GOST R 56666-2015
GOST R 56666−2015 Technical diagnostics. Acoustic method for diagnostics and remaining life assessment of side frames of car trucks. General requirements
GOST R 56666−2015
Group Т59
NATIONAL STANDARD OF THE RUSSIAN FEDERATION
Technical diagnostics
ACOUSTIC METHOD FOR DIAGNOSTICS AND REMAINING LIFE ASSESSMENT OF SIDE FRAMES OF CAR TRUCKS
General requirements
Technical diagnostics. Acoustic method of diagnostics and evaluation of a residual resource of side frames trucks wagons. General requirements
OKS 77.040.10
Date of introduction 2016−07−01
Preface
1 DEVELOPED by the Open joint-stock company «Scientific-research center of control and diagnostics of technical systems» (JSC «NIC KD») with the participation of Nizhny Novgorod state technical University n.a.R.E.Alekseev (NSTU them.R.E.Alekseeva)
2 SUBMITTED by the Technical Committee for standardization TC 132 «Technical diagnostics"
3 APPROVED AND put INTO EFFECT by the Federal Agency for technical regulation and Metrology, dated 22 Oct 2015 N 1617-St
4 INTRODUCED FOR THE FIRST TIME
Application rules of this standard are established in GOST R 1.0−2012 (section 8). Information about the changes to this standard is published in the annual (as of January 1 of the current year) reference index „National standards“ and the official text changes and amendments — in monthly information index „National standards“. In case of revision (replacement) or cancellation of this standard a notification will be published in the upcoming issue of the monthly information index „National standards“. Relevant information, notification and lyrics are also posted in the information system of General use — on the official website of the Federal Agency for technical regulation and Metrology on the Internet (www.gost.ru)
Introduction
Side frame trucks freight cars are one of the most important power components of the rolling stock, destruction of which leads to serious consequences.
The technology can significantly reduce the probability of failure of frames due to the presence of casting flaws, however, the risk of appearance and development of fatigue cracks remain.
In the operation of the frame in the structure of its metal is the accumulation of scattered damage, not detectable by traditional methods of testing, regulated by GOST 32699, which leads to dangerous macrocrack, the distribution of which the cast structure is very fast, therefore it is desirable to prevent its occurrence especially in areas of stress concentration.
Technical capabilities used in rail transport methods of nondestructive testing can be used to assess the degradation of the metal frames in the stages before the advent of the threat of macro defects, although these stages and present a major interest for the development of methods of evaluation of actual (not standard) individual residual resource of the frame.
Accumulated to date, the results of theoretical and experimental studies show that the method of inspection of metal condition of technical objects from the point of operation before the appearance of macro defects can be built on the basis of modern methods of physical acoustics.
This standard is designed to provide a methodological basis for the application of the acoustic method for the diagnosis and evaluation of individual residual life of the side frames of the car trucks.
1 Scope
This standard specifies General requirements for the method of performing acoustic measurements to diagnose and assess residual resource of the side frames of the car trucks, the relevant GOST 32400.
The standard can be used to determine the residual resource of the side frames after the appointed time of service and the subsequent appointment of a new designated life.
Calculation-experimental method recommended by this standard permits the use of additional methods of destructive and nondestructive testing, as well as the computational methods of mechanics damaged the environment to clarify the assessment of a residual resource.
This standard specifies:
— the contents and the order of the procedures of measurements with acoustic operation control distortion of the material of the side frames of car trucks;
— hardware requirements and software used in the measurement process;
— requirements for metrological provision of the method and apparatus used;
— requirements for registration of inspection results.
2 Normative references
GOST 7.32−2001 System of standards on information, librarianship and publishing. The report on research work. The structure and rules of registration
GOST 12.1.001−89 System safety standards. Ultrasound. General safety requirements
GOST 12.1.004−91 System safety standards. Fire safety. General requirements
GOST 12.1.038−82 standards System of labor safety. Electrical safety. The maximum permissible values of the touch voltage and currents
GOST 12.2.003−91 System safety standards. Equipment production. General safety requirements
GOST
GOST 12.3.002−75 System safety standards. The process of production. General safety requirements
GOST 27.002−89 reliability of the technique. Basic concepts. Terms and definitions
GOST 427−75 Rulers measuring metal. Specifications
GOST 2768−84 Acetone. Specifications
GOST 2789−73 surface Roughness. Parameters and characteristics
GOST 6616−94 thermoelectric Converters. General specifications
GOST 16465−70 the electronic measuring Signals. Terms and definitions
GOST 17299−78 ethyl Alcohol technical. Specifications
GOST 20799−88 Oils. Specifications
GOST 30489−97* (EN 473:1992) the Qualification and certification of personnel in nondestructive testing. General requirements
________________
* Access to international and foreign documents referred to here and hereinafter, can be obtained by clicking on the link to the site shop.cntd.ru. — Note the manufacturer’s database.
