15. APTA PR-M-S-015-06 Standard For Wheel Flange Angle

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APTA PR-M-S-015-0615. APTA PR-M-S-015-06Standard for Wheel Flange Angle forPassenger EquipmentApproved May 18, 2007APTA PRESS Task ForceAuthorized June 2, 2007APTA Commuter Rail Executive CommitteeAbstract: This standard defines the minimum flange angle and the minimum length ofsurface on the flange, over which the angle must be maintained. These wheel flangeparameters are important in reducing the risk of low speed wheel climb derailments. Thestandard also provides drawings of wheel profiles that are compliant with the requirementsof this standard.Key Words: railroad wheel, flange angle, low speed wheel climb derailment, wheel profile,rail profile, Nadal.Copyright 2007 byThe American Public Transportation Association1666 K Street, N. W.Washington, DC 20006-1215All rights reserved.No part of this publication may be reproduced in any form,in an electronic retrieval system or otherwise,without the prior written permission ofThe American Public Transportation Association.15.1Volume V – Mechanical

APTA PR-M-S-015-06Introduction(This introduction is not part of APTA PR-M-S-015-06, Standard for Wheel Flange Angle forPassenger Equipment.)In November 1998, APTA issued Technical Bulletin 1998-1, on Commuter Car SafetyRegarding: Wheel Running Surface Manufacture and Reprofiling Contour. The bulletinrecommended a minimum flange angle of 72 (suggested tolerance 3 and -2 ) be achievedat the gage point, 3/8 inch above the standard base line.The 1998-1 Technical Bulletin is superseded by this standard which requires that on all newand reprofiled wheels, a flange angle of no less than 72 shall exist over a continuous lengthof at least 0.1 inches along the surface of the flange where it will contact the rail.The standard also provides drawings of narrow flange wheel profiles that are compliant withthe requirements of this standard. Some wheel profiles currently in use such as the AAR S621-79 can produce flange angles less than that required in this standard due to variation intolerances. Railroads choosing to continue the use of the AAR S-621-79 wheel profile,should observe strict adherence to the railroad’s quality assurance plan to confirm thattolerance stack-ups do not cause non-compliance with the flange angle requirements of thisstandard.15.2Volume V – Mechanical

APTA PR-M-S-015-06ParticipantsThe American Public Transportation Association (APTA) greatly appreciates thecontributions of the following individual(s), who provided the primary effort in the draftingof the Standard for Wheel Flange Angle for Passenger Equipment:Steve Dedmon, ChairSusan KristoffCameron LonsdaleBrian MarquisDavid SchanoesMark StewartBrian WhittenAt the time this standard was completed, the Passenger Rail Equipment Safety Standards(PRESS) Mechanical Committee included the following members:Dave Carter, ChairSteven AbramopaulosM. AndrianiGordon BachinskyJack BarnasKen BarnishAl BieberGeorge BinnsBrad BlackRick BrilzChris BrockhoffDick BrussDave BrooksMark CampbellGary CarrJohn CasaleAl CherenGeorge A. ChipkoSteve ChrismerRoger CollenRichard ConwaySteve CostanzoJack CoughlinTim CumbieErik CurtisGraham CurtisRichard CurtisSteve DedmonJohn M. DermodyGreg DvorchakEd DeittMagdy El-SibaieJohn ElkinsDave ElliottOwen EvansGary FairbanksRonald L. FarrellAndrew F. FarillaBenoit FilionChuck FlorianGreg GagarinJohn GoliberJeff GordonThomas GrantHarry HaberKevin HeidrichFrancois HenriKen HesserChristopher HollidayPaul E. JamiesonJames JewellRichard JohnsonJoe KalousekJoe KahrBob KellsLarry KelterbornKevin KeslerPaul KezmarskyPeter KlauserSunil KondapalliJohn P. KonradSusan KristoffRick LaueNicolas LessardJason LipscombCameron LonsdaleBen LueWilliam LydonSusan MadiganDan MagnusEric MagelFrank MaldariGeorge ManessisJean MajorJohn MardenteJames MartinBrian Marquis15.3Keith McCarrickDon MininiHeiner MoehrenDonald MorrisseyDak MurthyLarry NiemondThomas O’BrienFrank OriolesGeorge PayneFernando PascualTom PeacockJohn Pearson, Jr.Jim PilchIan PirieRichard PolleyJohn PosterinoAnand PrabhakaranChuck PrehmJohn PunwaniRuss QuimbyJames G. ReesAl RomanCarol RoseTom RowbottomDaniel RuppertJohn RutkowskiTom RusinMichele SalvatoreRadovan SarunacFred SchaerrHans-Dieter SchallerDavid SchanoesPeter SchumacherBill SearsRebecca SidelingerKevin SimmsTom SimpsonAlbert C. SongCarlos SosaRex SpringstonMark StewartMonique StewartPhilip M. StrongChris StudcartDick SwaneyBob SwearingenAli TajaddiniKI. TakeshitaJoe TalafousClive ThornesRichard TrailMike TrosinoTom TsaiBob TuzikRichard VadnalArun VirginkarJohn WagnerDavid WarnerDouglas WarnerCharles WhalenBrian WhittenGary WidellJames WilsonBruce WigodWerner H. WodtkeClifford WoodburyBob WrightP. YablonskyH. YamamoriGreg YovichAllan ZarembskiJohn ZolockSteve ZuiderveenVolume V – Mechanical

