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Fatigue Test Rig

1. 5 1 1 Counter The machine should give the number 29 12 2011 RI BUC A of cycles of tension and compression 5 1 2 User operated The machine should stop in case of 06 01 2012 R2 BUC A emergency emergency stop 5 1 3 Test specimen The machine should apply adequately 06 01 2012 R3 BUC A fixture gripping force to ensure tightness and avoid slack of the test specimen 5 1 4 Movement of Linear movement 06 01 2012 BUC test rig The machine should apply the load A axially R4 Test specimen must be exposed to an alternating tension compression cycle B R5 5 1 5 Teststop The machine must stop when test 06 01 2012 R6 BUC B specimen breaks 5 1 6 Testtime The testing time for standard specimen 06 01 2012 R7 BUC B should not exceed 24 hours HOGSK OLEN i Buskerud FiR Fatigue Test Rig Requirement specification rev 2 0 5 2 System requirements 5 2 1 Vibrations No resonance must be created neither 06 01 2012 RS BUC A in machine nor in surrounding areas 5 2 2 Life cycle The performance degradation should 06 01 2012 R9 BUC A durability be a minimum of 7 of the delivered accuracy after 3 years of service 5 2 3 Machine The machine weight divided by the 06 01 2012 R10 BUC B weight area it occupies should not exceed the floor carrying capacity NS 3473 2003 5 2 4 Test material The machine is primarily designed to 06 01 2012 R11
2. em i F H HOGSKOLEN i Buskerud Fatigue Test Rig Test report for T28 A FIR i Buskerud Fatigue Test Rig Test report rev 1 0 12 0 Introduction The purpose of this test is to check if the deflection in the frame is less than 0 5mm If the Deflection exceeds 0 5mm the test has failed The frame needs to be stiff and it deflection is not wanted 13 0 Abbreviations SW SolidWorks kN kilo Newton 14 0 Limitations The possibility of testing this will reduce since there is not produced and assembled a physical test rig and the testing will only be done with the use of FEM analysis 15 0 Execution of the test 15 1 What is tested Test T28 from the test specification is tested It is checked if the deflection in the frame of the Fatigue Test Rig is less than 0 5mm A FIR HOGSKOLEN i Buskerud Fatigue Test Rig Test report 16 0 Test results URES mm 3 539e 002 3 244e 002 2 949e 002 2 654e 002 2 360e 002 2 065e 002 1 770e 002 1 475e 002 1 180e 002 e 8 848e 003 b EM 2 949e 003 1 000e 030 Figure 1 FEM analysis of the deflection in the rectangular beam rev 1 0 The testing of the rectangular beam in figure 1 shows a deflection of 0 035mm when being exposed to 11kN at the centre of the beam simulating the cylinder in use Figure 2 FEM analysis of the deflection in the H beam URES mm 1 738e 002 1 593e 002 1 449e 002 1 304e 002 1 159e 002 1 014e 002 8 6
3. 2 325e 004 2 035e 004 1 744e 004 1 453e 004 1 163e 004 3 720e 005 5 81 35e 005 2 907e 005 1 000e 030 0 0003488mm The maximum displacement is located at the surface at the bottom of the component which is in contact with the wedges The displacement analysis satisfies requirement ref R28 Requirement Specification rev 1 4 ANTAA 28 H GSKOLEN i Buskerud FIR Fatigue Test Rig Technical document rev 1 0 7 12 The fastener Figure 32 Fastener The bolt has to provide enough force to allow a tight fix of the test specimen It is crucial that the specimen is held in place during the test The hexagonal bolt has the dimension of M27x1 and the specification of 8 8 which means it has a yield strength of 8x8x9 81 627 MPa Calculations Torque the bolt need to be tightened with Torque needed to fasten a triangular thread M F rn tan amp 1 9 F axial load or force Tin thread radius 2 eu angle of friction tan e aw p zogen zi Q pitch angle o TFA u coef ficient of friction 2a profile angle of thread 60 A FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 Torque needed to loosen a triangular thread M F rn tan amp 1 0 In the contact face a friction force occur which counteract the pull of the bolt The friction force of this moment is Ms p F rm Where F axial force My coef ficient
4. After this is done the Fatigue test Rig is operational A 6 F R i Buskerud Fatigue Test Rig User manual rev 1 0 4 0 Operation instruments 4 1 Start button Figure 3 Start button is green The start button is the green button This button starts the cycling in the valve and the cylinder moves 4 2 Pressure sensor switch Turn to the wanted set if value Figure 4 Where to set the wanted test pressure The pressure sensor switch is a switch to set a given work pressure for the cylinders The switch is set by rotating the center knob The needle in the manometer shows what the pressure the cylinder will work on e FIR H GSKOLEN 7 i Buskerud Fatigue Test Rig User manual rev 1 0 4 3 Manual emergency stop button Figure 5 Manual emergency stop button which is big and red The manually emergency stop button is used when something out of the ordinary happens and it is wanted to stop the test rig and hydraulic pump completely Push the button and the rig stops 4 4 Automatic emergency rope pull Figure 6 The emergency rope pull switch This is an automatic emergency device which is pre set to stop the test rig if the cylinder goes outside the move area This is also the device that stops the rig and hydraulic pump when the test is done This device does not need any manual attention e FIR H GSKOLEN 8 i Buskerud Fatigue Test Rig User manual rev 1 0 4
5. BUC 5 2 4 Test material Check the material data of the test specimen to ensure it s construction steel with a modulus of elasticity of 200GPa E 200GPa Check the material data of the test specimen to ensure it s aluminium with a modulus of elasticity of 70GPa E 70GPa 06 01 2012 T11 T12 BUC 5 2 5 Machine dimensions Perform physical measurements of the machine and measurements in SW to make sure it s able to go inside C151 06 01 2012 T13 BUC 5 2 6 Power supply Check that all electric systems is using 220V and attach it to an outlet of 220v to verify that everything works as it should 06 01 2012 T14 BUC 5 2 7 Frame stiffness Perform calculations to ensure the frame has a factor of safety of at least 2 against fatigue 06 01 2012 T15 BUC 5 2 8 Deflection Perform a FEM analysis on the frame to check the deflection 23 04 2012 T28 Group A cn H GSKOLEN i Buskerud FIR Fatigue Test Rig Test Specification rev 2 0 5 3 Test of result requirements 5 3 1 Measuremen t units Manually check if the output is using the SI units 06 01 2012 T16 BUC C 5 3 2 Results Visually inspect output data to check if number of cycles until fracture is listed Visually inspect the output data then check for forces applied 06 01 2012 T26 T27 BUC A 5 3 3
6. Deviation Perform a test with the same criteria at the HiG lab and check for deviation 06 01 2012 T19 BUC B 5 3 4 SN Graph Observe that the laptop is showing a SN curve after the 10 tests are done 06 01 2012 117 BUC C 5 3 5 Data log Try to access earlier test data and verify 06 01 2012 T18 BUC C HOGSKOLEN i Buskerud FiR Fatigue Test Rig Test Specification rev 2 0 5 4 Test of environmental requirements of 1 meter and verify 5 4 1 Testing Verify that all components of the 06 01 2012 T20 BUC A conditions machine are designed to tolerate temperatures from 5 30 C with a FEM analyses and data sheets for the components 5 4 2 Noise level Test with a dB meter at a distance 29 12 2011 T21 Group B 5 5 Test of other requirements up to standard 5 5 1 Operator Check and verify that all personnel 06 01 2012 T22 BUC A safety protection equipment is ready for usage and that all protection housing is functional 5 5 2 User manual Check and verify that all aspects of 06 01 2012 T23 BUC A user functions is covered and explained in detail 5 5 3 User friendly Let an engineer student try to use 06 01 2012 T24 Group A the machine and confirm that he understands from the user manual how to use it 5 5 4 Test Manually inspect and measure the 06 01 2012 T25
7. Sensur av hovedoppgaver H gskolen i Buskerud b Avdeling for Teknologi HOGSKOLEN Prosjektnummer 2012 11 For studie ret 2011 2012 i Buskerud Emnekode SFHO 3200 Prosjektnavn Testing av utmatting i st l og aluminium Fatigue Test Rig Fatigue testing of steel and aluminum Fatigue Test Rig Utf rt i samarbeid med H gskolen i Buskerud Avdeling for Teknologi Ekstern veileder Kjell Enger Sammendrag Denne rapporten inneholder dokumentasjon av de ulike fasene i produktutviklingen Oppgaven gikk ut p designe en maskin for teste utmatting i st l og aluminium Det skulle designes en komplett test maskin med tilh rende teknisk l sning Stikkord e Utmatting e H gskolen i Buskerud e Maskiningenigr Produktutvikling Tilgjengelig JA Prosjekt deltagere 0g karakter Navn Karakter Kjetil Haugmoen Kj ndal Espen S tre Kolberg Dato 30 mai 2012 Navn Olaf Hallan Graven Navn Intern Veileder Intern Sensor Ekstern Sensor Table of contents 1 Vision document 2 Requirement specification 3 Test specification 4 Project plan 5 Concept round 1 6 Concept round 2 7 Technical document 8 Test report 9 User manual g H GSKOLEN i Buskerud Department of Technology Kongsberg Title of document Vision document Version 2 0 Course code name SFHO3200 H11 Hovedoppgave med prosjektstyring Group Members Espen S tre Kolberg Kj