GOST 32400−2013 side-Frame and bolster beam cast trucks train freight cars
GOST 32699−2014 side-Frame and bolster beam moulded three-element two-axle freight cars Railways of 1520 mm gauge. non-destructive testing Methods
GOST R 8.563−2009 State system for ensuring the uniformity of measurements. Techniques (methods) of measurements
GOST R 12.1.019−2009 System of standards of occupational safety. Electrical safety. General requirements and nomenclature of types of protection
GOST R 55725−2013 nondestructive testing. Piezoelectric ultrasonic transducers. General technical requirements
GOST R ISO 5725−2-2002 Accuracy (trueness and precision) of methods and measurement results. Part 2. The basic method for the determination of repeatability and reproducibility of a standard measurement method
Note — When using this standard appropriate to test the effect of reference standards in the information system of General use — on the official website of the Federal Agency for technical regulation and Metrology on the Internet or in the annual information index „National standards“ published as on January 1 of the current year, and the editions of the monthly information index „National standards“ for the current year. If replaced with a reference standard, which was given an undated reference, then it is recommended to use the current version of this standard, taking into account all enabled in this version modifications. If replaced with a reference standard, which is given a dated reference, it is recommended to use the version of this standard referred to above by year of approval (acceptance). If after approval of this standard in the reference standard, which is given a dated reference, a change affecting a provision to which reference, the provision is recommended to be applied without taking into account this change. If the reference standard is cancelled without replacement, the position in which reference is made to him, recommended to be used in part not affecting this link.
3 Terms, definitions, symbols and abbreviations
3.1 this standard applies the following terms with respective definitions:
3.1.1 operational damage: the Dimensionless quantity, changing in the process of operation of the lateral frame 0 at the beginning of operation to 1 in the transition of the frame material in the ultimate state according to GOST 27.002 calculated on the basis of the results of acoustic measurement and calculation methods used in the mechanics of damaged environment.
3.1.2 superficial damage: Damage of material of the side frame in the surface layer to a depth of 1 mm, the averaged propagation path of a pulse of surface acoustic waves Rayleigh (base Converter).
3.1.3 volumetric damage: Damage of material the side frames, averaged over the thickness in the measurement area and the width of the transducer of longitudinal elastic waves.
3.1.4 microdamages: Structural microdefects (micropores, microcracks, etc.), not detectable by standard methods of fault detection, developing in the process of operation of the frame and leading to the emergence of dangerous cracks.
3.1.5 reference pulse: a Specially formed impulse, which is calculated relative pulse delay of the surface acoustic wave of Rayleigh.
3.1.6 relative mileage: the ratio of the mileage of the car at the time of diagnosis to the actual resource frame.
3.2 this standard applies the following designations: — pulse delay of elastic surface Rayleigh waves relative to the reference pulse when n repeated measurements, NS
=1, …, n;
— the average value of pulse delay of elastic surface Rayleigh waves relative to the reference pulse, NS;
the delay value
reduced to 20 °C, NS;
values
for the new frame, NS;
— average delay
for a new frame, NS;
the delay value
reduced to 20 °C, NS;
is the limit value of the delay
before the appearance of macrodefects;
— surface damage;
— the temperature of the surface to be inspected frame, °C;
— the surface temperature of the new frame, °C;
— thermo-acoustic coefficient of Rayleigh waves, 1/°C;
— delay of the second pulse of the reflected elastic longitudinal wave relative to the first by n repeated measurements, NS
=1, …, n;
— average delay value of the second reflected pulse of longitudinal elastic waves with respect to the first, NS;
values
for the new frame, NS;
— average delay
for a new frame, NS;
— bit analog-to-digital Converter used controls;
the magnitude of the first reflected pulses in n repeated measurements;
— the average value of the magnitude of the first reflected pulse;
values
for the new frame;
the average value
for the new frame;
values of the noise parameter equal to the ratio of noise power to the power of the first reflected pulse;
— the average value of the noise parameter;
values of the noise parameter for the new frame;
— the average value of the noise parameter for the new frame;
— the value
given by the value
equal to 2/3 of its maximum;
— the value
for the new frame;
— limit value
corresponding to the onset of macrodefects;
— volumetric damage;
— the mileage of the car at the time of diagnosis of the condition of the frame, thousand km;
the actual resource of the frame is the mileage of the car until the threat macrodefects in the frame material, thousand.
