IRS Spec. No. R-64/98 (Rev.2) GOVERNMENT OF INDIA MINISTRY OF RAILWAYS (RAILWAY BOARD) INDIAN RAILWAY STANDARD SPECIFICATION FOR RUBBER WASHERS USED IN THE PRIMARY AND SECONDARY SUSPENSION OF MAIN LINE AND EMU COACHES SERIAL No, R-64/98 (Rev.2) Issued By: Research Designs and Standards Organization Manak Nagar, Lucknow - 226011. Page | of 12IRS Spee, No. R-G4/98 (Rev.2) Gause No. | oe a Foreword Deserip 3 ‘Construstion 7 4 Workmanship and finisiy | 4 5 Sonpling and criteria for conformity + é Tests 4 A = | 7 Inspection ° TION -B Clause No. [ Deseviption PSeape PREEEEEE } } [SER RESSESESEESSESE SESE SSESEESEES! ESSER SEES A | 7) Rajuiremens | I 3 Testing iucibnies y 1 7 J Quahiy Control requirements 10 TEESE ee Bi) Page 2 of 1304 03 0.6 IRS Spec. No. R-64/98 (Rev.2) GOVERNMENT OF INDIA MINISTRY OF RAILWAYS. (RAILWAY BOARD} INDIAN RAILWAY STANDARD SPECIFICATION, FOR RUBBER WASHERS USED IN THE PRIMARY & SECONDARY SUSPENSION OF MAIN LINE AND EMU COACHES Serie] No. R-O4.98 (Rev.2 JON. FOREWORD This speeiteation is issued under the fied sevial No. R-G4 These rubber washers are used in primary & secondary suspension of ICF type bogies of the BG/MG main Tine voaches and Hloetvic Multiple Unit Stock. These washers are used for beiter shock ani heise absorption This specification is thanted to cover the regitements of all types ofsuch ruber washers required for coaches provided with ICP type bogies to fscilitite procurement and manufacture. In formuting this specification, due considerstion has beer indigenous availability of raw me and compounding techniques, wen te the rials, the latest development in the field ef palymers ‘This specificution imeads to cover Hie technical provisions relating 10 supply of the material and does 0 all the provisions of a contract, In this specification. certain critical characteristics of the rubber as specified in R-O4.9S (Rev.1) have been upgruled and revised This specification supersedes R-64/98 (Rev.1) SCOPE, This specificatin for Rubber washers used in the primary & secondary suspension of mainline and EMU coaches consisis of nwo sections i.e. Section-A and Section-B Szction-A covers the technical requirements, methods of sampling and tests of Rubber washers and Section-B covers infrastructure requirements of manufacture, testing end quality control53 61 611 IRS Spec. No. R-64/98 (Rev.2) The rubber compound used fer the Akunufacture of rubber washers shall be ot od revistat quality. Accordingly, the rubber compound shall be a suitable Acrylonitrile, Butadiene CO- Polymer or blend with other synthetic rubber of oil resistant type, so as to conform the provisions of this specification. 0. RUC DN The rubber washers shall be moulded with smooth finish as per the dimensions and tolerances stipulated in the relevant drawings supplied by the purchaser, WORKMA ‘SHIP AND FINISH. The rubber washers shall be free fom manufacturing defects like laminations, biowholes, cracks ete. SAM! NG AND CRITERIA FOR CONFORMITY The washers shail be off for inspection within three months of their manufacture For acceptances. inspection and syst washers of one design oF pa a dot shall consist of SOG Nos. of the rubber thereo! and made out of sume eonspasition of the rabbe compound and processed and vulcanized in the simitar manner and co the same de For carrying out the tests as indicated in clause 6, five samples shall be drawn per lot by Simple Random Sampling method as per IS: 4905. Should the test samples fail to meet the requirements. additional ten samples from the same lot shall be drawn for vetesting. Should any of the retest sumples fail to meet the requirements; the entire lot shall be rejected and made unusable in the presence of the Inspecting officer/purchaser The selection of a test sample, for a particular test shall be at the discretion of the Inspecting officer:Purchaser. For the purpose of deciding whether a particular requirement of this schedule is complied with. the final value observed or calculated, expressing the result of a test or analysis. shall be rounded off in accordance with 1$:2, The number of significant places retained ‘in the rounded off value should be the same as that of the specified value in this schedule. All the test procedures shall be as per 1S: 3400, methods of test for vulcanized rubbers. ‘The test specimens shill be tken from finished product Page 4 of 13IRS Spee. No. R-64/98 (Rev.2) N.B. The samples afer oF during the compression test shall not show the presence af any cyaek 6.2 Properties of the rubber compound of rubber washers used in primary & secondary suspension of main line & EMU coaches, S.No. | Properties Values To Feisife arene: Non =ePPEPeEEE Ze 2. [Blongaiion at break (Sa) Min, ; 300 i 3.) Compression set (%) at 100 > | 30 24 =O/-2 hrs. May. [ 4 T [Hardness (Shore "AD O70 | 5.