'ITfm \Wf,IT - mq-,:rlWi Government of India-Ministry of Railways

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EPBX (0522) 2451200 DID (0522) 2450115
Fax (0522)2458500 010(0522)2455310

No:SV.FIAT Spring Dated:- 04.01.2017

~

CMEs,
n
All Indian Railways &
ICF, RCF, MCF

Sub: - Maintenance of Flexi Coil Springs of LHB coaches.

Ref:- This office letter of even no. dated 08-12-14 & 16-07-15.

While instructions were issued for maintenance of Flexi Coil Springs after Audit of
workshops & Depots and discussions held with OEMs from abroad vide letters
referred above; and a definite trend of improvement in performance were observed,
however, of late the failures of springs of secondary suspension in LHB coaches
have resurfaced and a large number of cases have been reported in the recent past.
In order to overcome this, it is necessary that the instructions already issued by
ROSa be implemented in the right earnest. It need not be re-emphasized that apart
from the maintenance instructions issued for steel coil springs other components
which have a bearing on the proper functioning of the suspension system like
centering disc, Miner pad, Emergency rubber spring be properly maintained. Apart
., from components of susr: ~~ nsion system, other sub-assemblies like longitudinal and
lateral bump stops, lateral damper, Yaw damper and rubber metal elements be
ensured in proper condition and all bogie clearances properly maintained in order to
ensure that springs are not subjected to unusual forces. The maintenance
instructions for springs are reiterated below :

1. The pairing of springs should be ensured whenever the springs are changed
or removed for repair/overhauling.
2. The spring should be closely watched for occurrence of corrosion particularly
in the zone of contact in first and second coil. As soon as the corrosion is
noticed; the spring should be attended without any delay or exception.
3. Proper functioning A the dampers should be ensured. In case of any doubt the
dampers should be removed and got serviced/overhauled. The dampers
should be necessarily tested in SS-1 schedule in the workshop.
Ref: CGW 0001 Page 1 of 24 Date of issue Spec. No.
(Rev. – 4) April, 2012 RDSO/2011/CG-02

INDIAN RAILWAYS

Technical Specification for Hot Coiled Cylindrical Spring

for use in suspension of I.R. coaches having FIAT
Design Bogies
for
Rail Spring Karkhana, Gwalior

S No. Date/month Revision Page Reasons of Revision

of Issue /Amendment no.
1. April 2012 Nil Nil New

Issued by:

Research Designs & Standards Organisation

Manak Nagar, Lucknow – 226 011.

Ref: CGW 0001 Page 2 of 24 Date of issue Spec. No.
(Rev. – 4) April, 2012 RDSO/2011/CG-02

CONTENTS

S.No. Description Page No.

1.0 Preamble 3
2.0 General 4
2.1 Scope 4
2.2 List of ref. Specifications 4
3.0 Spring Classification 5
4.0 Raw Material 5
4.1 Choice 5
4.2 Chemical Composition 6
4.3 Manufacture 6
4.4 Stamping 6
5.0 Bars 6
5.1 Manufacture 6
5.2 Properties 7
5.3 Marking 8
6.0 Rods 8
6.1 Manufacture 8
6.2 Properties 8
7.0 Springs 9
7.1 General 9
7.2 Formation of Ends 10
7.3 Stamping 10
7.4 Hot Coiling 11
7.5 Heat Treatment 11
7.6 End Grinding 12
7.7 Scragging 12
7.8 Crack Detection 13
7.9 Surface Treatment and protection 13
7.10 Properties 14
8.0 Testing 17
9.0 Inspection 18
10.0 Quality Records 22
11.0 Guarantee 22
12.0 Final Acceptance of Springs 22
13.0 Packing &Transport 23
14.0 List of FIAT Spring Drawings 23
Ref: CGW 0001 Page 3 of 24 Date of issue Spec. No.
(Rev. – 4) April, 2012 RDSO/2011/CG-02

Technical Specification for Hot Coiled Cylindrical Spring for use in

suspension of I.R. coaches having FIAT Design Bogies for
Rail Spring Karkhana, Gwalior

1.0 Preamble:

Indian Railways had entered into Transfer of Technology (TOT) agreement with
M/s LHB, Germany for procurement of 24 numbers of all Stainless Steel Light
Weight, High Speed Coaches suitable for operations at 160 kmph on existing
Indian Railways track. M/s LHB had chosen M/s FIAT for the Bogie design.

The FIAT Bogies use following specification for the Helical Springs:

a) FIAT technical specification No. 17.248.100 Version 05

b) FIAT technical specification No. 17.471.101 Version 01.

Rail Spring Karkhana, Gwalior has been set up in technical collaboration with M/s
Grueber, Germany and the OEM for FIAT Springs is also M/s Grueber. Till date
Rail Coach Factory, Kapurthala has been importing the springs for FIAT Bogie
primarily from M/s Gruber and subsequently added more OEMs. Procurement
has been through FIAT technical specifications mentioned above.

