~~f: CGW 0001 (Rev. - 4) Page 1 of 14 Date of issue: Nov., 2015 Spec. No.

RDSO/Z015/CG-03
,.'

INDIAN RAILWAYS

SPECIFICATION
FOR

BRAKE DISC

FOR
LHB TYPE MAINLINE BG COACHES

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

Issue Amendment Amendment
1. November, - - First issue
2015

o
Issued by
RESEARCH DESIGNS & STANDARDS ORGANISATION
Manak Nagar, lucknow - 226011

Signahire
Name & Prepared By: - Approv y:.
Designation Vivek Anand Anil Kumar Singh
JElE&S and BrakesiCarria e Director/E&S and BrakesiCarria e
Ref: CGW 0001 (Rev. - 4) Page 2 of 14 Date of issue: Nov., 2015 Spec. No. RDSO/2015/CG-03

CONTENTS

CLAUSE DESCRIPTION PAGE

NO.
No.

1. FOREWORD 3

2. DEFINITION AND EXPLANATION 3

3. SCOPE 3

4. PARTICULAR REQUIREMENTS 3
5. FUNCTIONAL REQUIREMENTS 4
6. DESIGN REQUIREMENTS 4
7. PERFORMANCE REQUIREMENTS 6
8. QUALIFYING REQUIREMENTS 6
9. SUBMISSION OF TECHNICAL DOCUMENTS 6
10. APPROVAL OF DRAWING 8
11. DIMENSIONS AND TOLERANCES 8
12. MANUFACTURE 9
13. PROTOTYPE INSPECTION 9
14. PURCHASE INSPECTION 9
15. TESTS 10

16. FIELD TRIAL 11

17. GURANTEE 11
18. AFTER SALES SERVICE 11
19. MARKING 12

20. PACKING 12

21. ANNEXURE-I 13

22. ANNEXURE - II 14

Signature {
Name & Prepared By: - ed By:-
Designation Vivek Anand raveen Kumar
JE/E&S and Brakes/Carriage Dy. Director/ E&S and Brakes/Carriage
Ref: CGW 0001 (Rev. -4) Page 3 of 14 Date of issue: Nov., 2015 Spec. No. RDSO/2015/CG-03

PART-I: GENERAL CONDITIONS

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

1.2 This specification is intended to cover the provisions related to grey Cast Iron brake disc
to be pressed onto the Wheel set axle.
1.3 Following standards as applicable may be referred to in conjunction with this
Specification:
a. UIC 541-3
b. EN 14535-1

c. EN 14535-3
d. DIN 27205-3
2.0 DEFINITION AND EXPLANATION
2.1 'PURCHASER' means the Indian Railways on behalf of the President of the Republic of
India who are purchasing the brake disc.
2.2 'INSPECTING AUTHORITY' means the organization or its representative nominated by
the purchaser to inspect the brake disc on his behalf. .

2.3 The Research Designs & Standards Organisation, Manak Nagar, Lucknow-22601.1 is
hereafter referred to as 'ROSO'.
2.4 Rail Coach Factory, Kapurthala (Punjab) is hereafter referred to as RCF.
2.5 The Indian Railways is hereafter referred to as IR

3.0 SCOPE

3.1 This specification covers the technical requirements related to manufacture, supply,
inspection, performance and testing of Axle Mounted Brake Disc to be pressed onto the
wheel set axle of LHB type mainline BG coaches on Indian Railways and does not
include all the necessary provisions of the contracts.
4.0 PARTICULAR REQUIREMENTS
4.1 The firm willing to supply Axle Mounted Brake Disc for use on LHB type coaches of
Indian Railways shall register themselves with RDsa. Vendor approval process
guidelines are available at ROSO website www.rdso.indlanrailwavs.aov In.