__[ Ash comiem (%#) Max. | 6. Accelerated Ageing at 100 = 1°C i — | rT | \ mee ot Ete IS: 3406 Pr. Vi at 27 | LoL 2a tener Poteeniage ebeatge j 6.2.8 Compressive Load Defteetion Test for BG Coaches 6.281 Lower Rubber Washers tor Primary Suspension ‘The test shall he eavicd out at room temperature (27 +2 °C) and the machine speed of 10 25 mavniaute. Two washers shat! be subjected, in a suitable fixture shown inv figure 1, 10 3 successive londinys of 4 1 and in the fourth cycle, the deflections at the loads 2, 3 & 41 shall be recorded with the help dial gaugeldigital read out. At the boginning of the touch eyele, the deflection shall be taken as zev0 at a foad of 10 ky ‘The deflection of lower and upper washers shall be within specified limits as given below. At the maximtsm loading the sample shall not show any evidence of cracking. Licoad (Foune) Deflection (mm) | 5 = 15% Measurement taken after one hour of the test shall not show a variation in thickness by more than 2% of the original dimension. Page $ of 12IRS Spee. No. R-64/98 (Rev.2) 6.2.8.2 Upper Rubber Washer for Primary Suspension ‘The test be carried out ti the mrsimer given in para 6.2.8.6 However, tie fivture fr thas. test shall be as shown in figure 2. The deflection shall be within the limits as given below. At the maximum loucing the sample shall not show any evidence of cracking, Measurement taken alter one boar of test shall not show a variation in thickness by more than 2% of the original dimensions. 6.2.9 — Compressive Load Deflection Test ior Lower and Upper Washers of MG coaches, Upper Washer for EMU Trailer Coaches, Lower Washers for EMU Motor Coaches and Rubber washers for Secondary suspension application, The test shail be ¢ washers vied OULD janner as described in para 6.2.8.1 on lower end upper nies inline with BG coaches and the sumpies shalll satisfy the enionts ay stipulated in relevant drawings, Av the maximum {1 not show any evidence of eracki 2 suitable load deflection reqs loading the sample si Measurements t9hco after one hour of test shall-not show a variation in thiel move than 2% oF the original dimensien 7. INSPECTION The mannfactuner wwe for the preparation of requisite test pieces and supply Sree of charge wl equipment, labour and apparatus for all the tests at his premises Should the manufacturer fail to provide fucilities at his own works for carrying out the prescribed tests, fhe shall svange for carrying out these tests by an approved testing agency as agreed to by the inspecting authority The mvanuficturers shai! furmish to the purchasing/inspecting authorities, at all reasonable times the details of tests and other information and records in respect of Quality Assurance Plan (QAP) in force at their works for the material and processes used for the manufacture of rubber washers. 73 The purchaser or the inspecting olficer shall have access at all reasonable times to the works where the matettal or the Hlngs are being manwfactured/tored Page 6 af 1210, IRS Spec. No. R-64/98 (Rev.2) MARKING The letters IRS. the mouth'year of manufacture, the drawing No, and the manufacturer's name or initial or trade mark shall be efearly moulded on each washer as per size and lection nndiewted in the releva drawing: PACKING The washers shall he dusted with French Chalk to IS: 380 and suitably protected st damage during transit and starage STORAG! The washers stall be stored in a covered shed protected from direct sunlight in the original packing, During s.orage, they shall not be allowed to come in contact with Liquids of semi solid materials, solvents, ails and greases, SHELF LIFE Shelf life of the ne hers. without uny deterioration in their el be minimum Tificea months fiom the date of supply: wcleristics, shall2.0 21 IRS Spee, No. R-64/98 (Rev.2) SECTION ‘ov The Schedule of Techiical Requiremens covers the noms for manufacture of lower & upper rubber washer for primary & secondary suspension application on coaching stock, REQUIREMENTS: The ventars sect ‘seaval Shall comply sll the below mentioned reguiirements, General & Manufacturing Facilities: Covered urea with udequate space for storage of raw rubber, carbon and chemicals should be available, which is “ice from dampness and humidity. The weighing facilities for measuring, various raw material constituents and the product at imermediate stages The following facilities are requived a. Electronic ‘veiyhing balance of min 5 kg. capacity b. Mechamea. spring balance of the capacity of mimmum 50 ke. Wis ensured that the weighing machines calibre calibranon is specified { regularly and the fequeney of A. suitable capaeity. clase nidsiag mall (Banbury) foe mina purpose (mening ox number) should be available. ‘The requirement of Bunburty mixing mill is prefereble However, availability of at least one kneader is essential Ensure that open mixing anill for sizing of rubber sheets is available, The open mixin mill should be equipped with suitable cooling arrangement and digital temperaiu indicator (min. 1 10.) Su fable size press for euitin; suber blanks should be availble. Ensure that a suitable size dic and punch facility 10 cut the blanks to the size ‘This is required in cuse the product is manufactured with compression mouldi In case of t availa 1s proce nisfer moulding process a suitable size shearing facility would be sufficiet An automatic thermic heating moulding press having provision of heating the pl hydrautically/stearn, The press should be fully equipped with temperature contro digital temperature indicators and the