prCEN/TS 13001-3-3:2007 Cranes - General design - Part 3-3: Limit states and proof of competence of wheel/rail contacts (. . 3-3. ). CEN/TS 96 (n). , , , , . (IDT) 4
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prCEN/TS 13001-3-3-2009
prCEN/TS 13001-3-3:2007 ( .).
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EN 1993-6:2005.
3-3.
3-3.
Cranes General design Part 3-3. Limit states and proof of competence of wheel/rail contacts 2010-01-01
III
prCEN/TS 13001-3-3:2007 (E)
Scope
This Part 3-3 of EN 13001 is to be used together with Part 1 and Part 2 and as such they specify general conditions, requirements and methods to prevent mechanical hazards of wheel/rail contacts of cranes by design and theoretical verification. This standard covers steel and cast iron wheels. The following is a list of significant hazardous situations and hazardous events that could result in risks to persons during normal use and foreseeable misuse. Clauses 5 to 6 of this standard are necessary to reduce or eliminate the risks associated with the following hazard: Exceeding the limits of strength. This Technical Specification is applicable to cranes that are manufactured after the date of approval by CEN of this standard, and serves as reference base for the Technical Specifications for particular crane types. NOTE
CEN/TS 13001-3-3 deals only with limit state method according to EN 13001-1.
Normative references
The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN 13001-1, Cranes General Design Part 1: General principles and requirements EN 13001-2, Cranes General Design Part 2: Load actions EN ISO 6506-1, Metallic materials Brinell hardness test Part 1: Test method (ISO 6506-1:2005) EN ISO 12100-1:2003, Safety of machinery Basic concepts, general principles for design Part 1: Basic terminology, methodology (ISO 12100-1:2003) ISO 4306-1:1990, Cranes vocabulary Part 1: General ISO 12488-1, Cranes Tolerances for wheels and travel and traversing tracks Part 1: General
3 3.1
Terms, definitions, symbols and abbreviations
Terms and definitions
For the purposes of this Technical Specification, the terms and definitions given in EN ISO 12100-1:2003, EN 1991-1:1994 and Clause 6 of ISO 4306-1:1990, and the following apply. Unit-conform hardness * Some formulas used for calculations within this document refer to a so called unit-conform hardness HB based on the Brinell hardness HBW given as a value without unit according to EN ISO 6506-1. The unit of HB* has to match with the unit of the modulus of elasticity used in the calculation. Using SI-units, the unitconform hardness is given by
HB * = HBW
N mm 2
(1)
where *
HB
is the unit-conform Hardness;
prCEN/TS 13001-3-3:2007 (E)
HBW EXAMPLE NOTE
3.2
is the value of the Brinell hardness.
A Brinell hardness HB of 300 results into a unit-conform hardness HB* = 300 N/mm.
Annex B provides a table of hardness conversion.
