0/- 1/4
E 6 11 5 15/16" 1 13/16" 7 5/8" 3" max 5.6915 7.032 8 1/4" 7 5/16" 6 7/16" 62 1/2" 78" 88" 1 15/16" 1" 8 66 1/8" 2" 10 15/16" 1 1/4" 28"
min. 5.6905 7.030 + 0/- 1/4
F 6 1/2 12 6 7/16" 1 13/16" 7 5/8" 3" max 6.1915 7.532 8 3/4" 7 7/8" 7 3/8" 62 1/2" 79" 89 5/8" 2 1/8" 1 1/8" 7 66 1/8" 2 1/8" 11 3/4" 1 1/4" 28"
min. 6.1905 7.530 + 0/- 1/4
G 7 12 5 15/16" 2 5/16" 7 5/8" 3" max 7.004 8.002 9 1/2" 8 9/16" 8" 62 1/2" 79" 89 1/4" 2 5/16" 1 1/4" 7 67 1/8" 2 1/4" 11 1/16" 5/8" 415"
min. 7.003 8.000 1/8
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K 6 1/2 9 4.853" 3.397" 7 5/8" 3" max 6.1915 7.532 8 3/4" 7 7/8" 7 3/8" 62 1/2" 79" 87.156" 2 1/8" 1 1/8"7 69.294" 2 1/8" 8.931" .250" 10
min. 6.1905 7.530 0.20
Wheels and Axles
L 68 4.457 3.293 7 5/8" 3" max 5.6915 7.032 8 1/4" 7 5/16" 6 7/16" 62 1/2" 78" 85.5" 1 15/16" 1" 8 69.086" 2" 8.207"
min. 5.6905 7.030
M 79 4.750 3.500 7 5/8" 3" max 6.5040 7.532 9 1/2" 8 9/16" 8" 62 1/2" 79" 87.500" 2 1/8" 1 1/8" 7 69.500" 2 1/8" 9.000"
min. 6.5030 7.530
Fig. C.3 Axle for freight car roller bearingraised wheel seat (page 2 of 2)
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M-101 APPENDIX C
MATERIAL: ASTM A-576, GRADE 1045 OR EQUIVALENT. PARTS TO BE HARDENED AND SURFACES MARKED G ARE TO BE GROUND. BREAK SHARP CORNERS. TOLER-
ANCE ON ALL DIMENSIONS TO BE 1/64 IN. UNLESS OTHERWISE SPECIFIED.
Fig. C.4 Pin-type gauge for cap screw holes in ends of roller bearing axles
Standard 1979; Revised 1982, 1998
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APPENDIX C M-101
FINISHED DIMENSIONS
AXLE SIZES
E 6" 11"
F 6 2" 12"
1
16"
1
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. WHEN SECONDHAND
AXLES ARE RECENTERED, DIAMETER AND DEPTH MAY BE INCREASED SUFFICIENTLY TO PRODUCE AN ACCURATE 60 CENTER.
Fig. C.5 Axle centering and gauge for axle center and lathe center
Adopted 1944; Revised 1966, 1979
Paragraph 17.2
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Specification
M-107/M-208
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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. Fol-
lowing quenching, the wheels shall be charged into a furnace for tempering to meet the require-
ments 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 Recom-
mended 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.
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8.2 An analysis of each heat of steel shall be made by the manufacturer to determine the percent-
age of the elements specified in paragraph 8.1. This analysis shall be made on a test specimen
taken during the pouring of the heat. The chemical composition thus determined, together with
such identifying records as may be desired, shall be reported to the purchaser or purchasers repre-
sentative and shall conform to the requirements specified in paragraph 8.1.
8.3 Chemical Analysis
Chemical analysis of each heat of steel shall be made by one of the test methods listed below. All
analyses should note which method is used for the carbon and/or chemical determinations.
8.3.1 Test Method 1
The carbon determinations should be one of the following test methods:
8.3.1.1 Total carbon by the combustion gravimetric method, ASTM E-350 Standard Test Meth-
ods for Chemical Analysis of Carbon Steel, Low-Alloy Steel, Silicon Electrical Steel, Ingot Iron,
and Wrought Iron.
8.3.1.2 Total carbon by the combustion thermal conductivity method, ASTM E-1019 Standard
Test Methods for Determination of Carbon, Sulfur, Nitrogen, Oxygen, and Hydrogen in Steel and
in Iron, Nickel, and Cobalt Alloys.
8.3.1.3 Total carbon by combustion, followed by quantitative infrared analysis, ASTM E-1019
Standard Test Methods for Determination of Carbon, Sulfur, Nitrogen, Oxygen, and Hydrogen in
Steel and in Iron, Nickel, and Cobalt Alloys.
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Note: Class D alloy steel wheels must meet all chemical requirements for Class C wheels and have
approval of the AAR WABL Committee.
10.2 Method of Measurement
Measurement must be made in accordance with ASTM E-10 (latest revision) on the front face of
the rim with the edge of the impression not less than 3/16 in. from the radius joining face and
tread. Before making the impression, any decarburized metal shall be removed from the front face
of the rim at the point chosen for measurement. The surface of the wheel rim shall be properly pre-
pared to permit accurate determination of hardness.
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If values do not meet the requirements in Table 11.1, an additional five wheels from five heats
shall be tested. All five wheels must meet the requirements in Table 11.1. If one or more wheels
fail to meet the requirements in Table 11.1, testing per paragraph 11.5 shall be repeated after a
process and/or design change is made. All wheels from heats that have a test wheel that failed to
meet the requirements in Table 11.1 shall be reheat-treated, and one wheel from the heat shall be
tested. If this wheel fails to meet the requirements in Table 11.1, all wheels from the heat shall be
scrapped. Only one reheat treatment shall be allowed.
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16.0 FINISH
16.1 Wheels shall be rough bored and shall not have black spots in the rough bore. Front hub face
of wheels (1-W, 2-W, and MW) shall be parallel to the plane of the vertical reference line and may
be smooth forged, cast, or machined. The back hub face may be smooth forged, cast, or machined.
16.2 The contour of tread and flange shall be as shown in Figs. B.11, B.12, or B.13 as applicable.
Wrought steel wheels must be machined and finished smooth without excessive tool chatters. Cast
steel wheels shall be as cast, machined, or ground, at the option of the manufacturer. Minimum and
maximum flange thickness, height, and throat radii gauges shown in Standards S-661 and S-662
shall be used to check proper profile. Wheels that do not meet the criteria must be scrapped or recon-
toured.
16.3 Wheels must be free of all condemnable in-service defects. As-produced surfaces must be
free from abrupt changes in surface contours. Spot grinding or machining to remove surface
defects must not exceed a depth of 1/8 in. (0.125 in.; 3.2 mm). Sectional properties must meet all
dimensional requirements following repair of surface defects. Repaired surfaces must have a max-
imum surface roughness of 500 in. prior to final shot peening. Repaired surfaces must provide a
uniform transition to the as-produced surfaces.
16.4 Wheels shall not be covered with any substance to such an extent as to hide defects.
16.5 Wheel profile is to be checked using wide flange profile gauge shown in Fig. B.14. There will
be no more than 1/32-in. variation from the profile.
17.0 MARKING
17.1 Identification markings shall be legibly stamped as shown in Figs. B.4 or B.5. Wheels for
freight service must be hot stamped or cold stamped on the back hub face. If any stamped charac-
ters are missing or illegible, these shall be replaced by cold stamping in the proper place in the
marking sequence. Passenger car wheels may be hot stamped or cold stamped on front or back (as
specified by purchaser) hub face. When ordered, locomotive wheels may be hot or cold stamped on
the back rim face; or hot or cold stamped on the front hub face; or hot or cold stamped on the back
hub face providing finish machining will completely remove the markings on the back hub face.
Locomotive wheels that are to receive final hub machining by the purchaser may be ordered with
markings paint stenciled on the wheel plate. After final machining, the purchaser will cold stamp
the markings on the front hub face. For wheels having raised cast-on markings, the markings shall
be legible characters and be as shown in Fig. B.7. For all wheels, stamping should be centered
approximately on the hub. No wheel manufactured after May 1, 2009, may be bored and applied
with any portion of the wheel manufacturers hub stamp closer than 1/8 in. from the inner hub
diameter and no closer than 1/8 in. from the outer hub diameter. No wheel manufactured before
May 1, 2009, may be bored and applied with any portion of the wheel manufacturers hub stamp
breaking over the edge of the inner or outer hub diameter.
17.2 The tape size of all wheels shall be paint stencilled on back plates in characters at least 1 in.
high. An H shall also be paint stencilled on the front plate at least 1 in. in height on those wheels
of curved plate, heat-treated configuration. Stencil paint must be white and have a minimum ser-
vice life of 1 year.
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18.0 INSPECTION
18.1 The inspector representing the purchaser shall have free entry, at all times while the work
on the purchasers contract is being performed, to all parts of the manufacturers works that con-
cern the manufacture of wheels ordered. The manufacturer shall afford the inspector, free of
charge, all reasonable facilities and necessary assistance to satisfy the inspector that the wheels
are being furnished in accordance with these specifications. Internal defects are usually detected
by ultrasonic testing. Such test shall be used in the manufacture of all wheels. The method to be
followed and the equipment to be used shall comply with the requirements as shown in
paragraph 18.4. Tests and inspection shall be made at the place of manufacture prior to shipment,
unless otherwise specified.
18.2 The purchaser may make tests to govern the acceptance or rejection of the wheels in pur-
chasers own laboratory or elsewhere. Such tests shall be made at the expense of the purchaser.
18.3 All tests and inspections shall be so conducted so as not to interfere unnecessarily with the
operation of the works.
18.4 Ultrasonic Inspection
For detecting internal discontinuities in the rim of all steel wheels, ultrasonic inspection shall be
made by following either the procedures shown below or an AAR-approved equivalent. Equipment
used in these procedures shall comply with the following requirements.
Each manufacturer shall maintain a documented test method and procedures for ultrasonic
inspection of all railroad wheels manufactured under this specification.
18.4.1 Equipment
18.4.1.1 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.
18.4.1.2 The transducers shall be of the type whose composition and dimensions are appropriate
for the test method used.
18.4.1.3 The ultrasonic inspection shall be performed with an automated scanning system. An
automatic flaw alarm system shall be used in conjunction with the ultrasonic instrumentation.
18.4.1.4 A suitable couplant shall be used between the test surface and the transducer. The cou-
plant shall be free of air bubbles. Rust inhibitors, softeners, and wetting agents may be added to
the couplant.
18.4.2 Time of Inspection
Inspection shall be performed after final thermal processing.
