code of procedures for ultrasonic testing of axles … · 2019-10-17 · code of procedures for...

CODE OF PROCEDURES FOR ULTRASONIC TESTING

OF

AXLES AND WHEEL OF LARGE TRACK MACHINES

REFERENCES

S.NO. MACHINE MODEL

POSITION OF AXLE

REPORT/DRAWING REFERRED

RDSO LETTER NO.

DATE OF ISSUE

1. Unimat 08-275

Axle UD62.4901 SP 1668/1676

TM/HM/7

15/22.01.2008

2. UNIMAT 08-275-3S, DGS-62N, 09-3X and UNIMAT COMPACT M

Axle WN02-120.184.1SP 1668/1676

TM/HM/7

15/22.01.2008

3. RM80, FRM 80 and RM 76

Axle 64.02.2249 TM/HM/7

15/22.01.2008

4. CSM (09-32) and DUOMATIC (08-32)

Driving axle UD 62.3301 SP 1668/1676

TM/HM/7

15/22.01.2008

5. Track Machine Wheels

--- RDSO report no.IRS R-34-2003

TM/HM/7 Vol.III

02/06.6.2006

6. UTV90TT (Phooltas)

Powered axle

M/s. Phooltas. TM/HM/7 Vol.III

26/28.02.2007

7. CSM (09-32)

Satellite or Driving Bogie axle

CPOH Drg. No. C-1411 CSM

TM/HM/7

07.2.2003

8. DUOMATIC

Driving axle IRTMTC Drg. No. D-1402 DUO-R1

TM/HM/7

07.2.2003

9. UNIMAT

Front driving axle

CPOH Drg. No. UNI-1402

TM/HM/7

07.2.2003

10. UNIMAT

Rear driving axle

CPOH Drg. No. UNI-1401

TM/HM/7

07.2.2003

11. CSM (09-32)

Running axle

IRTMTC Drg. No. C-1406 CSM

TM/HM/7

07.2.2003

CONTENT

S.NO. MACHINE MODEL POSITION OF AXLE PAGE NO.

1. Unimat 08-275

Axle 1-10

2. UNIMAT 08-275-3S, DGS-62N, 09-3X and UNIMAT COMPACT M

Axle 11-20

3. RM80, FRM 80 and RM 76

Axle 21-30

4. CSM (09-32) and DUOMATIC (08-32)

Driving axle 31-39

5. Track Machine Wheels

--- 40-46

6. UTV90TT (Phooltas)

Powered axle 47-61

7. CSM (09-32)

Satellite or Driving Bogie axle

62-75

8. DUOMATIC

Driving axle 62-75

9. UNIMAT

Front driving axle 62-75

10. UNIMAT

Rear driving axle 62-75

11. CSM (09-32)

Running axle 62-75

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CODE OF PROCEDURE OF ULTRASONIC TESTING OF TRACK

MACHINE UD62.4901 SP. 1668/1676 AXLE FOR 08-275 OF M/s PLASSER

INDIA Pvt. Ltd. IN SERVICE (TENTATIVE).

1. SCOPE : To ensure safety and reliability of rolling stocks, axles are

required to be examined periodically for presence of cracks. This

code stipulates the testing procedure, calibration method and

sensitivity setting for detection of cracks in Track Machine

UD62.4901 SP. 1668/1676 Axle for 08-275 of M/s Plasser India Pvt.

Ltd. in service.

2. NORMATED REFERENCES: The following RDSO / IS standards contain

provisions, which through reference in this text constitute provisions of

this code of procedure. At the time of publication, the editions

indicated were valid.

Specification No. Title

RDSO specification No.

M&C/NDT/104/2000

(Rev.1) April 2005

or

Technical specification for battery cum-

mains operated ultrasonic flaw detector

having memory calibration and 100 mm X

80 mm screen.

RDSO specification

No.M&C/NDT/125/2004

Portable digital ultrasonic flaw detector with

A-scan storage.


WD-17-MISC-92

Soft grease

IS:1628-1986

Reaffirmed in Feb.1996

Axle oil

IS: 1875-1992 Carbon steel billets, blooms, slabs and bars

for forging.

IS:12666-1988

Reaffirmed in 1993

Methods for performance assessment of

ultrasonic flaw detection equipment.

of 75

3. PROCEDURE OF EXAMINATION:

3.1 Equipment and accessories to be employed:

3.1.1 Equipment: Ultrasonic flaw detector approved by RDSO, Lucknow to

RDSO specification No.M&C/NDT/104/2000 (Rev.1) April 2005 or

No. M&C/NDT/125/2004 or any other ultrasonic flaw detector

meeting RDSO specification No. M&C/NDT/104/2000 (Rev.1) April

2005 or No. M&C/NDT/125/2004.

3.1.2 Accessories : Far end scanning : Normal probe of 2.5 MHz, 20/25mm dia.,

Lead zirconate titanate or crystal of similar characteristics.

Near end low angle scanning : Normal probe of 2.5 MHz, 15/20 mm

dia., Lead zirconate titanate or crystal of similar characteristics with

perspex wedge capable of producing ultrasonic wave at 17.5o angle or

angle probe of 17.50 .

High angle scanning : Normal probe of 2.5 MHz, 20/25 mm dia.,

Lead zirconate titanate or crystal of similar characteristics with perspex

wedge capable of producing ultrasonic wave at 37 o

angle or angle

probe of 370 having dia. of curvature 140 +

200 mm .

3.1.3 Couplant: Soft grease or axle oil (medium) to RDSO specification No. WD-

17- MISC-92 or IS :1628 (86) Reaffirmed in Feb. 96 .

3.1.4 Standard bar : 50mm dia. x 500 mm long and 50mm dia. X 182 mm long

steel bar to designation 45C8 of IS:1875 –1992 rolled/forged and

normalized having grain size No.5 or finer to ASTM/E-10-39T.

3.2 Personnel engaged in testing: Testing of Axles shall be done only by trained

and certified personnel having valid RDSO certificate. Under no

circumstances testing shall be carried out by any other personnel not

meeting this requirement.

3.3 Scanning techniques :

3 .3.1 Far end scanning : This technique shall be used for testing the full length

of the axle from gear end as well from free end .

