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GOVERNMINT OF INDIA
MINISTRY OF RAILWAYS

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SCHEDULE OF TECHNICAL REQUIREMENTS FOR
TRACTION MOTOR SUSPENSION BEARINGS USED ON
BG_DE LOCOMOTIVES

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vDr~c'] 2005
Specification No.MP- 0.2402.01 (Revision- 02)
October- 2005

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RESEARCH DESIGNS & STANDARDS ORGANISATION
MANAK NAGAR, LUCKNOW - 226011

Technical supply requirements for Traction Motor Suspension Bearings for BG Diesel Electric locomotives

Technical supply requirements for Traction Motor

Suspension Bearings for BG Diesel Electric locomotives
1.0

SCOPE

1.1

This specification covers technical supply requirements of material for finished

traction motor suspension bearings of BHEL design (Type A) and GE design
(Type B). The GE design does not have anti friction metal lining on the collar.

1.2

The existing specification is being revised to incorporate Ultrasonic test as per

M&C report No. K-294 (Refer Para 6.2.2)

2.0

MATERIAL

2.1

Shell: Type A backing bearing shell castings shall conform to Grade V bronze to
IS: 1458-65 (Specification for Railway Bronze Ingots and Castings. Type B
bearing shell castings shall conform to Class IV of IS: 1458-65) amendment 2E May, 1966.

2.2

Antifriction lining: Material used for antifriction lining shall conform to Grade 84
of IS: 25-66 (Specification for antifriction bearing alloys) and cast centrifugally.

3.0

CHEMICAL COMPOSITION

3.1

The chemical composition of the bronze shell casting shall be as given in table 1.
Table 1
Constituent

Type A %

Type B %

Tin
Lead
Zinc
Phosphorus (max.)
Iron (max.)
Antimony (max.)
Iron & Antimony (max.)
Aluminium (max.)
Total of other elements incl.
Iron & antimony (max.)
Copper plus incidental nickel

4.0 - 6.0
4.0 - 6.0
4.0 - 6.0
0.05
0.3
0.3
0.5
0.01

6.0 - 8.0
9.0 - 11.0
0.5 max.
0.05
0.3
0.4
0.5
0.01

0.6
Balance

0.7
Balance

Note: For the purpose of utilising scrap containing a high percentage of tin, it shall
be permissible for the supplier to supply tin up to a maximum of 7.0 percent.
3.1.1 Some proportion, not exceeding 50% of reclaimed bearing metal, by judicious
selection of material and adopting good melting practice, may be used for casting
the shell but it is essential to ensure that two grades of metal should not be
melted and mixed as the bearing metal.
Specification no.MP-0.2402-01 (Revision- 2), October- 2005

Page 1 of 4

Technical supply requirements for Traction Motor Suspension Bearings for BG Diesel Electric locomotives

3.2

The anti friction metal shall have the following chemical composition;
Grade
Alloy
Alloy elements percent:
Sn
Sb
Pb
Cu
Impurities percent maximum:
Fe
As
Al
Bi
Zn
Cd
Total of indicated impurities,
percent

84
Sn Sb 10 Cu 5
84 Min.
9.0 - 11.0
0.3 max.
5.0 - 6.0
0.08
0.1
0.005
0.05
0.008
0.1
0.17

3.2.1 The manufacturer shall, preferably, not cast the lining out of reclaimed metal. By
adopting suitable melting practice after proper segregation of harmful
contaminated impurities, however, 25% max. reclaimed metal can be used.
3.2.2 Manufacture of suspension bearings using old and used shell, obtained by
running out the white metal lining, is not permissible.
4.0

PHYSICAL PROPERTIES
The material of bronze shell shall satisfy following physical requirements:

4.1

Tensile Test
The material when tested in accordance with IS: 2654-64 shall have the tensile
properties given in table-2
TABLE-2
Sl.
Mode of casting of
No.
test piece
1.
Sand cast (cast on)

Property and unit

Tensile strength
Min. kgf/ mm2
Elongation Percent Min.

2.

Sand cast (separately Tensile strength

cast)
Min.kgf/mm2
Elongation percent Min.

Specification no.MP-0.2402-01 (Revision- 2), October- 2005)

Type A

Type B

19.00

16.00

21.00

18.00

12

Page 2 of 4

Technical supply requirements for Traction Motor Suspension Bearings for BG Diesel Electric locomotives

5.

MANUFACTURE

5.1

The bearing shell shall be carefully cast to ensure clean castings free from
harmful casting defects such as blowholes, honeycombs, overheated structures,
shrinkage etc.

5.2

The surface to be lined should be either machined, ground with coarse portable
grinder or shot blasted until the surface is bright all over. After ensuring that the
surface preparation is complete, the shells should be degreased with hot caustic
soda (10 - 15%). The temperature of the alkaline solution bath should be about
60 to 70 deg.C. The shells shall be thoroughly washed in running water.