8. The other guide bearing the group has gotten an interest in is POM polyoxymethylen which is widely technical used for production subjects or strong precision mechanics POM is distinguished by a high degree of rigidity and mechanical strength it is easy to manufacture and has outstanding resilience Because of these properties POM is often used for the manufacture of precision parts 9 The mechanical industry uses these for cogwheels rollers wheels sliders and guide rails It is used when it is desired a maintenance free function and dimensional stability The POM would secure an almost friction free movement between the stabilizer bar and the guide rods A i FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 12 0 Drive Medium 12 1 Idea 1 Pneumatic Pneumatic systems are commonly used in tests which require a small amount of force That is because air as a drive medium not provides a large amount of forces without having a very large cylinder which also requires more room Besides that air as a drive medium is compressible this could lead to deviation in the test results A system driven on pneumatic requires a large amount of air supply which has to be delivered by a compressor and an external pressure vessel Pros e Possible to let excess pressure in the air e No harmful vapors e Not flammable e Environmentally pleasant Cons e Requires large equipment in terms of forces needed e
9. 0 275N ue NA cos4 NA sin 4 0 393 6N Ley NA sin 4 NA cos 4 dos NA 393 6N 0 0419NA 393 6N NRS 0 9581 411 2N NA 411 2 sin 4 28 67N Y 1 Since this calculation is based on a0 of the wedges the actual force needed will be 28 67N 40 1146N 6 S FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 FEM analysis Stress Figure 36 Wedge stress 1 146kN axial The analysis of the wedge shows a maximum stress of 8 596 MPa The FEM analysis will have some deviation to an actual test run due to the friction force and the normal force that acts on the wedges Displacement Figure 37 Displacement wedges 1 146kN axial Displacement analysis shows a maximum displacement of 0 001mm The maximum displacement is located at the upper left side of the wedge A s FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 7 14 Locking bolt Figure 38 Locking bolt To ensure a tight fixture of the cylinder to the lower specimen fixture a stud bolt is shrunk fitted into the lower specimen fixture The bolt is cooled down sufficient for it to be pushed in to the lower specimen fixture and through the hole in the cylinder rod This will ensure a strong connection between the parts and will eliminate any play The locking bolt has the dimensions of 42x120 mm FEM analysis Stress Fig
10. 8 2750N 0 793m 1963mm x 200000 0 0055mm 1 3 F S 355 1 4 253 FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 The calculations on the previous page show that the maximum stress in the material is 1 4MPa which gives us a F S of 253 From this calculation one can conclude that the guide rod and frame structure is rather oversized The displacement in the rod is a maximum of 0 0055mm FEM analysis Stress von Mises Nim 2 1 588 208 3 1 523 625 0 1 459 041 8 1 394 458 5 13288754 1 265 292 1 1 200 708 9 11361256 10715424 1 006 959 2 942 375 9 877 792 8 813 209 5 gt Yield strength 355000000 0 Figure 9 Stress analysis of the guide rod The FEM analysis shows a max stress in the rod of 1 588MPa which corresponds quite good with the manual calculations FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 URES mm 8 633e 003 7 913e 003 7 194e 003 6 4758 003 5 755e 003 5 036e 003 4 316e 003 3 597e 003 2 878e 003 2 158e 003 1 439e 003 7 194e 004 1 000e 030 Figure 10 Displacement analysis of the guide rod The analysis show a maximum displacement of 0 0086mm At the analysis the maximum displacement is located in the bottom of the rod where the force is applied A FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 Calculations To ensure the design of the rig is o
11. It is also important that the students plan the time ahead needed to complete the project 4 0 Project model There are many different project models some models are made to cover special needs in a project The project model is a very important tool in the working with a project and we need to choose the best suited model for our project The model shows the different phases the project would need to go trough to be successful The model helps us through the project and points us in the right direction without necessarily following it by every step Some of the most common models are e Waterfall e Prototyping e Evolutionary e Incremental 4 1 Waterfall The waterfall model is the most common model for development of bigger systems The approach is based on a thoroughly analysis of the system before the design phase is started It includes an in depth analysis of the previous phase There are some pros and cons with this kind of approach It is a simple model with clearly defined milestones On the other hand this model is not very flexible and leads to an early fix of the requirement specification which could lead to a poor outcome an H GSKOLEN i Buskerud Fatigue Test Rig Project plan rev 2 0 4 2 Prototyping Prototyping model leads to a rapid development of the product There are vague specifications and is not often used on larger projects The model is based on an open dialog with the customer The des
12. Standard ASTM e606 04 7 http www skf com portal skf home products maincatalogue 1 amp lang en amp newlink 9 0 70 26 05 2012 8 http www vxb com page bearings CTGY 20mmLinearMotionSystems 26 05 2012 9 http www plasticsportal net wa plasticsEU en GB portal show content products engineering plastics ultraform 26 05 2012 10 http finnloeken no prisliste tekniske plaster content text 79f3d1dd 3003 4fea 89fc 3942c62fc926 1331643740031 ny lager prisliste tekniske plaster pdf 26 05 2012 11 Test rig at HIG Kenneth Kalv g 12 http fatigue testresources net us axial fatigue testers 104 810le516 modular fatigue tester 8500 Ib 15 hz 24 03 2012 13 http biltema no no Verktoy Trykkluft Kompressorer Kompressor 55B 90 17659 14 02 2012 14 http www coastpneumatics com metric valves EVS Series Valves pdf 28 05 2012 15 At BUCs property FIR H GSKOLEN i Buskerud ER Fatigue Test Rig Concept round 2 rev 2 0 16 Nestun J rgen Hydraulikk i teori og praksis Gyldendal forlag 2003 ISBN 82 585 1381 8 17 http www boschrexroth com modules BRMV2PDFDownload dll db brmv2 amp lvid 1 143366 amp mvid 6218 amp clid 20 amp sid A72F75B92917B38020BBF31D58EDB7C6 amp sch M 28 05 2012 18 Steinar haugnes Olje hydraulikk generell innf ring s 40 41 19 www 3dcontentcentral com 28 05 2012 20 http www westernsafety com rockford rockfordpg3 html 28
13. Upper specimen fixture The specimen fixture is one of the main components of the rig It is made on the basis of the ASTM e606 standard The fixture has to provide clamping force onto the specimen during testing In the upper part of the bracket there is milled out a 65x70x35 mm rectangle to allow fastening of the bolt This clearing also makes room to fasten the bolt with a wrench In the lower part of the milled out rectangle it is a tapped hole M27x1 that goes through to the lower section of the specimen fixture This hole is to be used for the tightening of the test specimen In the lowest part of the specimen fixture is it milled out a second rectangle with the dimensions of 60x60x30 mm This cutout is made to house the power transfer which is the intermediary between the bolt and the wedges On the surface in lowest part of the fixture a wedge shaped hole is milled out The cutout is 40mm deep and goes through the frame of the fixture Dimensions of the upper specimen fixture are Height 125mm Width 80mm Length 100mm Thickness middle section 20mm A FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 FEM analysis Stress von Mises N mm 2 MPa Figure 21 Stress analysis upper specimen fixture at 11kN 13 1 16 6 15 1 13 5 12 1 10 6 9 1 76 6 0 45 3 0 15 0 0 Yield strength 325 0 The FEM analysis show a stress of 1