Symbols and abbreviations
For the purposes of this Technical Specification, the symbols and abbreviations given in Table 1 apply. Table 1 Symbols and abbreviations Symbols, abbreviations
Load-bearing width
Dw
Wheel diameter
Em
Mean modulus of elasticity
Er
Modulus of elasticity of the rail
Ew
Modulus of elasticity of the wheel
Wheel load
FRd,f
Limit design contact force for fatigue
FRd,s
Limit design contact force
FSd,f
Design contact force for fatigue
FSd,f,i
Design contact force in contact
FSd,s
Design contact force
Fu
Minimum contact force
ff
Factors of further influence in fatigue
f f1
Decreasing factor for edge pressure in fatigue
f f2
Decreasing factor for non-uniform pressure distribution in fatigue
f f3
Decreasing factor for skewing in fatigue
f f4
Matching material factor in fatigue
f f5
Decreasing factor for driven wheels in fatigue
fy
Yield point
f1
Decreasing factor for edge pressure
f2
Decreasing factor for non-uniform pressure distribution
f 4w, f 4r
Description
Matching materials factor for wheel or rail in fatigue
prCEN/TS 13001-3-3:2007 (E)
Table 1 (continued) Symbols, abbreviations
HBW
Brinell Hardness
HB *
Unit-conform hardness
HR *
Rockwell hardness
HV *
Vickers hardness
Index of one rolling contact with FSd, f,i
iD
Number of rolling contacts at reference point
itot
Total number of rolling contacts during the useful life of wheel or rail
Exponent for wheel/rail contacts
kc
Contact force spectrum factor
rk
Radius of the rail surface or the second wheel radius
r3
Radius of the edge
sc
Contact force history parameter
Sc
Classes of contact force history parameter sc
Width of projecting non-contact area
Z mp , Z ml
Description
Depth of point of maximum shear for point or line contact
Skewing angle
Part of the skewing angle
due to the slack of the guide
Part of the skewing angle
due to tolerances
Part of the skewing angle
due to wear
cf
Minimum contact resistance factor
General resistance coefficient; m = 1.1
Risk coefficient
Partial safety factors
Radial strain coefficient ( v = 0,3 for steel)
vc
Relative total number of rolling contacts
Dynamic factors (see EN 13001-2)
General
In all cranes, wheels and rails (or wheels and supporting area or guide rollers and guide means) are stressed by loads (described by a load spectrum) and by rolling contacts. Both constitute the contact force history parameter sc (see 6.3.3). The contact force history parameter is used for the selection of wheels and rails. It is independent of time. NOTE 1 For the purpose of this standard guide rollers and their guiding means as well as wheels running on the surface of a member shall be considered as wheels and rails.
prCEN/TS 13001-3-3:2007 (E)
The proof of competence for static strength and the proof of competence for fatigue strength shall be fulfilled for the selection of wheels and rails. This standard is for design purposes only and should not be seen as a guarantee of actual performance. NOTE 2 This standard is applicable for metallic wheel/rail contacts only. Other materials require the applicability of the Hertz theory of contact pressure.
Proof of static strength
5.1
General
For the proof of static strength of all wheel/rail contacts it shall be proven that for all relevant load combinations of EN 13001-2:
FSd,s FRd,s
(2)
where
5.2
FSd,s
is the design contact force;
FRd,s
s the limit design contact force.
Design contact force
The design contact force
FSd,s of all wheel/rail contacts shall be calculated for all relevant load combinations
of EN 13001-2, taking into account the respective dynamic factors
partial safety factors
and where
required the risk coefficient n . The most unfavourable load effects from the position of the mass of the hoist load and from the crane configuration shall be taken into account.
5.3
Static limit design contact force
5.3.1
General
A contact force of the magnitude of the static limit design contact force
FRd,s causes permanent radial
deformation of 0,02 % of the wheel radius.
The static limit design contact force
FRd,s depends on:
materials properties (modulus of elasticity and hardness) of wheel and rail;
contact case (point contact or line contact);
geometry (radii of wheel and rail);
decreasing effects (stiffness, edge effects).
5.3.2
Equivalent modulus of elasticity
When the elastic modules of wheel and rail are different, the equivalent modulus of elasticity shall be calculated as
prCEN/TS 13001-3-3:2007 (E)
Em =
2 E w Er E w + Er
(3)
where
Em is the equivalent modulus of elasticity ;
E w is the modulus of elasticity of the wheel;
(In case
Er
is the modulus of elasticity of the rail.
Ew
= Er then of course
Em = E w
= Er )
Values of the elastic modules for selected materials are given in Table 2. Table 2 Values of elastic modules for selected materials Material of wheel, material of rail
5.3.3
modulus of elasticity of the wheel in N/mm
Steel
210 000
cast iron
176 000
Hardness
The static limit design contact force shall be calculated in terms of the unit-conform material hardness HB (see 0) in the contact areas.
If the hardness of wheel and rail are different, the lower value shall be taken. For hardened materials it shall be ensured that the hardness assumed in calculations reaches deeper into the material than the point of maximum shear. 5.3.4
Point contact
Formula (4) gives the static limit design contact force
shear is situated at depth
FRd,s for cases of point contact the point of maximum
Z mp below the surface.