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18.4.3 Calibration
18.4.3.1 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. The instrument sensi-
tivity level should be adjusted to produce an approximate full-scale reflection from the reference
standards of paragraphs 18.4.3.2, 18.4.3.3, 18.4.3.4, and 18.4.3.5.
18.4.3.2 For axial testing of all wheels, the reference standard shall be a 1/8-in.-diameter flat-bot-
tom hole generated perpendicular to the rim face and to a depth of 1 1/2 in. (1/16 in.) at the
mid-thickness of the rim. See Fig. B.1
18.4.3.3 For radial testing, the reference standard shall be a 1/8-in.-diameter flat-bottom hole
generated from the inside diameter of the rim perpendicular to the tread surface, and shall be a
minimum of 1 1/4 in. from the tread surface. See Fig. B.2.
18.4.3.4 A distance amplitude correction (DAC) shall be used for axial and radial testing of
wheels. To ensure detection, the DAC will be generated for each testing direction in the following
manner.
Holes shall not be located close to each other so as to impede the response from each hole individu-
ally.
18.4.3.4.1 Axial
As a minimum, two additional 1/8-in.-diameter flat-bottom holes shall be generated at whatever
depth the manufacturer chooses. The creation of the DAC shall be accomplished using the refer-
ence standard and the response(s) from additional holes. Typical depths for the three holes could
be 1 1/2, 2 1/2, and 3 1/2 in. All holes should be generated from the front or back rim face. See
Fig. B.1. Individual depth standards shall be permitted.
18.4.3.4.2 Radial
To facilitate creation of a DAC, as a minimum, one additional 1/8-in.-diameter flat-bottom hole
shall be generated in one-wear and two-wear wheels, and, as a minimum, two additional
1/8-in.-diameter flat-bottom holes shall be generated in multi-wear wheels. Calibration shall be
accomplished using the reference standard, and the response(s) from the additional holes shall be
used to create the DAC. Table B.1 shows the depth of reference standard holes for the different
wheel types. See Fig. B.2. Individual depth standards shall be permitted.
18.4.3.5 Alternate calibration standards may be used when authorized by the AAR WABL Com-
mittee. Manufacturer shall document and demonstrate the correlation between the 1/8-in.-diame-
ter flat-bottom hole and the proposed alternate standard.
18.4.3.6 An alternate method for axial testing of cast steel wheels is to use loss of back reflection.
The reference standard shall be a 3/8-in.-diameter concave bottom hole generated to a depth of
1/8 in. at the front rim face. See Fig. B.3.
18.4.3.7 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, i.e., wrought or cast. Reference
standard need not be the same AAR design as the wheels being inspected.
18.4.3.8 Recalibration
Conduct ultrasonic calibration to ensure system conformance to required specifications. Check the
ultrasonic system and calibration of the instrument per documented procedures using a calibra-
tion standard when any of the following occurs:
Damage to any part of the ultrasonic system
Change in transducers, cables, and other accessories
Loss of power or equipment malfunction
Whenever ultrasonic instrumentation is first turned on
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18.5.3 Equipment
18.5.3.1 Magnetizing Apparatus
The magnetizing apparatus shall be capable of inducing suitable magnetic fields within the entire
plate area of the wheel to facilitate the disclosure of both circumferentially and radially oriented
discontinuities. The magnetizing currents used shall be large enough to induce magnetic fields of
sufficient intensity to disclose surface discontinuities 1/4 in. long. The use of prod-type contacts is
prohibited.
18.5.3.2 Lighting Apparatus
The inspection shall be performed in a darkened booth with the area of the wheel to be inspected
illuminated with properly filtered black light. The black light shall have a predominant wave-
length of 4000 to 3400 , and the intensity of the black light, measured at the surface to be
inspected, shall be a minimum of 75 footcandle at point of inspection.
18.5.3.3 Inspection Medium
18.5.3.3.1 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.
Each time the bath is renewed, the bath container should be cleaned out and the agitation and cir-
culation system should be flushed with 1 or 2 gal of clean carrier. Filtering screens should be
removed and cleaned by blowing with air. In preparing the new bath, only recommended materials
should be used. The amount of powder should be carefully weighed out in accordance with the
material manufacturers recommendation and be added directly to the bath containing the correct
amount of carrier. It is recommended that powder be added directly over the sump so that it will be
drawn quickly into the pump and circulated. The amount of carrier and powder used and the date
of preparation should be recorded on a regular form set up for this purpose, as outlined in
paragraph 18.5.3.3.6.
18.5.3.3.2 Concentration and contamination of the bath solution should be tested weekly as fol-
lows: pump and agitation system should be operated for 20 minutes and then the solution should
be run through a hose and nozzle for 30 seconds. Using a regular 100-mL centrifuge tube, fill the
centrifuge tube with 100 mL of the solution. Allow the bath solution to settle for the time recom-
mended by the manufacturer of the type of powder used, making sure that the tube is not sub-
jected to excessive vibration during the settling period. Each horizontal division represents
0.1 mL, and a correct reading in volume of particles must be as stipulated by the powder manufac-
turer. The check also should note contamination caused by dirt, chips, or other foreign matter set-
tling with the powder. Contamination also is indicated when the carrier appears to acquire more
than usual fluorescence or when the magnetic particles appear to have lost fluorescent qualities.
This condition can be readily observed when the settling tube is exposed to ultraviolet light. The
readings obtained are to be shown on the regular report form as outlined in paragraph 18.5.3.3.6.
18.5.3.3.3 The ultraviolet light should be tested weekly using a light meter, such as a type having
75-footcandle scale with a 10 multiplying disc or equivalent or a meter that responds specifically
to the ultraviolet range of 3650 (365 nm). The latter type meters are calibrated in microwatts
per square centimeter. The meter should be held a fixed distance of 15 in. from the light source
(from the black light filter surface to the meter-sensing element) and should have a minimum
meter reading of 525 W/cm2.
18.5.3.3.4 The conversion factor from footcandles (for light meters) to microwatts per square cen-
timeter is 5.7 times the footcandle reading (at 15 in. distance).
18.5.3.3.5 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. Before taking read-
ings, it should be known that the glass black light filters are clean. Reports of this test are to be
shown on regular form as outlined in paragraph 18.5.3.3.6.
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18.5.3.3.6 A regular form should be prepared embodying the information to be shown on monthly
and weekly tests as outlined above, and this form should be on hand at the wheel shop and avail-
able to AAR inspectors.
18.5.3.3.7 Prepackaged, self-contained solutions, including aerosol sprays, may be used provided
that the following conditions are met:
18.5.3.3.7.1 The solution is agitated frequently to ensure that magnetic particles remain in solu-
tion.
18.5.3.3.7.2 A detectability test is performed daily on each package in use and a record is kept
per paragraph 18.5.3.3.6. The test consists of inspection of a test wheel with a known crack of at
least 1/4 in. long or an equipment manufacturers approved test piece that will indicate and verify
the following:
Proper brilliance of ultraviolet light
Proper concentration of bath solutions
Proper magnetic power source and operation of equipment
Note: Test wheel or test piece must be thoroughly cleaned of the last test indicators before testing.
This must be verified by ultraviolet light before the test is started.
18.5.4 Preparation for Inspection
The surface shall be scale free before magnetic particle inspection.
18.5.5 Detection of Discontinuities
This inspection shall be performed to detect discontinuities whose axes may be in any direction.
Continuous or residual magnetization shall be used with adequate coverage by the inspection
medium.
18.5.6 Time of Inspection
The magnetic particle inspection shall be performed following final machining or grinding on wheel
plate.
18.5.7 Rejection
Rejection of magnetic particle discontinuity indications must take place if any plate surface indica-
tion is 1/4 in. in length or longer in any direction. Discontinuities may be removed by machining or
grinding where sufficient stock remains. Such wheels shall be retested by magnetic particle
inspection.
18.6 Personnel Requirements for Ultrasonic Inspection
18.6.1 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,
Recommended Practice SNT-TC-1A, latest edition.
18.6.2 All personnel conducting inspection setups and machinery setups will be trained and qual-
ified to meet the criteria for NDT Level II for ultrasonic testing as defined by the American Society
for Nondestructive Testing, Recommended Practice SNT-TC-1A, latest edition.
18.6.3 Each manufacturer will employ the services of an individual who will be trained and qual-
ified to meet the criteria for NDT Level III for ultrasonic testing as defined by the American Soci-
ety for Nondestructive Testing, Recommended Practice SNT-TC-1A, latest edition.
19.0 CERTIFICATION
At the purchasers request, a certification shall be made the basis of acceptance of the material.
This shall consist of a copy of the manufacturers test report that the material has been sampled,
tested, and inspected in accordance with the provisions of the specification. Each certificate so fur-
nished shall be signed by an authorized agent of the supplier or manufacturer.
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M-107/M-208
20.0 REJECTION
20.1 Wheels represented by samples that fail to conform to the requirements of these specifica-
tions will be rejected.
20.2 Wheels that show injurious defects subsequent to original inspection and acceptance at the
manufacturers works, or elsewhere, will be rejected, and the manufacturer shall be notified.
21.0 REHEARING
Samples tested in accordance with this specification that represent rejected wheels shall be held
for a period of 14 days from date of the test report. In case of dissatisfaction with the results of the
tests, the manufacturer may make claim for a rehearing within that time.
22.0 This specification includes Appendices A and B; and Figs. B.1 through B.14.
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APPENDIX A M-107/M-208
APPENDIX A
AUTHORIZATION FOR DELIVERY OF WHEELS FOR AAR INTERCHANGE
SERVICE
1.0 Each manufacturer must obtain an authorization for delivery of wheels for AAR interchange
use from the Committee prior to delivery.
2.0 The manufacturer applying for delivery authorization must provide the AAR with an
electronic copy of the following documentation.
2.1 A descriptive drawing of the wheel type as it will be produced. The descriptive drawing will
provide the following information:
2.1.1 A full-scale drawing showing the wheel cross-section from center of the hub to top of the
flange. The drawing may show either a single profile with tolerances or, preferably, two profiles,
with one depicting the minimum inner tolerances and the other the maximum outer tolerances in
such a way that a wheel section laid on the drawing would fall between the two profiles. This
would allow analysis of wheels produced to this drawing.
2.1.2 A notation of the wheel type and heat-treatment classes of the wheels to be produced.
2.2 A brief description of the design analysis method and the results of the analysis. The pre-
ferred analytic procedure is that covered in S-660. If there is no design analysis, a statement
should be made to this effect along with a summarization of the design considerations. If the appli-
cant would like the AAR to perform the S-660 design analysis on a contract basis, the applicant
should request details from the AAR.
