TB/T 3548-2019 PDF English
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TB/T 3548-2019: Strength design and test accreditation specification for rolling stock-General---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/TBT3548-2019
TB
RAILWAY INDUSTRY STANDARD
ICS 45.060.20
S 51
Partially replacing TB/T 1335-1996
Strength Design and Test Accreditation Specification
for Rolling Stock – General
Issued on. APRIL 08, 2019
Implemented on. NOVEMBER 01, 2019
Issued by. National Railway Administration of the People’s Republic of
China
Table of Contents
Foreword... 3
1 Scope... 5
2 Normative References... 5
3 Terms and Definitions... 6
4 Coordinate System and Unit System... 7
5 Classification of Rolling Stock... 8
6 Structural Strength Requirements... 9
7 Material Properties... 24
8 Verification Procedures... 24
9 Test Apparatus and Test Point Layout... 26
Appendix A (Normative) Test Method of Structure Dynamic Strength... 29
Appendix B (Informative) Commonly Used Materials and Mechanical Properties
of Rolling Stock... 32
Appendix C (Normative) Strength Requirements of Main Structural Equipment
on the Vehicle... 44
Bibliography... 49
1 Scope
This Standard specifies the terms and definitions, coordinate system and unit system,
classification, structural strength requirements, material properties, verification
procedures, and test equipment and measurement point layouts for the strength
design and test of rolling stock.
This Standard is applicable to the strength design and test accreditation of rolling
stocks, EMUs, and passenger cars. Special rolling stocks and urban rail vehicles can
be implemented by reference (except for special test requirements).
2 Normative References
The following documents are essential to the application of this document. For the
dated documents, only the versions with the dates indicated are applicable to this
document; for the undated documents, only the latest version (including all the
amendments) is applicable to this document.
GB/T 228.1 Metallic Materials - Tensile Testing - Part 1.Method of Test at Room
Temperature
GB/T 4549 (all parts) Railway Vehicle Vocabulary
GB/T 32059 Fatigue Load Test Method for Windows, Doors of High Speed
Multiple Unit
TB/T 1451 Foreside Windscreen for Locomotives and Motor Units
TB/T 3094 Vestibule Diaphragm of Locomotive and Rolling Stock
TB/T 3107 Unit Combined Windows for Railway Passenger Car
TB/T 3108 Sliding Plug Door for Railway Passenger Car
3 Terms and Definitions
For the purposes of this document, the terms and definitions given in GB/T 4549 (all
parts) and the following apply.
3.1 Rolling stock
The locomotives, EMUs, passenger cars, and freight cars running on the track are
collectively referred to as rolling stock.
3.2 Car body
Supported by the bogie, it mainly plays a bearing role and is an integral part of the
rolling stock.
3.3 Car body structure
The main load-bearing structure of the car body is composed of one or more of the
main structural parts such as the underframe, side walls, end walls, roof, and cab.
3.4 Connecting device for equipment
Fasteners for installing equipment and related local load-bearing structure or
installation structure.
3.6 Bogie frame
The integral welded parts that are used to connect the axle box and transmit the force
in the bogie; they are generally located between the primary suspension and the
secondary suspension.
3.7 Exceptional load
Occasionally, the maximum load that does not affect the integrity of the rolling stock
and the normal operation.
4 Coordinate System and Unit System
4.1 Coordinate system
The coordinate system is shown in Figure 1.The longitudinal direction of the rolling
stock corresponds to the X-axis, the transverse direction corresponds to the Y-axis,
and the vertical direction corresponds to the Z-axis.
All parameters of this Standard are expressed in the basic units and the derived units
of the International System of Units (SI) (Value-g is 9.81 m/s2).
5 Classification of Rolling Stock
5.1 Classification of structure
According to the structural characteristics and design use, the rolling stock is divided
into four types. locomotive (L), EMU (U), passenger car (P) and freight car (F), and
then further divided according to structural requirements.
5.2 Locomotives
5.4 Passenger cars
The non-articulated railway vehicles for passenger transportation and trailers and
control cars in relatively articulated power-concentrated EMUs are classified in this
category. Its structure type is identified as P.
5.5 Freight cars
The non-articulated railway vehicles used for the goods transportation are classified
into this category (excluding special freight cars such as long and large freight cars).