APTA PR-M-S-015-06Table of Contents1. Overview .15.51.1 Scope.15.51.2 Purpose.15.52. References .15.53. Definitions, abbreviations, and acronyms .15.63.1 Definitions.15.63.2 Abbreviations and acronyms.15.64. Flange Angle Criteria .15.75. Inspection and Maintenance .15.75.1 Inspection .15.75.2 Maintenance .15.7Annex A (informative) Wheel Flange Angle .15.8Annex B (normative) Wheel Profiles .15.10B.1 Purpose .15.10B.2 APTA 120 Wheel Profile .15.11B.3 APTA 140 Wheel Profile .15.12B.4 APTA 140M Wheel Profile.15.13B.5 APTA 220 Wheel Profile .15.14B.6 APTA 240 Wheel Profile .15.15B.7 APTA 320 Wheel Profile .15.16B.8 APTA 340 Wheel Profile .15.17Annex C (informative) Bibliography .15.1815.4Volume V – Mechanical

APTA PR-M-S-015-06APTA PR-M-S-015-06Standard for Wheel Flange Angle for PassengerEquipment1. Overview1.1 ScopeThis wheel flange angle standard applies to all new and reprofiled wheels used on railroadpassenger equipment of all types, including non-passenger carrying cars and locomotivesthat are intended for use in passenger service on the general railway system of the UnitedStates. Other wheel parameters including tread taper are outside the scope of this standard.The passenger rail industry will phase this standard into practice over the 36 month periodfrom June 30, 2007 to July 1, 2010.1.2 PurposeThe purpose of this document is to provide minimum requirements for the wheel flangeangle to reduce the risk of wheel climb derailments. See Annex A.This standard supersedes APTA Technical Bulletin 1998-1, on Commuter Car SafetyRegarding: Wheel Running Surface Manufacture and Reprofiling Contour. The bulletinrecommended a minimum flange angle of 72 (suggested tolerance 3 and -2 ) be achievedat the gage point, 3/8 inch above the standard base line.2. ReferencesThis standard, where applicable, shall be used in conjunction with the followingpublications. If the following publications are superseded by an approved revision, theapproved revision shall apply.AAR Manual of Standards and Recommended Practices, Section G-II, Figure 4.37(Concluded), Narrow Flange Tapered Tread Contour – Locomotive and Amtrak (formerStandard S-621-79)AAR Manual of Standards and Recommended Practices, Section G, Figure B.12, AAR-1BNarrow Flange Contour for Freight Car Wheels (Standard S-669)15.5Volume V – Mechanical

APTA PR-M-S-015-063. Definitions, abbreviations, and acronyms3.1 Definitions3.1.1 flange angle: The flange angle (δ) is the maximum angle found on the surface of thewheel flange, measured with respect to the axis of the wheel set as shown in Figure 1.Figure 1 - Flange Angle Definitionδ3.2 Abbreviations and acronymsAARAPTACSTTFRANRCCPRESSAssociation of American RailroadsAmerican Public Transportation AssociationCentre for Surface Transportation Technology (division of National ResearchCouncil Canada)Federal Railroad AdministrationNational Research Council CanadaPassenger Rail Equipment Safety Standards15.6Volume V – Mechanical