timers, There should be a provision to se presses in such a way that the required pressure, the time period and the temperatur be synchronized for subsequent series manufacture of a particular product w disturbing the setting on the machine (min. 2 nos.). Minimum two number presses ¢ be available Page 8 of 1234 3.10 TRS pee. No, R-64/98 (Rev.2) Suitably designed divs and r avaiable oulds'tansfer moulds for the product (min. 2 no.) should be Mt is enisured that the moulds are measured for the accuracy for various dimensions at Jeast on weekly basis or after a production of 500 pieces and ihe observations o” the mould are recorded. In-house availability of minimum infrastructure for maintenance and polishing of dies and moulds TESTING FACH ETTS: Tensile testing machines capabie to read the foal and elongation as per the requirement of the product should be available, The tensile testing machine should have all the provisions in agcordunce with para 4.2 of IS 3400 Part a. A universal testing machine with Joad indicator having a least-eoun of minimum 20 kg, The capacity of te machine should be adequate 10 work the same at specified speeds and it should be capable 10 apply. he required load for testing of the products for vinious defection parameters in with the stipulated specifications. b. The universal testing mac'ine should also have the facility te draw a graph fer various deflection characteristics as per the requirement of the product Ensure that a rehom is maimainad of de Aor is aweaiable and it is being used retary, Ensure that the yeeond ches, which te checked on rehometer Minimum wo ranabers alr ovens should be available to faeititae the testing in accordance with pura 42 & 6.2 af IS 34000 Past X. Minimum one number auiffle 1 ¢ should be available. Ensure that minimum two numbers shore A hardness lester with standard test pieces are available. Specific gravity testin spre st one number, should be available. Ensure that the facifiues for prepa s test specimen as pet IS 3400 Part | are existing Below mentioned measuring mstruments in adequate number shoud be available Micrometers b. Dial gangs cc. Vernal calipers d. Go ~ No-Go gattyes for all the important dimensions for a specific product Minimum ine number chemical balance and a crucibte for measuring ash content should also be available. Page 9 of 124.0 41 43 46 47 48 49 IRS Spec. No. R-64/98 (Rev.2) Compre be avai iow set testing appar he us in decordance with para 4.1 of IS 3400 Part } should Minimum ovo sets suiteble fxures for compression loud deflection test as per the drawings speciiied in the relevant specification of product should be available, QUALITY CONTROL REQUIREMENT: ‘There should he a system 10 ensure the traceability of the product from raw material save to finished product This sestem shoukd also ilitale to idlemtily the rave material composition (font the fiwish produet ste Ensure that the system of First in First out’ is followed for raw material and the intermediate siaye product. Ensure that there is Quality Assurance Plan for the product detailing various asp. © Organisational chart © Hlow process chart Stage inspeetion details © Varios parameters and to ensure control aver them, The QAP shali be ava guidelines & epplicition ble as pier ihe requirements dewiled in Vendor 2 orm” -HL-03: 200) “There should be ot lest one rubber technologist having a minima bachelor’s de, relevant field & 5 yews experience or a person with dipiouna in relevant field with 12 years experienes, He should be five from day-to-day production, testing & quality conto! responsibilty, He should be mainly responsible lor development aa product, analysts of products, control over raw material. conective uetion in case af difficulties in achievin: the parameters. ree in Ensure that the in-charge of the Quality Contvol Section is having a quulification of minimum bachelor’s Jegree in the relevant field & have Min. $ years experience or a diptoma holder with Min. }2 yeurs experience. He should be actively involved in day-to- day activities of quality control / stage inspection / compliance of QAP ete. The firm should have acquired ISO: 9001- 20UU certification or QS certification and the product for which an approval is sought should be broadly covered in the scope of the certification for manufactured & supply ‘The Quality manual of the firm for ISO: 9001- 2000 should clearly indicate at any stage the control over manufacturing and testing of the said railway product. Ensure that proper anaiysis is being done on monthly basis to study the rejection at various internal st nented, Ensure that al the relevant specifications, IS standards are available with the firm. Page 10 of 12IRS Spec. No. R-64/98 (Rev.2) 4,.NOS.M16 SCREW FLAT STEEL a PARTING PLATE e112 SPECIMEN: NNN Seat MACHINE TABLE. SECTION A-A 7 | $ _ & 250 CRS \ I 250_CRS 225 COMPRESSIVE LOAD DEFLECTION TEST GADGET FOR LOAD DEFLECTION TESTS ON BG LOWER RUBBER WASHER [Fig-1 Page 11 of 12IRS Spec. No R-64/98 (Rev.2) SPECIMEN LOAD 30 MACHINE TABLE ~ 0168 SECTION A-A GADGET FOR COMPRESSIVE LOAD DEFLECTION TESTS ON BG UPPER RUBBER WASHERS WHEN TWO SAMPLES | ARE TESTED TOGETHER S| FIG—2 | | Page 12 of 12