14. controls the main component when the electro magnets on the directional valve activate the slide When the slide is activated it sends directional pressure to the opposite site of the main slide and the main slide is pushed to the relevant side 16 The Olsen valve does function with a closed centre This is actually not wanted because of the need to bleed off the hydraulically cylinder to be able to retain the test specimen after a test is done A i FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 E spool iere inni d Figure 25 Function and inside of Olsen valve 16 i FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 13 2 Final concept valve 13 2 1 Bosch Rexroth directional spool valve Figure 26 Direct directional spool valve The direct directional spool valve has properties like the directional valve used on top of the Olsen valve but in this case the valve directly controls the fluid The magnets on each side react when it gets a signal of 24V and switch to the wanted position If the magnet spool a on the left of the picture gets 24V voltage it switch the slide inside to open fluid output A and opens fluid output B when magnet spool b on the right side of the picture gets 24V voltage 17 The center position is open between the lines to the cylinder and to the reservoir which is desirable J J spool KONAN Figure 27 Function a
15. 330MPa 0 00007853m P 25914N 6 35mm Ass Tr A T 0 003175 A 0 0000316m P Omax A P 355MPa 0 0000316m P 11218N DIER By reducing the diameter of the test specimen to 6 35mm the project will end up with a more cost efficient solution compared to the larger more robust 10mm test piece Due to the smaller diameter the forces applied from the rig could be reduced significantly These factors leads to that both the machine and the test specimen will be less expensive to produce The group then decided that the smaller diameter specimen were the best solution to use for the project and will be used in the final design p FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 9 0 Frame design 9 1 Idea 1 Figure 1 Idea frame Based on the earlier design from the first round the group came up with a more compact design The decision to utilize a center mounted cylinder made the group look at alternative solutions to the lower frame The earlier H profile used in round one would not be suitable for attachment of a double rod cylinder as it would lose its stiffness A FIR i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 9 1 1 Upper frame Figure 2 HE280B beam The heavy duty H beam upper frame used in the previous concept was quite over dimensioned and would withstand far more stresses than necessary The dimensions of the beam is 500x280x280m
16. 355J2H carbon steel with yield strength of 355MPa and E module of 210GPa 12 Channel bars The material used for the channel bar is hot rolled S355J2G3 steel with yield strength of 355MPa and E module of 210GPa 12 Support legs The material used for the support leg is hot rolled 355J2G3 steel with yield strength of 355MPa and E module of 210GPa 12 8 2 Internal components Test specimen The test specimen is made out of S355J0 steel with yield strength of 355MPa and E module of 210GPa 12 Guide rods The guide rods are made out of 355JO steel with yield strength of 355MPa and E module of 210GPa 12 POM bushing The POM bushing is made out of Polyoxymethylene with a tensile strength of 65MPa and E module of 3GPa 13 Upper and lower specimen fixture The upper and lower specimen fixture is made out of S355J0 steel with yield strength of 355MPa and E module of 210GPa 12 i N 49 F R H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 Cylinder bracket The cylinder bracket is made out of 355JO steel with yield strength of 355MPa and E module of 210GPa 12 Power transfer The power transfer is made out of 355JO steel with yield strength of 355MPa and E module of 210GPa 12 Fastener The power transfer is made out of ISO 8 8 steel with yield strength of 640MPa and E module of 210GPa Wedge lock The wedge lock is made out of S355J0 steel with y
17. 5 50Other requirements sanden ans 9 A FIR H GSKOLEN i Buskerud Fatigue Test Rig Requirement specification rev 2 0 1 0 Document history 29 12 2011 0 1 Started and edited 03 01 2012 0 2 Written introduction 06 01 2012 0 3 Edited requirements 09 01 2012 0 4 Rewritten requirements added table of contents 10 01 2012 1 0 Finalized document 28 12 2012 1 1 Edited requirements 13 02 2012 1 1 1 Edited 26 02 2012 1 2 Added hierarchy 02 03 2012 1 3 Finalized document 23 04 2012 1 31 Added R28 10 05 2012 1 4 Grammar and spell check 24 05 2012 1 41 Read through and checked 29 05 2012 2 0 Spell check and layout Finalized document Table 1 A FIR H GSKOLEN i Buskerud Fatigue Test Rig Requirement specification rev 2 0 2 0 Abbreviations BUC Buskerud University College 3 0 Introduction This task is given by BUC which is located in Kongsberg The need for a replacement of a fatigue machine is the background for the project The existing machine is old and does not fulfill the demands of a reliable machine to be used by the students It consists of an electromotor which delivers the power to rotate the test specimen The specimen is held in place on the one side of the axle while it s subjected to bending load on the other side This rotation is providing a reversible bending moment that eventually causes the specimen to fail The main goal of this p
18. 5 Hydraulic pump start and configure The start button on the hydraulic pump is green When this is pushed the pump should start There is also a handle bar to configure the work pressure of the pump a FIR H GSKOLEN 9 i Buskerud Fatigue Test Rig User manual rev 1 0 5 0 User instructions 5 1 Step 1 The first thing to do is to set the pressure sensors to the wanted work pressure The work pressure is the pressure the cylinders will work with and the pressure in the cylinder has a direct connection to the force exposed to the test specimen A calculation is needed to work on the right pressure for wanted force Calculation 1 Max appliance is 75 bar F A p 10 14 72 75 10 11004N b 247575 748 75b P 541 10 777 14710 a When calculating the pressure needed the number to change is 11000 in the calculation This number is the force wanted Example If wanted force on test specimen is 8000N the calculation is this d b seta 54 42 55b PER mun Sr The pressure sensors are set in this matter Turn to the wanted set value Figure 7 How to set the pressure switch H GSKOLEN 10 i Buskerud Fatigue Test Rig User manual rev 1 0 5 2 Step 2 The door of the test rig needs to be opened Use the handle to open Figure 8 How to open the door 5 3 Step 3 The test specimen needs to be placed in the test specimen fixture The test specimen should be betw
19. Buskerud PE E CE HOGSKOLEN i Buskerud Department of Technology Kongsberg Title of document Concept round 1 version 2 0 Course code name SFHO3200 H11 Hovedoppgave med prosjektstyring Group Members Espen S tre Kolberg Kjetil Haugmoen Kj ndal Internal Supervisor Jamal Safi Date 29 05 2012 We confirm that the submitted assignment is entirely our work Espen Kolberg Kjetil Kj ndal Fatigue Test Rig Concept round 1 Document history 29 02 2012 0 1 Added introduction hydraulic 0 2 21 03 2012 Added fixture test specimen dimension 1 0 23 03 2012 Changed font size page layout 1 1 30 03 2012 Changed headlines dates 1 2 14 05 2012 Grammar and spell check 2 0 29 05 2012 Finalized document Table 1 Document history rev 2 0 An H GSKOLEN i Buskerud FIR Fatigue Test Rig Concept round 1 rev 2 0 1 0 Introduction The document shows which concepts that are made in round 1 of the bachelor project and has as intension to show what ideas that were considered and which ideas that were chosen as approved It will show the decisions made and why they were made We will explain ideas why they were considered and what made us either throw the idea away or choose one There are different solutions to choose from and every concept has something new about it This is to know what is out there and what ideas
20. DVD 6 LANGUAGES EXECUTABLE ON WIN98SE NT4 0 ME 2000 XP VISTA WIN7 MAC OS SUSE LINUX 3 6ED1058 0BA02 0YA1 1 REFERENCE HARDWARE LOGO 447 00 1 447 00 r LOGO AM2 AQ EXPAN MODULE PU DC 24V 0 4 r 2 6ED1055 1MM00 0BA1 4540386 1 20MA 2AQ 0 10V 995 00 1 995 00 Ld Ld LOGO 230RC LOGIC MODULE DISPL PUN O 115V 230V RELAY 8 DI 4 DO MEM 200 BLOCKS 1 6ED1052 1FB00 0BA6 4510358 1 EXPANDABLE WITH EXTRA MODULES 230V AC DC 1080 00 1 1080 00 Pris netto 3207 00 Table 3 The cost of Siemens PLC The Siemens PLC is more cost efficient than the Eaton PLC and the Siemens PLC comes with software to program the PLC Since this project only requires a PLC with 5 inputs and 2 outputs the Eaton PLC is superfluous with its 12 inputs and 6 outputs and the Siemens PLC will match better with the need The Siemens PLC LOGO 230RC is chosen for this concept FiR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 19 0 Resources and references 1 Bedford Anthony Fowler Wallace Engineering mechanics Pearson 2008 ISBN 13 9789810679394 2 http www hubert no shop php controller category amp action groups amp id 4 28 05 2012 3 Hibbeler R C Mechanics of materials Pearson 2011 ISBN 13 9789810685096 A Vollen ystein Statikk og fasthetsl re ISBN 978 82 562 7152 8 5 http biltema no no Bil MC Verktoy og verkstedutstyr Lofteverktoy Hydraulisk jekk 15221 18 03 2012 6