2.3 A statement advising the specific areas in which the wheel design may not be compatible with
normal shop machinery and handling equipment, standard storage facilities, and wheel transport
cars in general use.
3.0 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.
The initial authorization will be for the delivery of 32,000 wheels. If the manufacturer requests
additional delivery authorizations, the second will be for 20,000 wheels (52,000 total) and the third
will be for 20,000 wheels (72,000 total). Additional allotments or unconditional approval for
unlimited quantities will be given after that, provided all required conditions are met.
3.1 A new wheel type (such as CH-36, CJ-36, or J-33) that is made for the first time by the
requesting manufacturer will require the following prior to being granted unconditional approval.
If necessary, WABL will designate a sponsor railroad to assist the manufacturer in meeting these
requirements.
3.1.1 A minimum of 5,000 wheels installed from the first allotment will have been tracked to
provide mileage and will have achieved 200,000 miles in service.
3.1.2 Ultrasonic testing to wheelshop requirements for turned wheels will be performed for 30 or
more wheels with at least 200,000 miles of service and with sufficient rim metal to be reapplied.
Provided all other criteria are met, upon successful completion of ultrasonic testing, conditional
approval, unlimited quantity will be granted. The 30 wheels will then be placed in service and
tracked. Ultrasonic testing to wheelshop requirements of turned wheels will be performed for 10 of
the 30 wheels reapplied after 100,000 miles additional service. Provided all other criteria are met,
upon successful completion of the ultrasonic testing, unconditional approval will be granted. Test
costs will be paid by the proponent, and data provided in the form of C-scans will be captured with
an AAR observer present and provided to WABL.
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M-107/M-208 APPENDIX A
3.1.3 At least one out of every 1,000 wheels produced in the initial allotment will be tested for
microcleanliness according to paragraph 9.0 of this specification. Results will be reported to the
Wheels, Axles, Bearings, and Lubrication Committee Manager within 90 calendar days. Electronic
reporting is preferred. Send results to
Email: wabl@aar.com
Facsimile: 719-585-1895
Mail: AAR WABL Committee Manager
Transportation Technology Center Inc.
P.O. Box 11130
Pueblo, Colorado 81001
3.2 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. Authorization may be withdrawn if service performance
so dictates.
4.0 Changes to any wheel design by the producer must be reviewed by the Committee before
delivery authorization may be granted.
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APPENDIX B M-107/M-208
APPENDIX B
QUALIFICATION OF MANUFACTURERS PLANT AS A PRODUCER OF
WHEELS 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 wheels. In the event it is desired to deliver mounted wheel sets,
information indicating that equipment is available to comply with the wheel mounting
requirements of the AAR Manual of Standards and Recommended Practices, Section G, Part II,
Wheel and Axle Manual should be included.
2.0 After review of the data submitted with the application, the Committee will authorize the
applicant to contact the AAR for information concerning product testing. Normally this will consist
of the applicant furnishing three wheels, at applicants 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 the plant where the wheels are to be produced for proper equipment
and, if mounted wheels are to be provided, an AAR inspection will be arranged for the wheel shop.
These inspections will require that all out-of-pocket expenses be borne by the applicant. These
inspections can be arranged concurrently with the test program if the applicant so requests.
4.0 All plants desiring to maintain their status as an AAR-approved manufacturer of wheels for
use in AAR interchange service must be inspected yearly with costs of inspection to be borne by
the wheel producer. Every effort will be made to inspect all plants in a given area at one time to
minimize costs, which will be prorated among the companies inspected.
5.0 In the event that a facility ceases production for less than 1 year and has not received its
scheduled annual inspection, an inspection of the facility is required prior to the delivery of any
items for use in interchange service. In the event a plant ceases production of wheels for AAR
interchange service for more than 60 days and less than 1 year, the AAR must be notified no later
than 2 weeks prior to reopening. In the event a plant ceases production of wheels for AAR
interchange service for more than 1 year, requalification will be required prior to delivery of any
items for use in AAR interchange service. An AAR inspection of the plant will be required, and
normally, the provisions of Appendix A will apply for all wheel designs that have been given an
authorization in accordance with the procedure outlined in paragraph 2.0 and subparagraphs. The
Committee may elect to require testing of wheels in accordance with Appendix B, paragraph 2.0.
6.0 In addition to the foregoing, wheel manufacturers must meet the requirements of the AAR
Manual of Standards and Recommended Practices, Section J, Specification M-1003, Specification
for Quality Assurance.
7.0 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, shot peening, and
heat-treating subcontractors inspected if they do not use their own facility. These inspections will
be made in conjunction with the facility inspection, and the cost will be borne by the applicant.
8.0 Wheel manufacturers using a native language other than English are responsible for the
accurate communication of all applicable AAR and customer requirements within the plant.
8.1 Plant practices and the final product must conform to the English language versions of any
applicable standards or specifications.
8.2 Critical records are defined as the standards, internal procedures, and forms necessary to
demonstrate compliance with this Specification M-107/M-208 and with MSRP Section J, Specifica-
tion M-1003. Critical records must be kept up to date with production and be maintained in Eng-
lish.
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M-107/M-208 APPENDIX B
Fig. B.1 Typical reference standard for rim face ultrasonic test
Paragraphs 18.4.3.2 and 18.4.3.4
Hole #1 reference hole
Holes #2 and #3 used for distance amplitude correction (DAC)
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M-107/M-208 APPENDIX B
Table B.1
Distance below Tread Surface
Wheel Design Reference Hole #1 Hole #2 Hole #3
One-wear two holes 1 1/4 in. 3/4 in.
Two-wear two holes 1 1/4 in. 3/4 in.
Multi-wear three holes 1 1/4 in. 3/4 in. 2 1/4 in.
Fig. B.2 Typical reference standard for rim tread ultrasonic test
Paragraphs 18.4.3.3 and 18.4.3.4.2
Hole #1 reference hole
Hole #2 and #3 used for distance amplitude correction (see Table B.1)
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M-107/M-208 APPENDIX B
MONTH
SERIAL NUMBER YEAR
MFGR.
CLASS
/8"
1
13/8"
1" MIN.
TAPE SIZE
Note 1 Stamping is to consist of manufacturers serial number, date of manufacture, manufacturers identification, and
class of heat treatment. Stamping is limited to 14 characters, and the design designation shall be stencilled on
the back plate with paint using characters at least 1 in. in height.
Note 2 Stamping is to be spaced a minimum of 1/8 in. between characters and 1 3/8 in. between groups. The stamping
shall be located not less than 1/4 in. from the inner edge of the rim.
Note 3 Dies used to produce characters shall be not less than 3/8 in. in nominal height at crest, and hot stamping shall
be nominally 3/32 in. in depth. Italicized characters (sloping upward to right) shall be used.
Note 4 All wheels will be marked for class using letters L, A, B, C, or D, as appropriate.
Note 5 All stamped characters must be stamped with a low-stress die design to a minimum depth of 0.015 in. or an
AAR-approved alternative.
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APPENDIX B M-107/M-208
MFGR.
CLASS
YEAR
/8"
/8"
3
3
MONTH GK
77 B
12
1 3/8
"
38
/"
MI
N.
54
J33
18
.
MIN
89
Note 1 When ordered, locomotive wheels and wheels for passenger service may be ordered stamped on the front or
back hub face. Wheels for freight service are stamped on the back hub face.
Note 2 Stamping is to consist of manufacturers serial number, date of manufacture, manufacturers identification, class
of heat treatment, and design designation in the order shown above. The hub stamping of locomotive wheels
may be applied by the purchaser after final machining of the hub. Wheels that are to be marked by the purchaser
should be furnished with all marking stencilled on the front plate with paint using characters at least 1 in. in height.
Note 3 Stamping is to be spaced a minimum of 1/8 in. between characters and a minimum of 1 3/8 in. between groups
and located approximately central of the hub face. No wheel manufactured after May 1, 2009, may be bored and
applied with any portion of the wheel manufacturers hub stamp closer than 1/8 in. from the inner hub diameter
and no closer than 1/8 in. from the outer hub diameter. No wheel manufactured before May 1, 2009, may be
bored and applied with any portion of the wheel manufacturers hub stamp breaking over the edge of the inner
or outer hub diameter.
Note 4 Stamps used to produce characters shall be not less than 3/8 in. in height and shall not have sharp edges.
Note 5 All wheels will be marked for class using letters L, A, B, C, or D, as appropriate.
Note 6 The three groups (1) design; (2) serial number; and (3) date of manufacture, manufacturer, and class will be
spaced approximately equidistantly around the hub face.
Note 7 All stamped characters must be stamped with a low-stress die design to a minimum depth of 0.015 in. or an
AAR-approved alternative.
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M-107/M-208 APPENDIX B
SERIAL NUMBER
09 7511
MONTH
08
DESIGN YEAR
CJ-33
78 S0 C
MFGR.
CLASS
TRADEMARK
Note 1. Characters to be cast on the back plate of wheels shall, at least, show the manufacturers serial number, date of
manufacture, manufacturers identification, class, and design designation.
Note 2. Cast markings shall be legible characters, at least 1 in. high and so spaced to allow related characters to be readily
distinguished as a group.
Note 3 All wheels shall be marked for class using letters L, A, B, C, or D, as appropriate.
Note 4 The three groups (1) design; (2) serial number; and (3) date of manufacture, manufacturer, and class must be clearly
separate.
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M-107/M-208 APPENDIX B
Standard Standard
Wide Flange Narrow Flange
Dimensions and Dimensions and
Tolerances Tolerances
1 + 16 1 + 16
1 1
A
0 0
1 38 + 32
1 + 116
B 1 532
32
3 0
L 5 2332 18 5 2332 18
(5 12 18 alternate)
Pa/ 7 14 See Note
R2 2 12 18 See Note
K 0.0865 0.0663
a/ Except A-28 = 7 18
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M-107/M-208 APPENDIX B
L
TAPING
LINE B
D R
O1 O2
P
C
L
STANDARD AAR WHEEL TYPESWIDE-FLANGE CONTOURFOR FREIGHT CAR SERVICECARBON STEEL
AAR A-28 E-28 A-30 J-33 M-33 P-33 H-36 J-36 K-36 B-38 C-38 D-38
TYPE CA-28 CA-28 CA-30 CJ-33 CM-33 CP-33 CH-36 CJ-36 CK-36 CB-38 CC-38 CD-38
STATUS STND STND STND STND STND STND STND STND STND STND STND
DATE 1952 1985 1946 1956 1961 1984 1962 1962 1962 1964 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 F, K E F, K D, E D, E D, E, F, G F F F G G G
CLASS
MAX. CAP.
