TB/T 3395.4-2015 Fastening systems for high-speed railway - Part 4: WJ-7 fastening system
1 Scope
This part specifies the composition, assembly performance, technical requirements for parts and components, inspection methods, inspection rules, marking and packaging, as well as storage and transportation of WJ-7 fastening systems.
This part is applicable to WJ-7 fastening systems for ballastless tracks of high-speed railways.
2 Normative references
The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.
GB 443-1989 Lubricating oils for total loss systems L-AN
GB/T 41 Hexagon nuts - Product grade C
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 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 700 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 moulding and extrusion plastics
GB/T 1222 Spring steels
GB/T 1348 Spheroidal graphite iron castings
GB/T 1412 Pig iron used for spheroidal graphite cast iron
GB/T 1690 Rubber, vulcanized or thermoplastic - Determination of the effect of liquids
GB/T 2411 Plastics and ebonite - Determination of indentation hardness by means of a durometer (shore hardness)
GB/T 2828.1 Sampling procedures for inspection by attributes - Part 1: Sampling schemes indexed by acceptance quality limit (AQL) for lot-by-lot inspection
GB/T 3103.1-2002 Tolerances for fasteners - Bolts, screws, studs and nuts
GB/T 3280 Cold rolled stainless steel plate, sheet and strip
GB/T 3398.2 Plastics - Determination of hardness - Part 2: Rockwell hardness
GB/T 3512 Rubber, vulcanized or thermoplastic - Accelerated ageing and heat resistance tests - Air-oven method
GB/T 5779.1 Fasteners - Surface discontinuities - Bolts, screws and studs for general requirements
GB/T 6461 Methods for corrosion testing of metallic and other inorganic coatings on metallic substrates - Rating of test specimens and manufactured articles subjected to corrosion tests
GB/T 7244 Single coil spring lock washers, heavy type
GB/T 7760 Rubber, vulcanized or thermoplastic - Determination of adhesion to a rigid substrate - 90 degrees peel method
GB/T 9441 Metallographic test for spheroidal graphite cast iron
GB/T 10125 Corrosion tests in artificial atmospheres - Salt spray tests
GB/T 15822.1 Non-destructive testing - Magnetic particle testing - Part 1: General principles
HG/T 3866 Vulcanized rubber - Determination of coefficient of cold resistance under compression
JB/T 9151.1 Method of verification for fasteners - Size and geometry - Bolts, screws, studs and nuts
TB/T 1495.2 Type I fastening system - Spring clip
TB/T 1495.4 Type I fastening system - Flat washer
TB/T 2329 Fatigue test method for spring clips of Types I and II fastening systems
TB/T 2478 Metallographic grading atlas for spring clips
TB/T 2626 Specifications for rubber pads used under railway concrete sleepers
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 Composition of fastening system
A WJ-7 fastening system consists of T-bolt, nut, flat washer, spring clip, insulating block, iron backing plate, underrail backing plate (rubber or composite backing plate), insulating buffer backing plate, heavy-type single coil spring lock washer, flat cushion block, anchor bolt, and cast-in sleeve. It may also include underrail height adjustment backing plate (or filling backing plate) and height adjustment backing plate under iron backing plate. The coupling and assembly of the fastening system is shown in Figure 1.
Figure 1 Assembly diagram of WJ-7 fastening system
4 Assembly performance
4.1 Longitudinal rail restraint
When tested in accordance with TB/T 3396.1, the longitudinal rail restraint of each group of fastening system shall be at least 9kN (if equipped with Type W1 spring clip and rubber backing plate), and shall be 4.0kN±1.0kN for small-restraint configurations (with Type X2 spring clip and composite backing plate).
4.2 Assembly clamping force
When tested in accordance with TB/T 3396.2, the assembly clamping force of each group of fastening system shall be at least 18kN (if equipped with Type W1 spring clip); at least 6kN for small-restraint configurations (with Type X2 spring clip).
4.3 Fatigue performance of fastening assembly
4.3.1 The fastening system in the standard assembled state shall be subjected to fatigue test in accordance with TB/T 3396.4, and after 3×106 load cycles, no parts or components shall be damaged, and the gauge expansion shall not be greater than 6mm; the change rate of longitudinal rail restraint, assembly clamping force, and static stiffness for fastening assembly before and after the fatigue test shall not be greater than 20%, 20%, and 25% respectively.
4.3.2 The fastening system with rail height adjusted to 26mm shall be subjected to fatigue test in accordance with TB/T 3396.4, and after 3×106 load cycles, no parts or components shall be damaged, and the gauge expansion shall not be greater than 6mm.
4.4 Insulation performance
Foreword II
1 Scope
2 Normative references
3 Composition of fastening system
4 Assembly performance
5 Technical requirements for parts and components
6 Inspection methods
7 Inspection rules
8 Marking and packaging
9 Storage and transportation
10 Laying and maintenance/repairs
Annex A (Normative) Test method for friction coefficient of insulating buffer backing plates and height adjustment backing plates under iron backing plates
Annex B (Informative) Laying and maintenance/repairs of WJ-7 fastening systems
TB/T 3395.4-2015 Fastening systems for high-speed railway - Part 4: WJ-7 fastening system
1 Scope
This part specifies the composition, assembly performance, technical requirements for parts and components, inspection methods, inspection rules, marking and packaging, as well as storage and transportation of WJ-7 fastening systems.