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

Name & Prepared By: - ed By:- Approve

Designation Vivek Anand Praveen Kumar Anil Kumar Singh
JElE&S and Brakes/Carria e D . Directorl E&S and BrakeslCarria e Director/E&S and BrakeslCarria e
Ref: CGW 0001 (Rev. -4) Page 4 of 14 Date of issue: Nov., 2015 Spec. No. RDSO/2015/CG-03

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

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

5.0 FUNCTIONAL REQUIREMENT

5.1 The brake disc of axle mounted disc brake system shall fulfill the following requirement,
under Indian Railway service conditions without crack, damage over permitted under
DIN27205-3, damage or degradation other than normal wear of the friction face beyond
permissible limits

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

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

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

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

6.0 DESIGN REQUIREMENT

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

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

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

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

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

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

Signature (
Name & Prepared By: - ed By:- Appr ed By:-
Designation Vivek Anand Praveen Kumar Anil Kumar Singh
JElE&S and Brakes/Carriage D . Director/ E&S and Brakes/Carriage Director/E&S and Brakes/Carriage
Ref: CGW 0001 (Rev. - 4) Page 5 of 14 Date of issue: Nov., 2015 Spec. No. RDSO/201S/CG-03

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

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

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

6.8.1 Transmission of brake power.

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

6.9 A minimum true specific weight shall be of great importance

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

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

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

6.13 Cooling fins that are arranged radially between the friction surfaces provides for
sufficient cooling at the friction ring. They convey a stream of cooling air from the hub
through the interior of the friction ring to the outside, using a centrifugal force that is
controlled by speed.

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

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

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

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

Signature /
Name & Prepared By: - d By:- Appro
Designation Vivek Anand veen Kumar Anil Kumar Singh
JElE&S and Brakes/Carria e . Director/ E&S and Brakes/Carriage Director/E&S and Brakes/Carriage
Ref: CGW 0001 (Rev. -4) Page 6 of 14 Date of issue: Nov., 2015 Spec. No. RDSO/201S/CG-03

7.0 PERFORMANCEREQUIREMENTS

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

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

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

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

8.0 QUALIFYING REQUIREMENTS

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

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

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

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

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

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

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

9.0 SUBMISSIONOF TECHNICAL DOCUMENTS

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

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

Name & Prepared By: - ed By:- Approved By: -

Designation Vivek Anand Praveen Kumar Anil Kumar Singh
JElE&S and Brakes/Carriage Dy. Director/ E&S and Brakes/Carria e Director/E&S and Brakes/Carria e
Ref: CGW 0001 (Rev. - 4) Page 7 of 14 Date of issue: Nov., 2015 Spec. No. RDSO/201S/CG~03

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

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

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

a) Introduction
b) Table of contents
c) Summary
d) Physical properties of each material used for the disc. This table shall include but not
iimited to:
• Yield strength
• Ultimate strength
• Elongation
• Tension modulus
• Compression modulus
• Shear modulus
Minimum values shall be used and shall be selected from material specification

e) Views of key structural areas (spoke, hub-friction ring connections, etc.) showing
member locations and geometry, and indicating the material and thickness of each.
Other FEA views may be required where critical stresses are identified.
f) A tabulation or fatigue curve justifying the contractor's selection of allowable fatigue
stresses for the disc material for each transition or joint, and the tatique-cntical stress
ranges. The FEA report shall include a description of how this process is carried out.
g) The complete test report must be submitted including procedure, raw and induced
data, and summary of results, including:
• Structural sketches and/or layouts of the critically stressed locations showing.
locations and shapes depicted in scale, thickness, section properties and
material.
• Diagrams displaying extemally applied loads and boundary conditions,
• Colour plots of the stress under each loads and boundary conditions.
• Natural frequencies of the disc.