Indian Railways has now decided to step up the production of LHB-FIAT

Coaches and all type of coaches such as AC-2 Tier, AC-3Tier, GS, SCN, SLR
are planned for manufacture. Rail Spring Karkhana, Gwalior has commissioned
the line for manufacturing for FIAT Springs in Aug 2011. As asked by RSK
Gwalior, RDSO has prepared this technical specification to enable them to
undertake the manufacturing of appropriate quality of FIAT springs.

This specification is meant for guidance purpose only. This Specification

may be altered and changed in future on basis of experienced gained
during FIAT spring production at RSK, Gwalior.
Ref: CGW 0001 Page 4 of 24 Date of issue Spec. No.
(Rev. – 4) April, 2012 RDSO/2011/CG-02

2.0 GENERAL

2.1 Scope

2.1.1. This specification is applicable for high performance cylindrical springs used in
the suspension of IR coaches of LHB design having FIAT bogies and similar
other applications. Described springs are manufactured out of circular section hot
wound round bars having rolled forged ends.

2.1.2. Procurement of spring steel to be used in the manufacture of these springs shall
be done only from reputed manufacturers previously approved by RDSO

2.1.3. Spring steel bars duly inspected and passed by RDSO shall be used for
manufacture of springs.

2.1.4. The technical conditions for the delivery and supply of cylindrical springs shall be
as follows:

• As per special technical provisions as appear on the drawings.

• As per technical provisions of this specification, in as much as these do
not conflict with the special provisions mentioned in the drawings.

2.2 List of Reference Specifications:

(i) ISO 683-14 Heat Treatable steels, alloy steels and free cutting steels;
Part-14: hot rolled steels for quenched and tempered
springs.

(ii) ISO 1462 Metallic coatings; Coatings other than those anodic to the
basis metal; Accelerated corrosion tests; Method for the
evaluation of the results.

(iii) ISO 2162-1 Technical product documentation; springs; part-1;

simplified representation.

(iv) ISO 2162-2 Technical product documentation; springs; part-2;

presentation of data for cylindrical helical compression
springs.

(v) ISO 2162-3 Technical product documentation; springs; part-3;

Vocabulary.

(vi) ISO 3887 Steel, non-alloy and low-alloy; determination of depth of

decarburization.
Ref: CGW 0001 Page 5 of 24 Date of issue Spec. No.
(Rev. – 4) April, 2012 RDSO/2011/CG-02

(vii) ISO 4288 Rules and procedures for the measurements of surface
roughness using stylus instruments.

(viii)ISO TR 4949 Steel names based on letter symbols.

(ix) ISO 4540 Metallic Coatings; Coatings cathodic to the substrate;

Rating of electroplated test specimens subjected to
corrosion tests.

(x)ISO 4967 Steel; determination of content of non-metallic inclusions;

Micrographic method using standard diagrams.

(xi)ISO 9227 Corrosion tests in artificial atmospheres; salt spray tests.

(xii)ISO/TR 10108 Steel, conversion of hardness values to tensile strength

values.

(xiii)ISO 10209-1 Technical product documentation; vocabulary; Part-1;

terms relating to technical drawings; general and types of
drawings.

The reference to various specifications as above quoted herein shall generally be taken
as reference to the latest version of the specification concerned.

Specific provisions in this document will take precedence over those contained in the
above specifications where these are not in conformity with one another.

3.0 SPRING CLASSIFICATION

3.1 Depending upon their loading condition, springs have been grouped into classes
denoted by the following letters:

A - Springs used mainly in axial compression.

B - Springs used in axial compression and lateral bending and fitted
according to CHASSE value and direction (Flexicoil)

4.0 RAW MATERIAL

4.1 Choice

The following grades of steel may be chosen for use by spring manufacturers,
Ref: CGW 0001 Page 6 of 24 Date of issue Spec. No.
(Rev. – 4) April, 2012 RDSO/2011/CG-02

Bar Diameter (mm) Material Norm No.

<40 mm 51 Cr V4 ISO 683 Part-14
25 to 65mm 52 Cr Mo V4 Or prEN10089
52 Si Cr Ni 5

For rod diameter over 65 mm, the material must be explicitly stated on the
drawing.

4.2 Chemical Composition

4.2.1 Since the duty cycle of springs covered by this specification will be very tough,
following restrictions are considered essential for the raw material composition:

Maximum sulphur content - 0.015% by weight

Maximum Phosphorous content - 0.015% by weight

4.3 Manufacture

Steel shall be manufactured by electric, duplex or a combination of these

processes routed through secondary refining furnace. The routing of the steel
through vacuum de-gassing plant is essential as an additional requirement.

4.4 Stamping

Following information shall be hot stamped on each billet by the steel

manufacturer.

