TB/T 3276-2011 PDF English
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TB/T 3276-2011: [Including 2017XG1] Rails for high speed railway---This is an excerpt. Full copy of true-PDF in English version (including equations, symbols, images, flow-chart, tables, and figures etc.), auto-downloaded/delivered in 9 seconds, can be purchased online: https://www.ChineseStandard.net/PDF.aspx/TBT3276-2011
RAILWAY INDUSTRY STANDARD OF
THE PEOPLE’S REPUBLIC OF CHINA
ICS 45.080
S 11
Rails for high speed railway
ISSUED ON: JULY 15, 2011
IMPLEMENTED ON: AUGUST 01, 2011
Issued by: Ministry of Railways of the PRC
Table of Contents
Foreword ... 5
1 Scope ... 6
2 Normative references ... 6
3 Terms and definitions ... 7
4 Grading and selection ... 8
4.1 Grading ... 8
4.2 Selection ... 8
5 Information required for ordering ... 8
6 Type dimensions, length, weight, and tolerances ... 9
6.1 Type dimensions ... 9
6.2 Length and weight ... 9
6.3 Dimension tolerances ... 9
6.4 Straightness and distortion tolerances ... 10
6.5 Bolt hole ... 11
7 Technical requirements ... 12
7.1 Manufacturing method ... 12
7.2 Designation and chemical composition ... 12
7.3 Tensile properties ... 13
7.4 Hardness ... 13
7.5 Microstructure ... 13
7.6 Decarburization layer ... 13
7.7 Nonmetallic inclusions ... 13
7.8 Macrostructure ... 15
7.9 Drop hammer ... 15
7.10 Surface quality ... 15
7.11 Ultrasonic flaw detection ... 16
7.12 Residual stress of rail flange ... 17
7.13 Fracture toughness ... 17
7.14 Fatigue crack growth rate ... 17
7.15 Fatigue ... 17
8 Test methods ... 17
8.1 Inspection items, inspection frequency, sampling locations, and test methods .. 17
8.2 Hydrogen content ... 20
8.3 Total oxygen content and nitrogen content ... 20
8.4 Hardness ... 21
8.5 Microstructure ... 21
8.6 Drop hammer ... 21
8.7 Ultrasonic flaw detection ... 22
8.8 Residual stress of rail flange ... 25
8.9 Fracture toughness ... 25
8.10 Fatigue crack growth rate ... 25
8.11 Fatigue ... 26
9 Inspection rules ... 28
9.1 Supervision ... 28
9.2 Type inspection ... 28
9.3 Exit-factory inspection ... 28
9.4 Re-inspection and judgement ... 29
9.5 Rounding off of numerical values ... 30
10 Marking and quality certificate ... 31
10.1 Marking ... 31
10.2 Quality certificate ... 32
11 Quality assurance ... 32
11.1 Quality assurance system ... 32
11.2 Quality assurance period ... 33
Appendix A (Normative) Type dimensions of 60 kg/m rail ... 34
Appendix B (Normative) Impermissible defects on transverse acid-leached test
piece of rail ... 36
Appendix C (Normative) Method for determining the longitudinal residual stress
of rail flange ... 48
Appendix D (Normative) Test method of rail plane-strain fracture toughness KIC
... 50
Appendix E (Normative) Sample plate diagrams for inspection of geometric
dimensions of rail ... 54
Bibliography ... 64
Amendment No.1 [2017XG1] TB/T 3276-2011 “Rails for high speed railway”65
Rails for high speed railway
1 Scope
This Standard specifies the type dimensions and tolerances, technical
requirements, test methods, inspection rules, marking and quality certificate,
quality assurance, etc. of the rails.
This Standard applies to 60 kg/m hot-rolled rails for high speed railway
operating at speeds of 200 km/h and above. Rails for railway operating at
speeds greater than 160 km/h and less than 200 km/h may refer to it for
implementation.
2 Normative references
The following documents are indispensable for the application of this document.
For the dated references, only the editions with the dates indicated are
applicable to this document. For the undated references, the latest edition
(including all the amendments) are applicable to this document.
