KSKSKSKS KS R 9221

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Wheels for railway rolling stock
KS R 9221:2008

Translated and Published by    Korean Standards Association   

Translation without guarantee

In the event of any doubt arising, the original standard in
korean is to be evidence

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2012-02-27, 한국철도공사에 라이센스를 부여하며 불법 복사 및 무단 배포를 금합니다.
 KOREAN INDUSTRIAL STANDARD
KS R 9221:2008

Wheels for railway rolling stock

1 Scope

This Korean standard specifies carbon steel rolled wheels (hereinafter, referred to as wheels) used for
railway rolling stock with the maximum speed of below 150 km/h.

2 Normative References

The following referenced documents contain provision which, through reference in this text,
constitute provisions of this standard. These normative references apply the latest version.

KS B 0801, Test pieces for tensile test for metallic materials

KS B 0802, Method of tensile test for metallic materials
KS B 0805, Method of brinell hardness test
KS B 0809, Impact test pieces for metallic materials
KS B 0810, Method of impact test for metallic materials
KS B 0817, General rule of ultrasonic testing of metals by the pulse echo technique
KS D 1801, General rules for chemical analysis of iron and steel
KS D 1802, Methods for determination of phosphorus and iron and steel
KS D 1803, Methods for determination of sulfur in iron and steel
KS D 1804, Determination of carbon in iron and steel
KS D 1805, Determination of silicon in iron and steel
KS D 1806, Methods for determination of manganese in iron and steel

3 Terms and definition

For the purposes of this document, the following terms and definitions apply.

3.1
Wheel contact surface
abrasion areas of a cylinder part of wheels which come in contact with railways

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KS R 9221:2008

3.2
Rim
edge portion of wheels including the surface which comes in contact with railways

3.3
Boss
part of wheels where axles are pressured

3.4
Plate
circular plate which connects the rim with the boss

4 Types

As shown in Table 1, type of wheels is categorized by use.

Table 1 ― Types of wheels

Symbol Use Note

RSW1 Rolling stock Quenching or tempering for rim
RSW2 Electric locomotive or electric rail car Quenching or tempering for rim
RSW3 Diesel locomotive or diesel rail car Quenching or tempering for rim

5 Requirements

a) Wheels must be consistent in quality, and there must be no marks, scratches, exfoliation, pulling
and other defects under a normal condition.
b) Wheels are manufactured by steel which is dissolved by using Basic oxygen furnace, Open-hearth
furnace or Electric furnace. Deacidification process is performed on the steel in the furnace and
ladle and the steel is made by casting method or continuous casting method. When the casting
method is used, it should be made by lower casting.
c) Wheels are forged and then formed by rolling. The rim part must be heat-treated i.e. quenching
or tempering.
d) Wheel shapes (Figure 1) follow an authorized manufacturing drawing. Unless there is mutual
agreement between parties concerned, wheel shapes must meet the rules suggested by the below
Tables 2 and 3. If there are sectional marks on plate parts as well as around the section R of the
boss, the depth must be within 10 percent of the cylinder thickness.

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 KS R 9221:2008

Figure 1 ― Shapes of a wheel

Table 2 ― Allowable values of dimensions

unit: mm
Allowable values of dimensions
Plate Rim Inner Outer Boss Inner Height Central
thickness thickness diameter diameter thickness diameter of plate distance
Classification
of Rim of Boss of Boss parts of cross
section
of Plate
t1, t2 T d1 D1, D2 T1, T2 d l E
Wheels
Without +6 3 or -0 +15 10 or -4
with ±6.5 ±3
finishing 0 below -12 0 below -6
finishing
process
With +6 3 or -0 +15 10 or
for - ±6.5 ±3
finishing 0 below -12 0 below
section R
Wheels
Without +8 3 or -0 +25 10 or -4
without ±8.5 ±5
finishing 0 below -12 0 below -8
finishing
process
With +6 3 or -0 +25 10 or
for - ±8.5 ±5
finishing 0 below -12 0 below
section R

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KS R 9221:2008

Table 3 ― Allowable values of dimensions for rim

unit: mm
Allowable values of dimensions
Classification Location of rim Outer diameter of rim
C K D
Without finishing -1 +3 +8
process -3 +0 -2
With finishing +3 +5
-
process +0 -2

6 Inspection and test methods

6.1 Types of inspection and methods

The whole manufactured products are tested by the following items and determined when must pass
each test.

a) Appearance inspection In accordance with an authorized manufacturing drawing, there must be

no marks, polluted damage, exfoliation and other defects found through inspectors’ eyes.
b) Dimension inspection Dimensions of each part must be inspected to check if they are
consistent with the manufacturing drawing.