3.3 this standard applies the following abbreviations:
BRT — side frame trucks freight cars;
PAVR — surface acoustic Rayleigh waves;
PEP — piezoelectric Converter;
SK — means of control;
Wee — ultrasonic pulse.
4 General provisions
4.1 Recommended standard method is based on the existing dependencies between the parameters of propagation of elastic surface waves from body waves and the level of microdamage in the material structure of BRT gained in the course of its operation.
4.2 the method uses a manual method of ultrasonic pulse-echo contact testing with the use of combined and separate-combined piezoelectric converters according to GOST R 55725.
4.3 the Form of the emitted signal is a pulse with high frequency (ultrasonic) filling, with a smooth envelope and effective duration (at the level of 0.6 of the maximum amplitude) 2 to 4 periods of the fundamental frequency.
4.4 Measured characteristics of damage are the volume average of the ultrasonic beam, determined by the transverse dimensions probe material thickness and the type of waves.
Note — When using Rayleigh waves averaging results for the volume of distribution of surface waves determined by the base of the Converter, the size of its active elements and frequency.
4.5 Directly measured values are the delays (propagation times of the material) and the UI scale according to GOST 16465.
4.6 the Effect of temperature on the accuracy of measurement of informative acoustic parameters into account using the appropriate thermo-acoustic coefficients having the dimension of 1/°C. Their values must be contained in the database used by the UK or can be obtained experimentally according to the procedure described in Appendix A.
4.7 To diagnose and assess residual resource of BRT uses established during the endurance test of dependence between acoustic characteristics and the amount of mileage of the car.
4.8 Recommended in this standard method can serve as the basis for the drafting of methods of measurements GOST R 8.563.
4.9 In developing the techniques of measurements must be verified on the basis of a representative base experienced BRT.
5 safety Requirements
5.1 measurements allow personnel trained, training in a timely manner, certified in voluntary certification system to the appropriate level of qualification according to GOST 30489 according to [1], [2].
5.2 Under the control of the material condition of BRT operator should be guided by GOST 12.1.001, GOST 12.2.003, GOST 12.3.002 and safety regulations for electrical installations according to GOST R 12.1.019 and GOST
5.3 Facilities for measurements shall meet the requirements [3] and [4].
5.4 In the organization of works on control of the material condition of BRT must be met fire safety requirements according to GOST
6 Requirements for control devices
6.1 as CCS use installation consists of production equipment, or specialized ultrasonic devices certified in accordance with [5] and verified in accordance with [6].
6.2 In the structure of the IC must contain the following probes:
— combined direct transducer of longitudinal waves type П111−5,0, GOST R 55725;
— the Tr probe PWR type П122−3,0 GOST R 55725.
6.3 Assistive devices and materials
6.3.1 Grinding tool for surface preparation according to GOST
6.3.2 Thermocouple surface type TPP TPP 10 or 13 according to GOST 6616 for measuring the surface temperature of BRT.
6.3.3 Degreasing liquid (alcohol according to GOST 17299 or acetone GOST 2768) for surface preparation.
6.3.4 couplant (industrial oil brands-30A,-40A, AND 50A according to GOST 20799, water).
6.3.5 Capacity to store a contact liquid, a brush for applying a contact fluid on the surface of products, rags for wiping of ultrasonic equipment and the operator’s hands, a metal ruler 500 mm according to GOST 427 BRT for marking, marker or chalk for drawing labels on controlled products, log for log control.
6.4 SK must ensure the measurement of the echo method using the UI with a smooth envelope.
6.5 SK must ensure the sampling of the ultrasonic signal with a frequency that exceeds at least 10 times the maximum effective frequency of the used probes.
6.6 SK must contain an analog-to-digital converters have a precision of at least 12.
6.7 the UK should provide the possibility of determining the delays of elastic pulses by the method of signal transfer through zero [7].
6.8 Primary acoustic information for each dimension should always be stored on external media, protected from unauthorized access.
6.9 Documentation of SK must contain the measurement procedure and the documents that establish:
— the purpose and scope of the insurance;
— the composition and main characteristics of the hardware and software, including measurement error parameters of the UI;
— methods and means of achieving compatibility of the UK, including data, electrical, energy, software, development, and operational.
7 Requirements for building control
7.1 surface Roughness of BRT in the areas of measurement — not more than 40 µm according to GOST 2789.
