HOT AXLE

BY
S.K.SUMAN (CI/C&W)
 Hot axle box
• Hot axle box in a railway vehicle occurs when inadequate wheel-
bearing lubrication or mechanical flaws (bearing failure) cause an
increase in temperature. If undetected, the bearing temperature
can continue to rise until there is a bearing “burn-off” which may
cause a derailment.
• A hot box is the term used when an axle bearing overheats on a
piece of railway rolling stock. The term is derived from the journal-
bearing trucks used before the mid-20th century.
• Hot Axle is a phenomenon which causes due to breakage of ball
bearing of wagons or coaches which is moving on the rail track. It
arises due to the overloading and faulty condition of the bearing.
During Hot Axle the wheel become very hot and the movement or
the train stops due to jamming of bearing.
 Symptoms of hot axle
• Smell of Burning grease.
• Splashing of grease on wheel disc & Dis- coloring of grease.
• Light smoke from axle box.
• Dis-coloring of face plate.
• Axle box cover cut, bulged missing.
• Hotness of axle box by feeling.
• Axle may get locked and wheel skidding.
• Marks of splashing of grease on wheel and axle box visible at low speed or
at stationary.
• Discoloring of paint surrounded the axle box concerned.
• Red glows during the night time only.
• Metallic noise after grease has worked out and roller have seized.
• skidding of wheel at last stage.
• Tilting of Spring.
• Burning out of molten front cover in case of coaches.
 Hot box detector
• operation is the infrared “hotbox detector,” which, located at
trackside, detects the presence of an overheated wheel
bearing and alerts the train crew. The modern hotbox
detector identifies the location in the train of the overheating
and, employing synthesized voice recording, radios the details
to the train crew.
• Hot-Bearing Detector (HBD), sometimes also known Hot Box
Detector, is a technology that monitors the bearing
temperature as the train passes by. The detection is achieved
on real-time basis so a hot bearing can be traced and
monitored and alarm can be raised if the temperature
exceeds the alarm settings.
 Causes of Hot Box

• Defects of Lubricant
• Mechanical disorder
• Irregular loading
• Miscellaneous
 Defects of Lubricant

• Bad quality of grease.

• Excessive quantity of grease.
• Non availability / Inadequate quantity of
grease.
• Foreign material contained with grease.
 Mechanical disorder

• Defects in journal
• Defective bearing
• Defects in Axle box
• Cage broken
• Oozing out of grease due to perished rubber
seal
 Irregular Loading

• Uneven loading
• Over loading

Miscellaneous
• Derailment
• Defects in rail track
• Excessive speed
 Misc. Causes of Hot Axle

• Inadequate and insufficient lubrication

• Incorrect fitment
• Improper mounting
• Improper handling
• Excessive temperature or heating
• Excessive or uneven loading
• Impact loading
• Excessive Vibrations due to component wear and
tear
• Contamination (foreign particles, moisture)
 Misc. causes of Hot Axle

• Earthing not proper for welding work.

• Poor engineman ship.
• Land slide or stone hitting.
• Sudden change of signal expect.
• Poor maintenance of pathway.
• Wagon involved in Flood.
 How Can Detect Hot Axle
• During Rolling in Examination and Axle Box
filling
• While in Slow motion / Not in motion
Day time Night time
1. Smell of burning grease 1. Light smell of burning grease/ EM pad

2. Splashing of grease on wheel 2. Axle Box cover becomes Red Hot

disc & discoloring of grease
3. Light smoke from Axle box 3. Glowing of Axle Box
4. Discolouring of face plate 4. Hotness of axle box by filling/Non
contact thermometer.
5. Burning of EM pad over Axle Box
6. Hotness of Axle box by
feeling/Noncontact Thermometer
 While Run Through
Day Time Night Time
1. Screeching sound 1. Screeching sound
2. Axle may get locked and wheel skidding 2. Axle Box cover becomes Red Hot
3. Discoloring of Axle Box face plate 3. Sparks on Rail due to skidding
4. Smell of burning grease 4. Burning of EM pad and flame over Axle
Box
5. Vibrations of wagon /trolley
 Temperature on Non Contact
Thermometer