GB/T 223.14 Methods for Chemical Analysis of Iron, Steel and Alloy - The N-
Benzoy-N-Phenylhydroxylamine Extraction Photometric Method for the
Determination of Vanadium Content
GB/T 223.60 Methods for chemical analysis of iron, steel and alloy - The
perchloric acid dehydration gravimetric method for the determination of
silicon content
GB/T 223.62 Methods for chemical analysis of iron, steel and alloy - The
butyl acetate extraction photometric method for the determination of
phosphorus content
GB/T 223.63 Methods for chemical analysis of iron, steel and alloy - The
sodium (potassium) periodate photometric method for the determination of
manganese content
GB/T 223.68 Methods for Chemical Analysis of Iron, Steel and Alloy - The
Potassium Iodate Titration Method after Combustion in the Pipe Furnace for
the Determination of Sulfur Content
GB/T 223.71 Methods for Chemical Analysis of Iron, Steel and Alloy - The
Gravimetric Method after Combustion in the Pipe Furnace for the
Determination of Carbon Content
GB/T 223.82 Steel and iron - Determination of hydrogen content - Thermal
conductivity/infrared method after fusion under inert gas
GB/T 226 Test method for macrostructure and defect of steel by etching
GB/T 228 Metallic materials - Tensile testing at ambient temperature
GB/T 231.1 Metallic materials - Brinell hardness test - Part 1: Test method
GB/T 3075 Metallic materials - Fatigue testing - Axial-force-controlled
method
GB/T 4161 Metallic materials - Determination of plane-strain fracture
toughness
GB/T 4336 Carbon and low-alloy steel - Determination of multi-element
contents - Spark discharge atomic emission spectrometric method (routine
method)
GB/T 6398 Metallic materials - Fatigue testing - Fatigue crack growth method
GB/T 10561-2005 Steel - Determination of Content of Nonmetallic Inclusions
- Micrographic Method Using Standards Diagrams
GB/T 11261 Steel and Iron - Determination of oxygen content - The pulse
heating inert gas fusion-infra-red absorption method
GB/T 13298 Inspection methods of microstructure for metals
GB/T 19001 Quality management systems - Requirements
GB/T 20066 Steel and Iron - Sampling and Preparation of Samples for the
Determination of Chemical Composition
GB/T 20124 Steel and iron - Determination of nitrogen content - Thermal
conductimetric method after fusion in a current of inert gas
YB/T 081 Rule for rounding off of numerical values and judgement of testing
values for technical standards of metallurgy
3 Terms and definitions
The following terms and definitions apply to this document.
3.1 Heat
All slabs cast from a furnace of molten steel; but excluding the first slab cast
from the next furnace of molten steel entering into tundish casting.
3.2 Sequence
Continuous casting of the same designation by molten steel of different heats
in tundish.
3.3 Transition area
The part cast by a mixture of two furnaces of molten steel.
4 Grading and selection
4.1 Grading
The nonmetallic inclusions in the steel are divided into two grades, A and B.
4.2 Selection
This Standard specifies two steel designations of U71MnG and U75VG. High
speed railways above 250 km/h and high speed passenger railways of 200 km/h
~ 250 km/h shall select U71MnG rails. High speed passenger and freight mixed
railways of 200 km/h ~ 250 km/h shall select U75VG rails.
For nonmetallic inclusions of rails for high speed railway above 250 km/h, it
shall adopt Grade A. For nonmetallic inclusions of rails for high speed railway
of 200 km/h ~ 250 km/h, it shall adopt Grade B.
5 Information required for ordering
When the user is ordering, it shall provide the following basic information:
a) Product name;
b) Product standard number;
c) Steel designation;
d) Rail type and applicable speed range (or grade of nonmetallic inclusions);
e) No-hole or hole rail (number of holes, one end drilled or both ends drilled);
f) Length, quantity, and off-size rate;
g) Other requirements.
7.8 Macrostructure
The macrostructure of the etched test piece of cross-section of rail shall comply
with the provisions of Appendix B.
7.9 Drop hammer
The rail shall be subjected to a drop hammer test. The sample, after being
hammered once, shall not be broken. Deflection values shall be given in the
quality certificate for reference.