• Name and trademark of the manufacturer

• Type of steel
• Cast number
• Month & Year
• Size

5.0 BARS

5.1 Manufacture

The bars shall be manufactured by hot rolling process and the size of the ingots,
billets or continuous cast billets (raw material) for any given size of bar shall be
such that a minimum reduction ratio of 16:1 from the minimum cross sectional
area of the ingot or continuous cast billets to the maximum cross-sectional area
of the bar is ensured.
Ref: CGW 0001 Page 7 of 24 Date of issue Spec. No.
(Rev. – 4) April, 2012 RDSO/2011/CG-02

5.2 Properties

5.2.1 Surface

5.2.1.1 Visual checks should indicate that bars are smooth and free from distortion, twist,
kinks and harmful defects namely seems, folds, laps, cracks, deep rooted seems,
holes deep pits, grooves, excessive scaling and non-metallic inclusion which may
lead to impairing of their serviceability.

5.2.1.2 The permissible depth of seams and laps in the bars shall not be more than 2%
of the bar diameter or 0.4 mm whichever is less.

5.2.2 Hardness

Hardness of ‘bar’ material may be mutually agreed upon between supplier and
purchaser.

5.2.3 Geometric condition

5.2.3.1 Tolerance on hot rolled bars diameter shall be within +1.0% / -0.8%.

5.2.3.2 Ovality of the bars should be controlled in such a manner that it complies with the
requirement contained in para. 6.1.2.

5.2.3.3 Bars shall be supplied in straightened condition and the limit for out of
straightness shall be 1.5 mm/metre length (maximum).

5.2.4 Metallurgy

5.2.4.1 Macro-etching

• In the cross-section (micro-section surface), no microscopic defects such

as cavities, pores cracks or liquidations are permitted. Macro etch level
shall not be worse than C2, R2, S2, of ASTM E-381 for blooms and
billets.

5.2.4.2 Microscopic

• Entire cross-section should have even annealed structure with depth of

rim decarburization should not be more than 0.4mm.

• Average grain size of the bar shall as per ASTM no.6 or finer.
Ref: CGW 0001 Page 8 of 24 Date of issue Spec. No.
(Rev. – 4) April, 2012 RDSO/2011/CG-02

• In longitudinal section, non-metallic inclusion rating shall not be worse

than 2.0 A,B,C,D for both thick and thin series when compared to the
chart for determining the inclusion content of secondary refined steels
(Fig.2) of IS:4163-1982.

5.3 Marking

Following information shall be stamped at the extreme ends of each bar:

• Name and trademark of the manufacturer

• Type of steel
• Smelt number
• Nominal diameter
• Nominal length
• Year

6.0 RODS

6.1 Manufacture

6.1.1 Rods shall be manufactured out of bars described in para 4 above.

6.1.2 Bars of such size shall be selected for rod manufacture which enables reduction
in its dia, after peeling and centreless grinding by atleast 6% of nominal rod
diameter or 2mm whichever is more.

6.1.3 Generally, the bars should be procured in exact lengths so that cropping of bars
does not become necessary in case of multiple /excess lengths, bars may be cut
to lengths by shearing /cutting carefully.

6.1.4 Bars as per para 5.2.3.3 shall be straightened in bar straightening machine
before undertaking peeling and centreless grinding operation.

6.1.5 Straightened bar shall be peeled and ground to make rods. Peeling and grinding
is mandatory requirement.

6.2 Properties

6.2.1 Surface:

6.2.1.1 On the surface, defects which can be seen by the naked eyes (e.g. cracks,
wrinkling, longitudinal grooves, inclusions, burned spots, tool marks & dent
marks) or depressions from handling and transport are not permitted.
Ref: CGW 0001 Page 9 of 24 Date of issue Spec. No.
(Rev. – 4) April, 2012 RDSO/2011/CG-02

6.2.1.2 Magnaflux testing of 100% bars according to EN 10228-1 should indicate

surfaces completely free of cracks, seam, inclusions, lap, etc.

6.2.1.3 Surface finish of rods shall be 5 microns (µm) values.

6.2.2 Shape & Dimensions:

6.2.2.1 The limit for out of straightness of rods shall be within 1mm/m length maximum.

6.2.2.2 The diameter of straight rods must be within the following limits:

Diameter of rods Tolerance

in mm In mm
06 - 10 ± 0.075
10 - 18 ± 0.090
18 - 30 ± 0.105
30 - 50 ± 0.125
50 - 80 ± 0.150

6.2.2.3 A thin corrosion protection layer shall be provided on the bar before dispatch.
Corrosion protection shall be adequate to last for period of two months under
storage in covered place. This shall not be in the form of oil/grease to prevent bar
slippage during end tapering operation. The chemical used be such as to burn off
or vaporize during heating at a temperature of 150 C & above leaving no residue.