Typical point contacts are shown in Figure 1.
prCEN/TS 13001-3-3:2007 (E)
Key
FRd,s =
zmp = 4,7
(10 HB )
* 3
3 2 3 1 v
1,5 Em D2w + r1k
HB * 2 1 2
m Em D2w + r1k
(4)
(5)
where
FRd,s
is the static limit design contact force for point contact;
z mp
is the depth of point of maximum shear;
Em
is the equivalent elasticity modulus;
is the radial strain coefficient ( v = 0,3 for steel);
Dw
is the wheel diameter;
rk
is the radius of the rail surface or the second wheel radius (see Figure 1);
HB
is the unit-conform hardness (see chapter 0) at the point of maximum shear;
is the general resistance coefficient;
m =1,1.
Figure 1 Point contact
5.3.5 5.3.5.1
Line contact General
Formula 6 gives the static limit design contact force
shear is situated at depth Z ml below the surface.
FRd,s for cases of line contact. The point of maximum
prCEN/TS 13001-3-3:2007 (E)
Typical line contacts are shown in Figure 2.
Key
FRd,s =
z ml = 7,8
(5 HB )
* 2
Dw b (1 v 2 )
HB* D w 1 v 2
m Em
Em
f1 f 2
(6)
(7)
where
FRd,s
is the static limit design contact force for line contact;
z ml
is the depth of point of maximum shear;
Em
is the mean modulus of elasticity;
is the radial strain coefficient ( v = 0,3 for steel );
Dw
is the wheel diameter;
is the load-bearing width (see Figure 2);
HB
is the unit-conform hardness (see chapter 0) at the point of maximum shear;
is the general resistance coefficient;
m =1,1;
f1
is the decreasing factor for edge pressure;
f2
is the decreasing factor for non-uniform pressure distribution.
Figure 2 Line contact
prCEN/TS 13001-3-3:2007 (E)
5.3.5.2
Edge pressure
Sharp edges at the end of the contact line of wheel or rail decrease the limit design contact force. This effect is taken into account by factor f1 , given in Table 3.
Figure 3 Edge pressure
Table 3 Factor edge
f1 for edge pressure
r3 / w
f1
r3 / w 0,1
0,75
0,1< r3 / w < 0,8
[0,5 + 0,25 (r3 / w)]/ 0,7
r3 / w 0,8
1,0
where
is the width of the projecting non-contact area and
r3 is the radius of the edge.
5.3.5.3
Pressure distribution
An ideal uniform distribution requires sufficient elasticity of the rail fixation or support and/or wheels in hinged legs. Otherwise deformation of the crane structure (e.g. bending of main girders) or tolerances in rail alignment result in non-uniform pressure distribution, decreasing the limit design contact force. This effect is taken into account by factor f 2 , given in Table 4 (Tolerance classes according ISO 12488-1). Table 4 Factor
wheels with self-aligning suspension
rail mounted on elastic adjustment to the wheel
support
allowing
rail support not allowing adjustment to the wheel
f 2 for pressure distribution
Tolerance class 1
Tolerance class 2
Tolerance class 3
Tolerance class 4
1,0
1,0
0,95
0,9
0,9
0,85
0,8
0,7
0,8
0,75
0,7
0,6
prCEN/TS 13001-3-3:2007 (E)
Proof of fatigue strength
6.1
General
For the proof of fatigue strength of all wheel/rail contacts it shall be proven that for each wheel and for all points on the rails
FSd,f FRd,f
(8)
where
6.2
FSd,f
is the design contact force for fatigue;
FRd,f
is the limit design contact force for fatigue.
Design contact force
The design contact force
FSd,f shall be calculated for regular loads (load combinations A of EN 13001-2), with
the respective dynamic factors
, partial
safety factors
p,
and risk coefficient
set to 1. The skewing
forces acting on guide rollers shall be considered as regular loads.
