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BGIWW BGIFR_ENG Test specification Internal

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2019-01-23 J Jensen SNCB / NMBS M7DD In preparation

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Testspecification 100377029
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This document and its contents are the property of Bombardier Inc. or its subsidiaries. This document contains confidential proprietary information. The reproduction,
distribution, utilization or the communication of this document or any part thereof, without express authorization is strictly prohibited. Offenders will be held liable for the
payment of damages.
© 2023, Bombardier Inc. or its subsidiaries. All rights reserved.
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Table of content
1 Introduction 3
2 Standards and documents 3
2.1 Standards 3
2.2 Documents 3
2.3 Drawings 3
3 Material and mechanical properties 4
4 Coordinate system 4
5 Mounting 5
6 Application of forces 5
7 Strain gauges 5
8 Test preparation 5
9 Static tests 5
9.1 Exceptional loads 5
9.2 Dynamic loads 6
10 Fatigue test 6
10.1 Execution of the fatigue test 7
11 Non destructive testing 7
12 Documentation 8
13 Measurement Positions 9

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Introduction

The anti-roll bar of the M7 bogie should be test with increased loads based on track test
data. This document describes the test program.

Standards and documents

The following documents are used:

1.1 Standards
[1] FKM 183 FKM Guideline 6th Edition, Analytical strength assessment of
components, 2012

1.2 Documents
[2] 100298824 Antir-roll bar calculation report, Rev _A, 02/10/17
[3] 100288362 SNCB / NMBS M7DD Bogie Trailer, Torsion Bar and Lever, Rev _D,
02/01/2019

1.3 Drawings
[4] 100292556 Rev _C Anti-roll bar
[5] 100299129 Rev _B Anti-roll bar installation
[6] 100291408 Rev _E Anti-roll bar lever

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Material and mechanical properties

The torsion bar is made of 52CrMoV4+QT and levers are made of 42CrMo4+QT. Those
parts are
respectively fabricated according to drawings 100292556 [4], 100 299 129 [5] and
100291408 [6] and also according to specification 100288362 [3].
Enhanced material properties are required compared to default values into European
standard
(EN10089 for torsion bar and EN10083 for lever). In particular, the enhanced material
properties of
the torsion bar are the same as those required for French market (SNCF ST358);

Table 1: Material data

Minimum Yield
UTS
Part Material limit
Rm [MPa]
Rp0.2 [MPa]
Torsion
52CrMoV4+QT 1370 1570-1750
bar
Lever 42CrMo4+QT 900 1000-1200

Coordinate system

The forces are based on the coordinate system of the following figure. Positive forces
aligned with the positive system axle.

F1

z
F2
x y

Figure 1: Anti-roll bar coordinate system and position of load

application

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Mounting

The anti-roll bar is mounted in the original bearing of the M7 anti-roll bar.

Application of forces

The vertical roll force should be applied by two cylinders.

The original ARB links are used to introduce the vertical load.

Strain gauges

The measurement includes 4 strain gauges and 2 strain gauge rosette.

Test preparation

Application of the strain gauges after the first non destructive testing before the static tests
starts.

Static tests

1.4 Exceptional loads

The first two load cases of Table 1 showing the 50 % load of the exceptional test. During the
test the strain / stresses have to be monitored and saved. After the 50 % load test the
measured stress values must be extrapolated to the 100 % force. If the extrapolation of the
50 % load stresses shows that the yield limit would be harmed in the 100 % load test: stop
the test and contact the customer.

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Table 2: Static test loads

Loadcase F1 F2
1.1 45.0 kN -45.0 kN
1.2 -45.0 kN 45.0 kN
1.3 90.0 kN -90.0 kN
1.4 -90.0 kN 90.0 kN
1.51 100.0 kN -100.0 kN
1.61 -100.0 kN 100.0 kN

1.5 Dynamic loads

Table 2 shows the dynamic loads. The signs of the force value are based on the coordinate
system shown in chapter 4. During the test the strain / stresses have to be monitored and
saved.

Table 3: Dynamic test loads

Loadcase F1 F2
2.1 52.5 kN -52.5 kN
2.2 -52.5 kN 52.5 kN
2.3 70.9 kN -70.9 kN
2.4 -70.9 kN 70.9 kN

Fatigue test

The fatigue test is based on the loads of Table 2. The following test program uses the
following load stages:

Table 4: Load stages for the fatigue test

Stag
Scale factor Fz N° of cycles
e
N1 1.0 70.9 1’000’000
N21 1.2 85.1 1’000’000
N31 1.4 99.3 1’000’000

As only 1 torsion bar is tested, the test load 70.9 kN for stage N1 is obtained by multiplying
the design load by a factor 1.35 according to FKM rules.

1
Optional test
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1.6 Execution of the fatigue test

Over all the test includes 1’000’0002 load cycles. During the test the time signal of all strain
gauges has to be measured. At least every 100’000 cycles the signal has to be recorded and
saved for least one minute.

Figure 2: Force / time graph for two load cycles

Non destructive testing

Six non destructive test (NDT) are part of the test program. The first non destructive test
takes place before the static tests start (incoming inspection). During the dynamic test stage
N1 every 200’000 cycles a NDT have to be done. Here a simplified NDT is sufficient. The
anti-roll bar remains in the test rig. NDT at the areas of the strain gauges.

2
3‘000‘000 cycles for the optional test program
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Documentation

All measurements have to be available to BT in an electronic format.

The following points have to be included in the test report

Result of the test
Documentation and photos of all strain gauges
Documentation and photos of the testrig including all used parts
Specification and certifications of the measurement equipment
Forces, displacements and stresses for all loadcases
Hysteresis diagrams of the static loadcases
Results of the crack detection

The test results should be delivered as Excel sheet.

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Measurement Positions

DMS02

DMS01

Figure 3: Position of strain gauges 01 and 02

Rosette04

Rosette03
1

DMS05
DMS06 ()

DMS01/02

Figure 4: Position of Rosette 03 and 04 and strain gauge 05 and 06

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Confidential and proprietary.