This group defines two structure types, and the corresponding type identifiers are as
follows.
6 Structural Strength Requirements
6.1 General requirements
6.1.1 Basic principles
6.1.1.4 For newly designed structures of rolling stock, the rods, plates, or shells that
bear the compressive load shall be checked for stability by calculation or test to avoid
structural failure due to loss of stability. The connection nodes of all load-bearing
members shall have sufficient rigidity, and the structure shall not be unstable. For more
complex structures, finite element analysis methods should be adopted.
6.1.2 General method
6.1.2.1 The carrying capacity of the rolling stock structure is evaluated according to the
following indicators.
6.1.2.2 In the static strength assessment, when calculating complex stress
components, Von Mises stress shall be calculated for ductile materials (except for
wood or other anisotropic materials and polymer materials).
6.1.2.3 For rolling stock components with simple structures, the load-bearing capacity
may be calculated by the methods of material mechanics, elastic theory, and structural
mechanics; for the calculation of the load-bearing capacity of complex components,
finite element analysis methods are recommended.
6.1.3 Load conditions
Load conditions generally include exceptional load conditions and operating load
conditions; and each load condition may include one or more independent loads.
Depending on the different structures, all or part of the load conditions can be included
in the calculation and/or test.
6.1.4 Acceptance criteria
6.1.4.1 Utilization rate
Under the specified load conditions, calculations and/or tests shall be used to verify
that the entire load-bearing member of the rolling stock or any individual component or
any equipment connection device does not undergo permanent deformation or
damage. The utilization rate of components in Formula (2) shall be no greater than 1.
6.3.6.2 Operating load conditions
6.3.6.2.1 The connection device for bogie frame equipment (except the connection
devices between the traction motor and the gearbox) shall be subjected to fatigue
assessment, and the inertial load shall be calculated according to the following
acceleration.
6.3.6.2.2 The fatigue design life of the connection device for bogie frame equipment
shall be determined, which shall be at least equal to the design life of the vehicle, or
the predetermined maintenance period when the equipment reaches the end of its
service life.
6.3.6.3 Vibration acceleration and force generated by the equipment
6.3.6.3.1 The acceleration of the inertial load calculated in 6.3.6.1 and 6.3.6.2 does not
include the local acceleration and force acting on the inside and on the surface of the
equipment. The structure shall be designed to withstand the influence from these local
accelerations or forces; and avoid local resonance.
6.3.6.3.2 The equipment that generates vibration acceleration and force shall at least
include.
6.3.7 Connection device for axle-box equipment
6.3.7.1 Exceptional load conditions
The connection device for axle-box equipment shall be able to withstand the inertial
load related to the acceleration below, and the inertial load as an exceptional test load
acts on the centreline of the axle.
6.3.7.2 Operating load conditions
7 Material Properties
7.1 Yield strength and tensile strength
The material property limit value shall adopt the lower limit value of yield strength and
tensile strength specified in the material technical specification; and the used value
shall be selected from the corresponding standard or technical document.
7.2 Fatigue strength
The material property data under fatigue load shall be selected from the standard or
related technical documents. Validated data shall be found. If no data is available,
these data shall be obtained through appropriate tests. In the absence of special
provisions, the number of load cycles is 107.
7.3 Common materials and their mechanical properties
Refer to Appendix B for common materials and their main mechanical properties of
metal materials. For other metal materials not listed in Appendix B, refer to relevant
standards or technical documents.
8 Verification Procedures
The purpose of the verification procedure is to prove that the design of the load-bearing
structure of the rolling stock can withstand the maximum load consistent with the
application requirements; and can reach the service life under the specified reliability
under normal operating conditions.
9 Test Apparatus and Test Point Layout
9.1 Test apparatus
Strain gauges or other validated stress test methods shall be used for stress
measurement; and displacement sensors shall be used for deflection measurement.
9.2.2 Pasting of strain gauges
Before pasting the strain gauges, the rust, oil stain and attachments on the surface to
be tested shall be removed. The surface to be tested shall be polished and the
maximum surface roughness Rα is 3.2µm; and then polished by emery cloth; the
polishing direction and the longitudinal direction of the patch are at an angle of 45° to
cross the pattern.