The time scale shall be calibrated to 250mm per main scale division of

compression wave. The normal probe of 2.5 MHz having 20/25 mm

dia shall be placed on the clean axle end faces with suitable couplant.

The probe shall be given slight rotary movement for proper acoustic

coupling while proving from ‘X’ end & ‘Y’ end. The expected signals

have been shown in Annexure.

of 75

3.3.2 Examination by Trace Delay Technique: This technique shall be

employed to examine the axle in part of 500 mm each. This

technique may be utilized for confirmation of the findings during

Far End scanning.

The expected signals have been shown in Annexure.

3.3.3 Near End - Low Angle Scanning: This technique is used for examination

of fatigue cracks in the raised seat inner fillet area, which remains

unscanned during far end scanning.

The time scale shall be calibrated to 100 mm per main scale

division for compression wave. The normal probe of 2.5 MHz having

15/20 mm dia shall be placed on the clean axle end faces with suitable

couplant. The probe shall be given slight rotary movement for proper

acoustic coupling while probing from ‘X’ end & ‘Y’ end. The expected

signals have been shown in Annexure.

3.3.4 High Angle Scanning : This technique may be employed for

confirmation of the findings during Near End Low Angle

Scanning.

The time scale shall be calibrated to 50 mm per main scale division

for shear wave with the help of 50 mm dia. X 182 mm long steel

bar (since 5 X 182 = 910 mm longitudinal wave is equivalent to 5 X

100 mm = 500 mm of shear wave).


shear wave. The normal probe of 2.5 MHz having 20/25 mm dia shall

be placed on the body of the axle at a distance of 120 mm from wheel

seat inner fillet with suitable couplant directing the central beam

towards wheel seat inner fillet. The probe shall be given slight rotary

movement for proper acoustic coupling. The expected signals have

been shown in Annexure.

3.3.5 Scale expansion: The analysis of oscillogram pattern having closely placed

echoes may be simplified by expanding the relevant part of the

pattern. This can be done with the scale expansion control provided

in the machine.

4. IMPORTANT NOTE :

1. Prior to ultrasonic testing it may be ensured that the axle end faces are

smooth for achieving proper acoustic coupling. If required, the end

faces of the Axle should be properly smoothened by filing /emery

finishing for achieving proper acoustic coupling.

of 75

2. In low angle and high angle scanning the onset of the signal in relation

to the initial pulse is a function of the thickness of the perspex wedge

at the probe index marking and the velocity of the ultrasonic wave in

the perspex.

3. If the thickness of the perspex wedge at the probe index marking is

more than the one used for the preparation of this code, the onset of

the signal is likely to shift towards right side of the standard position of

the signal.

4. It may be ensured that, calibration and sensitivity setting shall be

carried out before ultrasonic testing of the axles.

5. Various characteristics of the equipment and probes may be checked as

per IS-12666 at least once a month.

5. CRITERIA FOR ACCEPTANCE :

(a) Axle found to produce flaw signal other than those standard signals as

shown in the relevant trace patterns during scanning by Far End and

Near End Low Angle Scanning techniques shall be withdrawn from

service. Further confirmation of the defect may be carried out by Trace

Delay & high angle scanning.

(b) Axle found to produce signals as per the standard signals as given in

the Annexure should be declared satisfactory.

(c) During service, few standard signals may disappear due to change in

the geometrical configuration of axle. This aspect may be kept in view.

6. MAGNETIC PARTICLE TESTING:

Axles found defective during ultrasonic examination described above

should be subjected to magnetic particle examination after removal of

the wheels, bearings etc. as the case may be. Record of magnetic

particle examination and observations made shall be maintained in the

register.

7. RECORDING OF TEST DETAILS:

Ultrasonic personnel conducting the test shall maintain a register

indicating the complete details of axle identification, technique

employed, observation made , code of procedure followed and his

remarks. He should also record his observations on visual examination

of the axles.

of 75

Annexure-I

Theoretical calculations and relative positions of signals of axle of Tie

Tamping Machine UD62.4901 SP 1668/1676 axle for 08-275 of Plasser India

Pvt. Ltd. (Tentative).

(A) FAR END SCANNING : 1 Main Scale Div. = 250 mm (compression wave)

Probe: 20/25, 2.5 MHz

From ‘X’ End:

Sl

No.

DETAILS Distance

(mm)

Signal Echo

(Div.)

1. Direct reflection from axle end. 2162 8.6

2. Direct reflection from journal fillet 2021 8.0

3. Delayed reflection from fillet at a distance of

1669 mm from probing end

1942 7.8



1819 7.3



1669 6.7

6. Delayed reflection from wheel seat inner fillet 594 2.4



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From ‘Y’ End Side:

SL.

No.

Details Distance

(mm)

Signal Echo

(Div.)

1. Direct reflection from axle end 2162 8.6




1227 4.9



1104 4.4



954 3.8




(B) TRACE DELAY SCANNING:

From ‘X’ End: ( 1 main scale div. = 50 mm)

0-500 mm:

S.NO. DETAILS DISTANCE

(mm

SIGNAL

(divn.)

1. Direct reflection from wheel seat inner fillet 321 6.4


of 75

500 mm- 1000 mm

S. NO. DETAILS DISTANCE

(mm

SIGNAL

(divn.)


1000mm - 1500 mm NIL

1500mm - 2000 mm:


(mm

SIGNAL

(divn.)

1. Direct reflection from fillet at a distance of


169 3.4



319 6.4



442 8.8

2000mm - 2500 mm:


(mm)

SIGNAL

(divn.)



From ‘Y’ End: ( 1 main scale div. = 50 mm)

0-500 mm:


(mm

SIGNAL

(divn.)



of 75

500 mm - 1000 mm:

S. NO. DETAILS DISTANCE

(mm

SIGNAL

(divn.)


2. Direct reflection from fillet at a distance of 954

mm from probing end

454 9.1

1000mm - 1500 mm:

S.

NO.

DETAILS DISTANCE

(mm

SIGNAL

(divn.)