APTA PR-M-S-015-064. Flange Angle CriteriaOn all new and reprofiled wheels, a flange angle of no less than 72 shall exist over acontinuous length of at least 0.1 inches along the surface of the flange, as shown in Figure 2,where it would contact the rail should the wheel climb. Annex B provides examples of wheelprofiles which meet this requirement with new rail profiles 1 .The minimum flange angle of 72 includes manufacturing tolerances. In deciding on a flangeangle to meet the minimum specified, inspectability and manufacturing tolerances shall beconsidered.Figure 2 - Flange Angle Standard Criteria0.1 inch (min)72 (min)5. Inspection and Maintenance5.1 InspectionNew and reprofiled wheels shall be inspected in accordance with the railroad’s qualityassurance plan to confirm the acceptability of the flange angle. Acceptable inspectionmethods include, but are not limited to, go/no-go gauges, templates, or automated measuringtools. The quality assurance plan shall require verification of the accuracy and ability of theinspection tool to discriminate between compliant and non-compliant flange angles and toestablish a test frequency that provides adequate control of wheel profiling.5.2 MaintenanceThis standard is not intended to establish guidelines for the inspection or rejection of wheelflange angles while in service. Typically, flange wear results in a steeper flange angle, so theneed for verification applies more to new and reprofiled flange and tread contours. However,if a railroad has experience with flange angles that decrease with wear, APTA recommendsthat periodic maintenance inspections of the flange angle be established. Flange angles thatdecrease with wear can occur when introducing a new higher flange angle wheel on rail thathas worn to the original, lower flange angle wheel.1New rail profiles used – 100, 112, 115, 119, 132, 136 and 140 RE.15.7Volume V – Mechanical

APTA PR-M-S-015-06Annex A (informative) Wheel Flange AngleIn discussing wheel/rail interaction, an understanding of the wheel/rail interface is important.The wheel flange angle is an important part of a system that includes many variables, each ofwhich contributes in its own way to the overall behavior of the wheel as it moves along therail. The potential for a low speed flange climb derailment can be decreased when all ofthese variables, including flange angle are addressed in a comprehensive rail managementprogram. Nadal [C9] described some of these variables in the early 1900’s that includefriction control in addition to the flange angle. Rail gage spreading, superelevation, railcamber, angle of attack, duration/distance traveled of excess L/V ratio and the variables thataffect these parameters also play an important role in wheel climb derailments.The main factors in wheel/rail interaction and their relationship are stated clearly in Nadal’sformula: L tan (δ ) μNadal V 1 μ tan (δ )where:(1)µ coefficient of friction between wheel and rail.The variables in (1) are illustrated in Figure A1. The variable delta is that angle which isformed when the wheel flange surface and rail gage face surface are in contact. A wornwheel and/or rail profile can greatly affect the wheel/rail interface contact angle. Managingthe contact angle as outlined in this standard is an integral part of any wheel/rail interfacemanagement strategy. The flange angle is used as an approximation of the maximum contactangle.Figure A1 - Wheel/Rail Interaction Variables.VLNδμN15.8Volume V – Mechanical

APTA PR-M-S-015-06Nadal’s formula provides an insight into the potential for wheel climb between a specificwheel and a specific rail under specific conditions. Nadal’s formula is an industry acceptedapproach and is utilized because it is simple and straightforward, appropriate for maintainingsafety and the variables can be measured.Based on this formula, railroads have sought to optimize the wheel/rail interface bycontrolling the coefficient of friction through lubrication schemes, the rail gage face anglethrough grinding processes, and the wheel flange angle through periodic reprofiling. Somecommuter railroads have adopted the AAR-1B profile (developed for freight wheels) as awheel flange standard, because the profiled flange wears into a relatively optimal contour formaintaining a steep flange angle.The flange angle specification outlined in this standard requires that the maximum angle bemaintained over a distance, rather than at a discrete point. This will increase the probabilitythat a high interface or contact angle between the wheel and rail is maintained despitevariations in wheel and rail profiles.15.9Volume V – Mechanical

APTA PR-M-S-015-06Annex B (normative) Wheel ProfilesB.1 PurposeThis annex provides drawings of APTA Standard wheel profiles. The narrow flange wheelprofiles listed in the table below are examples that meet the requirements 2 of this standard.APTA Wheel ProfilesAnnexSeriesDesignationDescription120Based on (former) AAR S-621-79, 1:20 taper140Based on (former) AAR S-621-79 with 1:40 taperB.4140MBased on (former) AAR S-621-79 with 1:40 taper modifiedby NJT to provide flange angle of 72º-75ºB.5220Based on AAR-1B (AAR S-669), 1:20 taper, modified for5.5 inch wheel widthB.6240Based on AAR-1B (AAR S-669) modified for 1:40 taperand 5.5 inch wheel widthB.7320NRCC-COM20 developed by CSTT [C8] and funded byFRA340NRCC-COM40 developed by CSTT [C8] and funded byFRAB.2B.3100200300B.82Compliance with requirements based on analysis of wheel-to-rail contact geometry using 1:40 tie plate, 56.5 inch track gage and 53-3/16inch wheel back-to-back dimension.15.10Volume V – Mechanical