7.10 Surface quality
7.10.1 There shall be no cracks on the rail surface.
7.10.2 All the protruding parts (except the hot-rolling identification), which affect
the installation of fish plate, of rail running surface (i.e. rail crown), lower surface
of rail flange, and within 1 m from the rail end shall be ground.
7.10.3 The maximum allowable depth of rail wear, thermal scratches,
longitudinal lines, folds, scale indentation, rolling marks, etc. formed in the hot
state:
a) Rail running surface: 0.35 mm;
b) Other parts of rail: 0.5 mm.
In any part of the length of rail, longitudinal fore-plate scratches are only allowed
to have a maximum of 2. The depth shall not exceed the regulations. But on the
rail running surface, only 1 is allowed. Fore-plate scratches which occur
repeatedly along the same axis may be recognized as 1.
It is allowed that the maximum width of fore-plate scratch is 4 mm; the ratio of
width to depth is greater than or equal to 3:1.
The periodic hot-rolling marks produced by the rolls may be recognized as 1
and can be ground.
7.10.4 The maximum allowable depth of defects such as longitudinal and lateral
scratches of the rail formed in the cold state:
a) Rail running surface, lower surface of rail flange: 0.3 mm (The lower
surface of rail flange shall not have lateral scratches);
b) Other parts of rail: 0.5 mm.
7.10.5 There shall be no damage of martensite or white phase structure on the
rail surface; if any, it shall be eliminated.
7.10.6 Surface defect detection and grinding: The depth of surface defect shall
be detected by a depth detector. When the depth cannot be measured, it shall
be confirmed by test. When grinding surface defects, the contour of grinding
surface shall be smooth; it shall ensure that the microstructure of the rail after
grinding is not affected.
Maximum allowable grinding depth:
a) Rail running surface: 0.35 mm;
b) Other parts of rail: 0.5 mm.
In 10 m length of the rail, there shall be no more than 3 surface defects. 1
grinding may be done every 10 m. The number of grinding points for periodic
hot-rolling marks in the rail crown portion shall not exceed 3 per 50 m. The
geometric dimension tolerances and straightness of the rail after grinding shall
comply with the requirements of Table 1.
Within 1 m from the rail end, the rail running surface and the rail head side,
except for the protruding part, shall not be ground.
If the section size and straightness of the rail are unqualified, except for the
protruding part, it shall not adopt the grinding method for treatment.
When thermal and cold injuries of the rail meet the requirements of 7.10.3 and
(or) 7.10.4, the grinding may be omitted.
7.10.7 It shall, along the entire length of the rail, automatically detect the bottom
surface of the rail. The equipment used shall be capable of detecting the
artificial defect of the size shown in Table 7. The tolerance of the size of artificial
defect is ±0.1 mm. When using automatic rail flange detection technique to
detect, a blind zone of up to 5 mm wide is allowed on each side of the edge of
the rail flange. Every 8 h, USE test rails with artificial defects to calibrate once.
When the automatic detection equipment cannot work properly, it shall use an
artificial mirror to check.
Table 7 -- Size of artificial defect (in millimeters)
7.11 Ultrasonic flaw detection
The full length of the rail shall be continuously inspected by ultrasonic flaw
Defect depth Defect length Defect width
Table 10 (continued)
No. Inspection items
Inspection
frequency Sampling locations Test methods
10 Nonmetallic inclusions Once per lot
CUT longitudinally at the
rail head 10 mm ~ 15
mm from the top surface
of rail. The inspection
surface shall be parallel
to the top surface of the
rail and centered. The
area shall not be less
than 200 mm2
Method A of GB/T 10561-2005
11 Macrostructure Once per furnace TAKE randomly 1 sample GB/T 226
12 Drop hammer Once per lot TAKE randomly 1 sample See 8.6
13 Ultrasonic flaw detection Piece by piece Full length See 8.7
14 Dimensions Piece by piece Full length anywhere
Appendix E sample plate or
laser automatic detection
equipment
15 Straightness and distortion Piece by piece See 6.4
Rail production plants shall
use online laser automatic
detection equipment to detect
the full-length straightness of
the rail. The straightness of rail
end shall be measured using a
1 m, 2 m ruler and feeler
gauge. The distortion of rail
end shall be measured using a
twisted ruler
16 Surface quality Piece by piece Full-length all surfaces Naked eye, rail flange automatic detection
17 Residual stress of rail flange
Once every 2
years
CUT at a location at least
3 m from the rail end See 8.8
18 Fracture toughness
Once every 5
years
CUT at a location at least
3 m from the rail end
according to Figure D1
See 8.9
19 Fatigue crack growth rate
Once every 5
years
CUT at a location at least
3 m from the rail end
according to Figure 10
See 8.10
20 Fatigue Once every 5 years
CUT at a location at least
3 m from the rail end
according to Figure 11
See 8.11
8.8 Residual stress of rail flange
The determination of the residual stress of rail flange is carried out in
accordance with the method specified in Appendix C.
