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TB/T 3395.3-2015 English PDF (TBT3395.3-2015)

TB/T 3395.3-2015 English PDF (TBT3395.3-2015)

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TB/T 3395.3-2015: Fastening systems for high-speed railway Part 3: Type V fastening system

This Part specifies the fastener composition, assembly performance, technical requirements of parts, inspection methods, inspection rules, marking and packaging, storage and transportation of type V fastening system. This Part is applicable to type V fastening system for high-speed railway with ballasted tracks.
TB/T 3395.3-2015
TB
RAILWAY INDUSTRY STANDARD OF
THE PEOPLE REPUBLIC OF CHINA
ICS 45.080
S 11
Fastening systems for high-speed railway - Part 3: Type V
fastening system
ISSUED ON: JULY 15, 2015
IMPLEMENTED ON: FEBRUARY 01, 2016
Issued by: National Railway Administration
Table of Contents
Foreword ... 3
1 Scope ... 4
2 Normative references ... 4
3 Fastener components ... 6
4 Assembly performance ... 7
5 Technical requirements for parts ... 8
6 Inspection method ... 15
7 Inspection rules ... 23
8 Signs and packaging ... 26
9 Storage and transport ... 27
10 Laying and maintenance repairs ... 27
Appendix A (Normative) Test method for compressive performance of gauge baffles ... 28
Appendix B (Informative) Laying and maintenance of type V fastening systems ... 31 Fastening systems for high-speed railway - Part 3: Type V
fastening system
1 Scope
This Part specifies the fastener composition, assembly performance, technical requirements of parts, inspection methods, inspection rules, marking and packaging, storage and transportation of type V fastening system.
This Part is applicable to type V fastening system for high-speed railway with ballasted tracks.
2 Normative references
The following documents are essential to the application of this document. For the dated documents, only the versions with the dates indicated are applicable to this document; for the undated documents, only the latest version (including all the amendments) is applicable to this standard.
GB/T 224 Determination of depth of decarburization of steels
GB/T 230.1 Metallic materials - Rockwell hardness test - Part 1: Test method(scales A, B, C, D, E, F, G, H, K, N, T)
GB/T 232 Metallic materials - Bend test
GB 443-1989 Lubricating oils for total loss systems L-AN
GB/T 528 Rubber, vulcanized or thermoplastic - Determination of tensile stress- strain properties
GB/T 531.1 Rubber vulcanized or thermoplastic - Determination of indentation hardness - Part 1: Durometer method (Shore hardness)
GB/T 699 Quality carbon structural steels
GB/T 1040.1 Plastics - Determination of tensile properties - Part 1: General principles
GB/T 1040.2 Plastics - Determination of tensile properties - Part 2: Test conditions for molding and extrusion plastics
TB/T 2329 Fatigue test method for type I and type II fastening elastic strip TB/T 2478 Grading diagram for elastic strip metallographic structure
TB/T 2626 Technical specification for rubber subplate under railway concrete track TB/T 3395.1 Fastening systems for high-speed railway - Part 1: General requirement TB/T 3396.1 Test methods for fastening systems of high-speed railway - Part 1: Determination of longitudinal rail restraint
TB/T 3396.2 Test methods for fastening systems of high-speed railway - Part 2: Determination for clamping force
TB/T 3396.4 Test methods for fastening systems of high-speed railway - Part 4: Test of fatigue performance of fastening assembly
TB/T 3396.5 Test methods for fastening systems of high-speed railway - Part 5: Determination of electrical resistance
TB/T 3396.6 Test methods for fastening systems of high-speed railway - Part 6: Effect of severe environmental conditions
TB/T 3396.7 Test methods for fastening systems of high-speed railway - Part 7: Vertical load test for cast-in fastening components
3 Fastener components
The type V fastening system is composed of spiral spikes, flat washers, elastic strips, gauge baffles, under-rail subplates (rubber subplates or composite subplates), embedded casings. It can also include height-adjusting subplates. The connection and assembly of the fasteners is as shown in Figure 1.