21. Figure 26 Cylinder bracket The cylinder bracket provides a good support structure for the cylinder The bottom flange has the dimensions of 140x45x15mm length x width x height On the flange there are cut holes M24x3 for mounting on to the lower frame The upper flange consists of two M24x3 extruded cuts for mounting the flange on to the cylinder bracket There are also a circular cut with a radius of 35mm which allow the bracket to fit around the cylinder A FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 FEM analysis Stress CALN 750kN e UK The stress analysis show a maximum stress of 21 2 MPa The maximum stress is located at the corner at the upper flange The stress in the fixture meets the requirement ref R15 Requirement Specification rev 1 4 Displacement Max 2 558e 001 Min 1 000e 030 Figure 28 Cylinder bracket displacement 2 750kN The displacement analysis shows a maximum displacement of 0 265mm The maximum value of the displacement is located at the very tip of the upper flange The displacement analysis satisfies requirement ref R28 Requirement Specification rev 1 4 A FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 7 11 The power transfer Figure 29 Power transfer The force passing is a cylindrical cup that transfers force from the bolt onto the wedges The component fits over
22. H 6 4 LAVE VE LTE 8 Test report for T10 seit eee 9 TB att gere e Te EET EIER CUERO LIQUIDI LIEN 10 8 0 Abbreviations IER 10 9 OLIMItatONS sa 10 10 0 Execution of the test als ee eeeseecescceeesceeeeeeeeesaececececaaeessaeeecaceceeaaessaneneaaeceeaaeseeeaessaeeeeaaeeeeaeeseneetens 10 10 1 What is tested RE 10 A 10 11 1 Critical fall ULES cec me 11 A NO NS 11 As A O O RE SES IE RESET 11 TILA EV ALU At OM 11 Testreportfor EE 12 120 Introduction EE 13 TS O AIDDREVIat ONS vicio ti dt 13 14 0 LimitatiONS pts 13 15 0 EXECUTION of THE test rece dara 13 15 1 What is tested tuvo m 13 HERMES LIP NE 14 17 0 Critical failure iii a Aaa 16 AN AAA EE EE 16 17 2 EQUIDIT GIA EE 16 H GSKOLEN i Buskerud Fatigue Test Rig Test report rev 1 0 lk SEET EE 16 1 0 Document history 07 05 2012 0 1 Document startup 29 05 2012 1 0 Tests T4 T10 and T28 are added Finalized document Table 1 Document history A FIR HOGSKOLEN i Buskerud Fatigue Test Rig Test report for T4 A FIR i Buskerud Fatigue Test Rig Test report rev 1 0 2 0 Introduction The purpose of the test is to check if the force is axially applied on the test specimen This is checked because if the force is not axially applied the test result
23. Pearson 2008 ISBN 13 9789810679392 5 Dahlvig Christensen Str msnes Konstruksjonselementer Gyldendal 2005 ISBN 82 585 0700 1 6 Safi Jamal supervisor 7 http www silicone jp e catalog pdf rubber e pdf 25 05 2012 8 http www sciencedirect com science article pii S0261306910002633 28 05 2012 9 http www astrup no asset 797 1 797_1 pdf 24 05 2012 10 http www kjmagnetics com specs asp 28 05 2012 11 http www halder de produkte artgroupdetail asp k 1 amp a 529 amp g 3 amp intas 1 amp s uk amp menu 296 amp submenu products 28 05 2012 12 http www digipaper fi ruukki_norway 44622 28 05 2012 13 http www thermosole com products datasheet Polyacetal pdf 28 05 2012 14 SolidWorks material data 15 http www fjero com skitse asp parent produkter amp kategorinr 13 amp sprogkode DK amp del te kn amp katnr 4 22 05 2012 16 Haugsnes Steinar Oljehydraulikk Gyldendal 2008 ISBN 978 82 585 0436 5 17 http www boschrexroth com 28 05 2012 18 http www oilpathhydraulics com au bar manifolds and subplates html 27 05 2012 19 http www boschrexroth com modules BRMV2PDFDownload dll db brmv2 amp lvid 1143366 amp mvid 6254 amp clid 20 amp sid DF7014D9BEA72611055DCFAE9FF5F1E1 amp sch M 20 Tocci Widmer Moss Digital Systems Principals and Applications Pearson Prentice Hall 2007 TN FIR HOGSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 21
24. Sub plate Figure 63 Sub plate for mounting of the directional valve 18 The sub plate is mounted on to the direct directional valve This sub plate acts as a transition from the valve to the hydraulic pipe fittings The side with the small holes is mounted on the valve and fittings on the hydraulic piping are mounted in the holes underneath A FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 10 The machine control system 10 1 Logic components NOR gate latch Produces Q Q 0 b c RESET Figure 64 NOR gate latch function 20 Input Output Figure 65 NOR gate latch The NOR gate latch is a SR flip flop without the clock signal therefore the name It is put together by two OR ports with inverted output and connections to make a function The NOR gate latch has as function to give a signal after receiving a signal either in set or reset input When the NOR gate latch gets a signal to set it sends out a 1 on Q output and 0 at not Q When reset gets a signal the NOR gate latch sends a signal 1 to output not Q and a 0 to output Q 1 is signal O is not The concept of a latch circuit is important to creating memory devices The function of such a circuit is to latch the value created by the input signal to the device and hold that value until some other signal changes it 20 OR gate Input Output Figure 66 OR gate 20 The OR gate is a gate which gives a
25. Switch 2 2000 pc 4000 28 0 Steel plate with logo 1 64 kg 64 29 0 Door handle 1 50 pc 50 130 0 PLC 1 3207 pc 3207 31 0 Relay 1 100 pc 200 32 0 Emergency button 1 50 pc 964 33 0 Reset button i 50 pc 50 134 0 Startbutton T 50 pc 25 135 0 Transformer 1 400 pc 400 136 0 Pressure switch 2 1700 pc 3400 37 0 Bolts M24 hex bolt 12 12 pc 144 38 0 Bolts M5 unbrako 24 pcs 100 139 0 Bolts M3 unbrako 32 pes 40 0 Bolts M8 unbrako 8 pes 3 141 0 Sub plate to hydraulic valve 1 832 832 Total ex vat 20662 3 Vat 25 Total inc vat 25827 88 Figure 79 Price estimate with components available from BUC 67 H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 Priceestimate Priceestimate without parts from BUC Description 2 Cost per item Unit 1 0 HE160B S355J0 upper frame 1 300 Cuttings 300 2 0 Channel Bar side frame 2 300 600 3 0 Cylindrical guiderods availible from BUC 4 8 37 m 200 4 0 Cylinder bracket 4 100 400 5 0 Squarebeam lower frame 835530 160X80X10 MM 1 300 Cuttings 300 6 0 Power transfer 1 kg 23 7 0 Doubleacting Cylinder HM85 FFL GV K 1 2500 pc 2500 8 0 Fixture bolt 10 pcs 20 9 0 Upper specimenfixture 5355J0 0 1m3 7 8 30 kg 234 10 0 Wedges 1 5 kg 10 11 0 Lower specimenfixture 5355J0 9 30 kg 270 12 0 Stud bolt 1 30 kg 30 13 0 Hydraulic hoses 4 161 m 644 14 0 Vibration absorption 4 75 pcs 300 15 0 Bosch Rexroth 4WE 6 J6X EG24K4 directional valve 1 3000 pc 3000 16 0 Plexiglass front 1
26. instead of circular The machine is to be used by the students at BUC where they can observe the behavior of metal when subjected to variable loadings The test specification includes a description of how the requirements will be tested The different tests will ensure that the machine is built and performs according to the requirements set in the project All of the requirements have their own ID which makes it easier to find a specific requirement A number in the requirement specification corresponds with a similar number in the test specification By using this method it is easy to track the different requirements and their functional tests Nm 3 F R HOGSKOLEN i Buskerud Fatigue Test Rig Test Specification rev 2 0 4 0 Test strategies During the design process of the project all of the designs will be tested in SolidWorks with the Final Element Method FEM This software has the possibility to perform analysis of components and parts in our design It is also possible to subject the components to different types of stresses In doing this it makes it possible to estimate approximately the dimensions needed in the design We test bottom up there we start with the smallest components and then assemble these together afterwards NN 4 F R H GSKOLEN i Buskerud Fatigue Test Rig Test Specification rev 2 0 5 0 Test specification 5 1 Test of functional requirements 5 1 1 Counter Visua