7.0 SPRINGS

7.1 General

7.1.1 Manufacturing sequence shall include the following operations, in order given
below:

S.No. Process
1. Formation of ends & Stamping
2. Hot coiling
3. Quenching
4. Tempring
5. End grinding
6. Shot Peening
7. Crack Testing
8. Phosphating
Ref: CGW 0001 Page 10 of 24 Date of issue Spec. No.
(Rev. – 4) April, 2012 RDSO/2011/CG-02

9. Primer
10. Scragging
11. Pre-load Testing
12. Final Painting
13 Load Deflection Testing

7.2 Formation of ends

7.2.1 Both the ends of the rod shall be tapered by Taper rolling to a length which shall
be equivalent to an arc angle of 270º (minimum) formed by end coils of the
spring. This is meant to ensure a firm bearing of about 75% of the mean coil
circumference at support surfaces of the finished springs. Formation of ends by
hammering is totally unacceptable.

7.3 Stamping

7.3.1 The ends of rods (para 7.2) shall be heated in an electric indirect heating or LPG
furnace etc, which are equipped with temperature controller and recorders.
Temperature to which these ends shall be heated should be predetermined
according to composition of the material.

7.3.2 After the ends have attained desired temperature, following particulars shall be
legibly hot stamped on both tapered ends (outer side) in serial order.

** *** **** **** *****

Material Manufacturer’s Month & Drawing Heat
Code Code Year of Code Number
Production

e.g. CV ABC 0101 A01 001

Ref: CGW 0001 Page 11 of 24 Date of issue Spec. No.
(Rev. – 4) April, 2012 RDSO/2011/CG-02

7.3.3 Materials Code for the various materials shall be as under:

51 Cr V4 - CV
52 Cr Mo V4 - CM
52 Si Cr Ni5 - SN

7.3.4 Stamping shall be done on the outer surface of the ends in the tapered end area.

7.3.5 The stamping depth must be adequate to ensure that the stamping particulars
remain legible even after grinding and finish coating/painting of the springs.

7.3.6 Tool used for stamping must be rounded.

7.3.7 Size of letters of stamping shall be 5 mm on rods having diameter above 20mm
and 3mm for bars having diameter 20mm or less. No marking shall be done on
springs made from rods of diameter of 9.5 mm and below.

7.4 Hot coiling

7.4.1 Rods with tapered ends shall be heated in LPG fired or electric indirectly heated
furnace of minimum 10 mtrs, equipped with automatic temperature indicators,
controllers and recorders and soaked sufficiently at that temperature in an
controlled atmosphere (Soaking/Heating time = 0.83 x Bar Dia. minute).

7.4.2 With minimum time lag, rod shall be removed from the heating furnace and
coiling end pitching done in a high speed automatic coiling and pitching machine.

7.4.3 Pre heated mandrel shall be used for coiling and water shall not be allowed to
come in contact with heated rod.

7.4.4 Coiling machine used for the purpose shall have in-built features to maintain
uniformity of pitch and gap between end coil and adjacent coil without the need
for any manual adjustment.

7.4.5 Development of end turn of spring shall be as per para 7.2.1 figure. Transition
from the end turn to the active turn shall be in a most extended and continuous
manner possible.

7.5 Heat Treatment

Ref: CGW 0001 Page 12 of 24 Date of issue Spec. No.
(Rev. – 4) April, 2012 RDSO/2011/CG-02

7.5.1 With minimum time lag, coiled rods (called springs) as per para 7.4 shall be oil
quenched in a suitable quenching medium. The temperature of which is
maintained within 40º - 70º C in order to ensure optimum quenching conditions.

7.5.2 After quenching operation, tempering of springs shall be done in a continuous

conveyor type TEMPERING FURNACE. For producing required level of temper
and hardness, springs shall be heated to pre-determined temperature range for
sufficient length of time.

7.5.3 Furnace used for tempering shall be either LPG fired or electric indirect heating
type equipped with independent pyrometer for each zone to control temperature
within ± 10º C or below.

7.5.4 Since the heat treatment is carried out with the aim to achieve a homogenous
fine grain structure, the tempered martensitic distribution across the complete
cross-section of the active coil should be as under for various steel materials.

The tempered martensitic distribution across the complete cross-section of the

active coil should be uniformly distributed and hardness difference from core to
surface should not be more than 20 BHN.

7.6 End Grinding

Both the end surfaces of the spring should be ground to ensure square seating of
the spring. The ends should not have any sharp edge/burrs. The actual ground
end surface shall be atle ast 75% of the mean coil circumference of the spring.
The end faces of the spring should not have blue marks due to end grinding as
the same leads to temper brittleness.

7.7 Scragging

7.7.1 Each and every spring shall be scragged three times in quick succession.
Scragging load/height should be as laid down in the drawing. In case there is no
indication in the drawing, the springs shall be scragged home. The scragging
load in such cases should not exceed 1.5 times the theoretical axial load,
corresponding to home length.