PER WHEEL 32,875 24,375 32,875 27,500 27,500 32,875 35,750 35,750 35,750 39,375 39,375 39,375
(LB)
+1 +1 +1 +1 +1 +1 +1 +1 +1 +1 +1 +1
01 111/80 105/80 111/80 105/80 105/80 117/80 111/80 111/80 111/80 121/80 121/80 121/80
+1 +1 +1 +1 +1 +1 +1 +1 +1 +1 +1 +1
02 111/80 105/80 111/80 105/80 105/80 117/80 111/80 111/80 111/80 121/80 121/80 121/80
MAX FINISH
BORE 87/8 83/8 87/8 83/8 83/8 95/8 87/8 87/8 87/8 95/8 95/8 95/8
MIN HUB
WALL 11/8 11/8 11/8 11/8 11/8 11/8 11/8 11/8 11/8 11/4 11/4 11/4
P1 71/8 71/4 71/4 71/4 71/4 71/4 71/4 71/4 71/4 71/4 71/4 71/4
R 21/2 1/8 21/2 1/8 21/2 1/8 21/2 1/8 21/2 1/8 21/2 1/8 21/2 1/8 21/2 1/8 21/2 1/8 21/2 1/8 21/2 1/8 21/2 1/8
NOTES:
1. HUB LENGTH TOLERANCE IS BASED ON FINISHED DIMENSION.
2. 5 1/2 10 AXLE ALSO STANDARD FOR J-33 AND M-33; 5 1/2 10, 6 11, AND 6 1/2 12 AXLES ALSO STANDARD FOR P-33
Fig. B.9 Standard AAR wheel typeswide-flange contourfor freight car service
Paragraphs 2.1, 15.1, and 15.2
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APPENDIX B M-107/M-208
L
TAPING
LINE B
D R
O1 O2
P
C
L
02 +1 +1 +1 +1
130 103/40 131/4 1/8 131/4 1/8 111/20 131/4 1/8 131/20 131/4 1/8 131/4 1/8
P 61/2 1/8 71/8 61/2 1/8 61/2 1/8 71/8 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 101/4 81/2 915/16 915/16 91/4 915/16 103/4 915/16 915/16
BORE
MIN HUB **
13/8 11/8 11/8 11/8 11/8 13/8 11/8 11/8
WALL 11/8
NOTES:
1. WHERE DIMENSION R2 IS MARKED F, EXTRA STOCK OF 1/16 IN. TO 3/16 IN. OVER SPECIFIED DIMENSION MAY BE LEFT FOR MACHINING OF EACH FINISHED
SURFACE OR WHEEL MAY BE FURNISHED FINISHED TO EXACT DIMENSION SHOWN. HUB LENGTH TOLERANCE IS BASED ON FINISHED DIMENSION.
* REFERENCE GROOVE REQUIREDSEE RP-619
** HUB WALL THICKNESS MAY BE REDUCED AS NECESSARY FOR APPLICATION OF ROLLER BEARING WATER GUARD.
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APPENDIX B M-107/M-208
Detail A
Fig. B.12 AAR-1B narrow-flange contour for freight car wheels
Paragraphs 2.1, 15.1, and 16.2
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M-107/M-208 APPENDIX B
NOTE: WHEN WHEEL RIMS ARE REDUCED IN THICKNESS TO SUCH AN EXTENT THAT LATHE DOGS INTERFERE WITH THE 5/8-IN. RADIUS AT THE OUTER RIM
FACE, THIS RADIUS MAY BE REDUCED AS NECESSARY OR A CHAMFER USED. FREIGHT LOCOMOTIVE WHEEL RIMS SHALL BE MACHINED WITH A
MAXIMUM RADIUS OF 5/8 IN. ON THE OUTER RIM FACE. A CHAMFER IS ALLOWED TO EXTEND PAST THE RADIUS AT 45, BUT MUST BE NO LONGER THAN
0.4375 IN. MEASURED ALONG ITS LENGTH.
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APPENDIX B M-107/M-208
6.500
3
8 " 1.469
3
8 "
A 4.000
WHEEL CONTOUR ACCEPTANCE GAUGE
FOR AAR 1B NARROW & WIDE FLANGE
INTERSECTION POINTS
1 (0.0841873, -1.49764) R1.500
2 (0.4289, -1.4374) B 5 1.094
3 (0.769141, -1.2878) 2.8624 4
4 (1.02338, -0.950724)
5 (1.0603, -0.8128) BASELINE 3
1 2 R.5625
CENTERS OF RADII
A (0.000, 0.000) 1.987
B 0.480, -0.8053)
VERIFY WITH CONTOUR MAPPING MATERIAL:
MAX MANUFACTURE DEVIATION: .003" STAINLESS STEEL 17-7
8 " THICKNESS
1
MAX RECERTIFICATION DEVIATION: .005"
HARDENED
.750
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M-107/M-208 APPENDIX C
APPENDIX C
AUTHORIZATION FOR CLASS D WHEEL TEST ALLOTMENT
1.0 Each manufacturer must obtain an authorization for Class D test wheels from the Committee
prior to delivery. All requirements of the M-107/M-208 wheel specification and associated
appendixes apply to Class D wheels.
1.1 The intent of Class D is to provide wheel materials with superior resistance to tread damage
when compared to Class C wheels, without compromising any other safety performance character-
istics.
2.0 Class D wheel applicants must submit results from laboratory material tests as described in
paragraph 3.0 of this appendix, Material Testing. Upon acceptance of the laboratory test results,
the WABL Committee will authorize a test allotment of 5,000 wheels for field service testing in
interchange service.
3.0 MATERIAL TESTING
3.1 The following material testing is required. The applicant must contact the WABL Committee
to schedule an AAR observer. Three sample wheels must be tested. Unless otherwise approved by
WABL, an AAR observer is required. All costs for the tests and the observer are to be paid by the
applicant. Wheel materials should meet the minimum properties listed in Table 3.1.
3.1.1 Tension testing shall be conducted on two specimens at ambient temperature and two spec-
imens at 1,000 F. Specimens shall be taken from as close to the tread as possible (at least 1/8 in. of
the original wheel tread must remain visible at the ends of the test specimen) in the circumferen-
tial direction. Ultimate tensile strength, 0.2% offset yield strength, percentage elongation, and
percentage reduction of area shall be determined. Tests must be conducted per ASTM E21
(1,000 F) and ASTM A370 (ambient temperature), latest edition.
3.1.2 The microstructure shall be classified in the report and should be free of martensite. Six
microstructural specimens (1/2 in.2 section) shall be taken in the radial plane direction adjacent to
the microcleanliness specimens and must include the tread surface. The intent is to classify all
microstructures in the specimen, to include the tread surface. The report should contain sufficient
photographic evidence to support the conclusions.
3.1.3 Absence of tensile hoop stress shall be documented by a radial saw cut made to a depth at
least 1 in. deeper than the rim inner diameter. No opening of the cut shall be present at the conclu-
sion of the cut.
3.1.4 Hardness mapping of the test wheels shall be performed per M-107/M-208, Section 11.5. In
addition, Brinell hardness measurements shall also be taken along the centerline of the plate to
the hub inner diameter at approximately 1/2 in. spacing and reported for reference only.
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APPENDIX C M-107/M-208
3.1.5 Fracture toughness type testing shall be determined for two samples per test wheel at
70 F to 75 F according to ASTM E 399, latest edition. The sample shall be taken as shown in
Fig. 3.1. If a valid KIC is not obtained, then report the KQ value.
2.4" MIN
1" MIN
2.5
"M
IN
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M-967
Specification
M-967
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M-967
4.1.1.2 The following are features that shall be integral parts of the power pack:
Voltmeter
Dual-range ammeter with automatic switching or dual ammeters
Digital amp-hour meter
Polarity reversing switch
Overload protection
Infinitely variable voltage control
Instantaneous (1/2 cycle) safety cutout switch
Controlled ripple
4.1.2 Handles and Anodes
Handles for the process are conductive, must be matched to the amperes drawn for a given appli-
cation, should aid in dissipating heat, and must provide operator protection as well as ease of oper-
ation. The anodes must be of a material chemically inert to the electrolyte solution. The only
materials considered universally inert to all electrolytes used in the electrochemical metal deposi-
tion process are high-density, high-purity graphite or platinum with up to 11% iridium alloy. Other
anode materials may be used with a specific compatible solution; however, both the anode and
solution must be approved in writing by the process manufacturer. This written approval must
also be provided to the AAR. Where graphite anodes are used, graphite shall have less than 1%
metallics by volume, of a grade approved, in writing, by the process manufacturer for each electro-
lyte being used. This written approval must also be submitted to the AAR.
4.2 Solutions
4.2.1 The solutions used in the electrochemical metal deposition process are highly concentrated
water base chemicals. These include preparatory solutions for cleaning and activating the surface
to be coated, metal deposition solutions for coating, and metal removal solutions for polishing and
stripping. All metal deposition solutions must carry a batch number and be traceable to the manu-
facturers control batch and the axle repaired.
Note: Although several sources for electrochemical metal deposition solutions may be developed,
compatibility of the chemicals in the process is mandatory for process integrity. Therefore, in no
case will solutions, either preparatory or metal deposition, of different manufacturers be inter-
mixed or substituted into a buildup procedure.
4.3 A solution certified by the process manufacturer and annually verified by the axle recondi-
tioner 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. Documenta-
tion of the hardness test must include the test method and batch number(s) and be kept on record.
5.0 TECHNICAL REQUIREMENTS
5.1 Operator Qualification
The electrochemical metal deposition process is operator dependent and, therefore, only certified
personnel shall be permitted to process interchange equipment. Certification may be obtained in
any of the following manners:
5.1.1 Completion of a manufacturers theoretical course of instruction and a demonstrated ability
to repair axles consistently to the manufacturers process procedures.
5.1.2 Completion of a theoretical course certified by the process manufacturer and a demon-
strated ability to repair axles consistently to the manufacturers process procedures.
5.1.3 Completion of theoretical and hands-on training under direct supervision of a certified oper-
ator for a period as stipulated in the facilitys AAR Manual of Standards and Recommended Prac-
tices, Section J, Specification M-1003, Specification for Quality Assurance, to include a
demonstrated ability to repair axles.
