INDIAN RAILWAYS - rdso.ggn.rcil.gov.inrdso.ggn.rcil.gov.in/QAMD/QA_Mech/3795/RDSO_2015_CG_03.pdf · 1.1 LHB type coaches of Indian Railways have been design ... mounted disc brake

~~f: CGW 0001 (Rev. - 4) Page 1 of 14 Date of issue: Nov., 2015 Spec. No. RDSO/Z015/CG-03,.'

INDIAN RAILWAYS

SPECIFICATIONFOR

BRAKE DISC

FORLHB TYPE MAINLINE BG COACHES

S.No. Month/Year of Revisionl Page No. Reason ofIssue Amendment Amendment

1. November, - - First issue2015

oIssued by

RESEARCH DESIGNS & STANDARDS ORGANISATIONManak Nagar, lucknow - 226011

Signahire

Name &Designation

PreparedBy: -Vivek Anand

JElE&S and BrakesiCarria e

Approv y:.Anil Kumar Singh

Director/E&S and BrakesiCarria e

Ref: CGW 0001 (Rev. - 4) Page 2 of 14 Spec. No. RDSO/2015/CG-03Date of issue: Nov., 2015

Signature

CONTENTS

CLAUSE DESCRIPTION PAGENO. No.

1. FOREWORD 3

2. DEFINITION AND EXPLANATION 3

3. SCOPE 3

4. PARTICULAR REQUIREMENTS 3

5. FUNCTIONAL REQUIREMENTS 4

6. DESIGN REQUIREMENTS 4

7. PERFORMANCE REQUIREMENTS 6

8. QUALIFYING REQUIREMENTS 6

9. SUBMISSION OF TECHNICAL DOCUMENTS 6

10. APPROVAL OF DRAWING 811. DIMENSIONS AND TOLERANCES 8

12. MANUFACTURE 913. PROTOTYPE INSPECTION 914. PURCHASE INSPECTION 915. TESTS 10

16. FIELD TRIAL 11

17. GURANTEE 11

18. AFTER SALES SERVICE 11

19. MARKING 12

20. PACKING 12

21. ANNEXURE-I 13

22. ANNEXURE - II 14

{ed By:-

raveen KumarDy. Director/ E&S and Brakes/Carriage

Name &Designation

Prepared By: -Vivek Anand

JE/E&S and Brakes/Carriage

Ref: CGW 0001 (Rev. -4) Page 3 of 14 Date of issue: Nov., 2015 Spec. No. RDSO/2015/CG-03

PART-I: GENERAL CONDITIONS

1.0 FOREWORD

1.1 LHB type coaches of Indian Railways have been design for an operating speed up to160 Kmph and could go up to 200 Kmph. These coaches have been provided with axlemounted disc brake system as per UIC stipulation. The axle mounted brake disc is thatpart of vehicle brake system that serves to convert kinetic energy into heat by means offriction. Axle mounted brake disc are ring-shaped castings with crosswise cooling ribs.They are manufactured from cast steel or grey cast iron.

1.2 This specification is intended to cover the provisions related to grey Cast Iron brake discto be pressed onto the Wheel set axle.

1.3 Following standards as applicable may be referred to in conjunction with thisSpecification:

a. UIC 541-3

b. EN 14535-1

c. EN 14535-3

d. DIN 27205-3

2.0 DEFINITION AND EXPLANATION

2.1 'PURCHASER' means the Indian Railways on behalf of the President of the Republic ofIndia who are purchasing the brake disc.

2.2 'INSPECTING AUTHORITY' means the organization or its representative nominated bythe purchaser to inspect the brake disc on his behalf. .

2.3 The Research Designs & Standards Organisation, Manak Nagar, Lucknow-22601.1 ishereafter referred to as 'ROSO'.

2.4 Rail Coach Factory, Kapurthala (Punjab) is hereafter referred to as RCF.

2.5 The Indian Railways is hereafter referred to as IR

3.0 SCOPE

3.1 This specification covers the technical requirements related to manufacture, supply,inspection, performance and testing of Axle Mounted Brake Disc to be pressed onto thewheel set axle of LHB type mainline BG coaches on Indian Railways and does notinclude all the necessary provisions of the contracts.