7.7.2 Long duration scragging is to be introduced as a process check at regular

intervals and necessary documents of the test results are to be maintained. For
long duration scragging, the spring shall be compressed three times holding it at
the home load for two minutes in the first two strokes and for 48 hours at the last
stroke.

7.7.3 The scragged spring should not show further permanent set on subsequent
loading.
Ref: CGW 0001 Page 13 of 24 Date of issue Spec. No.
(Rev. – 4) April, 2012 RDSO/2011/CG-02

7.8 Crack Detection

100% of the springs shall be tested for crack detection in accordance with
Appendix ‘B’ of EN 10228-1 for both longitudinal and transverse cracks.

7.9 Surface Treatment and Protection

7.9.1 Shot Peening

All the springs shall be shot-peened in a continuous type shot peening machine,
preferably with self sieving arrangement in accordance with EN 13298 Annex C.
All care shall be taken to ensure uniform shot-peening over the entire area of
springs. The intensity of the shot shall be “ALMEN = 0.5”.

7.9.2 Phosphatizing

All the springs shall be phosphated by using zinc phosphate within 30 mins. after
shot peening. The thickness of coat shall be approx. 5-10 μm of fine crystalline
nature.

7.9.3 Priming

Priming shall be carried out using synthetic resin metallic primer

Synthetic resin metal primer:

Basis: Alkyd resin, air and oven dried.
Pigmentation: Zinc Phosphate, heavy chip, talcum, tinting pigments.
Solvent: Aromatic substances
Dry film thickness: Minimum 80 µm.

7.9.4 Coating lacquering

Synthetic resin dipping enamel:

Basis: Alkyd resin, air and oven dried.
Pigmentation: Lamp Black tinting pigments, extender.
Solvent: Aromatic substances - aliphates
Dry film thickness: Minimum 40 µm.

7.9.5 Colour:

The colour of coating lacquer is to be stated in the text of the order.

7.9.6 Special Spring Marking (besides stamping)

Ref: CGW 0001 Page 14 of 24 Date of issue Spec. No.
(Rev. – 4) April, 2012 RDSO/2011/CG-02

7.9.6.1 In addition to the stamping at end coil of the spring (para 7.3), each spring is
to be marked with a band of bronze, copper or brass. The band is secured with a
cyanogen acrylate adhesive (e.g. Loctite Js 496), or with a compression joint.
The following are to be stamped on the band:

-spring length under test load corresponding to tare condition in mm

-Value ‘X’ of the free alignment deviation in (mm) (only for category ‘B’
Springs).

Further, every flexicoil spring (category ‘B’) is also to be provided with a band
which marks the direction of the free alignment deviation.

- Band material: Aluminum-plastic adhesive tape (e.g. Tesaflex 171)

7.9.7 Coupling:

• Coupling for Category ‘B’ Flexi Coil Springs will be carried out as per FIAT
Technical Specification No. 17.471.101 Version 01.

7.10 Properties

7.10.1 General

The shape dimensions and direction of coiling should conform to the drawing.
When it is not specified in the drawing, direction of coiling shall be to the ‘right’.
Ref: CGW 0001 Page 15 of 24 Date of issue Spec. No.
(Rev. – 4) April, 2012 RDSO/2011/CG-02

7.10.2 Dimensional accuracy of unloaded spring (before painting):

It should conform to the following tolerances:

S.No Parameter Tolerance

1. Free height +1.5%, -0.5%

2. End squareness 1mm/100mm free height
3. Squareness *
4. Wire Diameter ±0.5% of wire dia or
±0.1mm whichever is less
5. External coil diameter, Douter 1.5% of Douter
6. Internal coil diameter, Dinner 1.5% of Dinner
7. Parallelism ±1.5mm per 100mm
outside dia of spring.
8. Concentricity of wound rods

RodØ≤30 O 0.2
RodØ<30 O 0.4

9. Planeness of the support (End) surface

Turn Diameter 0.5

Dm ≤ 250 mm

Turn Diameter 1.0

Dm > 250 mm

7.10.3 Behaviour of spring under load:

7.10.3.1 Under a vertical load which represents ‘ready to march condition’ i.e. tare
condition, both rod ends must rest against the first turn. This contact should
not be a point contact at tip or any other point but should be in the form of a
line of length not less than 30% of mean coil diameter (nominal). The
beginning of line of contact under this conditions should not further than 60º
from the end.