This part is applicable to WJ-7 fastening systems for ballastless tracks of high-speed railways.
2 Normative references
The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.
GB 443-1989 Lubricating oils for total loss systems L-AN
GB/T 41 Hexagon nuts - Product grade C
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 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 700 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 moulding and extrusion plastics
GB/T 1222 Spring steels
GB/T 1348 Spheroidal graphite iron castings
GB/T 1412 Pig iron used for spheroidal graphite cast iron
GB/T 1690 Rubber, vulcanized or thermoplastic - Determination of the effect of liquids
GB/T 2411 Plastics and ebonite - Determination of indentation hardness by means of a durometer (shore hardness)
GB/T 2828.1 Sampling procedures for inspection by attributes - Part 1: Sampling schemes indexed by acceptance quality limit (AQL) for lot-by-lot inspection
GB/T 3103.1-2002 Tolerances for fasteners - Bolts, screws, studs and nuts
GB/T 3280 Cold rolled stainless steel plate, sheet and strip
GB/T 3398.2 Plastics - Determination of hardness - Part 2: Rockwell hardness
GB/T 3512 Rubber, vulcanized or thermoplastic - Accelerated ageing and heat resistance tests - Air-oven method
GB/T 5779.1 Fasteners - Surface discontinuities - Bolts, screws and studs for general requirements
GB/T 6461 Methods for corrosion testing of metallic and other inorganic coatings on metallic substrates - Rating of test specimens and manufactured articles subjected to corrosion tests
GB/T 7244 Single coil spring lock washers, heavy type
GB/T 7760 Rubber, vulcanized or thermoplastic - Determination of adhesion to a rigid substrate - 90 degrees peel method
GB/T 9441 Metallographic test for spheroidal graphite cast iron
GB/T 10125 Corrosion tests in artificial atmospheres - Salt spray tests
GB/T 15822.1 Non-destructive testing - Magnetic particle testing - Part 1: General principles
HG/T 3866 Vulcanized rubber - Determination of coefficient of cold resistance under compression
JB/T 9151.1 Method of verification for fasteners - Size and geometry - Bolts, screws, studs and nuts
TB/T 1495.2 Type I fastening system - Spring clip
TB/T 1495.4 Type I fastening system - Flat washer
TB/T 2329 Fatigue test method for spring clips of Types I and II fastening systems
TB/T 2478 Metallographic grading atlas for spring clips
TB/T 2626 Specifications for rubber pads used under railway concrete sleepers
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 Composition of fastening system
A WJ-7 fastening system consists of T-bolt, nut, flat washer, spring clip, insulating block, iron backing plate, underrail backing plate (rubber or composite backing plate), insulating buffer backing plate, heavy-type single coil spring lock washer, flat cushion block, anchor bolt, and cast-in sleeve. It may also include underrail height adjustment backing plate (or filling backing plate) and height adjustment backing plate under iron backing plate. The coupling and assembly of the fastening system is shown in Figure 1.
Figure 1 Assembly diagram of WJ-7 fastening system
4 Assembly performance
4.1 Longitudinal rail restraint
When tested in accordance with TB/T 3396.1, the longitudinal rail restraint of each group of fastening system shall be at least 9kN (if equipped with Type W1 spring clip and rubber backing plate), and shall be 4.0kN±1.0kN for small-restraint configurations (with Type X2 spring clip and composite backing plate).
4.2 Assembly clamping force
When tested in accordance with TB/T 3396.2, the assembly clamping force of each group of fastening system shall be at least 18kN (if equipped with Type W1 spring clip); at least 6kN for small-restraint configurations (with Type X2 spring clip).
4.3 Fatigue performance of fastening assembly
4.3.1 The fastening system in the standard assembled state shall be subjected to fatigue test in accordance with TB/T 3396.4, and after 3×106 load cycles, no parts or components shall be damaged, and the gauge expansion shall not be greater than 6mm; the change rate of longitudinal rail restraint, assembly clamping force, and static stiffness for fastening assembly before and after the fatigue test shall not be greater than 20%, 20%, and 25% respectively.
4.3.2 The fastening system with rail height adjusted to 26mm shall be subjected to fatigue test in accordance with TB/T 3396.4, and after 3×106 load cycles, no parts or components shall be damaged, and the gauge expansion shall not be greater than 6mm.
4.4 Insulation performance
Contents of TB/T 3395.4-2015
Foreword II
1 Scope
2 Normative references
3 Composition of fastening system
4 Assembly performance
5 Technical requirements for parts and components
6 Inspection methods
7 Inspection rules
8 Marking and packaging
9 Storage and transportation
10 Laying and maintenance/repairs
Annex A (Normative) Test method for friction coefficient of insulating buffer backing plates and height adjustment backing plates under iron backing plates
Annex B (Informative) Laying and maintenance/repairs of WJ-7 fastening systems