27. is started and the pressure is configured by a handle to the wanted pressure e FIR H GSKOLEN 12 i Buskerud Fatigue Test Rig User manual rev 1 0 5 6 Step 6 When this is done you press the start button on the test rig and the hydraulic cylinder starts to work The PLC controls the compression and tension cycles 9 Push the start button 5 7 Step 7 The machine is set to stop when the test specimen breaks But if needed there is an emergency stop button which stops the cycle of compression and tension and stops the hydraulic pump If needed press the emergency stop button amp FIR H GSKOLEN 13 i Buskerud Fatigue Test Rig User manual rev 1 0 5 8 Step 8 When the test specimen is fractured and has broken into two parts The way to disassemble the test specimen from the fixture is first to loosen the bolt then to push the lower frame down The lower part of the test specimen is now loose and it can be taken out On the upper fixture frame the bolt is loosened and the upper part of the test specimen is taken The rig is now ready to be used again E Eu fcm en Illustration 1 shows that the test specimen is broken Illustration 2 shows that the bolt is loosened and the lower fixture frame is pushed down The same is done on the upper frame except that in the upper frame the test specimen is taken out There is not a need to push the upper frame Illustration 3 and 4 shows the upper part of th
28. more oil more hoses and a system to make sure the cylinders go parallel There is also not needed more than one cylinder to apply the needed load FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 1 rev 2 0 5 2 Idea 2 Figure 2 This concept consists of an axial tension compression load appliance but here with only two guidelines the danger of getting a crooked load appliance is there This has the same properties as ideal only that here there is only one hydraulic cylinder which makes this more economical The H beams used as lower and upper frame provides stiffness to the rig The lower frame is big and stable and the rig will withstand the forces applied 6 FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 1 rev 2 0 5 2 Concept 1 Figure 3 This is very suitable for tension compression loads since there is a hydraulic cylinder in the middle of the specimen fixture There are four cylindrical guiding rods that assure that the load is applied axially It is also difficult for the hydraulic cylinder to pull itself out of position with the 4 cylinder guiding rods The h beam is only used to show how it could be solved but this can be different It all depends on how much force that is applied on the beam But the h beam is good to use in this case because it will resist the forces applied axially and withheld stiffness in the beam 5 3 The decision Since the cl
29. rope DU 8 4 5 Hydraulic pump start and configure nn rnnnnnnnnnnnnnnns 9 SEOEECIg rire M 10 SUSEN LL 10 52 STEP Zane le NESEN ene 11 5 3 Step E EE 11 SS O 12 DiS STEP A cites cea E ae ate eri ie cae Gein ae ae 12 5 6 St pp Gu adds 13 E AA EE se SEEST DER 13 5 8 STEP Saa eee Pee 14 5 9 Step dan ee 15 6 0 Technical data the Fatigue Test Ris 16 7 0 Wiring ETC BE 16 TL Into the a E cuidad E EE deeg 16 7 2 PLC logically e e e UE 17 8 0 le tiara a 18 E 5 F R i Buskerud Fatigue Test Rig User manual rev 1 0 3 0 Installation When installing the test rig make sure you have these components ready e The complete Fatigue Test Rig with control system e A hydraulic pump e The hydraulic tubing The first thing to do is to make sure the test rig has all its components in the part list The Fatigue Test Rig should be connected and assembled together The only installation needed is to connect the pressure and reservoir lines from the hydraulic pump to the hydraulic valve and to connect the emergency stop circuit on the help circuit in the contactor which controls the electrical power in the hydraulic pump 3phase AC power Help Emergency li ine stop 230V 230V spool hg ne ms Figure 2 The contactor which control the electrical power of the hydraulic pump Where to connect the emergency stop button in the contactor
30. side the solution is not as straightforward and some manufacturing and machining is needed to integrate the collars In this case more time will be used on assembling and disassembling of the specimen FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 10 2 2 Concept choice In case of idea 1 with the quick locking handle both parties have agreed that though this concept will provide simple and quick loading of the specimen it will be difficult to optimize design and manufacture such many parts Furthermore many moving parts will increase possibility of fatigue failure mechanism With regard to idea 2 the client thought that this concept would become too difficult to use there would be a lot of efforts in placing the test specimen This will also get more complicated if one to use the same fastening concept on both bottom and top side The group had a meeting with the client to discuss the four concepts The client meant that idea 3 with horizontally mounted hydraulic would with time leads to oil leaks from the hydraulic press This concept would also have too many heavy parts which might affect the accuracy of the testing results In consulting with the client this concept has been frozen from further development Out of the four ideas presented the concept using bolt and wedge grip has been chosen for further development We found out that in case of using wedge grip it will be no need for applying
31. that could be possible Every one with different up and downsides In our work we wish to increase our knowledge within hydraulics solidworks and calculations and estimates We will also explore possibilities for workshop willing to produce our test specimens check out where we can get materials etc Our project plan is incremental and is based on several concept rounds where we discuss and improve our concept LAA H GSKOLEN i Buskerud Fatigue Test Rig Concept round 1 rev 2 0 Table of contents LO lk geet Le nc tii 3 2 O nhe Planning O O E 5 3 0 ADDEeVIAEIOTIS aar 6 4 0 Test specimen Kl ET D EE H CONCEDED E 7 By OT OSA Ce vr 8 KARTEN 8 GJ EEE EE 9 5 2 CODcept Ls 10 KEE EE 10 6 0 Test elen Ent ET E 11 6 1 Idea 1a Thread fixture desen 12 6 2 Idea 1b Thread tixtur Arcs A A iz 13 6 3 Concept 1 Collar fasten TE 14 6 4 The decile 14 ZO DIV Medium aa 16 TeV NASAL Hydraulic cia A eee ten Sene et 16 TL dia 17 7 3 Concept eI UII REBEL BES 17 TA DECISION pia 18 8 0 PNEUMATIC SysEem e De etset 19 MAE 19 8 2 Cylinder iit HEREIN UE URINE RE 20 8 3 10b s nd DIEI SS cee e tee e bereitet den tata 20 ERR lune 20 9 0 Resources and references ordenerne erne erne 21 EN HOGSKOLEN i Buskerud FIR Fatigue Test Rig Concept round 1 rev 2 0 2 0 The Planning In our proj
32. the material These structural abbreviations can cause the initiation of a crack The crack growth occurs slowly at first and as the crack grows into the material it occur faster until it has a critical size and a residual fracture occurs Figure 2 A test specimen shows fracture When testing for fatigue it is usually used a standard test specimen This is to examine and to collect data on material properties The fatigue testing is important when designing a construction or a machine the material fatigue data helps to choose the best possible material for the design There are also a lot simpler to test a small test specimen to get material data instead of a big construction with a weight of several tons When W hler conducted a fatigue test he used rotating bending and the fatigue testing equipment consisted of a rotating chuck with a force perpendicular to the test specimen Similar to the old fatigue test rig the school has in its workshop today Today solution of a fatigue test rig consists of apply the forces pure axially on the test specimen The experimentally determined W hler curve SN curve are to be used as a basis for all fatigue dimensioning This curve shows stress related to number of cycles until fracture giving a picture of the material lifetime at a given tension Material testing can be sorted into two categories Nondestructive tests and Destructive tests The use of nondestructive tests has increased in the industr