9.1.5 Hub & Friction ring connecting Bolt calculation report.

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

Signature
Name & Prepared By: - (I By:- Approved
Designation Vivek Anand aveen Kumar Anil Kumar Singh
JElE&S and Brakes/Carriage D'y'.Director! E&S and Brakes/Carria e Director/E&S and Brakes/Carriage
Ref: CGW 0001 (Rev.-4) Page8 of 14 Dateof issue:Nov., 2015 Spec. No. RDSO/201S/CG-03

9.1.7 Details of testing facilities available at manufacturers.

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

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

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

9.1.11 Operation and maintenance manual and service instructions.

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

10.0 APPROVAL OF DRAWING

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

10.2 The drawing shall be developed in SI units.

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

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

11.0 DIMENSIONS AND TOLERANCES

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

11.2 Broad specificatlon of the brake disc shall be as under:

a) Dimensions 640 x 110 mm
b) Outer Diameter of friction ring 640 +0/-1 mm
c) Inner Diameter of friction ring 350 mm .
d) Width offriction ring 110 +01-0.3 mm
e) Inner bore 199 mm (H6)
f) Width of hub 150 mm

Name & Prepared By: - ed By:- Ap ved By:-

Designation Vivek Anand Praveen Kumar Anil Kumar Singh
JE/E&S and Brakes/Carriage Dy. Director/ E&S and Brakes/Carriage Director/E&S and Brakes/Carriage
Ref: CGW 0001 (Rev. - 4) Page 9 of 14 Date of issue: Nov., 2015 Spec. No. RDSO/2015/CG-03

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

12.0 MANUFACTURE

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

12.2 Brake Disc shall be free from casting defects.

12.3 No sharp corners or edges shall be present.

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

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

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

12.7 The brake disc shall be carefully protected against corrosion.

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

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

12.10 Su rface protection shall be evident on the drawing.

13.0 PROTOTYPE INSPECTION

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

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

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

14.0 PURCHASE INSPECTION

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

Name & Prepared By: - d8y:- Appro e

Designation Vivek Anand veen Kumar Anil Kumar Singh
JElE&S and Brakes/Carnage Dy. Director/ E&S and Brakes/Carriage Director/E&S and Brakes/Carria e
Ref: CGW 0001 (Rev. - 4) Page 10 of 14 Date of issue: Nov. 2015 Spec. No. RDSO/2015/CG-03

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

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

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

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

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

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

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

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

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

15.0 TESTS

15,1 Type Test

The following test shall constitute type test and shall be carried out in accordance to EN
14535-3 (draft) at the time of Product approval of new entrant or at the time of design
change of existing design:

Signature I
Name & Prepared By: - ed By:- App ~ed By:-
Designation Vivek Anand Praveen Kumar Ani! Kumar Singh
JElE&S and Brakes/Carriage . Directorl E&S and Brakes/Carria e Director/E&S and Brakes/Carriage
Ref: CGW 0001 (Rev. - 4) Page 11 of 14 Date of issue: Nov., 2015 Spec. No. RDSO!2015/CG-03

b) Centrifugal Test
c) Ventilation Test
d) Heat dissipation test

15.2 Routine Test

15.2.1 The following test shall constitute routine test and shall be verified against value
specified in manufacturer's specification/QAP:
a) Chemical characteristics
b) Hardness
c) Tensile Testing
d) Microstructure
e) Magnetic Particle Testing
f) Residual imbalance

16.0 FIELD TRIAL

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

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

17.0 GUARANTEE

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

18.0 AFTER SALES SERVICE

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

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

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

Name & Prepared By: - ed By:- Appr By:-

Vivek Anand raveen Kumar Anil Kumar Singh
Designation
JElE&S and Brakes/Carriage Dy. Director/ E&S and Brakes/Carriage Director/E&S and Brakes/Carriage
Ref: CGW 0001 (Rev. - 4) Page 12 of 14 Date of issue: Nov., 2015 Spec. No. RDSO!2015!CG-03

18.3.1 Brief Details of brake disc.

18.3.2 Details of attention to be given during IOH/POH or any other schedule examination.
18.3.3 Details of tools & machinery for maintenance of brake disc.
18.3.4 Typical defects and their remedial measures.
18.3.5 Maintenance standards including clearances and tolerances at various locations and
permissible limits of wear for good service performance of equipments.
18.3.6 Firm shall submit the frequency and detailed work content of various inspection /
maintenance schedules necessary for maintenance of brake disc offered by them.
Whether these requirements are time based or distance travelled based shall be
indicated for each schedule.
19.0 MARKING

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

a) Manufacturer's data (manufacturer's name I trade mark), month & year of

manufacture and serial number.
b) Residual imbalance in gm (Data regarding residual brake disc imbalance shall be
located directly in the place where the imbalance occurs).