PARTICULAR REQUIREMENTS4.0

4.1 The firm willing to supply Axle Mounted Brake Disc for use on LHB type coaches ofIndian Railways shall register themselves with RDsa. Vendor approval processguidelines are available at ROSO website www.rdso.indlanrailwavs.aov In.

4.2 The firm should possess ISO: 9001 certificate issued by International AccreditationForum (IAF) under Multilateral Recognition Arrangement (MLA) for his works address,covering the items for which he seeks registration with ROSO.

Name&Designation


JElE&S and Brakes/Carria e

ed By:-Praveen Kumar

D . Directorl E&S and BrakeslCarria e

ApproveAnil Kumar Singh

Director/E&S and BrakeslCarria e

http://www.rdso.indlanrailwavs.aov

Ref: CGW0001 (Rev. -4) Page4 of 14 Date of issue: Nov., 2015 Spec. No. RDSO/2015/CG-03

4.3 The firm alongwith their principals/foreign collaborator shall have adequateinfrastructures for manufacturing, testing and quality control requirements of Brake Disc.This will be verified by the RDSO at the time of registration of the firm.

4.4 The firm shall submit their design of brake disc for approval of RDSO.

5.0 FUNCTIONAL REQUIREMENT

5.1 The brake disc of axle mounted disc brake system shall fulfill the following requirement,under Indian Railway service conditions without crack, damage over permitted underDIN27205-3, damage or degradation other than normal wear of the friction face beyondpermissible limits

5.1.1 Brake Disc shall permit a braking moment or torque to be generated, supported andtransmitted to the rail vehicle axle.

5.1.2 Brake Disc shall permit, by frictional engagement of a brake pad or pads, the conversioninto heat of the kinetic and potential energy involved in retarding the vehicles which isattributed to the use of the disc brake.

5.1.3 Brake disc shall absorb part or all of the kinetic and potential energy arising from thebraking of coaches.

5.1.4 Brake disc shall dissipate the absorbed energy by radiation, convection and conduction.

6.0 DESIGN REQUIREMENT

6.1 The axle mounted brake disc shall consist of the friction ring with cooling ribs and thehub. The friction ring of Brake Disc shall have to be cast as a single piece followed by itsmachining on required surfaces as per EN 14535-1. The thickness of the friction ring,and the size of the cooling ribs are related to prevent overheating during brakeapplication.

6.2 The brake disc (including friction ring and spokes) shall have adequate mechanical andthermal capacity for service on and off the Indian Railways, under the environmental andoperating conditions identified in Annexure-II.

6.3 Brake Disc shall be of 9/12 bolt design.

6.4 All parts of the brake disc shall be designed for fatigue strength.

6.5 In the design of axle mounted discs, the fatigue life of the connection between the huband friction ring must take into account cyclic loading from thermal and shockenvironments that are separately considered and are encountered in normal service.

6.6 The fatigue life at the most highly stressed location in the connection between the huband spoke, due to combined strains from thermal load and shock load, shall be equal toor greater than the projected service life of the friction ring or 20,00,000 km, whichever is

Signature (Name &Designation


JElE&S and Brakes/Carriage


D . Director/ E&S and Brakes/Carriage

Appr edBy:-Anil Kumar Singh

Director/E&S and Brakes/Carriage

Ref: CGW 0001 (Rev. - 4) Page 5 of 14 Date of issue: Nov., 2015 Spec. No. RDSO/201S/CG-03

and spoke, due to combined strains from thermal load and shock load, shall be equal toor greater than the projected service life of the friction ring or 20,00,000 km, whichever isgffia~~ •

6.7 Brake disc shall be designed and constructed in such a way that in case of hitting offlying stones raised from ballast track, it does not affect the functional efficiency or causefailure of disc.