33. to provide hydraulic fluid to apply pressure Make sure to transport the rig on the support legs to avoid unnecessary damage 2 5 Maintenance To make sure the test rigs lifetime is as long as possible make sure to be carefully on the maintenance The POM between the stabilizer bar and the cylindrical guide rods need to be lubricated every fifth time the test rig is in use When assembling the test rig make sure to lubricate the bolts to avoid thread galling The cylinder is self lubricated by the hydraulic fluid going through it and does not require lubrication 2 5 Environment The test rig needs to be placed on a standard workshop floor with floor load capacity of minimum 3kN m There is needed a hydraulic pump at the workshop the rig is used The temperature in the workshop should be between 5 30degrees to run the test rig without any problems Enjoy the use of your Fatigue Test Rig E 4 F R i Buskerud Fatigue Test Rig User manual rev 1 0 Table of Contents 1 0 Document Ador iaa 2 2 0 Important information c cccccccessessssececececeeseenaececececsesesaeaeeeeeceseesaeaeaeseessesseseeaeseeeessesseaaaeeneeesseeees 3 2 1 Intended PUTOS eto 3 prm UU eee 3 2 4 Wee 4 2S MAINTENANCE ainia 4 2 5 ENVIO TE 4 30 Install do EE 6 4 0 Operation RUE CN H 4 1 Start Eu LEE H 4 2 Pressure sensor switch sussie ER EEN ERE DERE ER NEDRE SEENDE RE SELE SED 7 4 3 Manual emergency stop button 8 4 4 Automatic emergency
34. will deviate from what results that actually is wanted 3 0 Abbreviations SW Solidworks 4 0 Limitations The possibility of testing this will reduce since there is not produced and assembled a physical test rig and the testing will only be done with the use of SW 5 0 Execution of test 5 1 What is tested The test is executed 07 05 2012 at the advanced hydraulic lab at BUC This test requirement is going to be tested with the use of SW to check for deviations according to each other in the design and to ensure that all components are lined up axially accordingly to each other According to the requirement the deviation axially between the test fixtures and the cylinder piston should be Omm and O degrees apart H GSKOLEN i Buskerud Fatigue Test Rig Test report rev 1 0 6 0 Test results The picture shows that the lines drawn to check for deviations are horizontal This means that there are no deviation in the dimension and no deviation in the angle between upper and lower test fixture H GSKOLEN i Buskerud Fatigue Test Rig Test report rev 1 0 To show the exact dimension to support the results there is a horizontal line over dimensioned to show the symmetry of both sides which shows that the two test fixtures both front and side is lined up axially and with Omm and Odegrees Figure 2 Lineup of the test rig from the front and side 6 1 Critical failures No critical failures which can
35. 0 Fatigue Test Rig The name of the project is discussed and we concluded with Fatigue Test Rig We find this name precise clear and simple and that this name explains the design task Project group members Name Espen S tre Kolberg 24 years old from Kongsberg Phone number 47 93841059 E mail e_kolber hotmail com Name Kjetil Haugmoen Kj ndal 24 years old from Larvik Phone number 47 98073056 E mail kjetilkjoendal hotmail com Project Main Group E mail gruppellftr gmail com A FIR H GSKOLEN 4 i Buskerud Fatigue Test Rig Vision document Project organizing and responsibility Espen S Kolberg Design and control responsible Responsible for design Responsible for the control system Responsible for manual calculations Responsible for the homepage Kjetil H Kj ndal Project leader Responsible for documentation Responsible for disposal of time Contact person Report to and have contact with internal supervisor Coordinate testing Responsible for FEM analysis The Client rev 2 0 BUC Buskerud University College is a University with different departments which offer several subjects and professions In the Department of Technology there are several bachelor degrees of engineering The Department of Technology has a Laboratory to be used as a practical educational method and as laboratory during the process with the bachelor degree As a supplement to the present in
36. 0 2 Electrical mPetre 58 10 3 Cole rio 63 AN Lu EE 67 12 O SQUICOS Ai iaa 68 A FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 1 0 Document history 04 04 2012 0 1 Created technical document 02 05 2012 0 2 Edited added figures calculations 26 05 2012 0 3 Added components calculations and text 29 05 2012 1 0 Finalized document Table 1 Document history 2 0 Intro This document will cover the technical aspects of the different parts in our rig The document will provide 3D models of the mechanical components used in the project The Fatigue Test Rig is both hydraulically and electrically operated and the document will include schematics of both solutions 3 0 Abbreviations BUC Buskerud University College SW Solid Works FEM Finite Element Method FTR Fatigue Test Rig F S Factor Of Safety POM Polyoxymethylene PLC Programmable Logic Controller AC Alternating Current DC Direct Current PMMA Polymetylmetakrylat A FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 4 0 Designations mm Millimeter kN Kilo Newton MPa Mega Pascal bar Bar p 5 E H GSKOLEN i Buskerud FIR Fatigue Test Rig Technical document rev 1 0 5 0 Finite Element Method The calculations vary slightly from the FEM analysis However taking into account that FEM uses a material library to pe
37. 05 2012 21 http www expo21xx com sensor 2183 st2 magnetic field sensor default htm 26 05 2012 22 http www eaton com ecm idcplg ldcService2GET FlLE amp allowlnterrupt 1 amp Revision SelectionMethod LatestReleased amp noSaveAs 0 amp Rendition Primary amp dDocName BR054000 01E 25 05 2012 23 http www elektrofag info pls 26 05 2012 24 http datasheet moeller net datasheet php model 256269 amp locale en GB amp It 29 05 2012 25 http support automation siemens com WW llisapi dll func cslib csinfo amp lang en amp objid 6ED10521FB000BA6 amp caller view 29 05 2012 FIR H GSKOLEN i Buskerud ONG HOGSKOLEN i Buskerud Department of Technology Kongsberg Title of document Document of technology rev 1 0 Course code name SFHO3200 H11 Hovedoppgave med prosjektstyring Group members Espen S tre Kolberg Kjetil Haugmoen Kj ndal Internal Supervisor Jamal Safi Date 29 05 12 We confirm that the submitted assignment is entirely our work Espen Kolberg Kjetil Kj ndal Fatigue Test Rig Technical document rev 1 0 Table of Contents 1 0 Document ENN A pa taadi tle uec exarata ctun pei lied inp ed Ge Pei DEESA PA 0 Hp EE ID cul dd 4 0 DesigNatiO E 5 0 Finite Element Method da 6 0 Developme
38. 1778N and a minus stroke of 8832N As the calculation show when the piston retracts it has a force that is 2946N less than when the piston is pushed out from the cylinder This is because of the smaller area at the side with the piston rod To make sure the specimen is subjected to equal forces in both cycles there would be a need for an extra component to adjust the pressure This can be solved by adding a pressure reducing valve to the system which is placed on the piston side of the cylinder but would complicate the system and lead to higher costs T Li Pressure transmitter 74 696 Pressure transmitter 10096 Figure 30 Function of hydraulics when using a single rod cylinder A i FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 14 2 Final concept cylinder 14 2 1 Double rod cylinder Figure 31 Double rod cylinder In double rod end cylinders the actuator has a rod extending from both sides of the piston and out both ends of the barrel This cylinder provides equal force on both tension and compressive cycles because of the area on both sides of the piston is equal Calculation YT This is illustrated in the following example 18 Piston diameter D 5cm Bar diameter d 2 8cm Work pressure p 60 bar _m D d d 7 A N gt 13 5cm n D d di mx 5 28 em S gt 5 13 50m Piston force F pxAx10 Ft A xp x 10 13 5 x 60x 10 8100N F A
39. 200 pc 200 18 0 Plexiglass rear 1 200 pc 200 19 0 Gliding bushings POM 4 70 m 280 20 0 POM cover 8 8 kg 64 21 0 Support legs 4 100 Cuttings 400 22 0 Magnet 1 40 pc 40 23 0 Testspecimen 10 8 33 pcs 83 3 24 0 Hinges 2 50 pcs 100 25 0 Counter Dayton 6X596 1 750 pc 750 26 0 Steel plate 1 69 kg 69 27 0 Emergency stop Rope Pull Switch 2 2000 pc 4000 28 0 Steel plate with logo 1 64 kg 64 29 0 Door handle 1 50 pc 50 30 0 PLC 1 3207 pc 3207 31 0 Relay 1 100 pc 200 32 0 Emergency button 1 50 pc 964 33 0 Reset button 1 50 pc 50 34 0 Startbutton 1 50 pc 25 35 0 Transformer 1 400 pc 400 36 0 Pressure switch 2 1700 pc 3400 37 0 Bolts M24 hex bolt 12 12 pc 144 38 0 Bolts M5 unbrako 24 pcs 100 39 0 Bolts M3 unbrako 32 pcs 50 40 0 Bolts M8 unbrako 8 pcs 3 41 0 Sub plate to hydraulic valve 1 832 832 Total ex vat 24506 3 Vat 25 Total inc vat 30632 88 Figure 80 Price estimate without components available from BUC 68 H GSKOLEN i Buskerud Fatigue Test Rig Technical document 12 0 The FTR ready for operation H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 13 0 Sources 1 ASTM International E606 04e 2 Vollen ystein Statikk og fasthetsl re ISBN 978 82 562 7152 8 3 http finnloeken no prisliste_tekniske_plaster content text_79f3d1dd 3003 4fea 89fc 3942c62fc926 1331643740031 ny lager prisliste tekniske plaster pdf 05 05 2012 4 Bedford Fowler Engineering Mechanics amp Statics