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M-967
5.1.4 The course shall provide the operator proficiency in the electrochemical metal deposition
process including the following:
Inspection and preparation of metal surfaces for electrochemical metal deposits
Selection of proper tools
Calculation of deposit thickness
Application of metal deposit
Proper finishing techniques
5.1.5 The demonstration of ability shall consist of properly repairing at least two journals with
each of the following defects:
For status code 3A:
a. Undersized journal greater than .003 in. below minimum
b. Seal wear ring groove greater than .008 in. deep
c. Water etch in cone area greater than .001 in. deep
d. Undersized journal and ring groove combination
e. Undersized journal and water etch combination
f. Undersized journal that has been previously rebuilt (nickel de-
posited to nickel over the entire journal)
For status code 3B:
a. Undersized journal greater than .003 in. below minimum
For status code 3C:
a. Undersized dust guard greater than 0.003 in. below minimum
5.1.6 Proper repairing shall be determined by testing 100% of the repaired journals in accordance
with paragraphs 5.2.1, 5.2.2, 5.2.3, and 5.2.4, except in the case of dust guard repairs where
paragraph 5.2.3 does not apply.
5.1.7 Adequate records to document the above demonstration of operator proficiency for certifica-
tion shall be maintained. Operator recertification is required annually and shall include the abil-
ity to demonstrate qualification by written examination and/or practical application as stipulated
in the facilitys quality assurance manual required by AAR Manual of Standards and Recom-
mended Practices, Section J, Specification M-1003, Specification for Quality Assurance.
5.2 Inspection Procedure
The quality of an electrochemical metal deposition deposit is most readily proven when secondary
processing such as machining or grinding is accomplished. However, since the process obtains sig-
nificant cost reduction when secondary processing is not required and the part is built to size,
other inspection procedures are available.
5.2.1 Visual Inspection
All deposits shall be smooth, uniform in color, and free of blisters, pits, nodules, porosity, excessive
edge build-up, and other defects that would affect the functional use of the axle. The deposit sur-
face of the repaired journal shall be free of burnings and stress concentrations. Burning is defined
as rough, coarse grained, or dark deposits caused by localized high current density or arcing.
Highly stressed deposits will normally be indicated by cracks or crazing. The above defects are
cause for rejection.
5.2.2 Adhesion Test
Each axle journal repaired by the electrochemical metal deposition process shall have an adhesion
test performed. The adhesion test is accomplished using Scotch #250 tape or an equivalent
high-tack-strength, pressure-sensitive tape as approved by the AAR. The adhesion test is accom-
plished as follows:
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M-967
5.2.2.1 Thoroughly clean and dry the processed surface with a method that will not adversely
affect tape adhesion.
5.2.2.2 Cut a piece of 1-in.-wide unused tape approximately 6 in. longer than the width of the pro-
cessed area.
5.2.2.3 Stick the tape longitudinally across the width of the processed area of the journal so that
approximately 1/2 in. of the base metal on each side is taped to ensure coverage of both edges of
the processed area. Tamp the tape down to ensure thorough adhesion.
5.2.2.4 Grip the loose end of the tape and rip rapidly upward (at a right angle to the surface),
removing the tape with a single jerk.
5.2.2.5 Inspect the tape and processed surface area. Any deposit nickel adhering to the tape and
part of the processed area visually lifted is cause for rejection.
5.2.3 Burnishing
5.2.3.1 The deposit is suspect if moderate burnishing will cause a nonadhering deposit to lift,
peel, or flake; therefore, an inspection sampling derived from ANSI/ASQC Z1.91993 shall be bur-
nished and retested in accord with paragraphs 5.2.1 and 5.2.2 with a minimum daily inspection of
5%.
5.2.3.2 Each active operator shall have at least one axle inspected for compliance with this para-
graph for each week of production.
5.2.3.3 A moderate burnishing shall be that which creates a 0.0001-in. to 0.0002-in. reduction in
journal diameter after being burnished.
5.2.4 Surface Finish
5.2.4.1 The deposit surface finish on the repaired journal must not exceed 63 in.
5.2.4.2 The deposit finish on the repaired dust guard must not exceed 125 in.
5.2.5 Dimensional Inspection
When restoration of the entire length of the journal is required, average journal diameters must be
within the prescribed tolerances for new axles except for the restored area of the journal diameter
outside the area bounded by the inboard edge of the seal wear ring contact area, to the outboard
edge of the outboard cone. The average journal diameter may be used to meet journal diameter
requirements for the AAR Manual of Standards and Recommended Practices, Section G-II,
Fig. 4.1. The radius of the journal fillet must meet the new axle dimensions. When restoring the
dust guard for use in fitted applications, the diameter of the repaired dust guard must be within
the prescribed tolerances for new axles.
6.0 GENERAL REQUIREMENTS
The requirements of the AAR Manual of Standards and Recommended Practices, Section G, Part
II, Wheel and Axle Manual, pertaining to axle repairs by this process and to facility certification
must be met. In addition to the foregoing, those facilities maintaining or requesting certification in
accord with M-967 must meet the requirements of the AAR Manual of Standards and Recom-
mended Practices, Section J, Specification M-1003, Specification for Quality Assurance.
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M-967 APPENDIX A
APPENDIX A
QUALIFICATION OF APPLICANTS FACILITY FOR REPAIRING AXLES BY
ELECTROCHEMICAL METAL DEPOSITION PROCESS
1.0 The applicant must provide the Technical Services Division with an application for approval,
as described in the AAR Manual of Standards and Recommended Practices, Administrative
Standards, Standard S-060. Applications shall be provided in electronic file format and must
include brochures, material safety data sheets, and any other information that provides a general
description of the facility equipment and process to be used in the electrochemical metal deposition
repair of axles.
2.0 After determining that the application is consistent with the requirements of this
specification, the Committee will authorize the applicant to contact the AAR for information
concerning product testing.
3.0 All costs are to be paid upon notification of the testing charges. Product testing shall consist
of the applicants furnishing a minimum of three axles with journals electrochemically repaired
and shall include (as required by the applicable status code number) the following:
3.1 Two journals having had only seal wear ring grooves greater than 0.008 in. repaired.
3.2 Two journals undersize greater than 0.003 in. below minimum with full length of journal
restored.
3.3 Two journals with full length of journal restored over repaired water etch greater than
0.001 in. on the outboard cone seat. This must reflect nickel over nickel restoration.
3.4 Two dust guards having the dust guards greater than 0.003 in. below minimum restored.
4.0 The following tests shall be performed at or under the observation of the AAR with the test
results being provided to the Committee.
4.1 Microhardness test as per ASTM-B-578, latest revision. Microhardness for electroplating on a
minimum 0.002-in. deposit material on a seal wear ring groove. Minimum microhardness should
be C50 Rockwell or 500 Knoop tested per ASTM B-578 with a 50-g load.
4.2 Visual inspection as per paragraph 5.2.1.
4.3 Adhesion test as per paragraph 5.2.2.
4.4 All journals and dust guards must be measured and meet dimensional requirements as per
paragraph 5.2.5.
4.5 All journals and dust guards must be measured and meet the surface finish requirements per
paragraph 5.2.4.
4.6 Mounting and removal of a bearing three times on journals with full length restored with a
minimum interference fit of 0.002 in. All journals must meet the requirements of paragraph 5.2.2.
4.7 Journals must meet burnishing and testing specifications per paragraph 5.2.3. Photographic
documentation will be developed to confirm compliance with paragraphs 4.1, 4.2, and 4.3 of this
appendix. Subsequent to performance of the test referenced in paragraph 4.6 of this appendix,
inspection will be performed in accordance with paragraphs 4.2 and 4.3 thereof.
4.8 Mounting and removal of a fitted backing ring three times on restored dust guards.
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APPENDIX A M-967
5.0 Subsequent to the satisfactory completion of the tests and approval of the test results by the
Committee, the AAR Technical Services Division will inspect the facility where the axles are to be
repaired for proper procedures and equipment, including a demonstration of the ability to meet
the requirements of this specification. These inspections will require a certification fee as per the
AAR Field Manual of Interchange Rules, Rule 120. These inspections may be arranged
concurrently with the test program.
6.0 It is considered necessary that each qualified applicant have enough axles in AAR
interchange service to develop meaningful performance data. Therefore, the applicant will be
required to deliver at least 150 axles during the first 2 years after receipt of AAR approval and at
least 1500 axles within any consecutive 5-year period for use in AAR interchange service. When
data to support the number of deliveries is not available to the AAR, the applicant will be asked to
provide this information by listing the required number of axles delivered and to which customers
delivery was made. In the event the delivery requirement is not met and upon notification by the
AAR, the applicant will be required to requalify.
7.0 Requalification will require at least a current plant inspection by the AAR and a certification
by the applicant that repaired axles are of the same process and material, subject to compliance
with the latest version of this specification, as previously approved by the Committee. The
Committee may elect to require verification of any or all of the provisions of Appendix A of this
specification for requalification.
8.0 In the event that a plant ceases production for more than 60 days but no more than 1 year,
the AAR must be notified no less than 2 weeks prior to reopening. In the event that a plant ceases
production for more than 1 year, requalification will be required prior to delivery of any items for
use in AAR interchange service. The Committee may elect to require testing of axles in accordance
with paragraph 2.0 of Appendix A.
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M-967 APPENDIX B
APPENDIX B
AUTHORIZATION FOR DELIVERY OF AXLES REPAIRED BY THE
ELECTROCHEMICAL METAL DEPOSITION PROCESS FOR AAR
INTERCHANGE SERVICE
1.0 Each applicant must obtain an authorization for delivery of repaired axles for AAR
interchange use from the Committee prior to delivery.
2.0 Authorization for delivery of repaired axles will be approved after review of the tests and of
the AAR Field Manual of Interchange Rules Rule 120 inspection report required by Appendix A.
Authorization may be withdrawn if service performance so dictates.
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S-601
Standard
S-601
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3.2 To inspect typical wheels that the manufacturer has released for shipment.
3.2.1 The inspections shall be in accordance with the requirements outlined in the AAR Manual
of Standards and Recommended Practices, Section G, Part II, Wheel and Axle Manual and in
M-107/M-208 of this manual.
3.2.2 Table 3.1 lists in detail defects that, through past experience, have been found to be detri-
mental to the performance of wheels in service:
Table 3.1 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 To report to the AAR Technical Services Division and manufacturer on the results of the
inspection.
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S-611
Standard
S-611
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S-612
Standard
S-612
NOTE:
THE SCALE ON THE WHEEL TAPE CAN HAVE A TOLERANCE OF .005
BETWEEN ANY TWO POINTS ON THE SCALE WITH NO ACCUMULATIVE
VARIATION. LINEAR DIMENSIONS SHOWN REPRESENT
MEASUREMENTS OF ACTUAL CIRCUMFERENCE OF THE WHEEL AND
NOT STRAIGHT LENGTH OF THE TAPE. GRADUATIONS ARE TO BE
SPACED 1/8 IN. APART WITH THE TAPE LAID FLAT.