7.2 the surface temperature of the BRT should be in the range from 5 °C to 40 °C.
8 the Procedure for preparation of the control
8.1 Areas of measurement selected in accordance with figure 1.
Figure 1 — Zone measurements
Figure 1 — Zone measurements
8.2 Prepare to control surface BRT in the areas of measurement in accordance with 7.1.
8.3 the Prepared surface shall have the dimensions 50% larger than the used probe.
8.4 Ready to work SK.
8.5 is Measured in the selected zones of the surface temperature of BRT T with the limit on the sinfulness of ±1°C.
8.6 Moisten the surface zones of the measurement contact liquid.
Note — Stated in 8.1−8.6 of the preparation for the measurement is the same for new and diagnosed BRT.
9 the Procedure of control
9.1 Connect to the SC Converter AVR.
9.2 In accordance with the user manual SK carried out the measurement of the delay of the impulse PAR with the reinstallation of the probe. The number of repetitions n must be at least 10.
As the measured delay should use the time intervals between the points of zero crossing of the working and reference pulses in accordance with figure 2.
9.3 Conduct the measurement of the delay for the study area BRT.
Figure 2 — Typical waveform of the measurement transducer PWR
1 — reference pulse; 2 — pulse PWR
Figure 2 — Typical waveform of the measurement transducer PWR
9.4 is Connected to the IC probe longitudinal waves.
9.5 Conduct a repeated (at least 10 times), measurement delay , scale
and noise settings
.
Delays are determined by the signal transfer through zero.
When measured by using the longitudinal transducer, check the automatic configuration levels and boundaries of the first and second reflected pulses.
The right border of the first reflected pulse should be approximately midway between the pulses (figure 3).
If necessary, the levels and limits must be set manually.
Figure 3 — Typical waveform of the longitudinal impulses
Figure 3 — Typical waveform of the longitudinal impulses
Note — Outlined in 9.1 to 9.5 the procedures for measuring the same for new and diagnosed BRT.
10 Processing of inspection results
10.1 For all measured acoustic parameters (array of values
,
,
,
,
,
,
,
) carry out a standard pre-statistical processing for elimination of blunders using the criterion of Smirnov in accordance with GOST R ISO 5725−2.
10.1.1 All parameter values are arranged in a variation row
10.1.2 Calculate the average value:
and standard deviation:
10.1.3 Define the values and
formulas:
10.1.4 Values and
compared to the criteria table values
.
When 
| 2,03 | for | |
| 2,18 | for a | |
| 2,41 | for | |
10.1.5 When the conditions are met
________________
* Numbering corresponds to the original. — Note the manufacturer’s database.
values and
are not considered faults and to calculate the relevant averages
using the entire ordered series
,
, …,
.
10.1.6 If the condition (5) or (6) (or both simultaneously) the corresponding values are excluded from the variational series.
EBank opening and servicing 10.1.7 After the corresponding reduction in the value of n for further calculations use a truncated variational series.
10.2 After exclusion of misses for all of the measured parameters to calculate the coefficients of variation .
10.3 Check the following conditions:
10.3.1 When all conditions are satisfied (7−10) go to 10.4.
10.3.2 If at least one of the conditions (7−10) was not performed for the corresponding acoustic parameter, a second measurement with a larger number n.
10.3.3 If the increase in the number of measurements n does not lead to fulfillment of the conditions (7−10), should decide on the possibility of further measurements with reduced accuracy.
10.4 Calculate values .
10.5 In the case that the surface temperature of the BRT at the time of measurement for a new frame at the time of diagnosis differs from 20 °C by more than 10 °C, instead of the values and (or)
in further calculations, use the values
and (or)
which is calculated by the formula:
In the absence in the database is SK thermoacoustic coefficients determined experimentally in accordance with the procedure described in Appendix A.
10.6 calculate the value of the surface damage according to the formula
where 
10.7 calculate the parameters of the linear regression ,
variable
by variable
by the formulas:
10.8 Calculate the value according to the formula
10.9 calculate the value of the volumetric damage by the formula
where 
If the values that
10.10 estimation of the relative residual life of the frame
10.10.1 In this standard under the relative residual resource of the frame means the value
10.10.2 determining the relative residual life based on the use obtained during the endurance test dependencies
Note — depending on the results of endurance tests based on (19) and (20) can be both functional and regression.
10.10.3 On the basis of the measurement results at the time of diagnosis values of bulk and surface distortion , and
using dependencies (19) and (20) determine the values of the relative residual resources
and
, as shown in figure 4.