40. 7 1 Into the PLC 230V ACin Transformer 24V DC out Start gu mess PLC Relay 1 ERA Side A of Valve wee a x1 Emergency ET yi 3 Sto stop SH T CJ ya Lo Relay 2 Side B of valve TT Fa JI Pressure sensor 1 F Say Pd Gnd Reset counter a H GSKOLEN 16 i Buskerud rev 1 0 Fatigue Test Rig User manual 7 2 PLC logically controller Reset counter x5 T Counter 24V x1 AND1 cu Q 3 af cy Display Pressure sensor 2 x2 AND2 SR1 vi EA a Emergency stop SR3 A x3 N OR1 Pressure sensor 1 x4 et AND3 SR2 y2 e y 2x2 dn l OR2 H GSKOLEN 17 i Buskerud Fatigue Test Rig User manual rev 1 0 8 0 Part list ITEM NO PART DESCRIPTION MATERIAL WEIGHT QTY TOTAL WEIGHT 1 H beam Upper frame 20 9Kg 1 20 9Kg 2 Rectangular Lower frame 19 7Kg 1 19 7Kg beam 3 Channel Bar Side frame 17Kg 2 34Kg 4 Cylindrical Guide rod 2 2Kg 4 8 8Kg rod 5 Stabilizer 4 7Kg 1 4 7Kg bar 6 POM C Bearing of guide 52 8g 4 211g guide rod bushing 7 POM cover 47 9g 8 383 2g 8 Fixture Lower specimen 9 5Kg 1 9 5Kg frame with fixture cylinder connection 9 Fixture Upper specimen 5 49Kg 1 5 49Kg frame fixture 10 Cylinder 4 9Kg 2 9 8Kg bracket 11 Power Power transfer 2 transfer between fixture bolt and wedges 12 Fixture bolt The fastener 2 13 Wedges Wedge lock 8 14 Stud b
41. 8 1 MPa The maximum stress is located in the center at the bottom of the frame where the cutout for the wedges is located This stress fulfills the requirement ref R15 Requirement Specification rev 1 4 Displacement Node value Figure 22 Displacement X Y Z Location 1 41 0 35 mm 7382 3 645e 003 mm URES mm 3 930e 003 3 502e 003 3 275e 003 2 947e 003 2 620e 003 2 292e 003 1 965e 003 1 637e 003 1 31 0e 003 9 824e 004 6 549e 004 3 275e 004 1 000e 030 Displacement analysis show a maximum displacement located at the center at the bottom of the frame The displacement analysis shows a deflection of 0 0039mm which satisfies requirement ref R28 Requirement Specification rev 1 4 H GSKOLEN i Buskerud 21 FIR Fatigue Test Rig Technical document rev 1 0 7 9 Lower specimen fixture Tapped holes for stabilizer bar Figure 23 Lower specimen fixture The lower specimen fixture consists mostly of the same design as the upper fixture It differs from the upper fixture by having a bracket for attachment of the cylinder The bracket makes a stiff construction for mounting of the cylinder There are also four tapped holes M8x1 on each side of the fixture These holes are made to allow fastening of the stabilizer bar that makes sure the cylinder apply the forces axially Dimensions of the lower specimen fixture are Height 235mm Width 80mm Length 100mm Thickness mid
42. 91e 003 7 243e 003 5 794e 003 4 346e 003 2 897e 003 1 449e 003 1 000e 030 The testing of the H beam in figure 2 shows a deflection of 0 017mm when being exposed to 11kN at the centre of the beam simulating the cylinder in use HOGSKOLEN i Buskerud FiR Fatigue Test Rig Test report rev 1 0 SA p Max 2 036e 001 W IMin 1 000e 030 Figure 3 FEM analysis of the deflection in the channel bar The testing of the channel bar in figure 3 shows a deflection of 0 2mm when being exposed to 5 5kN at the top of the beam simulating the cylinder in use 5 258e 002 4 820e 002 4 381e 002 3 943e 002 3 505e 002 3 067e 002 2 629e 002 2 191e 002 1 753e 002 1 314e 002 8 763e 003 4 381e 003 1 000e 030 Figure 4 FEM analysis of the deflection in the frame assembled together The testing of the frame assembled together shows a deflection of 0 05258mm when being exposed to 11kN at the centre of the h beam simulating the cylinder in use s FIR HOGSKOLEN i Buskerud Fatigue Test Rig Test report rev 1 0 17 0 Critical failures No critical failures were discovered in the test 17 1 Roles Kjetil Haugmoen Kj ndal Responsible for the test Espen S tre Kolberg Responsible for execution of test 17 2 Equipment e Solidworks e Finite Element Method 17 3 Evaluation The objective of this test was to check if the deflection in the frame would be less than 05mm The tests show that every frame c
43. AC DC 115 240V INPUT 8xAC DC SIEMENS F Figure 77 Siemens 6ED1052 1FB00 OBA6 Logo PLC After having been in contact with both Eaton and Siemens the project group chose to use PLC from Siemens This controller satisfies the need of controlling the system as well as being more cost efficient than the PLC provided by Eaton The OBA6 PLC operates with eight inputs and four outputs A a FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 Reset counter x5 Counter 24V Pressure sensor 2 Emergency stop Figure 78 PLC function diagram The PLC is mainly used as a logic circuit to control the cycles The x1 x2 etc is inputs on the PLC from the different mechanical and manual components and y1 y2 is outputs from the PLC to the relays that delivers electrical power to the valve The function of the PLC is to cycle automatic between side A and B on the valve Side A and B on the valve is different from each other there one initiate compression from the cylinder and the other initiate tension from the cylinder It consists of AND gates OR gates NOR gate latches and a counter How the PLC is set When the start button outside of the PLC is pushed the AND1 gets signal 1 The Q from SR3 is O and since it is inverted in to the AND1 gate AND1 gives a signal 1 ahead to set on SR1 reset on SR2 and set on SR3 SR3 now gives signal 1 to AND2 and 3 so these are ready
44. Added Frame hydraulic system bearing of guide rods counter and switches machine control system planning and theory and done grammar and spell check 2 0 29 05 2012 Finalized document Table1 Document history 2 0 Abbreviations BUC Buskerud University College SW Solidworks FEM Finite Element Method FTR Fatigue Test Rig F S Factor Of Safety POM Polyoxymethylen PLC Programmable Logic Controller 3 0 Designations i FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 mm Millimeter kN Kilo Newton MPa Mega Pascal 4 0 Introduction This document provides an insight of round 2 This round is more extensive than round 1 in terms of more details and work done regarding development of the product The group of two people has been working together since the start of the semester and is working more efficient as a result The knowledge from last round and new ideas are the ground stone for round 2 This leads to better solutions and better execution of new designs Knowledge in Solid Works and in the field of hydraulics is improving 5 0 Ideas vs Concepts This document contains the different ideas and concepts of the second round of concepts The best solutions from the first concept round which the group decided to develop further is implemented in this second round of concepts The ideas presented in this document were the starting point o
45. BUC B specimens test specimens to ensure they are H GSKOLEN i Buskerud FIR HOGSKOLEN i Buskerud Department of Technology Kongsberg Title of document Project plan Version 2 0 Course code name SFHO3200 H11 Hovedoppgave med prosjektstyring Group Members Espen S tre Kolberg Kjetil Haugmoen Kj ndal Internal Supervisor Jamal Safi Date 29 05 12 We confirm that the submitted assignment is entirely our work Espen Kolberg Kjetil Kj ndal Fatigue Test Rig Project plan rev 2 0 Table of contents 1 0 Document history rica illa 3 2 O Abbreviations M 3 NS 4 4 0 Project molina 4 TVETEN 4 SN REM 5 4 3 Evolutiona y EE 5 FL 5 5 0 Incremental develop mantis 6 AA E II NE 7 SLAM ida o 7 5 2 Loss E 7 62 Short term pes sete rado bi eva ERR e og EM iind td e i be vaa pruna Eie uiie 7 6 4 Long term lness nn nnnnnnnnnnnnnnnnnnnnnnnnnnnnnns 8 Ka Ee an Ee Sussie di 8 Ge Een 8 6 7 Supervisor SENG 8 6 8 Lack of knowledge eene een nnnnnn nnne nene tt nnns nisse ensis rasan anres nnns 9 7O RISK DIMECOTTEO REE ford i cunda Anae HM RENE Ene RER EVO PR nice 9 L Falling ln E 9 pad odorum EH 9 TIME rentado und eian 9 7 4 Lack of components nn nnnnnnnnnnnnnennnnnnnnnnnnnnnnnnrnnnnnnnnnnnnnns 9 7 5 Client ENT 10 EE 10 7 7 Ee e
