SLOVENSKI OSIST prEN 15049:2004

PREDSTANDARD december 2004

Železniške aplikacije – Vzmetenje - Torzijska vzmet, jeklena

Railway applications - Suspension components - Torsion bar, steel

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ICS 45.060.01 Referenčna številka

OSIST prEN 15049:2004(en)

© Standard je založil in izdal Slovenski inštitut za standardizacijo. Razmnoževanje ali kopiranje celote ali delov tega dokumenta ni dovoljeno
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 EUROPEAN STANDARD DRAFT
NORME EUROPÉENNE prEN 15049
EUROPÄISCHE NORM
September 2004

ICS

English version

Railway Applications - Suspension components - Torsion bar,

steel

Applications ferroviaires - Éléments de suspension - Barre Bahnanwendungen - Federungselemente - Drehstabfedern

de torsion, en acier aus Stahl

This draft European Standard is submitted to CEN members for enquiry. It has been drawn up by the Technical Committee CEN/TC 256.

If this draft becomes a European Standard, CEN members are bound to comply with the CEN/CENELEC Internal Regulations which
stipulate the conditions for giving this European Standard the status of a national standard without any alteration.

This draft European Standard was established by CEN in three official versions (English, French, German). A version in any other language
made by translation under the responsibility of a CEN member into its own language and notified to the Management Centre has the same
status as the official versions.

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CEN members are the national standards bodies of Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France,
Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Slovakia,
Slovenia, Spain, Sweden, Switzerland and United Kingdom.

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Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without notice and
shall not be referred to as a European Standard.
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EUROPEAN COMMITTEE FOR STANDARDIZATION

COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG

Management Centre: rue de Stassart, 36 B-1050 Brussels

© 2004 CEN All rights of exploitation in any form and by any means reserved Ref. No. prEN 15049:2004: E
worldwide for CEN national Members.
prEN 15049:2004 (E)

Contents Page

Foreword..............................................................................................................................................................3
Introduction .........................................................................................................................................................4
1 Scope ......................................................................................................................................................5
2 Normative references ............................................................................................................................5
3 Terms and definitions ...........................................................................................................................6
4 Symbols and abbreviations ..................................................................................................................7
5 Requirements .........................................................................................................................................8
6 Product definition ................................................................................................................................13
7 Mechanical properties for manufacturing .........................................................................................17
8 Tests and test procedures ..................................................................................................................17
9 Quality assurance and final approval ................................................................................................20
10 Marking of torsion bars .......................................................................................................................24
11 Packaging .............................................................................................................................................24

A.1 iTeh Standards

Annex A (normative) Material for hot formed and quenched and tempered torsion bars .......................25
General..................................................................................................................................................25
A.2 Material for torsion bars, steel ...........................................................................................................25
Annex B (normative) Inspection (https://standards.iteh.ai)
of torsion bars made of round bars by the magnetic crack
detection method .................................................................................................................................26
B.1
B.2
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Object ....................................................................................................................................................26
Tests......................................................................................................................................................26
B.3 Safety measures ..................................................................................................................................26
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Annex C (normative) Checking shot peening efficiency by the ALMEN method .....................................27
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C.1 Field of application ..............................................................................................................................27
C.2 Checking the procedure......................................................................................................................27
C.3 Equipment and installations...............................................................................................................27
C.3.1 ALMEN A2 test piece ...........................................................................................................................27
C.3.2 Test piece holder .................................................................................................................................28
C.3.3 ALMEN measuring device...................................................................................................................29
Annex D (normative) Examination for inclusions ........................................................................................30
D.1 Object ....................................................................................................................................................30
D.2 Test methods........................................................................................................................................30
D.2.1 Test method according to DIN 50 602 ...............................................................................................30
D.2.2 Test method according to NF A 04-106 .............................................................................................31
D.2.3 Test method according to SS 111116 ................................................................................................31
Bibliography ......................................................................................................................................................32

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 prEN 15049:2004 (E)

Foreword
This document (prEN 15049:2004) has been prepared by Technical Committee CEN/TC 256 “Railway
Applications”, the secretariat of which is held by DIN.