* Deviation from perpendicular at any point on the circumference shall not

exceed:-
a) At effective coil:
b) At ineffective coil:
(over a circumferential length
from its free end equal to 3.5
times the wire dia)
-by more than 1% of the nominal free height.
- by more than 1% of the nominal free height
plus 3mm.OR 2% of the nominal free
height (whichever is less)
Ref: CGW 0001 Page 16 of 24 Date of issue Spec. No.
(Rev. – 4) April, 2012 RDSO/2011/CG-02

7.10.3.2 In the remaining vertical load zone i.e. upto about 85% of the block length
load (para 7.10.4.2), the contact between end coil and first active coil at both the
ends must follow in a continuously rolling manner and may not be toppling over
support points and no ‘kinks’

7.10.3.3 The turn interval is to be held so exactly that no additional contact at any
other point on the spring upto load given in para 7.10.3.2 occurs.

7.10.4 Dimensional and other characteristic parameters under load (as per FIAT
drgs)

7.10.4.1 Vertical height at loads (mm)

Tare Nominal ±3% of nominal deflection at this load

Other loads Nominal ±6%4% of nominal deflection at this load

7.10.4.2 Solid/Block length (mm) ≤ (Ne+1.1)* (d+0.1)

Where Ne=No. of active turns.

d= rod dia in mm.

7.10.4.3 Vertical rigidity (N/mm)

7.10.4.4 Lateral Rigidity (N/mm) (for springs classified as ‘B’)

Tare ±5% of nominal value

Gross ±5% of nominal value
Max. load ±5% of nominal value
Ref: CGW 0001 Page 17 of 24 Date of issue Spec. No.
(Rev. – 4) April, 2012 RDSO/2011/CG-02

7.10.4.5 Chasse Value: (For springs classified as ‘B’)

Chasse value at normal gross load condition must not exceed the following
limit:

C= 0.018L+0.0072 L2/D
Where, L = Nominal free length of spring in mm
D = Nominal mean coil dia in mm
C = Chasse in mm

7.10.5 Mechanical Characteristics:

The mechanical characteristics such as yield point, breaking strength, elongation,

hardness and through hardening capacity must be guaranteed according to
following norms (valid for tempered state)

Material Norm
51Cr4 V prEN10089
52Cr Mo V4 prEN10089

7.10.6 Surface quality

Following values must be guaranteed after shot-peening operation of springs.

Almen value (mm) 0.50

Blasting medium Ø(mm) 0.6mm – 1.0 mm

8.0 Testing

7.1 Tests for ascertaining various requirments as stipulated on this specification shall
be as under:

S.No Test Relevent Specification/Method to be followed

1 Chemical composition of raw prEN10089

material and products i.e.bars &
rods
2 Hardness of surface ISO/TR 10108
3 Inclusion contents EN13298 AnnexD
4 Depth of decarburization & EURONORM 104
structure
5 Grain size EURONORM 103
6 Visual checks for defects EN13298.
7 Macro-examination EURONORM 103
Ref: CGW 0001 Page 18 of 24 Date of issue Spec. No.
(Rev. – 4) April, 2012 RDSO/2011/CG-02

8 Magnaflux testing EN 10228-1

9 Surface finish of rods EN ISO 4298
10 Dimensional and other checks of EN13298.
finished spring
11 Vertical stiffness tests The stiffness value is obtained from the load
difference and the length difference by
increasing the load from Fu to Fv and
recording the respective length Lu and Lv.
Ks =(Fv-Fu)/(Lu-Lv)
12 Transverse stiffness test (for The transverse static stiffness is calculated
group ‘B’ classification spring by following formula
only, and chasse evaluation (See Kt=1/2[{(QB1-QA1)/(rB1-rA1)}+{(QB2-QA2)/(rB2-
para 7.2 &7.3) rA2)}], refer EN13298
13 Tests to verify quality of shot EN13298 Annex C
peening (Almen test)
14 Tests to verify quality of EN13298.
phosphatizing
15 Breaking strength EN 10083-1
16 Elongation at breaking load EN 10002-1

7.2 Special test for measurement of lateral rigidity (for group ‘B’ classification
springs) and Chasse evaluation according to the EN13298.

7.3 Special test for evaluation of chasse value, direction and rotation etc. according
to the EN13298.

9.0 Inspection

9.1 General:

9.1.1 The material to be used in the manufacture of springs and the finished
springs shall be subjected to inspection by the Purchaser’s Inspector to
ascertain the quality of the material and the characteristics of the finished
springs. He shall be permitted to carry out all the checks necessary to ensure
that all the conditions specified for the manufacture of the material and of the
springs are adhered to.

9.1.2 The Inspecting official or the Purchaser shall have free access to the works of
the manufacturer at all reasonable times. He shall be at liberty to inspect the
manufacture of the springs at any stage and to reject any material that does not
conform to the specification.

9.1.3 The manufacture shall afford the Inspecting official, free of charge, all
reasonable facilities, by way of labour appliances and necessary assistance for
such test as may be carried out on his premises in accordance with this
Ref: CGW 0001 Page 19 of 24 Date of issue Spec. No.
(Rev. – 4) April, 2012 RDSO/2011/CG-02

specification. Where facilities are not available at manufacturer’s works, the

manufacturer shall bear the cost of carrying out such tests elsewhere.