8.9 Fracture toughness
The test of fracture toughness is carried out in accordance with the method
specified in Appendix D.
8.10 Fatigue crack growth rate
USE a three-point bending and one-sided notched sample to carry out the test
of fatigue crack growth rate. The sampling location and sample size are shown
in Figure 10. TAKE at least 3 samples on each sample rail and test under the
following conditions:
a) Test temperature: 15 °C ~ 25 °C;
b) Minimum cyclic loading/maximum cyclic loading R=0.5;
c) The three-point bending sample has a loading span of 4W (see Figure 10);
d) Cyclic loading frequency: 15 Hz ~ 40 Hz;
e) Test environment: Atmospheric environment in the test room.
For other relevant regulations, see GB/T 6398.
9 Inspection rules
9.1 Supervision
The purchaser has the right to supervise the various processes and various
inspections of the rail production and has the right to check these inspection
results.
9.2 Type inspection
9.2.1 Under the following conditions, the supplier shall perform type inspection:
a) Before new varieties are laid on the road;
b) Major changes have occurred in production processes and production
equipment, etc.;
c) Every 5 years in normal production;
d) Production is suspended for more than 6 months.
9.2.2 All inspections shall be performed in a qualified laboratory.
9.2.3 The supplier shall provide the purchaser with all inspection records,
calibrations, and calculated values on which the final result of type inspection
is based.
9.2.4 Type inspection includes all items in Table 10. Samples for No. 12 ~ No.
20 inspections shall be cut from straightened rails. No mechanical or thermal
treatment of these samples is made. The samples used for fracture toughness,
fatigue crack growth rate, and fatigue test shall be cut from 3 sample rails. The
sample rails shall be taken from different heats and different continuous casting
strand numbers. For the residual stress test, it shall select 6 sample rails. The
sampling locations and test methods for the inspections are shown in Table 10.
9.3 Exit-factory inspection
9.3.1 Lot grouping rule: Each lot consists of rails of the same designation and
the same model which are rolled from billets continuously cast from several
furnaces of molten steel.
9.3.2 The exit-factory inspection of the rails is carried out by the supplier’s
quality inspection department. If necessary, the purchaser has the right to
conduct sampling inspection. The specific items shall be separately agreed
upon by the supplier and the purchaser at the time of ordering.
9.4.4 Macrostructure
9.4.4.1 The white point of rails is not allowed to be re-inspected .
9.4.4.2 When the initial inspection of macrostructure does not meet the
requirements of this Standard, on both sides of the front and back of the
sampling location for the initial inspection of the same strand respectively, one
sample shall be taken for re-inspection. At least one of the two re-inspection
samples is taken from the rail of the same slab as the initial inspection sample.
It shall not accept the rail between the two re-inspection samples. If the re-
inspection results of the two re-inspection samples meet the requirements, the
remaining rails of this lot can be accepted. If there is a re-inspection sample
which is unqualified, sampling may be continued for inspection again until
qualified.
9.4.4.3 When it is difficult to recognize macrostructure defects, at higher
magnifications, further inspection may be performed.
9.4.5 Drop hammer
When the drop hammer inspection results do not meet the requirements of this
Standard, one sample shall be taken from all other heats of the same sequence
for inspection. For the furnace where the initial inspection is not qualified, on
both sides of the front and back of the sampling location for the initial inspection
of the same strand respectively, one sample shall be taken for re-inspection. At
least one of the two re-inspection samples is taken from the rail of the same
slab as the initial inspection sample. It shall not accept the rail between the two
re-inspection samples. If the results of the two re-inspection samples meet the
requirements, the remaining rails of this furnace can be accepted. If there is still
a re-inspection sample which is unqualified, sampling may be continued for
inspection again until qualified.