CTRB Axle box/Adopter State of bearing operating Action to be taken

temperature conditions
Up to 38 °C Above ambient Normal Wagon allowed
Temp. of bearing above Excessively warm/Hot Wagon to be detached
90°C
 Special instructions for Axle box
temperature of coaches
• If temperature is 80°C or beyond than coach should
be detach from the train
• Difference of temperature in same axle
Sl No. Difference in temperature Action Taken
1 Up to 10°C Allowed in same condition
2 10°C to 15°C Inform to next C&W
Examining point
3 16°C to 20°C Accompany with coach by
C&W staff up to destination
Non Contact Thermometer
 Preventions to be given during ROH
&POH to avoid Hot Axle
1. Earthing in wagons for welding should be done properly and very
close to the welding area so that electric current does not pass
through bearing, it will cause arcing between the rollers and raceways
leading to failure.
2. Work with clean tools in clean surroundings.
3. Keep bearings wrapped in polythene sheet when not in use.
4. Apply clean grease and keep grease in closed container when not in
use.
5. Grease seal and locking plate should be replaced by new.
6. RDSO approved brands of grease should be used.
7. Never mix up the different greases of different grades or even
different makes of same grade.
8. Don’t reuse locking plate.
 Continue---
9. End cap screws properly tighten with the help of torque wrench at specified
torque of 40 kg – meter (290 foot-pounds).
10. Each and every time lateral play of bearing must be check and UST of all
Axles should be done.
11. Load wear Zone area of bearing must be changed during fitment.
12. All tabs of locking plate are properly bent up against the flats of the cap
screw heads.
13. Damaged outer cup bearing should not be allowed in service.
14. It must be ensured by stamping particular of grease seal that the CTRB
would not complete more than 72 months by the time it becomes due for
next POH/ROH.
15. The dismounting of bearing by oxy cutting strictly prohibited , as above
such defects are considered very prone to generation of fatigue during
service.
16. Overhauling cycle of new CTRB to take place of 72 months interval.
17. Bearing Mounting force to be maintained 55 ±5 ton.
18. Quantity of grease is used 400+30 gms now a days in place of 430
±30 gms.
19. AAR approved Lithium base quality of grease must be used.
 Duties of railway servants in case of Hot Axle/ any unusual condition on Running Train:-

1. Any railway servant, observing a hot axle, any hanging part, broken spring, and load shifting etc. on a running
train must do everything in his power to stop the train and warn the train staffs.
2. Take immediate steps to short down the electric supply of OHE in electrified section.
3. If all attempts fail to draw attention of the train staffs, the Station Master/ Cabin Master/ ASM/ Switch Man
shall inform the SM of the station in advance to stop and examine the train and shall inform the section
controller.
4. On receiving the massage “Stop and Examine the Train” the SM shall not admit the train directly at station
unless he is satisfied that the train has come to a stop at the first stop signal. Then only the approach signals
shall be taken OFF for admission of train on Main Line.
5. In the event of the main line being not available and the train is to be received on a loop line, the SM, after
ensuring that the train has come to stop outside the first stop signal, shall arrange to advise the LP of the train
of the reason of the train being so stopped through a Station Staff/Points Man. The speed of train, while
admitting on loop line, shall not be more than 10 KMPH.
6. The LP on being so advised shall examine the train to ascertain if it would be safe to work the train up to the
station negotiating the crossover for entry into the loop line. The train, thereafter, shall be piloted up to the
station after fixed signals have been taken OFF and it has been ascertained by the LP that it is safe to do so. The
LP while negotiating the facing points shall observe the speed restriction, which under no circumstances, shall
exceed 10 KMPH.
7. The vehicles/wagon with hot axle must not be worked onward with the train, instead they would be
detached from the train or repaired.
8. If an axle box is observed to be running hot in the block section the train must be brought to a stand
immediately and the axle box is examined by the LP. The LP should exercise his discretion with regard to the
restricted speed at which it is safe for the vehicles or wagons to travel. On arriving at the first block station with
detaching facilities the vehicles or wagons must be detached from the train.
9. Water must not be poured on the Hot Axle for to cool it but wait until it gets cooled by itself. If there is fire
on the hot box then fire extinguisher, sand, soil can be used to extinguish the fire.
10. The vehicles/wagons with hot axle shall be detached from the train on arrival at the station. And it will be
entered in the Wagon Exchange Register and the concerned TXR shall be informed about it. BMW-4.10 shall be
followed for other instructions.
EXPANDED VIEW OF CARTRIDGE TAPERED ROLLER
BEARING
Timken Roller Bearing
 STEP WISE PROCESS OF HOT AXLE CTRB FAILURE
INVESTIGATION

➢ Hot axle CTRB received at wheel shop.