9.1.4 The finished spring shall be presented for inspection in batches of not more
than 1000. The springs shall be presented for inspection after the application of
the protective coating against corrosion. The Inspecting official is free to have the
sample springs shot peened for various tests.

9.2 Stage-I (rolled bars) at spring manufacturer premises:

9.2.1 The steel and rolled bar manufacturer shall submit to the spring manufacturer
necessary test certificates of the following tests, carried out by him apart from the
documents pertaining to the steel manufacture and refining details, ingot shape
and size of the rolled product, cropping yield etc.

a) Chemical composition of the ladle analysis and product analysis.

b) Inclusion contents in bars
c) Reduction Ratio.
d) Depth of decarburization
e) Surface hardness
f) Grain size
g) Dimensions
h) Macro-examination.

9.2.2 While carrying out the inspection of rolled bars at spring manufacturer’s
premises, the RDSO inspector would pay special attention to the following:-

a) Size of ingots/billets used as verified from the records of the steel

manufacturer.
b) Dressing of complete billet by general surface grinding and freedom
from surface defects.
c) Discarding of end portions at both ends of each billet and freedom
from piping.
d) The size of ingot used shall be checked, recorded and verified that
minimum reduction ratio of 16:1 is ensured for the rolled bars offered
for inspection.

9.2.3 The RDSO Inspector shall examine various registers and records maintained
by the spring manufacturer to verify heatwise checks carried out by them on
various parameters and manufacturing practice like production of ingots with
wide end up and hot top cropping of each ingot/primary rolled billet etc.
Ref: CGW 0001 Page 20 of 24 Date of issue Spec. No.
(Rev. – 4) April, 2012 RDSO/2011/CG-02

9.2.4 The RDSO Inspector shall carry out the following minimum checks as per
sampling given in para 8.2.5 and maintain records. Testing method as per para
7.1 shall be followed. He may draw any additional number of samples and carry
out tests at his discretion. He shall also have the right to cross check any of the
above parameters by actual tests at his discretion and at the cost of the spring
manufacturer.

9.2.5 Sampling (random)

S. Test Sampling
N.
1. Chemical analysis 2 samples per heat per section.
2. Hardness 10 bars per heat.
3. Macro-examination 0.5% subject to min. of 5 bar per heat.
4. Depth of decarburization 3 bars per heat per section.
5. Inclusion contact 3 samples per heat per section.
6. Grain size 3 bars per heat per section.
7. Visual checks for defects 2%bars per heat per section.
8. Verification of dimensional tolerances 5 samples per heat per section.

9.2.6 Records for all the above tests shall be made available for scrutiny of inspector
Sample and records of the above tests shall be preserved for atleast three
months for counter check by Inspector, if he so desires.

9.2.7 RDSO Inspector may pick up two samples per 1000 tonnes of material offered
and send the same to approved agency for confirmatory test for chemical and
metallurgical properties at Spring Steel Manufacturer’s expense. This test should
not form part of purchase acceptance test but will only serve as a counter check
on Spring Steel Manufacturer’s quality control practice.

9.3 Stage II (During manufacture of rods):

9.3.1 During manufacture, records pertaining to checking of 100% of the rods for
minimum material removal, surface finish, dimensional checks and cracks and
crack detection by magnaflux testing shall be kept by the spring manufacturer.

9.3.2 The RDSO inspector shall be allowed to examine various records and registers
maintained by the spring manufacturer to verify checks carried out by them in
respect to clause 8.3.1.

9.3.3 In addition, spring manufacturer should submit a certificate certifying that

“Magnaflux test as per clause 5.2.12 has been carried out on full length of 100%
Ref: CGW 0001 Page 21 of 24 Date of issue Spec. No.
(Rev. – 4) April, 2012 RDSO/2011/CG-02

of the centreless ground bars against particular purchase order”. This certificate
should be submitted to the Inspecting Authority as well as consignee railway.

9.4 Stage III (Springs)

9.4.1 For each batch of finished springs or part thereof presented for inspection, tests
as per para 8.4.2 shall be carried out on springs randomly selected by the
purchaser’s inspector.

9.4.2 Sampling from the batch of finished springs

S.No. Test Samples per Batch

1. Depth of Decarburization 3
2. Core Hardness 3
3. Surface Hardness 10
4. Crack Detection 2% subject to a min. of 10 springs.
5. Dimensional check (unloaded) 3% subject to a min. of 10 springs.
6. Scragging 3% subject to a min. of 10 springs.
7. Dimensional Checks & chasse* 2% subject to a min. of 10 springs.
check (loaded)
8. Grain Size 3
9. Chemical composition 1
10. Vertical and Lateral* Rigidity 1% subject to a min. of 10 springs.
11. Inclusion Rating 3 samples
12. Mechanical Characteristics 3 samples
13. Almen Test 3 samples
* for spring of Group ‘B’ only.