This document is currently submitted to the CEN Enquiry.

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prEN 15049:2004 (E)

Introduction
This European Standard was prepared at the beginning of 2002 with the aim of incorporating the existing
documents, such as UIC leaflets (International Union of Railways) and the internal standards of the various
railways as well as national standards into one standard.

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 prEN 15049:2004 (E)

1 Scope
This European Standard applies to torsion bars made of steel for anti-roll bar systems used on railway
vehicles.

This European Standard includes straight and bended torsion bars, but does not detail the other components
of the anti-roll bar systems such as levers, bearings, bushes etc.

This European Standard constitutes guidelines on the following topics:

 design;

 specification of technical requirements;

 production requirements;

 tests;

 supply conditions.

2 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
iTeh Standards
document (including any amendments) applies.

(https://standards.iteh.ai)
EN 10228-1, Non-destructive testing of steel forgings — Part 1: Magnetic particle inspection.

EN 10204:2000-08, Metallic materials — Types of inspection documents.

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EN 10089, Hot-rolled steels for quenched and tempered springs — Technical delivery conditions.

SIST
EN 10045-1, Charpy impact test on metallic EN 15049:2008
materials — Part 1: test method.
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EN 10002-1, Metallic materials — Tensile testing — Part 1: Method of testing at ambient temperature.

EN 473, Non-destructive testing — Qualification and certification of NDT personnel — General principles.

EN ISO 3887, Steels — Determination of depth of decarburization (ISO 3887:2003).

EN ISO 643, Steels — Micrographic determination of the apparent grain size (ISO 643:2003).

ISO 14284, Steel and iron — Sampling and preparation of samples for the determination of chemical
composition.

ISO 10209-1, Technical product documentation — Vocabulary — Part 1: Terms relating to technical drawings
— General and types of drawings.

ISO 4288, Geometrical Product Specifications (GPS) — Surface texture: Profile method — Rules and
procedures for the assessment of surface texture.

ISO 2162-3, Technical product documentation — Springs — Part 3: Vocabulary.

ISO 83, Steel — Charpy impact test (U-notch).

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prEN 15049:2004 (E)

ISO/TR 10108, Steel — conversion of hardness values to tensile strength values.

DIN 50602, Metallographic examination; microscopic examination of special steels using standard diagrams to
assess the content of non-metallic inclusions.

SS 111116, Steel — Method for estimation of the content of non-metallic inclusions — Microscopic methods
— Jernkontoret's inclusion — chart II for the assessment of non-metallic inclusions.

NF A04-106, Iron and steel. Methods of determination of content of non metallic inclusions in wrought steel.
Part II : micrographic method using standards diagrams.

3 Terms and definitions

For the purposes of this European Standard, the following terms and definitions given in ISO 2162-3 and the
following apply.

3.1
anti-roll bar system
suspension system having an influence on the rolling behaviour of the vehicle. Generally, it includes the
torsion bar and any other components

3.2
anti-roll bar
spring bar which is mainly stressed by a torsional moment. It can either be produced as a bended bar or a
straight torsion bar with levers iTeh Standards
3.3
straight torsion bar (https://standards.iteh.ai)
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straight spring bar which is mainly stressed by a torsional moment

NOTE The term "torsion bar made of steel" refers to the finished end product. For the purpose of simplification, the
term "torsion bar" will be used in the wording of this standard for anti-roll bars with torsion bars of round cross section and
made of steel. SIST EN 15049:2008
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3.4
bended torsion bar
are mainly U-shaped and manufactured out of round spring material.

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 prEN 15049:2004 (E)

4 Symbols and abbreviations

The symbols and abbreviations used in this standard are listed in table 1. All parameters are expressed as SI
basic units and units derived from SI basic units. Decimal multiples and submultiples of units defined in table 1
can be used.