5.2.1 Raw materials
The raw material of spiral spikes is high-quality carbon structural steel, alloy structural steel or cold heading steel. The performance of raw materials shall meet the requirements of GB/T 699, GB/T 3077 or GB/T 6478.
5.2.2 Type size
The type and size of the spiral spike shall comply with the design requirements; the position of the hexagonal head as relative to the center line of the bolt, the full run-out, the straightness of the bolt shall comply with the requirements of grade C in GB/T 3103.1-2002.
5.2.3 Appearance
5.2.3.1 There shall be no folds and wrinkles at the connection between the head of the spiral spike and the shaft.
5.2.3.2 Except for the first thread, the threads of the spiral spikes shall be even and complete.
5.2.3.3 Spiral spikes shall not be over-burned; the surface of the thread shall be smooth and clean, without cracks, dents, burrs, floating rust, flash, burns, oxide scales that affect the use.
5.2.4 Mechanical properties
The minimum actual tensile force of the spiral spike shall not be less than 190 kN; the elongation at break shall not be less than 12%; the hardness shall not be greater than 34 HRC.
5.2.5 Cold bending performance
There shall be no cracks on the threaded part of the spiral spike (after anti-rust treatment), after the 15?? cold bending test.
5.2.6 Anti-rust performance
The surface of the spiral spike shall be subject to anti-rust treatment. The spikes after anti-rust treatment shall meet the thread precision requirements; the protection level shall not be lower than level 5, after 120 h neutral salt spray (NSS) test. 5.3 Rubber subplate and composite subplate
5.3.1 Raw materials
The raw material of the rubber part of the rubber subplate and the composite subplate is mainly composed of natural rubber or synthetic rubber; reclaimed rubber shall not be sleeper and the rail shall be 0.5 mm.
5.4.3 Appearance
The surface of gauge baffles shall be uniform in color and free from visible defects, such as pinholes, burnt marks, flashes, burrs. The position of the parting line, the injection port and the ejector pin shall not be set on the contact plane of the gauge baffle, the sleeper and the rail.
5.4.4 Drainage rate
The gauge baffle shall be conditioned by absorbing water. The drainage rate of the gauge baffle, after water absorption conditioning, shall not be less than 0.4%. 5.4.5 Hardness
The hardness of the gauge baffle shall not be less than 105 HRR.
5.4.6 Internal voids
There shall be no air bubbles or voids inside the gauge baffle.
5.4.7 Insulation resistance
The insulation resistance of the gauge baffle shall be greater than 5 ?? 106 ??. 5.4.8 Compressive performance
The gauge baffle shall not be damaged after the compressive performance test; its warping value shall not be greater than 0.5 mm.
5.5 Embedded casing
5.5.1 Raw materials
The raw material of the embedded casing is glass fiber reinforced polyamide 66 or other materials, whose performance is not inferior. The physical and mechanical properties of raw materials shall meet the requirements in Table 3.
5.5.2 Type size
The type and size of the embedded casing shall meet the design requirements; the perpendicularity shall be 0.5 mm.
5.5.3 Appearance
The surface of the embedded casing shall be uniform in color; there shall be no visible defects, such as pinholes, burnt marks, flashes, burrs, except on the parting line with a height not greater than 0.5 mm. The internal thread shall not have defects, that prevent treatment.
6 Inspection method
6.1 Elastic strip inspection
6.1.1 Type and size inspection
The type and size of the elastic strips are checked, using special measuring tools and general measuring tools.
6.1.2 Visual inspection
Carry out visual inspection of the appearance of the elastic strip.
6.1.3 Crack inspection
The surface crack inspection of elastic strips shall be carried out, according to GB/T 15822.1.
6.1.4 Hardness test
The hardness test of the elastic strips shall be carried out, according to GB/T 230.1. The sampling part of the test piece is the middle part of the middle limb of the elastic strip (cutting length is about 13 mm ~ 21 mm); test four points within the range from the center of the cross section of the test piece to 1/2 radius; the reading accuracy is not less than 0.5 HRC. Take the average value of the last three points.