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

20.0 PACKING

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

. Signature
Name & Prepared By: - ed By:- App ed By:-
Designation VivekAnand raveen Kumar Anil Kumar Singh
JE/E&S and Brakes/Carriage D . Director/ E&S and Brakes/Carriage Director/E&S and Brakes/Carria e
Ref: CGW 0001 (Rev. - 4) Page 13 of 14 Date of issue: Nov., 2015 Spec. No. RDSO/2015/CG-03

ANNEXURE-I

DESIGN DATA AND LOAD CASES FOR BRAKE DISC

a) THERMAL LOAD AND BRAKING SCENARIO

S. Description Unit Emergency Service

No. Braking Braking
1. Mean Braking Radius (ml Meter 0.247 0.247
2. Wheel diameter (New) (m) Meter 0.915 0.915
3. Wheel diameter (Wom) (m) Meter 0.B45 0.B45
4. Mean Co-efficient of friction of Brake Pads - 0.35 0.35
5. Surface Area of Brake Pads crrr 400 400
6. Braked Mass Kg BOOO BOOO
7. Starting velocity Kmph 160 160
B. Final velocity Kmph 0 0
9. Brake application time Sec 4 4
10. Deceleration rate rn/sec" 1.2 0.80
11. Clamping force per disc kN 42 25
12. Kinetic energy MJ 7.9 7.9
13. Load cycles - 6000 62500

b) IMPACT LOAD

S.No. Description Vertical Axial

1. Standard Impact 25g 3g
2. Extraordinary Impact 100g 100g

Signature /
Name & Prepared By: - Ap ved By:-
Designation Vivek Anand Anil Kumar Singh
JE/E&S and Brakes/Carriage Director/E&S and Brakes/Carria e
Ref: CGW 0001 (Rev. -4) Page 14 of 14 Date of issue: Nov., 2015 Spec. No. RDSO/2015/CG-03

ANNEXURE-II
OPERATING CONDITIONS FOR BRAKE DISC

1. Coach Type LHB Type BG Passenger coaches

2. Axle Load 16.25t (rnax.)
3. Gross Load (Coach) 65t (max.)
4. Gross Load (Train) 1700t (max. without loco)
5. Operating speed (max) 160 Kmph
6. Maximum deceleration 1.3 m/sec'
7. Emergency Braking distance 1~00 meter
8. Wheel diameter 915 (New)
845 (Worn)
9. Wheelbase 2560rnrn
10. Minimum clearance above rail level 102 rnrn under loaded and worn
Condition
11. Maximum bogie rotation and swing 3.5°, 82rnrn
12. Track Parameters
a) Steepest Gradient 1 in 37
b) Sharpest curvature 175 m radius
c) Super elevation (max) 1765 mm max.
13. Environmental condition

a) Maximum temperature under sun 70°C

b) Maximum temperature under shade 45°C
c) Minimum temperature at Night - 5 -c
d) Altitude Sea level to 652 meters
e) Humidity 100% saturation during rainy
Season
f) Rain falls Fairly heavy
g) Atmosphere during hot weather Dusty
Environment: Coaches shall be working in coastal area with saline and corrosive
atmosphere.

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

a) Maximum vertical acceleration = 3.0 9

b) Maximum longitudinal acceleration = 5.0 g
c) Maximum transverse acceleration = 2.0 g

SignabJre /
Name & Prepared By: - ed By:- App ved By:-
Designation Vivek Anand Praveen Kumar Anil Kumar Singh
JE/E&S and Brakes/Carriage Dy. Directorl E&S and Brakes/Carria e Director/E&S and Brakes/Carria e