6.8 The connections between brake discs and wheel set axle must satisfy the followingrequirements:

6.8.1 Transmission of brake power.

6.8.2 Largely unrestricted thermal expansion of friction faces and friction segments.

6.9 A minimum true specific weight shall be of great importance

6.10 The friction ring shall be designed additionally with a view to minimizing their overallweight.

6.11 The friction ring of brake disc shall have a groove around their outside circumference toindicate the condemning limit and when they have to be exchanged.

6.12 The crosswise cooling ribs carry off the heat and serve simultaneously to maintain athermal balance within the friction rings.

6.13 Cooling fins that are arranged radially between the friction surfaces provides forsufficient cooling at the friction ring. They convey a stream of cooling air from the hubthrough the interior of the friction ring to the outside, using a centrifugal force that iscontrolled by speed.

6.14 Low-noise behavior by the brake disc under all operational conditions shall be of greatimportance.

6.15 The replacement of worn, damaged brake discs/sections without dismounting of thewheels should be possible.

6.16 Supplier should also offer split disc design so that replacement for damaged or wom outdiscs can be achieved with ease without the necessity of dismounting of wheels from theaxles.

6.17 Unless the purchaser requests otherwise, a suitable hole and groove feature shall beincorporated to facilitate pressurized liquid assisted assembly and/or disassembly of huband axle. The threaded hole connection is to be closed with a locking bolt G1/4A x 8 DIN910 and sealing ring A 14 x 20 x 1.5 DIN 7603.

Name &Designation

/ApproAnil Kumar Singh


SignaturePrepared By: -Vivek Anand

JElE&S and Brakes/Carria e

d By:-veen Kumar

. Director/ E&S and Brakes/Carriage

Ref: CGW0001 (Rev. -4) Page 6 of 14 Date of issue: Nov., 2015 Spec. No. RDSO/201S/CG-03

7.0 PERFORMANCEREQUIREMENTS

7.1 The brake disc is to be so designed that it provides faultless operation under theconditions of use mentioned at Annexure - II for a period of at least 6 years from thedate of commission.

7.2 Brake disc should be designed in such a way that it has minimum wear and tear andmaintenance possibility. The goal for the wear limit on friction faces and frictionsegments shall be 2 million kilometers.

7.3 Design of the brake disc shall be such that the performance is not adversely affectedunder extreme positions of wheel and suspension movements under maximum wearconditions.

7.4 The brake disc offered shall be suitable to work with any UIC approved Organic BrakePads suitable for speeds upto 200 Kmph and must qualify frictional and thermalcharacteristics as stipulated in UIC 541-3.

8.0 QUALIFYINGREQUIREMENTS

8.1 The firm shall have atleast 3 years of experience in manufacturing of Brake disc andsupplying to any reputed intemational Railways.

8.2 The FIRM should have adequate plant, machinery and manufacturing capacity formanufacture and supply the brake disc within the delivery schedule.

8.3 The FIR M should have a well-established quality control system and testing facility toensure adequate quality, at all stages of manufacture.

8.4 The general design and drawing of the brake disc shall be got approved from ROSO.

8.5 QAP for the manufacture and inspection of the brake discs should be prepared by theFIR M and submitted to RDSO for approval.

8.6 Routine and Functional tests on the brake disc shall be done as indicated in Clause 15.

8.7 The prototype testing of any new design brake disc (which is being used by IR for thefirst time) shall be witness by the RDSO at the firm premises. All the inspection andtesting charges including logistics/air fare etc. shall be bome by the FIR M.

9.0 SUBMISSIONOF TECHNICALDOCUMENTS

9.1 The following technical documents/details in triplicate shall be submitted by the Firmalong with application:

9.1.1 The clause by clause comments on this specification, confirming compliance with all theclauses and elaborating, wherever necessary shall be enclosed.