6.3
Limit design contact force
6.3.1
Basic formula
The limit design contact force
FRd,f =
Fu m
s c cf
FRd,f shall be calculated for wheels and rails separately by
ff
(9)
where
Fu is the minimum contact force;
sc is the contact force history parameter;
cf
is the minimum contact resistance factor;
cf = 1,1; ff
is the factor of further influences;
is the exponent for wheel/rail contacts;
m = 3 for cases of point contact and m = 10/3 for cases of line contact.
prCEN/TS 13001-3-3:2007 (E)
6.3.2
Minimum contact force
The limit design contact force of a wheel or rail stressed by rolling contact fatigue is characterized by the 6 minimum contact force Fu which represents the fatigue strength under 6,4 x 10 rolling contacts under constant contact force and a probability of survival (i.e. avoiding cracks, pitting, excessive wear) of 90 % . For a wheel one revolution is equivalent to one rolling contact, whereas for a selected point in the rail the passing over of any wheel represents one rolling contact. In cases where the wheel is not rolling but the load is fluctuating, one load cycle shall be considered as one rolling contact. The minimum contact force for wheel/rail is dependent upon either the surface hardness or on the yield point as given in Table 5. The lower value of Fu obtained from the equations in Table 5 shall be taken into account.
Fu is calculated separately for wheel and rail.
10
prCEN/TS 13001-3-3:2007 (E)
Table 5 Minimum contact force
Fu related to the surface hardness of
Fu related to the yield point of the wheel
wheel or rail
or rail material
(5,2 HB )
* 3
Point contact
3 2 3 1 v
1,5 Em D2w + r1k
(3,0 HB )
* 2
Line contact
Fu
(1,6 f )
Dw b (1 v 2 )
(1,8 f )
Em
3 2 3 1 v
1,5 Em D2w + r1k
Dw b (1 v 2 ) Em
where
Em v
is the radial strain coefficient ( v = 0,3);
Dw
is the wheel diameter;
rk
is the radius of the rail surface or the second wheel radius (see Figure 1);
HB fy b
6.3.3
is the equivalent elasticity modulus;
is the unit-conform hardness (see clause 0);
is the yield point of the material at the depth of maximum shear (if surface hardened, before that process); is the load-bearing width (see Figure 2).
Contact force history parameter
In analogy to stress history parameter (see EN 13001-1), the contact force history parameter is given by
s c = k c vc
(10)
where
kc
is the contact force spectrum factor;
vc
is the relative total number of rolling contacts.
The contact force history parameter shall be determined either by direct use of formula (10) or simplified (based on experience) by selection of a class S c from Table 6. If Table 6 is used, then in formula (9) the exponent m shall be set to 3, independent of the contact case. Table 6 Classes
S c of contact force history parameter sc
Class
Sc 0
Sc 1
Sc 2
Sc 3
Sc 4
Sc 5
Sc 6
Sc 7
Sc 8
Sc 9
sc
0,008
0,016
0,032
0,063
0,125
0,25
0,5
1,0
2,0
4,0
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prCEN/TS 13001-3-3:2007 (E)
6.3.4
Contact force spectrum factor
The contact force spectrum factor
F k c = 1/ i tot Sd,f,i i =1 FSd,f i tot
k c is calculated by
(11)
where
is the index of one rolling contact with
FSd , f ,i ;
itot
is the total number of rolling contacts during the specified life of wheel or rail (in general based upon the life of component or crane);
FSd,f,i
is the design contact force in contact i ;
FSd,f
is the maximum design contact force;
is the exponent for wheel/rail contacts.
6.3.5
Relative total number of rolling contacts
The relative total number of rolling contacts
vc =
vc is calculated by
itot iD
(12)
where
itot
is the total number of rolling contacts during the useful life of wheel or rail;
iD
is the number of rolling contacts at reference point:
6.4
iD = 6,4 10 6 .