TB/T 3548-2019
TB
RAILWAY INDUSTRY STANDARD
ICS 45.060.20
S 51
Partially replacing TB/T 1335-1996
Strength Design and Test Accreditation Specification
for Rolling Stock – General
Issued on. APRIL 08, 2019
Implemented on. NOVEMBER 01, 2019
Issued by. National Railway Administration of the People’s Republic of
China
Table of Contents
Foreword... 3
1 Scope... 5
2 Normative References... 5
3 Terms and Definitions... 6
4 Coordinate System and Unit System... 7
5 Classification of Rolling Stock... 8
6 Structural Strength Requirements... 9
7 Material Properties... 24
8 Verification Procedures... 24
9 Test Apparatus and Test Point Layout... 26
Appendix A (Normative) Test Method of Structure Dynamic Strength... 29
Appendix B (Informative) Commonly Used Materials and Mechanical Properties
of Rolling Stock... 32
Appendix C (Normative) Strength Requirements of Main Structural Equipment
on the Vehicle... 44
Bibliography... 49
1 Scope
This Standard specifies the terms and definitions, coordinate system and unit system,
classification, structural strength requirements, material properties, verification
procedures, and test equipment and measurement point layouts for the strength
design and test of rolling stock.
This Standard is applicable to the strength design and test accreditation of rolling
stocks, EMUs, and passenger cars. Special rolling stocks and urban rail vehicles can
be implemented by reference (except for special test requirements).
2 Normative References
The following documents are essential to the application of this document. For the
dated documents, only the versions with the dates indicated are applicable to this
document; for the undated documents, only the latest version (including all the
amendments) is applicable to this document.
GB/T 228.1 Metallic Materials - Tensile Testing - Part 1.Method of Test at Room
Temperature
GB/T 4549 (all parts) Railway Vehicle Vocabulary
GB/T 32059 Fatigue Load Test Method for Windows, Doors of High Speed
Multiple Unit
TB/T 1451 Foreside Windscreen for Locomotives and Motor Units
TB/T 3094 Vestibule Diaphragm of Locomotive and Rolling Stock
TB/T 3107 Unit Combined Windows for Railway Passenger Car
TB/T 3108 Sliding Plug Door for Railway Passenger Car
3 Terms and Definitions
For the purposes of this document, the terms and definitions given in GB/T 4549 (all
parts) and the following apply.
3.1 Rolling stock
The locomotives, EMUs, passenger cars, and freight cars running on the track are
collectively referred to as rolling stock.
3.2 Car body
Supported by the bogie, it mainly plays a bearing role and is an integral part of the
rolling stock.
3.3 Car body structure
The main load-bearing structure of the car body is composed of one or more of the
main structural parts such as the underframe, side walls, end walls, roof, and cab.
3.4 Connecting device for equipment
Fasteners for installing equipment and related local load-bearing structure or
installation structure.
3.6 Bogie frame
The integral welded parts that are used to connect the axle box and transmit the force
in the bogie; they are generally located between the primary suspension and the
secondary suspension.
3.7 Exceptional load
Occasionally, the maximum load that does not affect the integrity of the rolling stock
and the normal operation.
4 Coordinate System and Unit System
4.1 Coordinate system
The coordinate system is shown in Figure 1.The longitudinal direction of the rolling
stock corresponds to the X-axis, the transverse direction corresponds to the Y-axis,
and the vertical direction corresponds to the Z-axis.
All parameters of this Standard are expressed in the basic units and the derived units
of the International System of Units (SI) (Value-g is 9.81 m/s2).
5 Classification of Rolling Stock
5.1 Classification of structure
According to the structural characteristics and design use, the rolling stock is divided
into four types. locomotive (L), EMU (U), passenger car (P) and freight car (F), and
then further divided according to structural requirements.
5.2 Locomotives
5.4 Passenger cars
The non-articulated railway vehicles for passenger transportation and trailers and
control cars in relatively articulated power-concentrated EMUs are classified in this
category. Its structure type is identified as P.
5.5 Freight cars
The non-articulated railway vehicles used for the goods transportation are classified
into this category (excluding special freight cars such as long and large freight cars).
This group defines two structure types, and the corresponding type identifiers are as
follows.