6.1.5 Metallographic structure test
The metallographic structure test of the elastic strip is carried out, according to TB/T 2478. The sampling position of the test piece is the same as 6.1.4.
6.1.6 Decarburization layer test
The decarburization layer test of the elastic strip is carried out, according to GB/T 224. The sampling position of the test piece is the same as 6.1.4.
6.1.7 Residual deformation test
The residual deformation test of the elastic strip is carried out, according to TB/T 1495.2. The test tire type is as shown in Figure 2.
6.2.3 Mechanical performance test
The mechanical performance test of spiral spikes shall be carried out, according to GB/T 3098.1.
6.2.4 Cold bending performance test
The cold bending performance test of the spiral spike is carried out, according to GB/T 232, using a supporting roller bending device; the radius of the supporting roller is 24 mm; the diameter of the bending indenter is 72 mm.
6.2.5 Anti-rust performance test
The salt spray test (NSS test) and rating of spiral spikes are carried out, according to GB/T 10125 and GB/T 6461, respectively.
6.3 Inspection of rubber subplate and composite subplate
6.3.1 Type and size inspection
The type and size of rubber subplate and composite subplate shall be checked, using general measuring tools.
6.3.2 Visual inspection
The appearance of the rubber subplate and the composite subplate shall be inspected visually AND with a general measuring tool.
6.3.3 Hardness test
The hardness test of the rubber, in the rubber subplate and the composite subplate, shall be carried out according to GB/T 531.1, using a Shore A durometer. The hardness measurement point shall be selected, on the plane between the grooves of the subplate, which is not less than 10 mm away from the edge of the subplate. Test 5 different positions of each subplate. Take the median as the test result.
6.3.4 Test of tensile strength and elongation at break
The test of tensile strength and elongation at break of the rubber, in the rubber subplate and the composite subplate, shall be carried out according to GB/T 528, using the type 1 specimen. Take 6 specimens from each subplate, 3 of which are subjected to the performance test before aging, whilst the other 3 specimens are subjected to the performance test after aging. The aging test is carried out, according to GB/T 3512, under the aging conditions of 70 ??C and 168 h. After aging, the specimen needs to be standing for 16 hours before testing. The test result takes the median. 6.3.5 Test of 200% fixed elongation stress
h1 - The thickness of the subplate after the test, in millimeters (mm). 6.3.8 Oil resistance test
The oil resistance test of the rubber, in the rubber subplate and the composite subplate, shall be carried out according to GB/T 1690, using the type I specimen. Take 3 specimens from each subplate. The test medium is 46# engine oil, in accordance with the provisions of GB 443-1989. The test conditions are 23 ??C ?? 2 ??C. Fully immerse it for 24 h. Take the median as the test result.
6.3.9 Working resistance test
The working resistance test of rubber subplate and composite subplate shall be carried out, according to TB/T 2626.
6.3.10 Adhesive peel strength test
The adhesive peel strength specimen of the stainless steel plate and the rubber part of the composite subplate is prepared from the actual object. The test is carried out according to GB/T 7760.
6.3.11 Static stiffness test
The static stiffness test of the rubber subplate and the composite subplate shall be carried out, according to Appendix A of TB/T 3395.1.
6.3.12 Dynamic and static stiffness ratio test
Take the rubber subplate and the composite subplate, after the static stiffness test, to carry out the dynamic stiffness test, according to the provisions of Appendix B of TB/T 3395.1. Calculate the dynamic and static stiffness ratio after the test. 6.3.13 Fatigue performance test
The fatigue performance test of rubber subplate and composite subplate shall be carried out, according to Appendix C of TB/T 3395.1.