1. Delayed reflection from fillet at a distance of 954

mm from probing end

104 2.1

3. Delayed reflection from fillet at a distance of 954

mm from probing end

227 4.5

1500mm - 2000 mm : NIL

2000mm - 2500 mm:


(mm)

SIGNAL

(divn.)



of 75

(C) NEAR END LOW ANGLE SCANNING 1 Main Scale Div. = 50mm

(Compressive Wave)

Probe : 15/20mm, 2.5 MHz

FROM ’X’ & ‘Y’ END SIDE :

S.NO. Details Distance

(mm

Signal Echo

(div.)

1. Direct reflection from wheel seat inner fillet.

(Wedge : 17.5, Central beam at 36mm from

edge of axle)

340 6.8

HIGH ANGLE SCANNING: 1 Main Scale Div. = 50 mm (Shear wave)

Probe: 20/25mm. , 2.5 MHz

From ‘X’ & ‘Y’ END SIDE :


(mm)

Signal Echo

(div.)

1. Direct reflection from gear seat inner fillet.

(Wedge : 37 with dia. of curvature 140mm,

Stand off distance 120 mm from wheel seat

inner fillet.)

194 3.9

of 75


MACHINE WN02-120.184.1 SP 1. 1668/1676 AXLE FOR 08-275 3S, DGS-62,

09-3X & UNIMAT COMPACT M OF M/s PLASSER INDIA Pvt. Ltd. IN

SERVICE (TENTATIVE).




sensitivity setting for detection of cracks in Track Machine WN02-

120.184.1 SP1. 1668/1676 AXLE FOR 08-275 3S, DGS-62, 09-3X &

UNIMAT COMPACT M of M/s Plasser India Pvt. Ltd. in service.







M&C/NDT/104/2000

(Rev.1) April 2005

or




80 mm screen.

RDSO specification

No.M&C/NDT/125/2004


A-scan storage.


WD-17-MISC-92

Soft grease

IS:1628-1986


Axle oil


for forging.

IS:12666-1988

Reaffirmed in 1993



of 75







2005 or No. M&C/NDT/125/2004.










angle or angle


200 mm .











3 .3.1 Far end scanning : This technique shall be used for testing the full

length of the axle from gear end as well from free end .







of 75


employed to examine the axle in part of 500 mm each. This technique

may be utilized for confirmation of the findings during Far End

scanning.


3.3.3 Near End - Low Angle Scanning: This technique is used for

examination of fatigue cracks in the raised seat inner fillet area, which

remains unscanned during far end scanning.


of compression wave. The normal probe of 2.5 MHz having 15/20 mm

dia shall be placed on the clean axle end faces with suitable couplant. The

probe shall be given slight rotary movement for proper acoustic coupling

while probing from ‘X’ end & ‘Y’ end. The expected signals have been

shown in Annexure.


confirmation of the findings during Near End Low Angle Scanning.

The time scale shall be calibrated to 50 mm per main scale division for

shear wave with the help of 50 mm dia. X 182 mm long steel bar (since

5 X 182 = 910 mm longitudinal wave is equivalent to 5 X 100 mm = 500

mm of shear wave).

The time scale shall be calibrated to 50mm per main scale division of shear

wave. The normal probe of 2.5 MHz having 20/25 mm dia shall be placed

on the body of the axle at a distance of 130 mm from wheel seat inner fillet

with suitable couplant directing the central beam towards wheel seat inner

fillet. The probe shall be given slight rotary movement for proper acoustic

coupling. The expected signals have been shown in Annexure.



pattern. This can be done with the scale expansion control

provided in the machine.

4. IMPORTANT NOTE :


smooth for achieving proper acoustic coupling. If required, the end faces of

the Axle should be properly smoothened by filing /emery finishing for

achieving proper acoustic coupling.

2. In low angle and high angle scanning the onset of the signal in relation to

the initial pulse is a function of the thickness of the perspex wedge at the

probe index marking and the velocity of the ultrasonic wave in the perspex.

of 75

3. If the thickness of the perspex wedge at the probe index marking is

more than the one used for the preparation of this code, the onset of

the signal is likely to shift towards right side of the standard position of

the signal.

4. It may be ensured that, calibration and sensitivity setting shall be carried

out before ultrasonic testing of the axles.



5. CRITERIA FOR ACCEPTANCE:








(c) During service, few standard signals may disappear due to change in the

geometrical configuration of axle. This aspect may be kept in view.






register.






of the axles.

of 75

Annexure-I

Theoretical calculations and relative positions of signals of axle of Track

Machine WN 02-120.184.1 SP1. 1668/1676 for 08-275 3S, DGS-62, 09-3X &

UNIMAT COMPACT M of Plasser India Pvt. Ltd. (Tentative).


Probe: 20/25mm, 2.5 MHz

From ‘X’ End Side:

SL .

No.

DETAILS Distance

(mm)

Signal Echo

(Div.)





1525 6.1



1384 5.5

5. *Delayed reflection from fillet at a distance

of 1212 mm from probing end

1212 4.8

6. Delayed reflection from wheel seat inner fillet 634.5 2.5


8. Direct reflection from wheel seat inner fillet 321.5 1.3

of 75


SL.

No.

Details Distance

(mm)

Signal Echo

(Div.)





1741 7.0



1600 6.4



1428 5.7






0-500 mm:


(mm)

SIGNAL

(divn.)



500 mm- 1000 mm

S. NO. Details Distance

(mm)

Signal

(divn.)


of 75

1000mm - 1500 mm:


(mm)

Signal

(divn.)



212 4.2



384 7.7

1500mm - 2000 mm:


(mm)

Signal

(divn.)



25 0.5

2000mm - 2500 mm:


(mm)

Signal

(divn.)



of 75


0-500 mm:


(mm

Signal

(divn.)



500 mm - 1000 mm:


(mm)

Signal

(divn.)


1000mm - 1500 mm:

S.

NO.

Details Distance

(mm)

Signal

(divn.)



428 8.6

1500mm - 2000 mm :

S.

NO.

Details Distance

(mm)

Signal

(divn.)



100 2.0



241 4.8

of 75

2000mm - 2500 mm:


(mm)

Signal

(divn.)




(Compressive Wave)




(mm

Signal Echo

(div.)


(Wedge : 17.5, Central beam at 38 mm from

edge of the axle)

344 6.9


Probe: 20/25mm. , 2.5 MHz, Wedge 37



(mm)

Signal Echo

(div.)




inner fillet.)