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S-613
Part 1
Standard
S-613
NOTE 1:
MARK WHEEL DIAMETERS IN 1/8-IN.
FIGURES ON TAPE AS SHOWN ABOVE
AND AS INDICATED IN THE FOLLOWING
TABLE:
WHEEL DIA. TAPE SIZE
35 207
36 233
37 258
38 283
39 308
40 333
41 358
42 385
43 409
44 434
45 459
46 484
47 509
48 534
49 559
50 584
51 610
52 636
NOTE 2:
THE SCALE ON THE WHEEL TAPE CAN
HAVE A TOLERANCE OF .005
BETWEEN ANY TWO POINTS ON THE
SCALE WITH NO ACCUMULATIVE
VARIATION. LINEAR DIMENSIONS
SHOWN REPRESENT MEASUREMENTS
OF ACTUAL CIRCUMFERENCE OF THE
WHEEL AND NOT STRAIGHT LENGTH
OF THE TAPE. GRADUATIONS ARE TO
BE SPACED 1/8 IN. APART WITH THE
TAPE LAID FLAT.
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S-614
Standard
S-614
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S-615
Former Standard
S-615
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S-616
Former Standard
S-616
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S-617
Former Standard
S-617
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S-618
Former Standard
S-618
Adopted: 1976
Note: Steel Wheel Gauge1976 is to be suitably marked on the back side of the gauge in approx-
imately 1/8-in. letters. For the master gauge, see RP-614.
MATERIAL: .093-in. STAINLESS STEEL FOR BODY OF GAUGE AND .050-in. STAINLESS STEEL OF SUITABLE HARDNESS FOR GAUGE FINGER. TOLERANCES ON DECIMAL
DIMENSIONS TO BE .005 in. AND ON DIMENSIONS IN COMMON FRACTIONS TO BE 1/64 in. UNLESS OTHERWISE SPECIFIED. REMOVE BURRS AND SHARP EDGES.
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S-627
Standard
S-627
Adopted: 1998
Note: For the limiting wear condemning gauge, see Standard S-629.
Notch Detail
A B
0 3/16 1/4
1/4 1/8 1/8
1/2 1/8 3/16
3/4 1/8 1/8 Material: Stainless steel 304
Thickness: 3/32
1 3/16 1/4
1 1/4 1/8 1/8
1 1/2 1/8 3/16
1 3/4 1/8 1/8
2 3/16 1/4
2 1/4 1/8 1/8 NOTES:
1. UNLESS OTHERWISE SPECIFIED, MANUFACTURE TOLERANCES ARE .010.
2 1/2 1/8 3/16 2. BOXED DIMENSIONS ARE MINIMUM CHARACTERISTICS TO BE VERIFIED FOR RECERTIFICATION.
3. RECERTIFICATION TOLERANCE IS .015 IN.
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S-628
Standard
S-628
Adopted: 1998
Notch Detail
A B
0 3/16 1/4
1/4 1/8 1/8
Material: Stainless steel 304
1/2 1/8 3/16 Thickness: 3/32
3/4 1/8 1/8
1 3/16 1/4
1 1/4 1/8 1/8
1 1/2 1/8 3/16
1 3/4 1/8 1/8
NOTES:
2 3/16 1/4 1. UNLESS OTHERWISE SPECIFIED, MANUFACTURE TOLERANCES ARE .010.
2. BOXED DIMENSIONS ARE MINIMUM CHARACTERISTICS TO BE VERIFIED FOR RECERTIFICATION.
2 1/4 1/8 1/8 3. RECERTIFICATION TOLERANCE IS .015 IN.
4. THIS GAUGE CAN BE USED FOR 7/8-IN. OR LESS FLANGE ON LOCOMOTIVE WHEELS.
2 1/2 1/8 3/16
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S-629
Standard
S-629
Adopted: 1998
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S-630
GAUGE, WHEELSTANDARD
Standard
S-630
Adopted: 1998
Finger radii Centers
X Y
0.3125 0.00 0.00
0.251A 0.00 0.00
0.251B 0.755726 0.685488
1.3125 0.0536604 0.999073
0.7656 0.29881 0.573978
1.562 0.00 0.00
0.126 0.00 1.49899
Wide Flange Markings
0.5625 0.0332779 0.874367 (Optional)
0.1875 1.24331 0.610423
Material:
Rivet and thumb knob:
303 stainless steel
Hardened
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A
0 at 5 1.375
0 at 4 1.313
0 at 3 1.250
0 at 2 1.188
0 at 1 1.125 Wide Flange Markings
0 at 0 1.063 (Optional)
At B At C
0 1.264 0 1.483
2 1.210 2 1.408
3 1.168 3 1.364
4 1.120 Manufacture tolerance: .005 4 1.323
5 1.070 Recertification tolerance: .010 5 1.283
6 1.034 6 1.248
7 0.995 7 1.203
8 0.951 8 1.142
9 0.894 9 1.077
10 0.997
11 0.896
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S-649
Standard
S-649
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S-657
Standard
S-657
Adopted: 1980
1.0 SCOPE
This standard became effective April 1, 1981.
NOTES:
1. MATERIAL: AAR MANUAL OF STANDARDS AND RECOMMENDED
PRACTICES,SECTION G, SPECIFICATION M-107/M-208. CLASS B.
2. DESIGN: AAR STEEL PASSENGER CAR WHEEL M-36 OR CM-36, MULTIWEAR
TREAD, NARROW FLANGE CONTOUR.
3. MARKING: MSRP SPECIFICATION M-107/M-208.
4. TREAD: MSRP SPECIFICATION M-107/M-208 FIG. B.13, EXCEPT 1:40 TAPER.
5. PERMISSIBLE VARIATION IN DIMENSIONS: PER MSRP SPECIFICATION
M-107/M-208, FIG. B.8, EXCEPT AS SHOWN.
6. MACHINING:
A. MSRP SPECIFICATION M-107/M-208 AND AS SHOWN.
B. INNER FACE OF WHEEL HUB SHALL BE SQUARE WITH CENTERLINE OF
FINISHED WHEEL BORE WITHIN .002 TOTAL INDICATOR READING (TIR.)
C. WHEEL SHALL BE MACHINED ALL OVER.
D. MAXIMUM DYNAMIC UNBALANCE AT THE OUTSIDE DIAMETER OF THE RIM
SHALL NOT EXCEED 0.6 LB. STAMP UNBALANCE IN OUNCES ON THE INSIDE
FACE OF THE RIM AT THE HEAVIEST POINT. AS AN ALTERNATIVE, IT IS
ACCEPTABLE TO MACHINE THE WHEELS ON ALL SURFACES TO WITHIN A
DIMENSIONAL TOLERANCE OF .005 IN.
E. SURFACE FINISH ON ID OF RIMS, WEB, AND OD OF HUB SHALL BE 250 IN.
MAXIMUM AND SHALL BE 350 IN. MAXIMUM FINISH ON THE TREAD,
FLANGE, AND RIM FACES.
7. WHEEL PLATE AREA, ID OF RIM, AND OD OF HUB SHALL BE SHOT PEENED IN
ACCORDANCE WITH MSRP SPECIFICATION M-107/M-208.
8. WHEEL SHALL BE ULTRASONICALLY TESTED AND MAGNETIC PARTICLE
INSPECTED AFTER MACHINING IN ACCORDANCE WITH MSRP SPECIFICATION
M-107/M-208.
9. THE VENDOR SHALL FURNISH AMTRAK WITH WHEELS IN PAIRS WITH THE
SAME TAPE SIZE. IN ADDITION TO MSRP SECTION G, WHEELS AND AXLES,
TAPE SIZE MARKING REQUIREMENTS, THE TAPE SIZE ALSO SHALL BE
STENCILED ON THE WHEEL TREAD IN 1-IN. (MINIMUM HEIGHT) LETTERS.
10. THE WORD AMTRAK SHALL BE STENCILED ON THE INSIDE PLATE IN 1-IN.
(MINIMUM HEIGHT) LETTERS, COLOR WHITE.
11. WHEELS ARE FOR USE WITH TRUCKS HAVING INSIDE JOURNAL ROLLER
BEARINGS.
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Standard
S-658
+.03
.13 .00
.06 FINISHED AXLE
1.50
+.06
.44 .00 DIA. BEARING SEAT TO BE UNIFORM
CL AXLE DIAMETER THROUGHOUT. TAPER NOT TO
2.00 EXCEED .001 PER FOOT ON DIAMETER.
DIA.
1.94 SYMMETRICAL ABOUT CL (TYPICAL)
6.135 DIA.
1.63 DIA. 6.125 6.31 .015
DIA.
60 6.1915 DIA. .88 R TYP
6.6260 DIA.
DETAIL A 6.1905 WHEEL SEAT
6.6240 6.25 DIA. (TYPICAL)
LABORATORY
DETAIL B ACCEPTANCE
STAMP MFG. NAME OR MO. & YR. WHEELS
BRAND MOUNTED
PART NO.
.25
COLD ROLL RELIEF GROOVES OVER
GRADE OF AXLE 4.00 DIA. 4.00 DIA.
REGION SHOWN WITH ROLLER HAVING CONTOUR OF
.19 RADIUS. USE 1200 POUNDS ROLLER PRESSURE. F FOR F
5.81 DIA. .25 +.00
.05R START ROLLING AT
CHEMISTRY ONLY .
REF. HEAT NO. MONTH
.88 R THESE POINTS. ROLL DOWN GROOVE AND OVERLAP & YEAR
AT BOTTOM. WHERE MOUNTED
METHOD OF COLD-ROLLING RELIEF GROOVES STAMPING ONE END OF AXLE STAMPING OTHER END OF AXLE
.44
DETAIL C
Standard
S-660
4.3 While it is recognized that the thermal load cannot exist alone, it will not be advisable to
include combined mechanical (vertical and/or lateral) and thermal loads in the rim stress calcula-
tion because there are analytic complexities in calculating stresses close to the point of load appli-
cation. This leads to the following set of desired information:
4.3.1 A maximum effective stress on the surface of the plate, resulting from the individual or
combined action of vertical, lateral, and thermal loads.
4.3.2 Maximum effective stresses at designated points on the surface of the rim, resulting from
only a thermal load.
The maximum stress shall be found, regardless of wheel orientation. If the maximum stress occurs
at an orientation other than 0, the orientation must be specified in the tabulation of the results.