6.3.14 Compression cold resistance coefficient test
The compression cold resistance coefficient test of rubber subplate and composite subplate is carried out, according to HG/T 3866. The test temperature is -40 ??C. The compression rate is 20%. Cut out three cuboid test blocks, which have a cross-section of 10 mm ?? 10 mm and a thickness equal to the actual thickness, from the four corners of each rubber subplate. Take the arithmetic mean value as the test result. 6.4 Gauge baffle inspection
6.4.1 Type and size inspection
The drainage rate test is carried out, according to the following steps: a) After the water absorption conditioning process, the pre-embedded casing shall be allowed to stand for no less than 12 hours; then the initial mass shall be weighed, recorded as W1;
b) Place the pre-embedded casing in a heating furnace, at 120 ??C ?? 3 ??C for 2 hours continuously; weigh the mass within 3 minutes after taking it out; record it as W2. Calculate the drainage rate P, according to formula (4):
Where:
P - Drainage rate, expressed as a percentage (%);
W1 - The initial mass, in kilograms (kg);
W2 - The mass after heating, in kilograms (kg).
6.5.4 Tensile performance test
Put the pre-embedded casing into the test chuck with internal thread. Then screw all the threaded parts with the corresponding threaded screw into the casing. Slowly apply the load on the tensile testing machine, along the centerline of the casing, at a loading rate of 2 kN/s ~ 3 kN/s. When the load reaches 100 kN, hold for 1 min. Observe whether the inner and outer threads of the casing are damaged, after unloading. 6.5.5 Insulation resistance test
Carry out test, using a high resistance tester. First boil the embedded casing for 2 hours. Then fill it with 4% brine. Make the brine level 5 mm lower than the top surface of the embedded casing, to avoid overflow of brine during the test. Then put the pre-embedded casing into a glass tank, which is filled with 4% saline. Make the water level of the brine in the tank equal to the water level of the brine in the casing. Measure the resistance value, between the inner and outer saline of the casing, at a 500 V DC voltage. 6.6 Inspection of height adjustment subplate
6.6.1 Type and size inspection
Check the type and size of the height adjustment subplate, using a general measuring tool.
6.6.2 Visual inspection
a) Product name;
b) Specifications and models;
c) Quantity;
d) Weight;
e) Manufacturer name;
f) Manufacturing batch number;
g) Date of manufacture.
9 Storage and transport
9.1 Storage
9.1.1 Elastic strips, spiral spikes, flat washers should be stored indoors. If they are stored in the open air, they shall be covered with a roof or a sheet of tarpaulin; prevent the ground water from soaking the packaging.
9.1.2 Gauge baffles, embedded casings, height adjustment subplates shall not be stored in the open air. They shall not be stored in the same warehouse with acids, organic solvents and other chemicals. The temperature in the warehouse shall not exceed 60 ??C. 9.1.3 The subplate under the rail shall be stored in a clean, ventilated place, which is away from direct sunlight AND away from heat sources and chemical reagent pollution. The storage period is one year. During the storage period, the performance indicators of the subplate shall not be lower than the provisions of this standard. 9.2 Transportation
9.2.1 Fastener parts shall not be violently bumped or thrown, during transportation. 9.2.2 The subplate under the rail shall not be in contact with chemicals, which are harmful to rubber, such as oil and organic solvents, during transportation. Meanwhile it shall be protected from exposure to the sun.
10 Laying and maintenance repairs
Refer to Appendix B, for fastener laying and maintenance.
Appendix A
(Normative)
Test method for compressive performance of gauge baffles
A.1 Principle
Apply load to the gauge baffle, through the testing machine, to test the degree of warpage and damage of the gauge baffle.
A.2 Equipment
A.2.1 Testing machine
A testing machine, that can apply a load of at least 70 kN and has a precision level of level 1.
A.2.2 Mounting frame
A mounting frame, that can simulate the mounting position of the gauge baffle. A.2.3 Loading blocks
A loading block, which can simulate the application of lateral force by the rail to the gauge baffle, AND has the same cross-sectional size as the 60 kg/m rail bottom. A.3 Test procedure
A.3.1 Before the test, place the gauge baffle on the measuring platform, to measure the warping height of one corner, which is recorded as d1.
A.3.2 The test device for compressive performance of the gauge baffle is as shown in Figure A.1.

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