224 4.5

of 75


MACHINE 64.02.2249 AXLE FOR RM 80. FRM 80 & RM 76 OF M/s

PLASSER INDIA Pvt. Ltd. IN SERVICE (TENTATIVE).





64.02.2249 Axle for RM 80. FRM 80 & RM 76 OF M/s Plasser India

Pvt. Ltd. in service.







M&C/NDT/104/2000

(Rev.1) April 2005

or




80 mm screen.

RDSO specification

No.M&C/NDT/125/2004


A-scan storage.


WD-17-MISC-92

Soft grease

IS:1628-1986


Axle oil


for forging.

IS:12666-1988

Reaffirmed in 1993



of 75







2005 or No. M&C/NDT/125/2004.










angle or angle


200 mm .











3 .3.1 Far end scanning : This technique shall be used for testing the full

length of the axle from gear end as well from free end .







of 75


employed to examine the axle in part of 500 mm each. This technique

may be utilized for confirmation of the findings during Far End

scanning.



examination of fatigue cracks in the raised seat inner fillet area,

which remains unscanned during far end scanning.


division of compression wave. The normal probe of 2.5 MHz having

15/20 mm dia shall be placed on the clean axle end faces with suitable






Scanning.






shear wave. The normal probe of 2.5 MHz having 20/25 mm dia shall

be placed on the body of the axle at a distance of 132 mm from wheel

seat inner fillet with suitable couplant directing the central beam

towards wheel seat inner fillet. The probe shall be given slight rotary

movement for proper acoustic coupling. The expected signals have

been shown in Annexure.





4. IMPORTANT NOTE :





of 75




the perspex.

3. If the thickness of the perspex wedge at the probe index marking is more

than the one used for the preparation of this code, the onset of the

signal is likely to shift towards right side of the standard position of the

signal.




















register.






of the axles.

of 75

Annexure-I

Theoretical calculations and relative positions of signals of axle of Track

Machine 64.02.2249 axle for RM80. FRM80 & RM 76 M/s Plasser India Pvt.

Ltd. (Tentative).




SL .

No.

Details Distance

(mm)

Signal Echo

(Div.)



3. Direct reflection from wheel seat outer fillet 2032.5 8.1


1377.5 mm from probing end

1682 6.7


1377.5mm from probing end

1545 6.2



1377.5 5.5




of 75


SL.

No.

Details Distance

(mm)

Signal Echo

(Div.)






1879 7.5



1742 7.0



1574.5 6.3






0-500 mm:


(mm)

Signal

(divn.)


500 mm- 1000 mm


(mm)

Signal

(divn.)



of 75

1000mm - 1500 mm:


(mm)

Signal

(divn.)



377.5 7.6

1500mm - 2000 mm:


(mm)

Signal

(divn.)



45 0.9



182 3.6

2000mm - 2500 mm:


(mm)

Signal

(divn.)




of 75


0-500 mm:


(mm

Signal

(divn.)


500 mm - 1000 mm:


(mm)

Signal

(divn.)



1000mm - 1500 mm: NIL

1500mm - 2000 mm :

S.

NO.

Details Distance

(mm)

Signal

(divn.)



74.5 0.9



242 4.8



379 7.0

of 75

2000mm - 2500 mm:


(mm)

Signal

(divn.)





(Compressive Wave)




(mm)

Signal Echo

(div.)



edge of the axle)

380 7.6





(mm)

Signal Echo

(div.)




inner fillet.)

216 4.3

of 75


MACHINE UD62.3301 SP 1668/1676 (DRIVING) AXLE FOR 09-32 CSM &

08-32 DUOMATIC OF M/s PLASSER INDIA Pvt. Ltd. IN SERVICE

(TENTATIVE).





UD62.3301 SP 1668/1676 (Driving) Axle for 09-32 CSM & 08-32

Duomatic of M/s PLASSER INDIA Pvt. Ltd. in service.







M&C/NDT/104/2000

(Rev.1) April 2005

or




80 mm screen.

RDSO specification

No.M&C/NDT/125/2004


A-scan storage.


WD-17-MISC-92

Soft grease

IS:1628-1986


Axle oil


for forging.

IS:12666-1988

Reaffirmed in 1993



of 75







2005 or No. M&C/NDT/125/2004.










angle or angle


200 mm .











3.3.1 Far end scanning : This technique shall be used for testing the full length

of the axle from gear end as well from free end .


compression wave. The normal probe of 2.5 MHz having 20/25 mm dia shall

be placed on the clean axle end faces with suitable couplant. The probe shall

be given slight rotary movement for proper acoustic coupling while proving

from ‘X’ end & ‘Y’ end. The expected signals have been shown in Annexure.

of 75




Far End scanning.



examination of fatigue cracks in the raised seat inner fillet area,

which remains unscanned during far end scanning.


division

of compression wave. The normal probe of 2.5 MHz having 15/20

mm dia shall be placed on the clean axle end faces with suitable






Scanning.


for shear wave with the help of 50 mm dia. X 182 mm long steel bar

(since 5 X 182 = 910 mm longitudinal wave is equivalent to 5 X 100

mm = 500 mm of shear wave).


shear wave. The normal probe of 2.5 MHz having 20/25 mm dia shall be

placed on the body of the axle at a distance of 132 mm from wheel seat

inner fillet with suitable couplant directing the central beam towards

wheel seat inner fillet. The probe shall be given slight rotary movement

for proper acoustic coupling. The expected signals have been shown in

Annexure.



pattern. This can be done with the scale expansion control provided

in the machine.

4. IMPORTANT NOTE :





of 75




the perspex.

3. If the thickness of the perspex wedge at the probe index marking is more

than the one used for the preparation of this code, the onset of the

signal is likely to shift towards right side of the standard position of the

signal.




















register.






of the axles.

of 75

Annexure-I

Theoretical calculations and relative positions of signals of axle of Tie

Tamping Machine UD62.3301 SP 1668/1676 (Driving) for 09-32 CSM & 08-32

Duomatic of M/s Plasser India Pvt. Ltd. (Tentative).