➢ Dismounting of CTRB at wheel shop.

➢ Cleaning of CTRB components.

➢ Data recorded as per RDSO format.

➢ Cleaned CTRB is sent to CMT lab for failure

analysis.
CUP:

Brinelling Marks

Cup is inspected
visually to detect
different defects i.e.,
dent, flaking,
spalling ,brinelling,
rust, peeling heat
discoloration etc.

Flaking
 VISUAL INSPECTION OF CTRB COMPONENTS AT CMT LAB

❑ SEAL
▪ Seal is inspected
visually to detect
different defects
i.e., damage,
deformation,
rubber seal etc.
DAMAGE SEAL
 VISUAL INSPECTION OF CTRB COMPONENTS AT CMT LAB

❑ SPACER
▪ Spacer is inspected
visually to detect
different defects i.e.,
dent, flaking,
brinelling, rust,
peeling, spalling
etc.
SPACER
CONE ASSEMBLY

▪ Consists of cone,
cage and rollers.
▪ Cone assembly is
inspected visually
to detect different ROLLER (deformed) CONE
defects i.e., dent,
flaking, brinelling,
rust, heat
discoloration

CAGE (BROKEN)
FAILURE INVESTIGATION REPORT OF CTRB FAILED ON 02.01.2023
OF DHANBAD DIVISION

Wagon No. SC-10053943393

Rollers/cone Assembly Damage
Cup Damage
Grease Burnt
Grease seals Damage
End Cup Screws Not found
Locking plate & Tabs Not found
How failure detected Manually
 Failure Investigation of Hot Axle CTRB
• Visual-Examination:
• Longitudinal tearing was
observed on the Cup.(Fig. 1)
• Contaminated grease was
observed inside the groove
of the Cup. (Fig. 1)
• Spalling of metal was
observed on the inner
surface of the Cup. (Fig. 1)
 Failure Investigation of Hot Axle CTRB
• Visual-Examination:
• One of the cages was found
damaged and broken. (Fig. 2)
• Rollers of the same cone &
cage assembly were found
heavily deformed with plastic
flow.
 Failure Investigation of Hot Axle CTRB
• Visual-Examination:
• Contaminated grease was observed on
the inner side of the seal. (Fig. 3)
• Heat discoloration mark was observed
on the surface of the rollers of the
other cone & cage assembly.
• Circumferential wearing & flaking of
metal were observed on outer surface
as well as inner surface of the cone.
, Fig.2-seal,
• Other Showing broken
spacer & damaged
& both cage
seal wear- Fig.3- Showing contaminated grease
metal on on inner surface of the seal
rings were not received for
investigation
 Failure Investigation of Hot Axle CTRB
Conclusion:

It was damaged in such a condition that nothing

was intact. Therefore, it was not possible to reach
in final conclusion. So exact cause can not be
ascertained.
 PREVIOUS FAILURE
INVESTIGATION REPORTS
Failure Investigation of Hot Axle CTRB

Wagon No. ECR 9410132311

Date of Failure 01.12.2021

Bearing Make TIMKEN

Sr. No. of Cup 135778

Mfg. Date of Cup 02/2008

संदर्भ - Sr. Section Engineer (Wheel Shop)/ER/JMPW L.No.

F/WS/OFF/35(01), Dated: 04/03/2022.
 Failure Investigation of Hot Axle CTRB
• Visual-Examination:
• Pitting marks was observed on
outer surface of the cup. (Fig. 1)
• Spalling of metal, heat
discoloration & brinelling marks
were observed on the inner
surface of the cup. (Fig. 1)
• A crack was observed at the edge Fig.1- Showing pitting marks on
of the cup. outer surface and spalling, heat F
discoloration & brinelling mark
on inner surface of the cup.
 Failure Investigation of Hot Axle CTRB

• Visual-Examination:
• Circumferential wearing &
scoring were observed on
outer surface of one of the
cone.
• One of the cages was found
broken & damaged. (Fig. 2)