Name &Designation


Dy. Director/ E&S and Brakes/Carria e

Approved By: -Anil Kumar Singh

Director/E&S and Brakes/Carria e

Ref: CGW 0001 (Rev. - 4) Page 7 of 14 Date of issue: Nov., 2015 Spec. No. RDSO/201S/CG~03

9.1.2 Detailed drawing in A 1/A2 size of Brake Disc which shall contain details regardingmaterial specification, dimensions, estimated weight, testing parameters, markingparticulars, reference to manufacturing I original collaborator's drawing etc.

9.1.3 Material data sheet for all components i.e. friction ring, hub, bolts etc. shall be madeavailable for verification to the visiting inspection agency.

9.1.4 FEA report of brake disc offered to Indian Railways. The maximum stress from the FEAat the specified load, with a factor of safety of atleast 1.50, shall be less than theallowable fatigue limit. The FEA report must include an analysis for fatigue life showingthe damage factor due to loads imposed by vertical and lateral axle box acceleration andthermal loads resulting from friction between disc and brake pads The FEA report shallinclude but not limited to, the following:

a) Introductionb) Table of contentsc) Summaryd) Physical properties of each material used for the disc. This table shall include but not

iimited to:• Yield strength• Ultimate strength• Elongation• Tension modulus• Compression modulus• Shear modulusMinimum values shall be used and shall be selected from material specification

e) Views of key structural areas (spoke, hub-friction ring connections, etc.) showingmember locations and geometry, and indicating the material and thickness of each.Other FEA views may be required where critical stresses are identified.

f) A tabulation or fatigue curve justifying the contractor's selection of allowable fatiguestresses for the disc material for each transition or joint, and the tatique-cntical stressranges. The FEA report shall include a description of how this process is carried out.

g) The complete test report must be submitted including procedure, raw and induceddata, and summary of results, including:• Structural sketches and/or layouts of the critically stressed locations showing.

locations and shapes depicted in scale, thickness, section properties andmaterial.

• Diagrams displaying extemally applied loads and boundary conditions,• Colour plots of the stress under each loads and boundary conditions.• Natural frequencies of the disc.

9.1.5 Hub & Friction ring connecting Bolt calculation report.

9.1.6 The corresponding wear calculations and/or tests at the testing bench.



ApprovedAnil Kumar Singh


Name &Designation

(I By:-aveen Kumar

D'y'.Director! E&S and Brakes/Carria e

Signature

Ref:CGW 0001 (Rev.-4) Page8 of 14 Dateof issue:Nov.,2015 Spec. No. RDSO/201S/CG-03

9.1.7 Details of testing facilities available at manufacturers.

9.1.8 For a new entrant or in case of any design changes of the existing approved suppliersthe Type and routine test specification and test reports shall be submitted.

9.1.9 Performance reports issued by various Intemational Railways on their brake disc.

9.1.10 The firm shall enclose the supply details along with performance reports issued byvarious Intemational Railways for their brake disc.

9.1.11 Operation and maintenance manual and service instructions.

9.2 In addition to the above, further information, if required by the ROSO/lndian Railways,shall be promptly provided by the Firm.

10.0 APPROVAL OF DRAWING

10.1 The design/drawing of the Brake disc shall be developed based on the technical andperformance requirements given in this specification and sound engineering practice.The entire drawing shall be submitted by the firm with technical data and calculations toROSO for approval.

10.2 The drawing shall be developed in SI units.

10.3 Material grade/ specifications for each component shall be indicated on the relevantdrawings of the firm and the firm shall supply copies of translation in English of suchspecifications/ drawings other than Indian Standard Specifications to purchaser/ROSO.

10.4 Approval of the design means the approval of the general design features.Notwithstanding the approval, the contractor will be wholly responsible for theperformance of the Brake disc offered.

11.0 DIMENSIONS AND TOLERANCES

11.1 Brake discs are intended to be mounted on the axle to ReF Drg. NO.LW02100 alt 'Nil'. Itshall be ensured by the firm that disc/discs offered by him are suitable to be fitted on tothe axle as per this drawing.