(A)FAR END SCANNING : 1 Main Scale Div. = 250 mm (compression wave)



SL .

No.

Details Distance

(mm)

Signal Echo

(Div.)





1690 6.8



1567 6.3



1417 5.7



1481 5.9



1347.5 5.4



1185 4.7




of 75


SL.

No.

Details Distance

(mm)

Signal Echo

(Div.)





1479 5.9



1356 5.4



1206 4.8






0-500 mm:


(mm)

Signal

(divn.)



500 mm- 1000 mm


(mm)

Signal

(divn.)


of 75

1000mm - 1500 mm:


(mm)

Signal

(divn.)



206 4.1



356 7.1



479 9.6

1500mm - 2000 mm: NIL

2000mm - 2500 mm:


(mm)

Signal

(divn.)



of 75


0-500 mm:


(mm

Signal

(divn.)



500 mm - 1000 mm:


(mm)

Signal

(divn.)


1000mm - 1500 mm:

S.

NO.

Details Distance

(mm)

Signal

(divn.)



185 3.7



347.5 7.0



417 8.3



481 9.6

1500mm - 2000 mm :

S.

NO.

Details Distance

(mm)

Signal

(divn.)



367 7.3



490 9.8

of 75

2000mm - 2500 mm:


(mm)

Signal

(divn.)




(Compressive Wave)




(mm)

Signal Echo

(div.)



edge of the axle)

340 6.8


Probe: 20/25mm. , 2.5 MHz., Wedge 37

From ‘X’ & ‘Y’ END :


(mm)

Signal Echo

(div.)




inner fillet.)

100 3.0

of 75

METHOD OF ULTRASONIC TESTING & ACCEPTANCE STANDARD FOR LOCOMOTIVE WHEELS

(RDSO Report No.IRS R–34-2003

(TO BE USED FOR WHEELS OF LARGE TRACK MACHINES ALSO)

For detecting internal discontinuities in the rim and the hub of the wheel, ultrasonic inspection shall be carried out by following the procedure shown below and by using equipment which complies with the following requirements. Reference standard used for sensitivity setting shall be from wheels conforming to this standard. The surface finish of probing face shall be in accordance with the relevant wheel drawing. Ultrasonic inspection shall be performed after final thermal and machining operations.

A-1 ULTRASONIC TESTING ON WHEEL RIM

The rims of the wheels will be checked through ultrasonic inspection to detect the defects at two orientations.

i) Defect parallel to the rim face (axial testing)

ii) Defect parallel to the running tread (radial testing)

A-1-1 AXIAL TESTING

All wheels will be subjected to ultrasonic testing of rim through probing axially along the rim face to defect any flaw having orientation parallel to the rim face.

A-1-1-1 Equipment:

A-1-1-1-1 Automatic ultrasonic testing equipment shall be used. The instrument shall have a pulse echo transmitter and receiver and shall have an operating frequency range of 2 to 5 MHz. The manufacturer shall have on-line test facility to inspect 100% wheels. For determination of final rejection, manual ultrasonic equipments approved by the purchaser may be employed.

A-1-1-1-2 The transducers shall be of normal (o degree) type comprising of high sensitivity Piezo electric ceramic crystal operating at 2 to 2.5 MHz frequency and of 18-20 mm diameter.

A-1-1-1-3 An automatic flaw system shall be used in conjunction with the ultrasonic instrumentation to facilitate flaw indication beyond acceptable level.

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A-1-1-1-4 An immersion or contact type testing technique shall be used in automatic on-line testing. For manual testing of suspect wheels a suitable couplant shall be used between the test surface and

the transducer. In case of dispute in respect of couplant the decision of the inspecting officer shall be final and binding.

A-1-1-1-5 Calibration block 50mm x 50mm x 50mm block of steel to grade 45C8 of IS:1875.

A-1-1-1-6 Standard reference piece shall be from a portion of the wheel having a 3 mm diameter flat bottom hole drilled perpendicular to the rim face and to a depth of 25 + 2mm at the mid thickness of the rim (see fig. 4.1).

A-1-1-1-7 Alternate reference piece: Alternate reference piece shall be from a portion of the wheel having a small diameter hole of dia 3 mm drilled at a distance from the testing surface equal to the depth of the hole indicated in A-1.1.1.6 (see fig. 4.2). The instrument shall be adjusted to give an equal test value to that of

a 3 mm diameter flat bottom hole.

A - 1.1.2 Calibration

A-1.1.2.1 Time base: Set the time base of ultrasonic flaw detector using 0 degree longitudinal wave with the help of calibration block as mentioned in para A-1.1.1.5. Three multiple echoes will be observed.

A-1.1.2.2 Sensitivity setting: Sensitivity setting shall be done with the help of standard wheel piece (see fig. 4.1). Gain level should be adjusted to produce 60% height from the reference standard as mentioned in para A-1.1.1.6.

A-1.1.2.3 Alternatively sensitivity setting shall be done with the help of an alternate reference piece as mentioned in para A-1.1.1.7 (see

fig. 4.2) and shall be used only with the specific approval of the purchaser.

A-1.1.2.4 Reference standard for the inspection of heat-treated wheels shall be fabricated from heat-treated wheels.

A - 1.1.3 Scanning:

A-1.1.3.1 Wheels shall be inspected axially from either the out side or inside rim face by automatic scanning see figs. 4.1 and 4.2. For determining acceptance or otherwise, probing from both sides may be carried out.

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A-1.1.3.2 The speed of scanning shall permit efficient detection of the reference standard discontinuities.

A - 1.1.4 Rejection criteria:

A-1.1.4.1 Any wheel with a flaw indication equal to or larger than 60% of the full scale height shall be rejected. If more than 1 defect of amplitude 20% or above are observed, the wheel shall be rejected. If two defects of amplitude 20% or above are observed, and if these defects are closer than 50 mm the wheel shall be rejected.

A-1.1.4.2 Ultrasonic indications that result from wheel geometry or spurious signal shall not be valid cause for rejection. The judgement of the inspecting officer shall be final and binding in this respect.

A-1.1.4.3 The final disposal of rejection of wheels may be determined by manual resting of disputed areas. The surface finish of rim of reference standard will be almost same as that of wheels tested manually by contract probing.

