DVS 1612-2014 轨道车辆钢制焊接接头的设计与疲劳强度评估

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Subscription method: DVS Media GmbH, Post office box:10 19 65 ，Dusseldorf, Postcode: 40010，Tel: (02 11)15 91-0, Fax: (02 11)15 91-150

August 2014

DVS – German Association for

Welding and Related Methods

Design and Fatigue Strength

Assessment of Steel Welded Joints for

Railway Vehicles

DVS 1612 Page 2

vehicles and the corresponding design loads. The above points should be observed when the fatigue

strength values are applied in other areas.

The construction catalog is only an excerpt. This Directive helps the calculation engineers and

designers to perform welding and stress design and assists the welding engineers in solving quality

assurance and production tasks.

2 Scope of Application

This Directive applies to the design and layout on fatigue strength of arc welding joints used in

steels for railway vehicles. It is applicable for welded structures with steel plate thickness ≥ 2 mm

and for some types of construction with steel plate thicknesses ≥ 1.5 mm.

In this Directive, the classification of fatigue strength and weld performance class under different

safety requirements as well as the classification of safety requirements meets the requirements

establishing for relevant weld performance class as specified in Table 1 and Table 2 of DIN EN

15085-3. Vibratory stresses are applicable to the weld performance classes of CP A, B CP, CP C1

and CP C2 according to DIN EN 15085-3. If the weld performance classes are determined in light

of all the information given in this Directive, Table 2 in DIN EN 15085-3 is not required to be

referred to. In addition, conclusions obtained in accordance with DIN EN 15085-3 must be

observed.

The fatigue strength values contained in this Directive can also be used for the design of laser and

electron beam welded joints. As arc welding processes are usually adopted during maintenance or

repair work, the increased fatigue strength of laser or electron beam welded joints is not taken into

account.

3 Welding Production and Quality Assurance

In the design of welded joints in railway vehicle, the requirements of DIN EN 15085-3 should be

followed. The construction drawings shall be prepared in compliance with DIN EN 15085-3 and

DVS 1610.

Based on DIN EN 15085, it shall be ensured that the welded construction of railway vehicles is in

accordance with the weldability as specified in DIN 8528-1. Specifically, it shall be applicable to

the following conditions:

- The weldability of materials can be ensured if the materials meet the requirements of Section

6.1 in DIN EN 15085-3.

- The weldability of welding consumables can be ensured if the welding consumables chosen for

all the materials meet the requirements of Section 5.3 in DIN EN 15085-4.

- The welding safety of the design can be ensured if the construction can still withstand the

environment without taking the material behavior into account. DIN EN 15085-3 and DIN EN

15085-4 must be observed.

- The weldability in production can be ensured if the component class during construction and

the possible welding processes during operation are considered.

Notes: If the weldability can not be guaranteed in all respects, in order to ensure a smooth

production, the weld test class is recommended to be improved for the same weld performance class

(e.g.: materials applicable to welding: CP C2 - CT 2).

According to DIN 27201-6, in addition to the weldability of the construction, the construction shall

meet the testing requirements (non-destructive tests are necessary) and maintenance requirements

(see also DVS 1620 in DIN EN 15085-3 and Section 4.6, and Section 4.1 of this Directive).

For the classification of certification levels for components and parts, information in Annex A of

DIN EN 15085-2 shall apply. For the classification of weld performance class, Section 4.5 of this

Directive gives the simplified definitions in which the requirements of Table 2 in DIN EN 15085-3

DVS 1612 Page 3

are observed. In addition, relevant information to determine the safety requirements is also given in

this section, which is consistent with the contents extracted from the Annex G in DIN EN 15085-3.

Notes: It is particularly important to ensure that the certification levels for components and parts are

based on the definition of the weld performance class, since the certification level is primarily

dependent on the weld performance class according to DIN EN 15085-2.

According to DIN EN 15085, the welding test for welding construction in railway vehicles shall be

performed based on DVS 1620.

4 Design and Layout of Welded Joints

4.1 Design principles

In the structural design of welded joints, it is important to ensure

–Compliance with stress requirements,

–Compliance with production requirements,

–Compliance with material requirements,

–Compliance with test requirements,

–Compliance with warpage or bending requirements,

–Compliance with corrosion protection requirements,

–Compliance with economical efficiency

–Compliance with maintenance requirements,

–Compliance with mechanization and automation requirements.

Design in compliance with stress requirements is represented by the following aspects:

–Fewer stiffness cracks,

–Change in cross sections depending on the type of stresses (e.g.: differences in tensile /

compressive stresses, bending stress and torsional stress),

–Avoiding accumulation and crossing of cracks,

–Non-penetrated T-shaped joints formed on one side, e.g.: in rectangular support.

Design in compliance with production requirements means that the construction is fully accessible

during the welding process. Design in compliance with material requirements means that any

change in materials are considered, e.g.: deflection zones in profile steels and non-metallic

inclusions in rolled sheets as well as cold-formed sections in safety welding models. Design in

compliance with test requirements means that the construction is fully accessible during the testing.

In addition, the design principles given in DIN EN 15085-3 and the general information about the

design of welded joints listed in the technical literature shall be observed (e.g. reference books

compiled by A. Neumann and J. Ruge III and Volume 12 of DVS Professional Book Series; see

Literature for details).

4.2 Basics of design

The construction design of welded joints in railway vehicles shall follow different standards with

different requirements. The strength of car bodies is given in DIN EN 12663 and that of bogie

frame is given in DIN EN 13749. These standards also include requirements for the design of

welded joints, but without concrete strength values. For dynamic loads occurring during operation,

the fatigue strength for weld joints shall be designed according to these standards. Therefore, the

adopted material data shall meet the following requirements:

–Probability of survival p ü = 97.5% (at least 95%),

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摘要：

本文档详细解读德国标准DVS 1612-2014，专注于轨道车辆钢制焊接接头的设计与疲劳强度评估方法。该标准为轨道交通领域焊接结构的设计、制造及质量验收提供了科学依据，尤其针对钢制部件在循环载荷作用下的疲劳寿命和安全性。内容涵盖焊接接头的应力计算、疲劳强度分类、评估程序及设计优化建议，适用于轨道车辆制造、检修及质量管控人员。通过遵循该标准，可有效提升焊接结构的耐久性与运行可靠性，降低疲劳失效风险。文档适合工程师、技术管理人员及标准研究者参考使用，为轨道车辆焊接接头的合规设计与安全认证提供权威指导

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DVS 1612-2014 轨道车辆钢制焊接接头的设计与疲劳强度评估

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