6.2 Types of inspections and methods

a) Ultrasonic test is done for the whole manufacture product, whereas a chemical analysis test,
tensile strength, hardness or impact test is done in type checking.
b) For the chemical analysis test or mechanical quality test, one wheel from each steel furnace is
chosen from which test pieces are extracted. If all test pieces are considered fine, respective steel
products can be used.

6.2.1 Chemical analysis test

Chemical analysis test of wheels are presented in Table 4 in accordance with KS D 1801, KS D 1802,
KS D 1803, KS D 1804, KS D 1805, KS D 1806.

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 KS R 9221:2008

Table 4 ― chemical compositions of wheels

unit :%
composition C Mn Si P S Cu
Content 0.67 or below 0.6 ~ 0.9 0.15 or above 0.045 or below 0.045 or below 0.35 or below

6.2.2 Test for mechanical qualities

a) Tensile strength, hardness, impact test pieces are extracted from the rim part of wheels. With
hardness test pieces being in a cross section form as shown in Figure 2, hardness of each wheel
must be above the minimum values at the depth of 25 mm from the wheel contact point.
Hardness test is based on KS B 0805, while tensile strength or impact test pieces are extracted
from the marked areas shown in Figure 3 and 4.

unit: mm

Figure 2 ― Hardness test piece

unit: mm

Figure 3 ― Location of extracting tensile strength test piece

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KS R 9221:2008

unit: mm

Figure 4 ― Location of extracting impact test piece

b) The sample of KS B 0801 Issue 4 is used for tensile strength test of wheels in accordance with KS
B 0802.
c) The sample of a) U notch in Figure 2 of KS B 0809 is tested three times in accordance with KS B
0810.
d) Mechanical qualities of wheels must be within the figures of the below Table 5. The minimum
limits of strain and cross-section contraction rate are the lower limit of tensile strength and the
upper limit of tensile strength respectively. Strain or cross-section contraction rate for the mid-
range tensile strength is calculated through a rule-of -three sum.

Table 5 ― Mechanical qualities by type of wheels

Charpy impact
Tensile strength test Hardness test
test
Symbol Tensile Cross-section Absorption
Strain Hardness
strength contraction rate energy
(%) (HB)
(N/mm )2
(%) (J)
14 (min) 28 (min)
RSW1 835~960 248~285 20 or above
11 (min) 23 (min)
13 (min) 26 (min)
RSW2 930~1030 269~311 20 or above
10 (min) 20 (min)
11 (min) 22 (min)
RSW3 980~1130 294~341 20 or above
8 (min) 16 (min)

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 KS R 9221:2008

6.2.3 Ultrasonic test

Ultrasonic tester must have a frequency range of 2 to 5MHz. In accordance with KS B 0817, the
inspection is done after heat-treatment to check if there are internal discontinuous structures of all
rim parts of wheels. There must not be echoes due to internal defects.

6.3 Retest

Although there are some faulty mechanical qualities found, a retest can be done by using extracted
two blank materials. If one of the two fails to meet the standards again, the whole product in the
steel furnace can be annealed and re-heat treated for one more test. However, in this case, tensile
strength, hardness and mechanical qualities test are done for two wheels.

7 Marking and packaging

7.1 Marking

The following contents must be stamped in an easily-noticed place. The method of stamping (cold or
hot) and its location are subject to the agreement between parties concerned.

a) Manufacturing date (month / year)

b) Name of manufacturer
c) Number of steel furnace

7.2 Packaging

Finished products must be suited for transportation and storing.

－end－ 7

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 KS R 9221:2008

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Wheels for railway rolling stock
ICS 45.060

Korean Standards Association

http://www.ksa.or.kr

2012-02-27, 한국철도공사에 라이센스를 부여하며 불법 복사 및 무단 배포를 금합니다.