9.4.3 Records of individual test results as above will be kept by the spring
manufacturer for a period of 15 years following delivery and can be viewed upon
demand.

9.5 Rejection

9.5.1 During the sampling inspection, if any spring is found to be defective, another
sample of twice the size of the earlier sample should be selected for inspection. If
there is any rejection in the sample, the whole batch stands rejected. After
inspection, the inspecting officer shall affix his stamp/seal on each spring as
token of the spring having been passed by him.

9.5.2 The rejected springs shall be either gas cut or cross marked on one of the
effective coils with the help of grinding cutter so that the rejected springs do not
Ref: CGW 0001 Page 22 of 24 Date of issue Spec. No.
(Rev. – 4) April, 2012 RDSO/2011/CG-02

get mixed up with good springs at any stage. This should be done in the
presence of the inspecting officer immediately after the spring has been rejected.

10.0 QUALITY RECORDS

10.1 Alongwith the delivery of the springs, the spring manufacturer shall give a written
confirmation of construction and testing according to the order in the form of test
certificates as under:

Test Certification
• Mechanical characteristics Final acceptance test certificate
• Hardness and through hardening according to EN 10204
capacity (DIN 50049 – 3.1B)
• Structure examination
• Chemical composition
• Length under test load
• Vertical rigidity
• Alignment deviation (chasse)
Manufacturer’s test certificate
• Almen Test
according to DIN 56350 Part 18-4.2
• Magnaflux inspection
• Dimensional checks – loaded &
unloaded condition

11.0 GUARANTEE

The springs shall be guaranteed for a period of five years against any defect
imputable to manufacture from the date of delivery of the spring as stamped on
end coil or for a period of four years from the date of actual fitment whichever is
earlier. Springs that show, during the guarantee period, defects making them
either unfit for service or reduce the effectiveness of the life and which defects
may be imputable to manufacture shall be replaced free of cost by the
manufacturer.(Other than Railway manufacturer)

12.0 FINAL ACCEPTANCE OF SPRINGS

Final acceptance of the springs is reserved exclusively to CWM/RSK

Ref: CGW 0001 Page 23 of 24 Date of issue Spec. No.
(Rev. – 4) April, 2012 RDSO/2011/CG-02

13.0 PACKING & TRANSPORTATION

Spring is being placed first in “Ethylene Vinyl Acetate” Sheet of 1.5 mm thick bag
and then it is packed in 7 ply corrugated Carton Boxes. Subsequently the Carton
boxes are wrapped tightly by plastic strips using automatic machine.

The springs must be packed and transported in such a way that the coating
lacquer is protected from any damage.

LIST OF FIAT SPRINGS DRAWINGS

S.N. Drawing No. Description

Outer Dia
of Spring
Mean Dia
of Spring
Wire Dia

Height
Code

Free
1 1267412 FIAT Coach Pri Chair Car ( Inner) F02 26 324.5 138 164

2 1267411 FIAT Coach Pri Chair Car (Outer) F03 38 324.5 219 257

3 1277143 FIAT Coach Pri Generator Car ( Inner) F04 27 337 138 165

4 1277142 FIAT Coach Pri Generator Car (Outer) F05 40 337 219 259

5 LG01101 FIAT Primary GS (Inner) F06 27 313 138 165

6 LG01100 FIAT Primary GS (Outer) F07 40 313 219 259

7 LG05100 FIAT Coach Sec. GS (Inner) F08 36 593 245 281

8 LG05101 FIAT Coach Sec. GS (Outer) F09 55 637 376 431

Ref: CGW 0001 Page 24 of 24 Date of issue Spec. No.
(Rev. – 4) April, 2012 RDSO/2011/CG-02

9 LS05101 FIAT Sec. SLR (Outer) F10 52 660 372 424

10 LS05101 FIAt Sec.GSCN (Outer) F11 52 660 372 424

11 LS05100 FIAT Sec. SLR (Inner) F12 34 625 246 280

12 LS05100 FIAT Sec.GSCN (Inner) F13 34 625 246 280

13 1277146 FIAT Sec. Gen Side ‐1 (Outer) F14 57 708 372 429

14 1277145 FIAT Sec. Gen Side ‐1 (Inner) F15 38 664 243 281

15 1268836 FIAT Sec. Gen Side ‐2 (Outer) F16 55 702 372 427

16 1268837 FIAT Sec. Gen Side ‐2 (Inner) F17 37 658 243 280

17 1269514 FIAT Sec. Chair Car (Outer) F18 50 707 368 418

18 1269513 FIAT Sec. Chair Car (Inner) F19 34 663 246 280