11.2 Broad specificatlon of the brake disc shall be as under:a) Dimensions 640 x 110 mmb) Outer Diameter of friction ring 640 +0/-1mmc) Inner Diameter of friction ring 350 mm .d) Width offriction ring 110 +01-0.3 mme) Inner bore 199 mm (H6)f) Width of hub 150 mm



Name &Designation


Dy. Director/ E&S and Brakes/Carriage

Ap ved By:-Anil Kumar Singh


Ref: CGW 0001 (Rev. - 4) Page 9 of 14 Date of issue: Nov., 2015 Spec. No. RDSO/2015/CG-03

11.3 The imbalance of new discs shall be equal to or less than 16gm.

12.0 MANUFACTURE

12.1 Brake Disc shall be manufactured as per drawing approved by the RDSO.

12.2 Brake Disc shall be free from casting defects.

12.3 No sharp corners or edges shall be present.

12.4 The surface roughness on friction faces shall be .::: 16 IJm, except where otherwisespecified by the IR or purchaser.

12.5 The surface roughness on hub bore shall be between 0.81Jmto 3.2IJm, except whereotherwise specified by the IR or purchaser.

12.6 Hub connection to the friction ring shall be made properly. The connecting bolts shall betightened with the specified torque wrench.

12.7 The brake disc shall be carefully protected against corrosion.

12.8 The friction faces, friction segments and surfaces which are exposed to hightemperature shall not be provided with surface protection.

12.9 The remaining surfaces shall be provided with either an appropriate lacquer structure orgalvanic coating or phosphating.

12.10 Surface protection shall be evident on the drawing.

13.0 PROTOTYPE INSPECTION

13.1 The manufacturer shall offer at least 3 Nos. Prototype discs of a new or modified brakedisc, the necessary testing according to Para 15 of this FR specification shall be carriedout on test piece.

13.2 The Prototype inspection of brake disc shall be carried out by Carriage Directorate ofRDSO or their nominee at manufacturer's premises. The manufacturer shall provide,without extra charges material, tools and any other assistance, which may considernecessary for any test examination and dimensional checking.

13.3 After prototype clearance, the brake disc shall be subjected to field trial as per Para 16.0of this specification.

14.0 PURCHASE INSPECTION

14.1 The purchase inspection shall be carried out at the premises of the manufacturer whoare registered with ROSO. The followi rocedure shall be followed: -

Name &Designation


JElE&S and Brakes/Carnage

Appro eAnil Kumar Singh


d8y:-veen Kumar


Ref: CGW 0001 (Rev. - 4) Page 10 of 14 Date of issue: Nov. 2015 Spec. No. RDSO/2015/CG-03

14.2 The Inspecting Authority shall make audit checks of the manufacturing procedure'Internal Quality Assurance System' to ensure that the Brake Disc offered for inspectionis manufactured strictly as per 'Internal Quality Assurance System' and the manufacturerhas carried out all the testslinspections during manufacturing stage to ensure that theBrake Disc as well as their components are manufactured strictly to the specification/drawing and quality standard of the collaborator. During audit checks the inspectionAuthority shall see from the records of 'Internal Quality Assurance' that the Raw materialused for the manufacture of Brake Disc is as per specification laid down.

14.3 Manufacturer shall have to maintain the internal tests record and submit to theInspection Authority.

14.4 The Inspection Authority shall conduct the following checks/tests of the Brake Disc froma lot of 250 Nos. or part thereof.

14.4.1 2% or minimum three number Brake Discs picked up at random shall be checked fordimensions and tolerances, general workmanship and surface finish as per ROSaapproved drawings.

14.4.2 1% or minimum one disc picked up at random shall be verified for tests mentioned inclause 15.2.1 (a), (b), (c) & (d) of specification. The supplier shall produce relevant testreports of the test done on the test bars/chilled samples used for the manufacture ofparticular batchllotlheat of disc for the tests mentioned in clause 15.2.1 (a), (b), (c) & (d).