Data shall be provided in both tabular and graphical (contour) form. Constant stress contours
shall be labeled, and their spacing shall be chosen for clarity.
5.0 WHEEL LOADS
Load magnitudes should be a function of the maximum static rail load. The mechanical load mag-
nitudes are currently twice the maximum static rail load for a vertical load and the maximum
static rail load for a lateral load. The thermal loads also are proportional to the maximum static
rail load. Examples of currently approved loads are given in Table 5.1.
Table 5.1 Wheel load parameters
Thermal Load
Wheel Types Vertical Load (lb) Lateral Load (lb) (HP for 20 min.,
100% into wheel)
125 ton: 38-in. diameter 78,750 39,375 41.92
110 ton: 36-in. diameter 71,500 35,750 38.00
100 ton: 28-, 30-, 33-in. diameter 65,750 32,875 35.00
70 ton: 33-in. diameter 55,000 27,500 29.28
One Wear 28-in. diameter 48,750 24,375 25.95
Locomotive: 40-in. diameter and over 70,000 35,000 37.00
Note: Mechanical loads shall be introduced at several alternative locations.
5 23/32" 1/8"
+ 1/32"
- 3/32"
V1 13/8"
GAUGING POINT 1
/8"
V2
1" L1
Th
3 3/8"
3 7/16"
Fig. 11.1 Locations of assumed loadings for wide-flange, steel, freight car wheels
(not to scale)
Paragraphs 5.2 and 5.3
Standard
S-661
Adopted: 1991
1.0 SCOPE
1.1 This standard became effective March 29, 1991.
1.2 This standard supersedes MSRP S-602.
Notes:
1. Unless noted, all other tolerances are 0.0250.
2. Hanging holes optional.
3. Minimum 0.120-in. steel with minimum 55 RC hardness.
Standard
S-662
Adopted: 1991
1.0 SCOPE
1.1 This standard became effective March 29, 1991.
1.2 This standard supersedes MSRP S-603.
Notes:
1. Unless noted, all other tolerances are 0.0250.
2. Hanging holes optional.
3. Minimum 0.120-in. steel with minimum 55 RC hardness.
Standard
S-663
Adopted: 1991
1.0 SCOPE
1.1 This standard became effective March 29, 1991.
1.2 This standard supersedes MSRP S-604.
Notes:
1. Unless noted, all other tolerances are 0.0250.
2. Hanging holes optional.
3. Minimum 0.120-in. steel with minimum 55 RC hardness.
Standard
S-664
Adopted: 1991
1.0 SCOPE
1.1 This standard became effective March 29, 1991.
1.2 This standard supersedes MSRP S-604.
Notes:
1. Unless noted, all other tolerances are 0.0250.
2. Hanging holes optional.
3. Minimum 0.120-in. steel with minimum 55 RC hardness.
Standard
S-665
Adopted: 1991
1.0 SCOPE
1.1 This standard became effective March 29, 1991.
1.2 This standard supersedes MSRP S-605.
Notes:
1. Unless noted, all other tolerances are 0.0250.
2. Hanging holes optional.
3. Minimum 0.120-in. steel with minimum 55 RC hardness.
Standard
S-666
Adopted: 1991
1.0 SCOPE
1.1 This standard became effective March 29, 1991.
1.2 This standard supersedes MSRP S-606.
Notes:
1. Unless noted, all other tolerances are 0.0250.
2. Hanging holes optional.
3. Minimum 0.120-in. steel with minimum 55 RC hardness.
Standard
S-667
Adopted: 1991
1.0 SCOPE
1.1 This standard became effective March 29, 1991.
1.2 This standard supersedes MSRP S-607.
Notes:
1. Unless noted, all other tolerances are 0.0250.
2. Hanging holes optional.
3. Minimum 0.120-in. steel with minimum 55 RC hardness.
Standard
S-668
Adopted: 1991
1.0 SCOPE
1.1 This standard became effective March 29, 1991.
1.2 This standard supersedes MSRP S-608.
Notes:
1. Unless noted, all other tolerances are 0.0250.
2. Hanging holes optional.
3. Minimum 0.120-in. steel with minimum 55 RC hardness.
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 loco-
motive wheel design under normal railroad operating service conditions. The objective will be
achieved by comparing the results obtained from the application of this procedure to a fatigue cri-
terion 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 stan-
dard. These results form the basis of the AAR evaluation of the wheel design. Because the evalua-
tion 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 compu-
tational 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 pre-
scribed wheel design and heat-treatment schedule (identifying the initial temperature, quench du-
ration, 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.
180 0
270
Fig. 5.1 3-D rendering of locomotive wheel identifying angular reference positions (view is of front face of wheel)
The elements generated in the hoop direction shall have a maximum angular length of 10 or less.
The model shall have a plane of nodes at 45. The angular length of the elements on either side of
the 45 plane shall extend in the hoop direction by no more than 5. These requirements are illus-
trated in Fig. 5.2. The 0 plane is the plane on which the specified loads are applied. The 45 plane
is the plane at which the stress results are reported.
Fig. 5.2 Illustration of 3-D model created by revolution of 2-D axisymmetric model (view is of front face of wheel)
Fig. 6.1 Portion of model (red regions) in which stresses due to applied loads (L1 + V1 and V2) must be retained for
fatigue analysis of the new and worn rim conditions
6.2 Heat-Treatment Residual Stresses
The heat-treatment schedule shall be provided by the AAR WABL Committee for the benchmark
analysis to be performed for analyst qualification. The schedule identifies initial temperature,
quench duration and extent, annealing temperature and duration, and any dwell time that may ex-
ist between any steps in the heat-treatment process. Convective and radiative heat transfer shall
be accounted for on all exterior surfaces of the wheel as described in paragraph 10.0. All other sub-
missions to the WABL Committee according to this standard must utilize the heat-treatment sched-
ule proposed for the actual wheel design for which approval is sought.
6.2.1 New Rim Geometry
The purpose of this analysis is to establish the state of residual stress for the new rim geometry due
to the heat-treatment process including cool-down to room temperature. In a decoupled analysis,
the temperature history at each node shall be calculated first using thermal elements. Time begins
(t = 0) when the wheel exits the austenizing furnace at a uniform elevated temperature. The mate-
rial is considered to be strain-free at this point in time. The analysis ends (t = tn) when the wheel
reaches ambient temperature at the end of the cool-down period. This condition is satisfied when
the temperature at all nodes is within the range of ambient temperature plus 5 F.
In the second part of the decoupled analysis, the time-dependent nodal temperatures are applied to
the structural elements to obtain the residual stresses.
The relevant temperature-dependent material property data in paragraph 10.0 shall be used. At
the conclusion of the heat-treatment simulation, orthogonal (normal) stresses at each node in the
model in the region identified in Fig. 6.1 shall be retained.
6.2.2 Worn Rim Geometry
To determine the residual stress distribution in the worn wheel, elements are removed from the
model described above to arrive at the worn rim geometry. Element removal alters the residual
stress distribution. This technique involves modifying the stiffness matrix.
The relevant temperature-dependent material property data in paragraph 10.0 shall be used. After
removal of the rim material, orthogonal (normal) stresses at each node in the model in the region
identified in Fig. 6.1 shall be retained.
6.3 Interference Fit Analysis
The interference fit shall be accomplished by inserting a hollow axle stub into the wheel bore. A
nominal interference of 0.010 in. referenced to the diameter is assumed. For convenience, the hol-
low axle geometry shown in Fig. 5.2 (in which the axle bore diameter is 2 in.) may be used. The in-
terference fit stresses shall be determined for the new and worn rim conditions. The element
removal technique described above may be used to obtain the interference fit stresses for the worn
rim geometry.
Material properties for the wheel and axle shall be as defined in Standard S-660 (current version).
Orthogonal (normal) stresses at each node in each model in the region identified in Fig. 6.1 shall be
retained.
6.4 Required Stress Results
The analyses performed according to paragraphs 6.1, 6.2, and 6.3 yield eight sets of stress results,
or eight load cases, as shown in Table 6.1.
Table 6.1 Summary of load cases
Load Case Required Result at Each Node Condition
1 Orthogonal normal stresses under load V1+L1, new (full) rim
(SxL, SyL, SzL, TxyL, TyzL, TxzL)
2 Orthogonal normal stresses under load V2, new (full) rim
(SxL, SyL, SzL, TxyL, TyzL, TxzL)
3 Orthogonal normal stresses under load V1+L1, worn rim
(SxL, SyL, SzL, TxyL, TyzL, TxzL)
4 Orthogonal normal stresses under load V2, worn rim
(SxL, SyL, SzL, TxyL, TyzL, TxzL)
5 Orthogonal normal stresses Heat-treatment residual stresses, new (full) rim
(SxR, SyR, SzR)
6 Orthogonal normal stresses Heat-treatment residual stresses, worn rim
(SxR, SyR, SzR)
7 Orthogonal normal stresses Interference-fit stresses, new (full) rim
(SxP, SyP, SzP)
8 Orthogonal normal stresses Interference-fit stresses, worn rim
(SxP, SyP, SzP)
J 2 A ( J 1M + J 1R + J 1P ) Equation (1)
in which J'2 represents the octahedral shear stress and is defined as follows:
1---
1 2 2 2 2
J 2 = --- [ ( S x S y ) + ( S y S z ) + ( S z S x ) + 6 ( T xy
2 + T2 + T2 )]
yz xz Equation (2)
3
which, for the purposes of this standard, is characterized by the amplitudes of the stresses due to
the applied load as derived from the stress states on the load application plane (at 0) and on a ra-
dial plane located 180 from the load application plane. The amplitude of each nodal stress compo-
nent (Si, Tij) in Equation (2) is defined as follows:
1 1
S i = --- [ ( S iL ) 0 ( S iL ) 180 ] and T ij = --- [ ( T ijL 0 ) ( T ijL 180 ) ] Equation (3)
2 2
in which the subscripts 0 and 180 denote the value of each stress component on the respective
model planes (the regions identified in Fig. 6.1), and the superscript L denotes the stresses due to
the applied loads. These stresses are obtained from the analysis performed according to
paragraph 6.1.
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 and is defined as
follows:
1
J 1M = --- [ ( S xL + S yL + S zL ) 0 + ( S xL + S yL + S zL ) 180 ] Equation (4)
2
in which (SxL + SyL + SzL)0 are the orthogonal (normal) stress components at the nodes on the ra-
dial plane upon which the load is acting (at 0), and (SxL + SyL + SzL)180 are the orthogonal (nor-
mal) stress components at the nodes on a radial plane 180 away (the regions identified in Fig. 6.1),
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 6.2 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 6.3 and is defined as
follows:
J 1P = S xP + S yP + S zP Equation (6)
The values of the constants (A = 28 ksi and = 0.16) have been experimentally determined [5, 6].