Fig.1- Showing pitting marks on Fi

outer surface and spalling, heat Fig.2- Showing broken & ru
discoloration & brinelling mark damaged cage. an
on inner surface of the cup.
 Failure Investigation of Hot Axle CTRB
• Visual-Examination:
• One of the seal was found without
rubber & damaged at the edge.
(Fig. 3)
• Contaminated grease was
observed in the grooves of the
other seal. (Fig. 3)
• Heat discoloration mark was
observed on the inner surface of
one of the seal wear ring and on
marks on Fig.3- Showing one seal with
the rollers of the other cone &
ng, heat Fig.2- Showing broken & rubber & contaminated grease
ng mark cage assemblydamaged cage. and other seal without rubber.
e cup.
Failure Investigation of Hot Axle CTRB
Conclusion:

The failure of CTRB is due to overloading

and contamination of grease during service.
Failure Investigation of Hot Axle CTRB

Wagon No. SCR-22091622381

Date of Failure 23.12.2021

Bearing Make NBC/BRENCO

Sr. No. of Cup 78782

Mfg. Date of Cup 02/2012

संदर्भ - Sr. Section Engineer (Wheel Shop)/ER/JMPW L.No.

F/WS/OFF/35(02), Dated: 04/03/2022.
 Failure Investigation of Hot Axle CTRB
• Visual-Examination:
• Most of the vital components of
CTRB were not received for
failure investigation.
• Scoring & flaking of metal were
observed on outer surface of the
cup. (Fig. 1)
• Wearing, Spalling, flaking & flow
of metal were observed on the
inner surface of the cup. (Fig. 1)
• Bulging was observed at the edges Fig.1- Showing scoring on outer
Fi
of the cup. surface and spalling & flaking on
inner surface of the cup.
 Failure Investigation of Hot Axle CTRB
• Visual-Examination:
• One of the received cones
was found broken &
heavily damaged i.e.
bulging, plastic flow,
wearing & flaking etc.
(Fig. 2)

F
Fig.1- Showing scoring on outer
Fig.2- Showing one of the broken
surface and spalling & flaking on
& heavily damaged cone.
inner surface of the cup.
 Failure Investigation of Hot Axle CTRB
• Visual-Examination:
• Plastic flow of metal,
wearing & flaking of
metal were observed on
outer surface of the other
received cone (Fig. 3)

Fig.3- Showing plastic flow,

Fig.2- Showing one of the broken wearing & flaking on outer
& heavily damaged cone. surface of other cone.
Failure Investigation of Hot Axle CTRB
Conclusion:

The failure of CTRB may be occurred due to

overloading during service.
Failure Investigation of Hot Axle CTRB

Wagon No. WCR-22160975325

Date of Failure 11.01.2022

Bearing Make BRENCO

Sr. No. of Cup 215755

Mfg. Date of Cup 12/2019

संदर्भ - Sr. Section Engineer (Wheel Shop)/ER/JMPW L.No.

F/WS/OFF/35(02), Dated: 04/03/2022.
 Failure Investigation of Hot Axle CTRB
• Visual-Examination:
• Scoring mark was observed
on outer surface of the cup.
(Fig. 1)
• Contaminated grease was
observed inside the grooves
of inner surface of the cup.
• Heat discoloration was
observed on inner surface of Fig.1- Showing scoring mark on Fig.2
outer surface of the cup.
the cone.
 Failure Investigation of Hot Axle CTRB

• Visual-Examination:
• One of the cages was found
broken, deformed & damaged.
(Fig. 2)
• Other cone & cage assembly
was found broken, deformed
& damaged.
Fig.1- Showing scoring mark on Fig.2- Showing broken, deformed
outer surface of the cup. & damaged cage.
 Failure Investigation of Hot Axle CTRB

• Visual-Examination:
• Both of the seals were
found without rubber.
(Fig. 3)
• Plastic flow of metal &
deformation were
observed in most of the
n received
Fig.2- Showingrollers.
broken, deformed Fig.3-Showing both seals
& damaged cage. without rubber.
Failure Investigation of Hot Axle CTRB
Conclusion:

The failure of CTRB is due to overloading

and contamination of grease during service.
Failure Investigation of Hot Axle CTRB

Wagon No. SECR-12140310703

Date of Failure 26.01.2022

Bearing Make TIMKEN

Sr. No. of Cup 180149

Mfg. Date of Cup 02/2009

संदर्भ - Sr. Section Engineer (Wheel Shop)/ER/JMPW L.No.