14.4.3 Test reports for 2% or minimum three numbers Disc picked up at random shall beverified for tests mentioned in clause 15.2.1 (e) & (f) of specification.

14.5 In case the samples picked up fails in any of the tests/checks indicated at clause 14.4.1to 14.4.3, the entire lot of the Brake Disc shall be rejected by the Inspecting Authority.

14.6 Inspecting authority shall have access to all detailed manufacturing '/ originalcollaborator's drawings for all items of equipment. The firm shall be obliged to showthese drawings as and when called for.

14.7 The inspecting authority may deviate from the agreed procedure if and when foundnecessary to re-assure that the material is being fumished in accordance with thesespecifications. In this regard the manufacturer shall not be entitled to object on anyground whatsoever on the nature and procedure of testing that may be followed by theinspecting authority.

15.0 TESTS

15,1 Type Test

The following test shall constitute type test and shall be carried out in accordance to EN14535-3 (draft) at the time of Product approval of new entrant or at the time of designchange of existing design:

Name &Designation

ISignature




. Directorl E&S and Brakes/Carria e

App ~ed By:-Ani! Kumar Singh


Ref: CGW 0001 (Rev. - 4) Page 11 of 14 Date of issue: Nov., 2015 Spec. No. RDSO!2015/CG-03

b) Centrifugal Testc) Ventilation Testd) Heat dissipation test

15.2 Routine Test

15.2.1 The following test shall constitute routine test and shall be verified against valuespecified in manufacturer's specification/QAP:a) Chemical characteristicsb) Hardnessc) Tensile Testingd) Microstructuree) Magnetic Particle Testingf) Residual imbalance

16.0 FIELD TRIAL

16.1 The brake disc offered by the supplier shall be subjected to field trials on minimum 18coaches (Preferably 1 rake) for a period of minimum 2 years or 4,00,000 Km whicheveris later.

16.2 After the satisfactory performance of the field trials, the disc offered may be consideredfor regular service on Indian Railways and firm may be approved. The existing supplierswho have been successfully supplying Brake Disc for LHB coaches to Indian Railwayswill be exempted from the field trial.

17.0 GUARANTEE

17.1 The firm shall, at their cost, replace the Brake Disc failing prematurely or provingunsatisfactory in service for reasons attributed to defective/faulty design, defectivematerial or poor workmanship within a period of 72 months from the date of delivery or66 months from the date of fitment, whichever is earlier. This warranty shall survive,notwithstanding the fact that the brake disc may have been inspected, accepted andpayment thereof made by the firm.

18.0 AFTER SALES SERVICE

18.1 Firm may be required to send their technical expert during the installation andcommissioning of their brake disc on coach/coaches. The charges for this service shallbe quoted separately.

18.2 Firm shall also depute its technical expert on request by the Purchaser / ROSa toinvestigate and attend to specific problems that may come up during actual operation ofBrake Disc.

18.3 Firm shall supply at least 3 copies (Soft & hard copy both) of the Operation &Maintenance Manuals and Servicing Instructions to each coaching depot where LHBcoach maintenance is done:



Name &Designation

ed By:-raveen Kumar


Appr By:-Anil Kumar Singh


Ref: CGW 0001 (Rev. - 4) Page 12 of 14 Date of issue: Nov., 2015 Spec. No. RDSO!2015!CG-03

18.3.1 Brief Details of brake disc.

18.3.2 Details of attention to be given during IOH/POH or any other schedule examination.

18.3.3 Details of tools & machinery for maintenance of brake disc.

18.3.4 Typical defects and their remedial measures.

18.3.5 Maintenance standards including clearances and tolerances at various locations andpermissible limits of wear for good service performance of equipments.

18.3.6 Firm shall submit the frequency and detailed work content of various inspection /maintenance schedules necessary for maintenance of brake disc offered by them.Whether these requirements are time based or distance travelled based shall beindicated for each schedule.