A - 1.2 RADIAL TESTING:

All wheels will be subjected to ultrasonic testing of rim through probing circumferentially along the treat surface to detect any flaw having orientation parallel to the tread surface.

A -1.2.1 Equipment:

A-1.2.1.1 Equipment shall be same as described in clause A-1.1.1.

A-1.2.1.2 Calibration Block: 50x50x50mm block of steel to grade 45C8 of IS:1875.

A-1.2.1.3 Standard reference piece:

Reference piece will be from a portion of new wheel having 3 mm diameter flat bottom hole drilled from opposite to tread surface (see fig.5) to depth of 20mm.

A - 1.2.2 Calibration:

A-1.2.2.1 Time Base: Set the time base of ultrasonic flaw detector using O degree longitudinal wave with the help of calibration block as mentioned in para A.1.2.1.2. Three multiple echoes will be observed.

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A-1.2.2.2 Sensitivity setting: Sensitivity setting shall be done with the help of standard wheel piece as mentioned in para A-1.2.1.3 (see fig.5). Probing shall be done from the tread opposite to flat

bottom hole and the gain level shall be adjusted to produce an echo of 60% height of vertical scale of CRT. This gain level shall be reference gain for acceptance or otherwise for the wheel.

A - 1.2.3 Scanning :

Increase the gain level by 6dB over and above the gain level described at para A-1.2.2.2. Apply couplant on the tread surface, place the probe on this face and scan entire circumference on the wheel in case of contact type automatic scanning equipment. For immersion type of equipment, the wave propagation shall be through the liquid used for immersing the wheel. No back echo will appear. Care shall be taken during probing to cover full width of the tread. In case a flaw

signal is observed reduce the gain by 6 db.

A-1.2.4 Rejection criteria:

Any wheel with a flaw indication equal to or larger than 60% of the full scale height shall be rejected. If more than 3 defects of amplitude 20% or above are observed, the wheel shall be rejected. If two defects of amplitude 20% or above are observed, and if these defects are closer than 50 mm, the wheel shall be rejected.

A-1.2.5 The final disposal of rejection of wheels may be determined by manual testing of disputed areas. The surface finish of tread of reference standard will be almost same as that of wheels tested manually by contact probing.

A. 2 ULTRASONIC TESTING ON WHEEL HUB

Only such wheels, which pass ultrasonic test for the rim, shall be subjected to ultrasonic testing of hub.

A - 2.1 Equipment:

Equipment shall be the same as used for ultrasonic testing of the rim portion of the wheels, suitably calibrated for hub thickness. However, manual testing of hub will be permitted.

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For hub testing, the back wall echo shall be adjusted to full screen height using a wheel hub free from internal discontinuities.

Surface finish of reference piece shall be similar to wheels

tested if manual testing is resorted to.

A-2.2 Rejection criteria:

A-2.2.1 Any wheel with a flaw indication equal to or larger than 60% of the full scale height shall be rejected. If more than 3 defects of amplitudes less than 60% are observed, the wheel shall be rejected. If two defects of amplitudes less than 60% are observed, and if these defects are closer than 50mm, the wheel shall be rejected.

A-2.2.2 Where there is a partial suppression of the back echo and flaw echo is also absent the back echo shall not be less than 30% of the full screen height without change of testing parameters.

MARKING: Wheel conforming to the above ultrasonic stipulations shall be

stencilled ‘UT’ on the back plate with red colour paint using characters at least 25 mm in height or at such locations as may be shown on the drawing or specified by the purchaser.

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CODE OF PROCEDURE OF ULTRASONIC TESTING FOR AXLE

(POWERED) TO M/s PHOOLTAS TAMPER Pvt. Ltd., PATNA’s DRG. No.

UTV1-01 02/00 REV. 0 IN SERVICE (TENTATIVE).


required to be examined periodically for presence of cracks. This code stipulates

the testing procedure, calibration method and sensitivity setting for detection of in

service cracks of Axle (Powered) to M/s Phooltas Tamper Pvt. Ltd., Patna’s Drg.

No. UTV1-01 02/00 REV.0.







M&C/NDT/104/2000

(Rev.1) April 2005

or




80 mm screen.

RDSO specification

No.M&C/NDT/125/2004


A-scan storage.


WD-17-MISC-92

Soft grease

IS:1628-1986


Axle oil


for forging.

IS:12666-1988

Reaffirmed in 1993



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No. M&C/NDT/125/2004, July’2004 or any other ultrasonic flaw

detector meeting RDSO specification No. M&C/NDT/104/2000

(Rev.1) April 2005 or No. M&C/NDT/125/2004, July’2004.





perspex wedge capable of producing ultrasonic wave at 15o angle or

angle probe of 150 .



wedge capable of producing ultrasonic wave at 37.5 o

angle or angle

probe of 37.50 angle having dia. of curvature 176 +

200 mm .











3.3.1 Far end scanning : This technique shall be used for testing the full length

of the axle from both the ends.





coupling.

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Far End scanning.


examination of fatigue cracks if any, in the raised wheel seat inner

fillet area, which remains unscanned during far end scanning.


division of compression wave. The normal probe of 2.5 MHz having

15/20 mm dia fitted with a Perspex wedge capable of producing

ultrasonic wave at 150 or angle probe of 15

0 shall be placed on the axle

end face directing the central beam towards the wheel seat inner fillet.

The same procedure shall be followed for both the ends scanning.



Scanning.





High angle scanning is carried out from the body of the axle. The time

scale shall be calibrated to 50mm per main scale division of shear

wave with the help of 50mm dia. x 182 mm long steel bar ( since 5x

182mm = 910 mm longitudinal wave is equivalent to 5 x 100 mm =

500 mm of shear wave. A normal probe 20/25 mm dia fitted with

Perspex wedge of 37.50 or angle probe of 37.5

0 having dia of

curvature 176 + 20

0 mm shall be placed on the axle end facedirecting

the central beam towards the wheel seat inner fillet. The same

procedure shall be followed for both the ends scanningshall be placed

on the body of the axle at a distance of 132 mm from wheel seat inner

fillet with suitable couplant directing the central beam towards wheel

seat inner fillet. The probe shall be given slight rotary movement for

proper acoustic coupling. The expected signals have been shown in

Annexure.