Figure 4 — relative residual resource
Figure 4 — relative residual resource
10.10.4 For the relative residual life take a little of the values
and
.
11 Rules of registration of testing results
11.1 the results of the control record in the journal, the form of which is given in the recommended Appendix B.
11.2 Additional information you wish to write, the order of registration and storage of the journal (or conclusion) must be installed in the technical documentation for the control.
11.3 If the definition of a technical condition of the material of BRT is part of the research work, the results of control measurements should be made in accordance with the requirements of GOST 7.32.
11.4 the results of the survey should be maintained until the next control of BRT.
Annex a (mandatory). Determination of thermo-acoustic coefficients
Appendix A
(required)
A. 1 Definition of thermoacoustic coefficients is performed on the basis of the study of regression dependences of the delays of pulses par the
temperature Tof the control sample.
A. 2 Measurement of temperature dependences is carried out on a flat control samples of material of BRT in the laboratory.
Control samples should have a thickness not less than 5 mm, the transverse dimensions by at least 50% larger than the used probe and the surface roughnessRz not more than 40 µm according to GOST 2789.
A. 3 the surface Temperature of the sample is measured using a thermoelectric Converter according to GOST 6616.
A. 4 the Samples are heated to a temperature of 80 °C, then for a uniform temperature distribution maintained at room temperature to 60 °C.
A. 5 as the cooling of the sample at intervals of 5 °C is carried out temperature measurement of the sample surface and the corresponding delays
for each
, the values of temperature.
A. 6 thermo-acoustic coefficients calculated by the formula
where 
is the total number of measurements for a given sample.
A. 7 Measurement is repeated for 3−5 samples averaged results.
Appendix B (recommended). Form of the control Protocol
Appendix B
(recommended)
| „CLAIM“ Head | |||||||
| name of the organization | |||||||
| personal signature |
initials, surname | ||||||
| » | " | 20 | G. | ||||
PROTOCOL
determine the technical condition of the material side frame trucks freight cars using the acoustic method
(name, object code control) 1 measurement date | ||||||||
| 2 organization conducting the measurement | ||||||||
| 3 Owner car | ||||||||
| 4 information about the object control: date of manufacture | ||||||||
| the manufacturer | ||||||||
| material grade | ||||||||
| mileage, thousand km | ||||||||
| for more information about the test object | ||||||||
| 5 the equipment Used, head. N type probe | ||||||||
| 6 Sketch of the test object showing the location of areas of measurements and their numbering (in the app) | ||||||||
| 7 Conclusion about the presence of dangerous macro defects 8 the surface temperature of the object of control, °C | ||||||||
| 9 Name and code of the database | ||||||||
10 | ||||||||
Table 1 — values of acoustic characteristics in areas of measurement
| Zone number of measurements |
||||
Table 2 — Results of processing of measurements
| Zone number change rhenium |
The value of the surface damaged |
The value of the volume is damaged- |
Forecast take- |
Forecast take- |
Take |
| The research done by the operator: | |||
| personal signature |
initials, surname | ||
| Head of laboratory NDT: | |||
| personal signature | initials, surname | ||
Bibliography
| [1] |
RD 32 079−2005 wheel drive Model regulations on the preparation, training, periodical knowledge check and personnel certification for nondestructive inspection of enterprises for rolling stock and carriages |
| [2] |
PR 32.113−98 Rules of certification of personnel for nondestructive testing of technical objects of railway transport |
| [3] |
SNiP 2.09.03−85 Construction of industrial enterprises. Design standards |
| [4] |
SanPiN 2.2.½.1.1.1200−03 Sanitary-protective zones and sanitary classification of enterprises, constructions and other objects |
| [5] |
PR 50.2.105−09 State system for ensuring the uniformity of measurements. The procedure for approval of type of standard samples or type of measuring instruments |
| [6] |
PR 50.2.006−94 State system for ensuring the uniformity of measurements. The procedure of verification of measuring instruments |
| [7] |
MVI. Standard samples of time of passage of ultrasonic signals. The determination of basic metrological characteristics. IMP UB RAS, Ekaterinburg, 2007. 16 S. |
| UDC 620.172.1:620.179.16:006.354 |
OKS 77.040.10 |
Т59 |
| Keywords: technical condition, the side frame trucks freight cars, the echo method, the ultrasonic pulse, delayed pulses, scale pulses, a piezoelectric transducer, an elastic wave | ||
The electronic text of the document
prepared by JSC «Code» and checked by:
the official publication of the
M.: STANDARTINFORM, 2016