9.4.6 Decarburization layer
When the initial inspection result is unsatisfactory, it shall sample from two
adjacent rails of the same lot for re-inspection. If the re-inspection results of the
two re-inspection samples meet the requirements, the remaining rails of this lot
can be accepted. If the re-inspection sample is unqualified, sampling may be
continued on the adjacent-side rails for inspection again until qualified. It shall
not accept the rail between the two re-inspection samples.
9.5 Rounding off of numerical values
Except as otherwise provided in the contract or the order, when it is necessary
to assess whether the test result meets the specified value, the test result given
shall be rounded off to the digit position indicated by the specified value
standard number. The method for rounding off shall be in accordance with YB/T
081.
10 Marking and quality certificate
10.1 Marking
10.1.1 On the rail waist of one side of each rail, at least within every 4 m spacing,
it shall roll the following clear and raised marks. The character has a height of
20 mm ~ 28 mm and a bulge of 0.5 mm ~ 1.5 mm:
a) Marking of production plant;
b) Rail type;
c) Steel designation;
d) Manufacturing year (two digits at the end of rolling year), month.
10.1.2 On the waist of each rail, no less than 0.6 m from the rail end and no
more than 15 m of the spacing, USE a hot stamping machine (No cold stamping
is allowed) to stamp the following clear marks in order. The stamped characters
shall have a straight or circular arc surface. The character has a height of 10
mm ~ 16 mm, a depth of 0.5 mm ~ 1.5 mm, a width of 1 mm ~ 1.5 mm. The
sides shall be inclined. Letters and numbers shall be at an angle of 10° to the
vertical direction and have arc corners:
a) Heat;
b) Continuous casting strand number;
c) Continuously cast slab number;
d) Rail sequence number.
10.1.3 If the hot-printed mark is missing or has changed, it shall re-hot-print or
stencil on the rail waist.
10.1.4 After the rail is finished, a label is attached to the head of one end face
of the rail. The contents of the label shall include the rail standard number,
applicable speed range, model, steel designation, heat, length, etc. The label
barcode shall contain complete information on the hot stamping mark of the rail.
10.1.5 When there is no mark, or the mark is unclear and cannot be recognized,
it is not allowed to leave the factory.
When , the test results are valid.
D.5.5 The linearity criterion does not apply to the type IV load-crack opening
curve.
D.5.6 For all load-crack opening curves, it shall carry out the valid verification
of KQ value; that is, the sample thickness (B) and the crack length (a) shall be
equal to or greater than 2.5(KQ/RP0.2)2, where RP0.2 is the yield strength at a
fracture test temperature of - 20 °C.
D.6 Test report
D.6.1 When calculating test results and indicating the conditions specified
during the test, it shall record all measured values required.
D.6.2 It shall report all test results, including KIC, or KQ* , or KQ. Where KQ* is a
KQ value which simply cannot satisfy one or more of the following conditions:
a) Pmax/PQ >1.1;
b) A criterion of more than 2.5(KQ/RP0.2)2;
c) Does not meet the relationship between crack opening displacement and
load.
D.6.3 The average and standard deviation of KIC and KQ* shall be recorded as
specified in Table D.1.
Table D.1 -- Record of average and standard deviation of KIC and KQ*
Steel
designation
of rail
RP0.2 (-
20 °C)
MPa
KIC average
MPa • m1/2
Number of
measurem
ents for KIC
Standard
deviation
of sample
MPa • m1/2
KQ
average
MPa • m1/2
Number of
measureme
nts for KQ
Standard
deviation
of sample
MPa • m1/2
D.6.4 The average of at least 5 KIC shall be used for acceptance. When 5 KIC
values are not available, the KIC average for acceptance shall include KQ* . The
number of tests in these results shall be no less than 10. All KIC or KQ* values
shall meet the requirements of Table 8.
......
Source: Above contents are excerpted from the full-copy PDF -- translated/reviewed by: www.ChineseStandard.net / Wayne Zheng et al.
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