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4. IMPORTANT NOTE :








the perspex.





shown in Annexure ‘A’ during scanning by Far End and Near End

Low Angle Scanning techniques shall be withdrawn from service.

Further confirmation of the defect may be carried out by Trace Delay

Annexure ‘B’ or high angle scanning technique Annexure ‘A’ as the

case may be.


the Annexure ‘A’ by Far End and Near End Low Angle Scanning

technique should be declared satisfactory.








register.






of the axles.

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Annexure- A

Theoretical calculations and relative positions of signals for axle (powered) of

M/s Phooltas Tamper Pvt. Ltd. Patna’s to Drg. No. UTVI-01 02/00 Rev.0 in

service (Tentative).

(B) FAR END SCANNING : 1 Main Scale Div. = 250 mm (compression wave)


Probing from Gear End Side:

SL .

No.

Details Distance

(mm)

Signal

(Div.)


2. Delayed reflection from journal fillet 2376.5 9.5

3. Delayed reflection from Wheel seat outer fillet 2294 9.2


5. Direct reflection from Wheel seat outer fillet 2125 8.5

6. Delayed reflection from a fillet at a distance of


1911 7.6



1767 7.0


1587mm from probing end

1765 7.0



1609.5 6.4

10. Direct reflection from a fillet at a distance of


1587 6.3



1417 5.7

12. Delayed reflection from Gear seat fillet 1393 5.6

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14. Direct reflection from Gear seat fillet 1067 4.3




18. Delayed reflection from near end Groove 375.3 1.5


20. Direct reflection from near end Groove 125 0.5

PROBING FROM FREE END SIDE:

SL .

No.

Details Distance

(mm)

Signal

(Div.)








1917 7.7



1771 7.1




1593 6.4




1348 5.4


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1190.5 4.8



998 4.0






20. Direct reflection from near end Groove 125 0.5

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(B) NEAR END LOW ANGLE SCANNING 1 Main Scale Div. = 100 mm

(Compressive Wave)


PROBING FROM BOTH ENDS:


(mm)

Signal

(div.)


(Wedge : 15, Central beam at 30 mm from edge)

472 4.7

(C) HIGH ANGLE SCANNING: 1 Main Scale Div. = 50 mm (Shear wave)


PROBING FROM BOTH ENDS:

S.

NO.

Details Distance

(mm)

Signal

(div.)

1. Direct reflection from wheel seat inner fillet.(Wedge :

37.5 having dia of curvature 176mm or more, Stand

off distance 134 mm from wheel seat inner fillet.)

224 4.5

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Annexure ‘B’

(D) Trace Delay Scanning: 1 main scale div. = 50 mm (compressive wave)

Probe: 15/20 mm, 2.5 MHz

PROBING FROM GEAR END SIDE:

(0-500) mm


(mm)

Signal

(divn.)


2. Delayed reflection from near end groove 375.3 7.5


4. Direct reflection from near end groove 125 2.5

(500 mm- 1000) mm


(mm)

Signal

(divn.)



(1000mm – 1500) mm


(mm)

Signal

(divn.)



417 8.3




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(1500 – 2000) mm

S.

NO.

Details Distance

(mm)

Signal

(divn.)



411 8.2



267 5.3



265 5.3



109.5 2.2



87 1.7

(2000 – 2500) mm:


(mm)

Signal

(divn.)



3. Delayed reflection from wheal seat outer fillet 294 5.9


5. Direct reflection from wheal seat outer fillet 125 2.5

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PROBING FROM FREE END SIDE:

(0 - 500) mm:


(mm

Signal

(divn.)




4. Direct reflection from near end groove 125 2.5

(500 - 1000) mm:


(mm)

Signal

(divn.)



498 9.9



(1000 – 1500) mm:

S.

NO.

Details Distance

(mm)

Signal

(divn.)

1. Direct reflection from gear seat fillet 353 7.0



348 7.0



190.5 3.8

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(1500 – 2000) mm :

S.

NO.

Details Distance

(mm)

Signal

(divn.)



417 8.3



271 5.4




93 1.9


(2000 – 2500) mm:


(mm)

Signal

(divn.)






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Testing Procedure and Equipment used for Ultrasonic testing of the following Tie Tamping Machine axles in service:

1. CSM SATELLITE Or Driving Bogie axle to CPOH Drg. No. C-1411

CSM

2. Driving axle DUOMATIC to IRTMTC Drg. No. D-1402 DUO-R1

3. Driving axle front of Unimat to CPOH Drg. No. UNI-1402

4. Driving axle Rear of Unimat to CPOH Drg. No. UNI-1401

5. Running axle CSM to IRTMTC Drg. No. C-1406 CSM

Equipment and accessories recommended:

Equipment : Any Ultrasonic Flaw Detector approved by RDSO, Lucknow (specn. No.M&C/NDT/104/2000).

Accessories:

Probes and Wedges:

Far – end Scanning : Normal probe of 2.5 MHz, 20/25 mm dia Of lead zirconate titanate or similar crystal. Low Angle Scanning : Normal probe of 2.5 MHz, 15/20 mm dia Of lead zirconate titanate crystal with Perspex wedge 17.5°. High Angle Scanning : Normal probe of 2.5 MHz, 20/25 mm dia Of lead zirconate titanate crystal with Perspex wedge 37°, 140 mm Diameter of curvature for scanning wheel seat inner filler both for Free End and Gear End side.

Couplant : A suitable couplant like soft grease or Axle Oil (medium) shall

be used.

Calibration Bar : Round bars 50 mmx500 mm long and 50mm x 182mm

long are applicable. The round bars shall confirm to designation 45C8 of IS 1875 1992, rolled/forged and normalised. The grain size shall be ASTM 5 or finer when determined according to ASTM E – 19-39 T. Testing Procedure : Far End Scanning : This technique shall be used for testing the full length

of the axle. The time scale shall be calibrated to 250 mm per main scale division of compression wave. The probe shall be placed on the cleaned axle end face with suitable couplant. The probe shall be given slight rotary movement for proper acoustic coupling. Some stray signals may appear near the initial echo due to press fit components.