6 Structural Strength Requirements
6.1 General requirements
6.1.1 Basic principles
6.1.1.4 For newly designed structures of rolling stock, the rods, plates, or shells that
bear the compressive load shall be checked for stability by calculation or test to avoid
structural failure due to loss of stability. The connection nodes of all load-bearing
members shall have sufficient rigidity, and the structure shall not be unstable. For more
complex structures, finite element analysis methods should be adopted.
6.1.2 General method
6.1.2.1 The carrying capacity of the rolling stock structure is evaluated according to the
following indicators.
6.1.2.2 In the static strength assessment, when calculating complex stress
components, Von Mises stress shall be calculated for ductile materials (except for
wood or other anisotropic materials and polymer materials).
6.1.2.3 For rolling stock components with simple structures, the load-bearing capacity
may be calculated by the methods of material mechanics, elastic theory, and structural
mechanics; for the calculation of the load-bearing capacity of complex components,
finite element analysis methods are recommended.
6.1.3 Load conditions
Load conditions generally include exceptional load conditions and operating load
conditions; and each load condition may include one or more independent loads.
Depending on the different structures, all or part of the load conditions can be included
in the calculation and/or test.
6.1.4 Acceptance criteria
6.1.4.1 Utilization rate
Under the specified load conditions, calculations and/or tests shall be used to verify
that the entire load-bearing member of the rolling stock or any individual component or
any equipment connection device does not undergo permanent deformation or
damage. The utilization rate of components in Formula (2) shall be no greater than 1.
6.3.6.2 Operating load conditions
6.3.6.2.1 The connection device for bogie frame equipment (except the connection
devices between the traction motor and the gearbox) shall be subjected to fatigue
assessment, and the inertial load shall be calculated according to the following
acceleration.
6.3.6.2.2 The fatigue design life of the connection device for bogie frame equipment
shall be determined, which shall be at least equal to the design life of the vehicle, or
the predetermined maintenance period when the equipment reaches the end of its
service life.
6.3.6.3 Vibration acceleration and force generated by the equipment
6.3.6.3.1 The acceleration of the inertial load calculated in 6.3.6.1 and 6.3.6.2 does not
include the local acceleration and force acting on the inside and on the surface of the
equipment. The structure shall be designed to withstand the influence from these local
accelerations or forces; and avoid local resonance.
6.3.6.3.2 The equipment that generates vibration acceleration and force shall at least
include.
6.3.7 Connection device for axle-box equipment
6.3.7.1 Exceptional load conditions
The connection device for axle-box equipment shall be able to withstand the inertial
load related to the acceleration below, and the inertial load as an exceptional test load
acts on the centreline of the axle.
6.3.7.2 Operating load conditions
7 Material Properties
7.1 Yield strength and tensile strength
The material property limit value shall adopt the lower limit value of yield strength and
tensile strength specified in the material technical specification; and the used value
shall be selected from the corresponding standard or technical document.
7.2 Fatigue strength
The material property data under fatigue load shall be selected from the standard or
related technical documents. Validated data shall be found. If no data is available,
these data shall be obtained through appropriate tests. In the absence of special
provisions, the number of load cycles is 107.
7.3 Common materials and their mechanical properties
Refer to Appendix B for common materials and their main mechanical properties of
metal materials. For other metal materials not listed in Appendix B, refer to relevant
standards or technical documents.
8 Verification Procedures
The purpose of the verification procedure is to prove that the design of the load-bearing
structure of the rolling stock can withstand the maximum load consistent with the
application requirements; and can reach the service life under the specified reliability
under normal operating conditions.
9 Test Apparatus and Test Point Layout
9.1 Test apparatus
Strain gauges or other validated stress test methods shall be used for stress
measurement; and displacement sensors shall be used for deflection measurement.
9.2.2 Pasting of strain gauges
Before pasting the strain gauges, the rust, oil stain and attachments on the surface to
be tested shall be removed. The surface to be tested shall be polished and the
maximum surface roughness Rα is 3.2µm; and then polished by emery cloth; the
polishing direction and the longitudinal direction of the patch are at an angle of 45° to
cross the pattern.
......
Source: Above contents are excerpted from the full-copy PDF -- translated/reviewed by: www.ChineseStandard.net / Wayne Zheng et al.
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