Table 1 — Symbols and definitions

Symbols Dimensions Definitions

AR % Tolerance of the torsion spring rate
d mm Bar diameter
da mm Tip diameter of the head profile
df mm Root diameter of the head profile
G N/mm² Shear modulus
hz mm Height of tooth
4
Ιp mm Polar moment of inertia
l mm Shank length, Free length of torsion bar
L mm Length of torsion bar
le mm Spare length
lf
lh
mm
mm
iTeh Standards
Active length
Length of flute
lk mm (https://standards.iteh.ai)
Head length
lz mm Cylindrical part of shank
Mt N x mm
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Torsional moment
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MtA N x mm Torsional moment at the beginning of stress
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N - Stress cycles endured
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p N/mm² Surface pressure
R mm Bending radius of flute
Rm N/mm² Material strength
Rt N x mm/° Spring rate
Wp mm³ Polar moment of resistance
Wt N x mm Torsional work
z - Number of teeth
γ - Shearing
γK % Creep loss
γR % Relaxation
δ - Ratio of root diameter of the head profile to bar diameter
υ ° Angle of twist (degree)
ύ` - Angle of twist (radiant)
υA ° Angle of twist at the beginning of stress

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prEN 15049:2004 (E)

Table 1 — Symbols and definitions (continued)

Symbols Dimensions Definitions
ν - Ratio spare length to length of flute
τ N/ mm² Shear stress
τa N/ mm² Amplitude of shear stress
τm N/ mm² Mean stress
τzul N/ mm² Permissible shear stress
τF N/ mm² Yield point
τH N/ mm² Fatigue range
τN N/ mm² Calculated nominal stress

5 Requirements

5.1 Service conditions

The service conditions shall be defined by the customer to enable the anti-roll bar system designer and the
torsion bar manufacturer to provide an effective and safe product (service conditions, climatic conditions,
environmental conditions, etc.).

5.2 Functional requirements

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The technical specification shall be prepared in total by the customer or jointly by the customer and the
supplier. The technical specification should comprise for example the following documents:


(https://standards.iteh.ai)
general assembly drawing of the anti-roll bars or suspension system;

 component drawing; Document Preview

 technical data sheet. SIST EN 15049:2008
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The definition of the type of drawing is given in ISO 10209-1.

The principal characteristics of the torsion bar (form, dimension, material, stiffness, etc.) shall be determined
by the relevant design analysis.

In order to satisfy this requirement, a design analysis, which shall be part of the technical specification, shall
define at least:

 calculation method;

 loads and displacements utilised for the analysis;

 the following results:

 comparison of the calculated functional characteristics with the required characteristics (static
stiffness or flexibility, etc.);

 comparison of the calculated stresses with the allowable stresses of the selected material.

The customer and the supplier shall agree on the contents of the documentation and on the analysis method
to be used.

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 prEN 15049:2004 (E)

The following product requirements shall be defined by the customer:

Table 2 — Elements to be defined in the technical specification by the customer

Characteristic to be verified Reference To be agreed

space requirements 6.1 X
spring rate 5.3 X
maximum anti-roll angle or
moment, for static (exceptional 5.3 X
loads)
maximum anti-roll angle or moment
5.3 X
for dynamic (fatigue condition)
service life requirement 6.2.2 X
a
material 6.3.1
a
notch impact strength 8.4
surface protection 6.4 X
marking 10 X
a
Shall be agreed between customer and manufacturer.

5.3 Arrangement and design

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The individual bar with circular cross section is the starting point in the design of torsion bars.
(https://standards.iteh.ai)
The introduction of the torsional moment into torsion bars is mostly effected by rockers which are connected to

Document
with regard to the bar axis is transformed into a momentPreview
the torsion bar ends through positive or non-positive locking. By means of the rocker, a force acting vertically

into a displacement of the force introduction point.

and the resulting torsion of the free torsion bar end

SIST
The transformation of a vertical movement intoEN 15049:2008
a bar torsion attained by means of the rockers allows this
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combination to be used in an advantageous way as anti-roll device of rail vehicles.

The arrangement of the torsion bars as anti-roll device in the rail vehicle is effected in transverse direction, the
bar axis being for the most part aligned parallel to the track plane.

A principle representation for the purpose of symbol illustration is shown in figures 1 and 2.

The torsion bar (antiroll bar) and the stabilizer are working around zero position with alternating loads. They
are not pretensioned during manufacturing.