5.3

Following checks shall be carried out on the bearing shell before proceeding for
antifriction metal lining:
1. Check for important overall dimensions
2. Check for cracks.

5.4

Freshly prepared flux is to be used before tinning. Either of the two methods of
tinning i.e. by immersion of the shell in the bath of molten tin/solder and by the
use of stick of pure tin/solder can be used. During tinning, the bath temp. should
be kept as low as possible, 2700 C to 2800C for pure tin, 2200 C to 2300 C for
60/40 solder and the shells should be withdrawn immediately, as the desirable
fluid coating is obtained.

5.5

The anti friction metal lining shall be provided by centrifugal casting method.
Following safeguards shall be built into the system to obtain clean, dense
material free from porosities, oxides shrinkage cavities etc. with highest degree of
bond strength(i) Quick chilling and rapid rotation shall be ensured so that fine crystals are
produced in the white metal.
(ii) The process and QC procedures should be such as to reduce the problem of
segregation due to centrifugal action.

5.6

After completing the lining, the bearing shall be accurately machined to the
dimensions and tolerances specified in the drawing.

6.0

INSPECTION

6.1

Each finished bearing shall be subjected to the following checks apart from tests
stipulated in IS:1458-65 and IS:25-66.

6.1.1 Dimensional check - All important dimensions shall be checked with the drawing
to ensure that these are within permissible limits. Bearings not conforming to the
dimensions shown in the drawing shall be rejected.
6.1.2 The manufacturer shall install a suitable fixture in which a finished suspension
bearing complete can be fitted and tightened to the stipulated torque on the
traction motor. The dimensions and the ovality of the bearing bore shall be within
the specified limit when the same is checked on this fixture. This test should be
done on sampling basis as per the sampling plan given in clause 6.2.3.
6.2

Following tests shall be conducted to check the quality of bond between the white
metal lining and bronze shell.

Specification no.MP-0.2402-01 (Revision- 2), October- 2005

Page 3 of 4

Technical supply requirements for Traction Motor Suspension Bearings for BG Diesel Electric locomotives

6.2.1 Ringing test - The bearing shall be suitably suspended and tapped with a
hammer. The sound emitted shall have a ringing tone. The bearing giving a
dull sound as obtained in grey cast iron or castings having internal defects shall
be rejected.

6.2.2 Ultrasonic test - The quality of bond between the anti friction lining and the
bearing shell, shall be tested ultrasonically according to 'Metallurgical and
chemical report no. K-294' for Standardisation of ultrasonic testing technique of
suspension bearings of traction motor type 165 of WDM2 locomotive (Copy
enclosed).
6.2.3 In addition to the ultrasonic test on 100% basis, liquid penetrant test on edges
and corners, shall be done as a sample check. Sampling shall be done by
random selection of at least two bearings for a lot of 100 bearings or less and two
bearings per 100 bearings for a lot of 101 bearings or more.
7.0

TEST CERTIFICATE AND MARKING

7.1

Manufacturer/supplier shall provide test certificate giving test results covering

chemical composition and mechanical properties of material.

7.2

Each bearing shall be legibly marked with the following particulars as specified in
the drawing furnished by the purchaser:
(i) Manufacturers/Supplier's identification/trade mark
(ii) Serial number of the suspension bearing.
(iii) "UT" stamp against the serial number, on each bearing to indicate that the
bearing has passed the ultrasonic test.

8.0

PACKING
Each set of bearing shall be packed in an individual wooden box. A wooden
partition shall be kept between the two halves in order to avoid any chance of
one hitting the other piece. The wooden piece and the two halves shall be
secured tightly by packing strips. Further each half shall be packed in bubble air
packing.

Specification no.MP-0.2402-01 (Revision- 2), October- 2005)

Page 4 of 4

UDC 620. 179. 16: 625. 2.01

For official use only

GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
RESEARCH DESIGNS AND STANDARDS ORGANISATION
LUCKNOW

STANDARDISATION OF ULTRASONIC TESTING

TECHNIQUE OF SUSPENSION BEARINGS OF
TRACTION MOTOR TYPE 165 OF
WDM-2 LOCOMOTIVES

METALLURGICAL AND CHEMICAL REPORT NO. K-294

Printed MAY 1984

This report is based on ultrasonic tests conducted by the Metallurgical and Chemical
Directorate of RDSO. Every care has been taken in recording data accurately and in
analyzing it objectively. The views expressed in this report are subject to modification from
time in the light of fresh data. Further, they do not necessarily represent the views of the
Ministry of Railways (Railway Board), Government of India.
This report is the property of the RDSO and is meant essentially for official use. It
may not be loaned, reproduced in part or in full, or quoted as an authority without the
permission of Director General, RDSO, Lucknow.

K. N. Gupta
Director (M & C)
B. B. Ajmani
Additional Director (Met.)

CONTENTS
Description

S. No.
1.

Scope

2.

Equipment required

3.

Surface finish

Page

4.

Testing procedure .

5.

Limit of acceptance .