Equation (1) shall be evaluated at each node in each model in the region identified in Fig. 7.1 for
the four combinations of load cases shown in Table 7.1. If, under any load combination, Equation (1)
evaluates to false (the alternating stresses are greater than the static stresses) at any node in the
model(s), then fatigue is predicted, rendering the design unacceptable.
7.1 Results
The results obtained by application of the Sines criterion for the four load combinations described
in paragraph 7.0 shall be presented as four contour plots in the plane of the wheel cross-section on
which the mechanical loads act in a format similar to that shown in Fig. 7.2.
For each of these plots, the value to be contoured at each node location is the Sines parameter, SP,
which is the difference between the left-hand and right-hand sides of Equation (1), or
SP = J 2 [ A ( J 1M + J 1R + J 1P ) ] Equation (7)
Negative contour data (SP less than 0) indicate locations at which the Sines criterion is satisfied.
Positive contour data (SP greater than 0) represent fatigue-prone locations at which the Sines cri-
terion is violated. Fatigue-prone locations are unacceptable, and if identified through application of
this procedure, the proposed wheel design must be revised and the analysis procedure repeated un-
til no Sines criterion violations remain (SP < 0 everywhere in the specified plate region).
The minimum safety factor and the location in the wheel plate at which it occurs shall be reported
for each load combination. The safety factor represents the fatigue margin for the proposed wheel
design and is determined in the following way.
The analysis described in paragraph 7.0 yields a value for the Sines parameter (SP) at each node
for each of the specified nominal loading conditions. The stresses due to the mechanical loads are
recomputed assuming the nominal load (L1, V1, V2) is increased by a load factor n. Because the
model is linearly elastic, the stresses due to the mechanical loads (load cases 1 through 8 in
Table 6.1) increase proportionally.
The Sines parameter SP is recomputed for each node for each load combination described in
Table 7.1. Each node is now characterized by two values for SP: one due to the nominal load (load
factor = 1) and one resulting from the increased load (load factor = n). The safety factor at each node
is the multiplier (load factor) on the mechanical load necessary to cause the left-hand and
right-hand sides of the Sines criterion to be equal at this location (SP = 0). This concept is graphi-
cally depicted in Fig. 7.3:
B V2 <value> <value>
D V2 <value> <value>
0 - 180
reference plane
Fig. 8.1 Wheel in saddle-mode of vibration with reference plane for applied load
8.1.1 Finite Element Model
The three-dimensional model described in paragraph 5.6 shall be used.
8.1.2 Material Properties
Relevant material properties as defined in Standard S-660 (current version) shall be used. Thermal
effects are not considered in this analysis. The modal and harmonic response analyses are per-
formed assuming elastic material behavior.
8.1.3 Boundary Conditions
The outer surface of the hollow axle stub shall be fixed to the inner surface of the wheel hub. Axle
bore nodal degrees of freedom are fixed. Interference pressure between the hollow axle and wheel
hub is ignored in this analysis.
8.1.4 Modal Analysis Results
The lowest frequency at which the wheel vibrates in the saddle-mode shape as shown in Fig. 8.1
shall be reported to a minimum of three decimal places.
H2 3 1/16 in. from the back rim face for wide flange wheels
2 27/32 in. from the back rim face for narrow flange wheels
H3 1 1/2 in. from the back rim face for wide flange wheels
1 9/32 in. from the back rim face for narrow flange wheels
Fig. 8.2 Arrow indicates typical location of maximum residual circumferential (hoop) tensile stress in wheel rim fol-
lowing simulated heat treatment. This is referred to as cross-sectional Location X in Table 8.2 (legend omitted)
Table 8.2 Reporting format for stresses due to heat treatment and forced vibration (ksi)
Maximum Rim
Circumferential (Hoop) Circumferential (Hoop) Maximum Rim
Tensile Stress Following Stress Due to Circumferential (Hoop)
Load Case
Simulated Heat Treatment Forced Vibration Tensile Stress Due to
at Location X at Location X Forced Vibration
(see Fig. 8.2)
H2 <value> <value>
H3 <value> <value>
9.0 RESPONSIBILITY
9.1 Deviations
Once an analytical procedure has been qualified, it shall be the responsibility of the vendor to in-
form the AAR if he deviated from the conditions for which he is qualified. The vendor must demon-
strate that the new code still qualifies.
9.2 Auditing
In auditing the analysis done by vendors, the AAR may, at its discretion, require any vendor to re-
run the standard solution in its entirety or in part. Failure on the part of the vendor to comply shall
be grounds for disqualification.
Table 10.6 Yield strength Table 10.7 Creep strain rate [7]
53712-
y -----------------
Temp (F) 08 T + 460
(kips/in.2) & = 4.6410 ( eff
12.5 )e
0 80.00 in which
75 80.00 & = the creep strain rate (1/F)
100 79.94
eff = von Mises effective stress (ksi)
200 79.69
T = temperature (F)
300 79.44
400 79.20
500 78.95
600 77.71
700 76.32
800 67.77
900 54.91
1000 41.95
1100 32.77
1200 23.59
1300 14.63
1400 10.50
1500 8.94
1600 7.79
1700 6.63
1800 5.48
11.0 REFERENCES
1. Sines, G. 1955. Failure of Materials Under Combined Repeated Stresses with Superimposed
Static Stresses. NACA Technical Note 3495.
2. Sines, G. 1969. Elasticity and Strength. Needham Heights:Allyn and Bacon.
3. Sines, G., and J.L. Waisman, eds. 1959. Metal Fatigue. London:McGraw-Hill.
4. Stephens, R.I., A. Fatemi, R.R. Stephens, and H.O. Fuchs. 1980. Metal Fatigue in Engineering,
Hoboken:Wiley and Sons.
5. McKeigan, P.C., F.J. McMaster, and J.E. Gordon. 2002. Fatigue Performance of AAR Grade B
Wheel Steel at Ambient and Elevated Temperatures. ASME Paper IMECE2002-33240.
6. McMaster, F. J., G.P. Robledo. and J.E. Gordon. 2005. Fatigue Performance of AAR Grade A
Wheel Steel at Ambient and Elevated Temperatures. ASME Paper IMECE2005-82519.
7. Kuhlman, C., H. Sehitoglu, and M. Gallagher. 1988. The Significance of Material Properties on
Stresses Developed During Quenching of Railroad Wheels. Proceedings of the 1988 Joint ASME
IEEE Railroad Conference.
8. Metals Handbook. 1948. Vol. 1, 9th edition. Cleveland:American Society for Metals.
9. Slavik, D., and H. Sehitoglu. 1986. Constitutive Models Suitable for Thermal Loading. ASME
J. Eng. Mats. Techn. 108:108-312.
10. Lunden, R. 1991. Contact Region Fatigue of Railway Wheels Under Combined Mechanical Roll-
ing Pressure and Thermal Brake Loading. Wear. 144:57-70.
11. Orringer, O., D.E. Gray, and R.J. McCown. 1993. Evaluation of Immediate Actions Taken with
Cracking Problems Observed in Wheels of Rail Commuter Cars. DOT-VNTSC-FRA. 93:3.
12. Berg, N. A., and R. Alber. 1972. Tread Braking Versus the Wheel. Proceedings of the 64th An-
nual Convention of the Air Brake Association.
13. Metals Handbook. 1948. Vol. 1, 10th edition. Cleveland:American Society for Metals.
Recommended Practice
RP-608
49"
29"
1"
/4"
1
11/4"
11/4" 13/8"
3"
21/4"
/4" R.
/4"
1
11/4"
1
/2" R.
1
21/2"
38.002" 35"
37.998" 1
+ /64"
(6-55'-23" APART.)
383/32" -0"
SECTION A-A
1"R.
3"
3 6
5 0
/12"
31/2" 31/2"
31/2" 31/2"
MAKE MARKS AS SHOWN 52" DOWN TO 35"
1"R
.
60
/64"
52 3/32 0
1
52.002"
51.998"
51
A
38
L
C
MARK:
52
50
L
C
MARK:
ENLARGED VIEW MASTER DISK FOR CHECKING WHEEL CIRCUMFERENCE
OF MARK MEASURE OF 27" TO 38" DIAMETER WHEELS.
Recommended Practice
RP-609
Recommended Practice
RP-612
Desired mounting pressures are based on 13 ton/in. of diameter, expressed in the nearest 5 ton with
an allowable variation of 20% over and under, except the first three minimum pressures, which are
shown as 75 ton, being considered better practice for these sizes.
Recommended Practice
RP-613
Recommended Practice
RP-614
GAUGE, WHEELSIMPLIFIED
Recommended Practice
RP-615
DETAIL A
(FOR GROOVED TREAD MEASUREMENT)
MATERIAL: .093-in. STAINLESS STEEL. UNLESS OTHERWISE STATED. ALL TOLERANCES ARE .010 in. REMOVE BURRS AND SHARP EDGES.
Recommended Practice
RP-619
DESIGN D (in.)a/
CH 33 29
H 33 29
CA 34 30
NOTE:
THIS REFERENCE GROOVE IS OPTIONAL AND IS MACHINED AT A 34 30
THE REQUEST OF THE CUSTOMER UNLESS SPECIFIED AS
REQUIRED. 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.
Recommended Practice
RP-622
Recommended Practice
RP-629
Recommended Practice
RP-630
4"
Recommended Practice
RP-636
Adopted: 1991
1.0 SCOPE
This recommended practice can be used when checking with the following gauges: S-667 (wide
flange) and S-662 (narrow flange).
CONTACT
REQUIRED
CONTACT
REQUIRED
FLANGE THICKNESS
Recommended Practice
RP-637
Adopted: 1991
1.0 SCOPE
This recommended practice can be used when checking with the following gauges: S-665 (wide
flange) and S-661 (narrow flange).
CONTACT
REQUIRED
CONTACT
REQUIRED
FLANGE THICKNESS
Recommended Practice
RP-638
Adopted: 1991
1.0 SCOPE
This recommended practice can be used when checking with the following gauges:
Maximum Flange Thickness, Height and Throat Radii Gauges: S-665 and S-661
Maximum Limit Wear Gauges: S-663 and S-666
Minimum Flange Thickness, Height and Throat Radii Gauges: S-667 and S-662
Minimum Limit Wear Gauges: S-664 and S-668
CONTACT
REQUIRED
CONTACT
REQUIRED