F/WS/OFF/35(01), Dated: 16/03/2022.
 Failure Investigation of Hot Axle CTRB
• Visual-Examination:
• CTRB was received in oxy-cut
condition.
• One of cage and seal was stuck inside
the cup during oxy cut.
• Circumferential scoring marks were
observed on outer surface of the cup.
(Fig. 1)
• Contaminated grease was found inside
the groove of the seal stuck with the
cup as well as inside the groove of the
Fig.1- Showing circumferential
cup. (Fig. 1)
scoring marks on outer surface of
• Heat discoloration marks were the cup and contaminated grease
observed on the inner surface of the inside the groove.
cup.
 Failure Investigation of Hot Axle CTRB
• Visual-Examination:
• One of the cage was
found broken,
damaged &
deformed. (Fig. 2)

Fig.1- Showing circumferential Fig

scoring marks on outer surface of Fig.2- Showing broken , ma
the cup and contaminated grease damaged & deformed cage on
inside the groove.
 Failure Investigation of Hot Axle CTRB
• Visual-Examination:
• Deep brinelling marks with
plastic flow of metal were
observed on outer surface of
one of the cone and heat
discoloration mark was
observed on the inner surface
of the other cone. (Fig. 3)
• Rollers and one of the seal was
umferential Fig.3- Showing deep brinelling
er surfacenot
of Fig.2- Showing
received for broken
failure, marks with plastic flow of metal
nated grease damaged & deformed cage on outer surface of one of the
ove. investigation. cone.
Failure Investigation of Hot Axle CTRB
Conclusion:

The failure of CTRB is due to overloading

and contamination of grease during service.
Failure Investigation of Hot Axle CTRB
Wagon No. ECR-22101625708

Date of Failure 28.01.2022

Bearing Make TIMKEN

Sr. No. of Cup 474131

Mfg. Date of Cup 07/2011

सदं र्भ - Sr. Section Engineer (Wheel Shop)/ER/JMPW

L.No. F/WS/OFF/35(02), Dated: 16/03/2022.
 Failure Investigation of Hot Axle CTRB
• Visual-Examination:
• Circumferential scoring and pitting
marks were observed on the outer
surface of the cup. (Fig. 1)
• Spalling of metal and contaminated
grease inside the groove was observed
on the inner surface of the cup. (Fig. 1)
• Bulging was observed at the edge of
the cup. (Fig. 1)
• A groove formation was observed on Fig.1- Showing Circumferential
the inner surface of one of the seal and scoring on outer surface of cup.
Fig.2- Sh
Spalling of metal and
contaminated grease was observed and pits o
contaminated grease inside the
inside the groove of both the seal. of one
groove on the inner surface of the
cup and bulging at the edge of the
cup.
 Failure Investigation of Hot Axle CTRB
• Visual-Examination:
• Flaking of metals and pits
were observed on almost all
the rollers of one of the cone
and cage assembly. (Fig. 2)
• Contaminated grease was
observed in between one of
Fig.1- Showing Circumferential
the cage and cup assembly.
scoring on outer surface of cup.
Fig.2- Showing flaking of metals
Spalling of metal and
and pits on almost all the rollers Fi
contaminated grease inside the
of one of the cone and cage fla
groove on the inner surface of the
assembly.
cup and bulging at the edge of the
.
cup.
 Failure Investigation of Hot Axle CTRB
• Visual-Examination:
• Pitting & flaking of
metals were observed on
outer surface of the cone.
(Fig. 3)
• Contaminated grease was
umferential
observed
face of cup. inside flaking
Fig.2- Showing groove of
of metals
al and
and pits on almost all the rollers Fig.3- Showing pitting &
one of of
e inside the theonecage.
of the cone and cage flaking of metals on outer
urface of the
assembly. surface of the cone.
e edge of the
.
Failure Investigation of Hot Axle CTRB
Conclusion:

• The failure of CTRB is due to overloading

and contamination of grease during service.
Hot axle case – Adaptor cause
Hot axle case – Adaptor cause
 Damage Causes – CTRB Failure
• Grease seal damage – In transit or maintenance.
– Dent of casing
– Loose grease seal.
– Cocked out seal.
• Worn Adaptor / wrong adaptor.
– Non uniform load zone
– More stress
– Pinching effect

• Dynamic operating condition – Wheel / rail interaction.

– Grease weepage
– Cage damage
– Wear in bearing components.
– More load – More stress.

• Bearing misalignment
– Geometrical stress concentration.
– Edge loading / stress
– Increased end play.
THANK YOU