19.0 MARKING

19.1 The detailed form of the marking shall be defined on the drawing. The following datashall be applied to the part in a clearly recognized way:

a) Manufacturer's data (manufacturer's name I trade mark), month & year ofmanufacture and serial number.

b) Residual imbalance in gm (Data regarding residual brake disc imbalance shall belocated directly in the place where the imbalance occurs).

The above data shall be stamped/engraved, clearly legible, in an appropriate location.

20.0 PACKING

20.1 Supplier shall ensure that Brake Discs in an assembled condition are adequately packedbefore dispatch to prevent damage in transporting, handling and storage. The safetransportation shall be the responsibility of manufacturer.

Prepared By: -VivekAnand


Name &Designation

ed By:-raveen Kumar

D . Director/ E&S and Brakes/Carriage

App ed By:-Anil Kumar Singh


. Signature

Ref: CGW 0001 (Rev. - 4) Page 13 of 14 Date of issue: Nov., 2015 Spec. No. RDSO/2015/CG-03

ANNEXURE-I

DESIGN DATA AND LOAD CASES FOR BRAKE DISC

a) THERMAL LOAD AND BRAKING SCENARIO

S. Description Unit Emergency ServiceNo. Braking Braking1. Mean Braking Radius (ml Meter 0.247 0.2472. Wheel diameter (New) (m) Meter 0.915 0.9153. Wheel diameter (Wom) (m) Meter 0.B45 0.B454. Mean Co-efficient of friction of Brake Pads - 0.35 0.355. Surface Area of Brake Pads crrr 400 4006. Braked Mass Kg BOOO BOOO7. Starting velocity Kmph 160 160B. Final velocity Kmph 0 09. Brake application time Sec 4 410. Deceleration rate rn/sec" 1.2 0.8011. Clamping force per disc kN 42 2512. Kinetic energy MJ 7.9 7.913. Load cycles - 6000 62500

b) IMPACT LOAD

S.No. Description Vertical Axial1. Standard Impact 25g 3g2. Extraordinary Impact 100g 100g

Signature /Name&Designation



Ap ved By:-Anil Kumar Singh


Ref: CGW 0001 (Rev. -4) Page 14 of 14 Date of issue: Nov., 2015 Spec. No. RDSO/2015/CG-03

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

ANNEXURE-IIOPERATING CONDITIONS FOR BRAKE DISC

Coach Type

Axle Load

Gross Load (Coach)

Gross Load (Train)

Operating speed (max)

Maximum deceleration

Emergency Braking distance

Wheel diameter

LHB Type BG Passenger coaches

16.25t (rnax.)

65t (max.)

1700t (max. without loco)

160 Kmph

1.3 m/sec'

1~00 meter

915 (New)845 (Worn)

2560rnrn

102 rnrn under loaded and wornCondition

3.5°, 82rnrn

Wheelbase

Minimum clearance above rail level

Maximum bogie rotation and swing

12. Track Parameters

a) Steepest Gradientb) Sharpest curvaturec) Super elevation (max)

13. Environmental condition

1 in 37175 m radius1765 mm max.

a) Maximum temperature under sunb) Maximum temperature under shadec) Minimum temperature at Nightd) Altitudee)

70°C45°C- 5 -cSea level to 652 meters100% saturation during rainySeason

f) Rain falls Fairly heavyg) Atmosphere during hot weather DustyEnvironment: Coaches shall be working in coastal area with saline and corrosiveatmosphere.

Humidity

14. The vibrations and shocks normally to be encountered in service.

a) Maximum vertical accelerationb) Maximum longitudinal accelerationc) Maximum transverse acceleration

= 3.0 95.0 g2.0 g

==

App ved By:-Anil Kumar Singh


SignabJre /Name &Designation




Dy. Directorl E&S and Brakes/Carria e

Documents

INDIAN RAILWAYS - rdso.ggn.rcil.gov.inrdso.ggn.rcil.gov.in/QAMD/QA_Mech/3795/RDSO_2015_CG_03.pdf · 1.1 LHB type coaches of Indian Railways have been design ... mounted disc brake