Factor of further influences
6.4.1
Basic formula
The factor
f f takes into account further influences on the limit design contact force:
f f = f f1 f f 2 f f 3 f f4 f f 5 where
f f 1 to f f5 are the factors of influences as given in 6.4.2 to 6.4.6.
12
(13)
prCEN/TS 13001-3-3:2007 (E)
6.4.2
Edge pressure
Due to lateral movements of wheels the edge pressure acting on the surface opposite the edge may be neglected and the factor f f1 is set to 1. For the surface with the edge radius r3 (see Figure 2),
f f1 = f 1
(14)
where
f1 is the factor for edge pressure as given in 5.3.5.2.
6.4.3
Pressure distribution
For the proof of fatigue strength the pressure distribution may be neglected and 6.4.4
f f2 set to 1.
Skewing
A skewing wheel causes wear of wheel and rail and thus shortens the useful life. The wear is increased overproportionally in relation to the skewing angle . This effect is taken into account by factor f f3 .
ff3 = 1 f f3 = 3
for
for
>
5 /00
5 /00
(15)
where
= g + w + t
is the skewing angle of the crane in /00, calculated according to EN 13001-2.
The part of the skewing angle due to tolerances
shall be chosen according to the tolerance as given in
Table 7.
Table 7 Alignment angle of single wheel or roller
Alignment
Tolerance class 1
1,5 /00
6.4.5
Tolerance class 2 0
2,5 /00
Tolerance class 3 0
3,5 /00
Tolerance class 4 0
4,5 /00
Matching materials
Wear and mechanical abrasion of wheel and rail depend considerably on the combination of mechanical properties (e.g. type of material, hardening, ultimate strength) of wheel and rail. Matching materials cause equal wear of a wheel and a rail per rolling contact. Non-matching materials will increase wear of one partner and decrease wear of the other partner. This may be taken into account by factor f f4 . For a particular chosen pair of wheel and rail materials,
f f 4 shall be chosen such that:
13
prCEN/TS 13001-3-3:2007 (E)
f 4w =
1 f 4r
where
f f4 = f 4w
is the matching materials factor for a wheel,
f f 4 = f 4r
is the matching materials factor for a rail.
The factor f f 4 shall be chosen from experience in the range between 0,66 and 1,5. Examples are given in informative Annex C. 6.4.6
Mechanical drive factor
In an unclean environment the mechanical abrasion effects on the driven wheels may be taken into account by factor f f5 .
f f5 = 0,95 for driven wheels in unclean environment,
f f5 = 1,0
14
for non-driven wheels or wheels in clean environment.
(17)
prCEN/TS 13001-3-3:2007 (E)
Annex A (informative) Selection of suitable set of crane standards for a given application
Table A.1 Is there a product standard in the following list that suits the application? EN 13000:2004
Cranes Mobile cranes
EN 14439:2006
Cranes Tower cranes
EN 14985:2007
Cranes Slewing jib cranes
prEN 15011:2006
Cranes Bridge and gantry cranes
EN 15056:2006
Cranes Requirements for container handling spreaders
EN 13852-1:2004
Cranes Offshore cranes Part 1: General purpose offshore cranes
EN 13852-2:2004
Cranes Offshore cranes Part 2: Floating cranes
EN 14492-1:2006
Cranes Power driven winches and hoists Part 1: Power driven winches
EN 14492-2:2006
Cranes Power driven winches and hoists Part 2: Power driven hoists
Scheffler, M.: Grundlagen der Frdertechnik Elemente und Triebwerke. Vieweg Verlag 1994.
[4]
Calcul en fatigue du contact galet/rail, 1B2302 et 1B2303, J-F. FLAVENOT, CETIM, Juin 2003
[5]
A. EKBERG, E. KABO and H. ANDERSON An engineering model for prediction of rolling, contact fatigue of railway wheels, Fatigue Fracture Engineering Materials and Structures 25 (2002), pages 899-909
[6]
EN 1990:2002, Eurocode, Basis of structural design