APTA PR-M-S-015-06B.2APTA 120 Wheel ProfileBased on (former) AAR S-621-79, 1:20 taper.1 1/8525 1/16132-01111611458R583132R585811 1/16R16Taper 1:201 1/16-0 29R32R178Base Line364116GagePointETape Line31R232R58 YDFG XCBAHIGagePointJNode 0.1790-0.6250-0.7766-1.4008A-BB-CC-DD-EE-FF-GGage PointGHIJG-HH-II-JBeyond JSegment DetailsXRadius- CenterLineLine 90 11.8750-1.68050.6875Line 1:200.6250Line 90 Y- 6253.7188-1.4008Note: All coordinates relative to 'Gage Point', and all dimensions are inches.Flange angle must be no less than 72º over a continuous length of at least 0.1 inch.15.11Volume V – Mechanical

APTA PR-M-S-015-06B.3APTA 140 Wheel ProfileBased on (former) AAR S-621-79 with 1:40 taper.1 1/8525 1/16132-011116583132114R58R585811 1/16R16Taper 1:401 1/16-0 29R32R178Base Line364116GagePointTape Line31R232R58 YEDFG XCBAHIGagePointJNode 0.1790-0.6250-0.7004-1.3252A-BB-CC-DD-EE-FF-GGage PointGHIJG-HH-II-JBeyond JSegment DetailsXRadius- CenterLineLine 90 11.8750-1.68050.6875Line 1:400.6250Line 90 Y- 6253.7188-1.3252Note: All coordinates relative to 'Gage Point', and all dimensions are inches.Flange angle must be no less than 72º over a continuous length of at least 0.1 inch.15.12Volume V – Mechanical

APTA PR-M-S-015-06B.4APTA 140M Wheel ProfileBased on (former) AAR S-621-79 with 1:40 tapermodified by NJT to provide flange angle of 72º-75.1 1/8521.89803 3/32116-1/32*Flange Angle72 3 -0 R58R0.7030 0.048-0.078R58583 1/64164Taper 1:4029R32Base LineR178GagePoint0.028011658Tape Line31R23227232R58 YEDFCBAG XHIGagePointJNode t DetailsXRadius- CenterLineLine 90 .875-1.7824G-HH-II-JJ-K0.703Line 1:400.625Line 90 Gage PointGHIJY- 783.6875-1.3251Note: All coordinates relative to 'Gage Point', and all dimensions are inches.*Flange angle must be no less than 72º over a continuous length of at least 0.1 inch.15.13Volume V – Mechanical

APTA PR-M-S-015-06B.5APTA 220 Wheel ProfileBased on AAR-1B (AAR S-669), 1:20 taper, modified for 5.5 inch wheel width.5.5 0.1251.1563 0.0625-0.0000*Flange Angle0.00840.0370R1.5 0.0625R0.687575.0 0.375R0.5625 0.0625R0.375R0.375Taper 1:20(1:17 - 1:23)1.0 0.0625-0.0000Base Line1.7921R1.375GagePoint2.8438Tape LineR0.62504.875DC YEFGBA XHIJKGagePointLNode 9A-BB-CC-DD-EE-FF-GGage PointGHIJKLG-HH-II-JJ-KK-LBeyond LSegment DetailsXRadius- CenterLineLine 90 ne 75 0.56251.51.5Line 1:200.625Line 90 Y- 00.03870.84400.84403.7187-1.4169Note: All coordinates relative to 'Gage Point', and all dimensions are inches.*Flange angle must be no less than 72º over a continuous length of at least 0.1 inch.15.14Volume V – Mechanical

APTA PR-M-S-015-06B.6APTA 240 Wheel ProfileBased on AAR-1B (AAR S-669) modified for 1:40 taper and 5.5 inch wheel width.5.5 0.1251.1563 0.0625-0.0000*Flange Angle0.00840.0370R1.5 0.0625R0.687575.0 0.375R0.5625 0.0625R0.375R0.375Taper 1:40(1:37 - 1:43)1.0 0.0625-0.00001.7234Base LineR1.375GagePoint2.8438Tape LineR0.6254.875DC YEFGBA XH IJKGagePointLNode 3A-BB-CC-DD-EE-FF-GGage PointGHIJKLG-HH-II-JJ-KK-LBeyond LSegment

Regarding: Wheel Running Surface Manufacture and Reprofiling Contour. The bulletin recommended a minimum flange angle of 72 (s uggested tolerance 3 and -2 ) be achieved at the gage point, 3/8 inch above the standard base line. The 1998-1 Technical Bulletin is sup

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