STANDARDISATION OF ULTRASONIC TESTING TECHNIQUE OF SUSPENSION

BEARINGS OF TRACTION MOTORS TYPE 165 OF WDM-2 LOCOMOTIVES.
This code of procedure describes the details of ultrasonic testing technique to evaluate
the quality of the bond between white metal and bronze shell of suspension bearing of
traction motor type 165 of WDM-2 locomotives.
1. SCOPE: The code describes the testing technique to evaluate the quality of the bond
between White Metal and Bronze Shell of suspension bearing of traction motors type
165 WDM-2 locomotive.
2. EQUIPMENT REQUIRED
2.1 ULTRASONIC FLAW DETECTOR: Model UFD-67 of ECIL or FD-201A of vibronics
or any other having similar characteristics may be used.
2.2 PROVE: 2 MHz, 20mm diameter, double crystal lead zirconate-titanate as supplied by
ECIL or any other equipment having similar characteristics.
2.3 CALIBRATION BLOCK: International Institute of Welding Block or 25 mm thick
block of class 4 steel to IS: 1875- 1971, forged normalized and rough machined. Both endfaces shall be parallel.
2.4 ACOUSTIC COUPLANT: Lubricant grease conforming to grade 2 or 3 of IS: 507-1967.
3. SURFACE FINISH: The testing of the bearings should be conducted preferably before
machining the white metal. This will eliminate unnecessary marching of defective bearings.
The surface should be smooth to ensure good coupling.
4. TESTING PROCEDURE
4.1 Calibration: Calibrate the time scale to 10 mm per main scale division.
4.2 Calibration in terms of bronze/white metal: The following velocities should be taken
into consideration:
(i) Velocity of ultrasonic waves in steel = 5.9 x 106 mm/sec.
(ii) Velocity of ultrasonic waves in bronze = 3.83 x 106 mm/sec.
(iii) Velocity of ultrasonic waves in white metal = 2.16 x 106 mm/sec.
(iv) Velocity of ultrasonic waves in perspex = 2.73 x 106 mm/sec.

(a) Ratio of the velocity of ultrasonic waves, steel to bronze =

5.9 x 106
= 1.5
3.83 x 106

(b) Ratio of the velocity of ultrasonic waves, steel to white metal =

59.5 x 106
= 2.7
2.16 x 106

5.9 x 106
= 2.2
2.73 x 106
The ultrasonic waves have to traverse through the Perspex of 10 mm thickness (in the case of
ECIL probe used), white metal of 1.5-1.6 mm thickness and bronze of 17.22 to 17.31 mm
thickness. The thickness in terms of steel is as below:
(c) Ratio of the velocity of ultrasonic waves, steel to perspex =

(a) Thickness of perspex in terms of steel = 10 x 2.2= 22 mm

(b) Thickness of white metal in terms of steel = 1.5 x 2.7= 4.05 mm
(c) Thickness of bronze in terms of steel = 17.3 x 1.5= 26.0 mm
The total path travelled by ultrasonic waves in terms of steel is 22.0 plus 4.0 plus 26.0= 52
mm (approximately). The thickness in terms of steel for flange portion having 27.5 mm thick
bronze base and 35 mm thick white metal lining works out to 72.0 mm approximately.
4.3 SENSITIVITY: The sensitivity of the equipment should be adjusted so as to give four
full screen height back echoes from 25 mm thick portion of IIW block.
4.4 SCANNING: Clean the white metal surface and apply to couplant. Place the prove over
the white metal surface and scan the complete area. While scanning, the prove should be kept
2-3 mm away from the edge of the bearing to avoid stray signals.
4.5 TRACE PATTERNS: The trace patterns as obtained from sound bond are given in Fig.
1 and 2. Fig. 3 shows the pattern obtained from a bad bond. A defective bronze shell will be
give an abnormal pattern on the lines shows in Fig. 3A.
5. LIMIT OF ACCPTANCE
5.1 MAIN BEARING (SHELL PORTION): The sum total of the poor bond areas shall not
exceed 10% of the total bearing area, provided the largest individual defect is not more than
625 sq. mm and the defects are separated from each other by at least 50 mm and situated at
least 10 mm away from the edge. The standard test plate for comparison purposes is shown
in Fig. 4.
5.2 FLANGE: In the dovetail portion of the flange upto 25%, poor bond is allowed, provided
there is no poor bond within 15 mm circumferential length near the horizontal joint and such
areas are distributed and the largest individual poor bond area does not exceed 26 mm in
length.
In remaining area of the flange leaving the dovetail portions, maximum of 20% poor bond is
allowed provided there is no poor bond within the 25 mm circumferential length near the
horizontal joint and the largest individual poor bond does not exceed 25 mm in length.
GIPN-S5-477 RDSO Luck/83-1.6.84-350

This report is based on the work carried out by:

O. P. Srivastava, Ex- Assistant Director (NDT)
C. L. Piplani, Ex-Chief Research Assistant (NDT)