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Near End Low Angle Scanning: This technique is used for testing the vulnerable portion of the axle near the probing end. This technique is

meant for the examination of cracks, if any, in the raised wheel seat, which is not scanned during Far-End scanning or for conforming the flaw obtained to 100mm per main scale division for compression wave. A normal probe 15/20mm dia, fitted with a Perspex wedge of 17.5° angle shall be placed on the axle end face directing the central beam towards the wheel seat inner fillet, both for Gear End side and Free End side respectively.

High Angle Scanning : Depending upon the accessibility, this technique may be applied for conformation of the finding during Near End Low Angle scanning. The time scale shall be calibrated to 50mm per main scale division for shear wave. A normal probe of 20/25mm dia, fitted with Perspex wedge 37° having dia of curvature 140mm or higher shall be placed on the body of the axle with probe index marking at distance 104mm from wheel seat outer fillet both for Gear End & Free End side, for getting reflection from wheel seat inner fillet. The probe shall be moved forward and backward longitudinally from the mean position up to 20mm circumferentially.

Examination by Scale Expansion : The analysis of oscillogram pattern

having closely placed echoes may be simplified by expanding the relevant part of the pattern. This can be done with the scale expansion control provided in the Ultrasonic Flaw detector.

CRITERIA FOR ACCEPTANCE AND OTHERWISE :

Axle found to produce flaw signal other than those standard signals during scanning by far end and near end low angle technique (Conformed by high angle scanning ) shall be withdrawn from service. During service extra signals may appear due to change in geometrical configuration of axles. This aspect may be kept in view while declaring the serviceability of the axle.

BEFORE TESTING THE AXLES, CALIBRATE THE EQUIPMENT AND CHECK THE FUNCTION AND SENSITIVITY OF THE EQUIPMENT AND PROBES, USE ONLY THE EQUIPMENT AND ACCESSORIES MENTIONED IN THIS CODE.

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Theoretical calculations and relative positions of signals of CSM SATELLITE

OR Driving Bogie Axle to CPOH Drg.No.C-1411 CSM in service (Tentative)

(C) FAR END SCANNING : 1 Main Scale Div. = 250 mm (compression wave)


FROM FREE END SIDE:

SL .

No.

Details Distance

(mm)

Signal

(Div.)

1. Direct back reflection from axle end. 2166 8.7


3. Delayed reflection from journal fillet 2160 8.6


5. Delayed reflection from Wheel seat outer fillet 2152.5 8.6

6. Direct reflection from Bearing seat fillet 1425 5.7

7. Delayed reflection from Bearing seat fillet 1575 6.3



10. Delayed reflection from Gear seat fillet 1370.5 5.5





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FROM GEAR END SIDE:

SL .

No.

Details Distance

(mm)

Signal

(Div.)















(B) NEAR END LOW ANGLE SCANNING : 1 MSD = 100mm (Compression wave)

Probe 15/20 mm dia., 2.5 MHz

FROM FREE END SIDE & GEAR END SIDE :

S.No. Details Distance (mm) Signal (Div.)

1. Direct reflection from wheel sear inner fillet,

(Wedge = 17.5°, central beam at

22 mm from edge of axle)

355 3.6

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(C) HIGH ANGLE SCANNING : 1 MSD = 50mm (Shear wave)




1. Direct reflection from wheel seat inner fillet,


104 mm from Wheel seat inner fillet, Dia. of curvature = 140mm)

190 3.8

NOTE: POSITION OF SIGNAL MAY VARY WITH THE THICKNESS OF WEDGE.

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Theoretical calculations and relative positions of signals of Driving Axle

DUOMATIC to IRTMTC Drg.No.D-1402 DUO R1 in service (Tentative)



FROM FREE END SIDE:

SL .

No.

Details Distance

(mm)

Signal

(Div.)













FROM GEAR END SIDE:

SL .

No.

Details Distance

(mm)

Signal

(Div.)




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340 3.4

(C) HIGH ANGLE SCANNING : 1 MSD = 50mm (Shear wave)







190 3.8


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Theoretical calculations and relative positions of signals of Driving Axle Front

of Unimat to CPOH Drg.No.UNI 1402 in service (Tentative)

(D) FAR END SCANNING : 1 Main Scale Div. = 250 mm (compression wave)


FROM FREE END SIDE:

SL .

No.

Details Distance

(mm)

Signal

(Div.)














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FROM GEAR END SIDE:

SL .

No.

Details Distance

(mm)

Signal

(Div.)














NEAR END LOW ANGLE SCANNING : 1 MSD = 100mm (Compression wave)


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1. Direct reflection from wheel sear inner fillet,



355 3.6

© HIGH ANGLE SCANNING : 1 MSD = 50mm (Shear wave)







190 3.8


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Theoretical calculations and relative positions of signals of Driving Axle Rear

of Unimat to CPOH Drg.No.UNI 1401 in service (Tentative)



FROM FREE END SIDE:

SL .

No.

Details Distance

(mm)

Signal

(Div.)














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FROM GEAR END SIDE:

SL .

No.

Details Distance

(mm)

Signal

(Div.)
















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Theoretical calculations and relative positions of signals of Running Axle

CSM to IRTMTC Drg.No.C-1406 CSM in service (Tentative)

(A) FAR END SCANNING : 1 Main Scale Div. = 250 mm (compression

wave)

Probe: 20/25mm, 2.5 MHz FROM GEAR END SIDE:

SL .

No. Details Distance

(mm) Signal

(Div.)









(B) NEAR END LOW ANGLE SCANNING : 1 MSD = 100mm (Compression wave) Probe 15/20 mm dia., 2.5 MHz FROM FREE END SIDE & GEAR END SIDE :


1. Direct reflection from wheel sear inner fillet, (Wedge = 17.5°, central beam at 22 mm from edge of axle)

355 3.6

(C) HIGH ANGLE SCANNING : 1 MSD = 50mm (Shear wave) Probe 20/25 mm dia., 2.5 MHz FROM FREE END SIDE & GEAR END SIDE :


1. Direct reflection from wheel seat inner fillet, (Wedge = 3.7°, central beam at 104 mm from Wheel seat inner fillet, Dia. of curvature = 140mm)

190 3.8


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