46. BUC B test normal construction steel E 200GPa R12 The machine should also be able to B test aluminum E 70GPa 5 2 5 Machine The machine must be transportable 06 01 2012 R13 BUC B dimensions In out of the hydraulics lab C151 at the university 5 2 6 Powersupply The machine electricity connection 06 01 2012 R14 BUC B should fit into the norwegian standard outlet 5 2 7 Frame The frame must have fatigue safety 06 01 2012 R15 BUC B stiffness factor of at least 2 5 2 8 Deflection The maximum deflection in the frame 23 04 2012 R28 Group A has to be less than 0 5mm H GSK OLEN i Buskerud FIR Fatigue Test Rig Requirement specification rev 2 0 5 3 Result requirements 5 3 1 Measurement units All results must be shown in SI units 06 01 2012 R16 BUC C 5 3 2 Results Output data must show number of cycles until fracture One cycle is from 0 gt tension gt 0 gt compression gt 0 The user should be able to read the load and number of cycles throughout the test 06 01 2012 R26 R27 BUC A 5 3 3 Deviation The machine should give results within a tolerance of double industry tolerance when delivered to the university 4 296 ASTM E4 10 06 01 2012 R19 BUC B 5 3 4 SN Graph The system shall produce an SN graph on laptop after 10 tests are done 06 01 2012 R17 BUC C 5 3 5 Data log Output data with all resu
47. E DG1 pressure switch 25 The pressure sensor switch is a device that closes or opens electrical contacts when pressurized to a pre set value It is usually used where electrical signal should be triggered when the set pressure is achieved or exceeded 25 There are a lot of different types but the easiest to use is a manometer like device which is set by rotating the center knob Coding Operation Pressure Electrical connection pressure range resistant Device Pmin 2 Pmax up to socket EN bar 3 175 301 803 ISO 4400 DG 1 R 4 DG 1 RF 4 DG 1R FS 4 Figure 75 Pressure range of the HAWE DG1 The pressure switch can operate between 20 to 600bar and is adequate for our use The pressure switch measures the pressure and when the pre set value is achieved it gives an electrical signal into the PLC that the pressure is achieved A FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 10 3 Control of the rig To control the FTR the group started out with using only mechanical and manual equipment The group quickly realized that to make the cylinder cycle tension and compression without an operator would be difficult There was discussed with the client and internal supervisor and there was made a decision to start looking for various control systems for the rig The group decided on a mixture of both mechanical and digital control of the system It is used switches pressure sensors relay
48. It is a requirement that the machine s weight does not exceed the floor load capacity 2 The implementation of this test relies on checking if the machine s weight exceeds the allowable floor load capacity 11 1 Test results The machine weight is calculated using the SW to find the machine s volume Then this is multiplied by the material s density This is compared with the floor s carrying capacity that is obtained from NS EN 1991 1 1 2002 NA 2008 The hydraulic lab at BUC runs under the category C1 after the standard which has a load capacity of 3 0 kN per m and a concentrated load capacity of 4 0 KN The floor in the lab has an area of 30 m and will handle a total load of 9 tons The FTR has a weight of 130kg and is well within the loading capacity of the floor H GSKOLEN i Buskerud Fatigue Test Rig Test report rev 1 0 11 1 Critical failures No critical failures were discovered in the test 11 2 Roles Kjetil Haugmoen Kj ndal Responsible for the test Espen S tre Kolberg Responsible for execution of test 11 3 Equipment e Solidworks e Standard NS EN 1991 1 1 2002 NA 2008 11 4 Evaluation The objective of this test was to check if the Fatigue Test Rigs weight was higher than the allowable load capacity Since the concentrated load capacity is 4kN and the test rigs weight is 130kg the test is satisfactory The test was successful and the test rig can safely be used in the workshop intended at the University
49. No expertise at school A i FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 12 2 Final concept drive medium 12 2 1 Hydraulics Hydraulic is widely used in the industry because of its ability to apply large forces and to achieve a greater accuracy in testing The oil is not compressible and will not lead to deviations in relation to a pneumatic driven system where the air has the possibility to be compressed By operating the system using hydraulic this will result in a precise and stable process The use of hydraulic requires a relatively small piston area to achieve large forces due to the system s high pressure Use of the hydraulic system is suitable to achieve a soft startup of the system and will lead to a smooth transition when the machine alternates between tension and compression cycles This will avoid backlash or sudden changes which can lead to deviation in the test results Due to the large forces that can be achieved with a smaller diameter piston it s possible to make the system quite small Due to the drive medium of hydraulic it is self lubricating and does not require any external maintenance as long as the oil is kept clean Pros e 3 5 Hz up to 10 15Hz depends on stroke design costs 11 12 e No compression of drive medium greater accuracy e Low maintenance e Possibility to regulate frequency e Ability to regulate forces applied e Smooth transitions between load cyc
50. Relay Relay 230V in 230V to Valve out H Voltage from y output ov Input Output Figure 69 Relay 21 A relay is a control to pass something along In this case it passes through 230V voltage when given a signal A relay is often used in automobile industry 20 21 and a 4pin relay consists of two inputs two outputs a magnet and a switch reacting on the magnet One circuit has a magnet and the other circuit has a switch An example could be the power to the horn in an automobile When you press the horn a signal goes to a relay which then activates the magnet that opens for the voltage to the horn and a sound appear An FIR HOGSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 Contactor 3phase AC power Help Emergency li ine stop T bh e 230V uta 230V spool yl 230V motor Figure 70 Contactor 22 A contactor can be used to switch a large amount of electrical power through its contacts The most common use of contactor is in electrical motors 23 BUCs hydraulic pump is assumed to use this kind of contactor The contactor is used to supply large amount of electrical power when given a signal and this is its function When giving a signal to the contactor it connects the circuits and a help circuit connects and continues to supply signal to the magnet When this help circuit is broken the circuits A B C gets cut off and t
51. a deeper and broader understanding of what we have been taught by the University the last years Fatigue Theory Fatigue is a damage condition which appears when there is repeating fluctuations in a material This result in forming cracks which wanders through the material for each cycle done Fatigue is considered dangerous because it is hard to discover before the residual fracture occurs This is a significant problem because fracture can happen with loads below the static yield strength and can cause failure Wohler first systematically studied fatigue around 1850 in relation to repeating axle fractures with the Prussian government railroads H rkeg rd G 2004 W hler confirmed that fracture could appear after large amount of load cycles and with no other e FIR H GSKOLEN 7 i Buskerud Fatigue Test Rig Vision document rev 2 0 understanding of this topic W hler meant that with a large number of cycles the material would get tired and this lead to the expression fatigue It was not before around 100 years past W hlers groundbreaking test the fatigue phenomenon were connected to physical metal explanation The initiation of a crack appears when there are plastic deformations adding up causing shear instability which leads to micro fractures As the micro fractures increases the crack increases When manufacturing parts it is normal with small amounts of irregularities like for example pores at the surface of
52. a series CS1 non lube The cylinder works between maximum 10bar pressure and 0 5bar pressure 8 The piston speed is 50mm s which create a great potential frequency in the system 8 3 Tubes and fittings Figure 10 The tubes and fitting thought of using is nylon tubing series T and the fittings is a one touch fittings series KQ2 The tube has a max operating pressure at 15 bar 9 and is adequate The fittings can work with 30 bar 10 and is also adequate 8 4 Compressor Figure 11 The compressor is a two step pump housing and belt drive The pump reservoir is 90 liter and has a power of 4kW Maximum pressure given from the compressor is 10 bar 11 This compressor will be adequate to run the pneumatic system An i FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 1 rev 2 0 9 0 Resources and references 1 2 3 4 5 6 7 8 9 10 11 Frank helgestads pdf Copy from a design book Test rig ved HIG Kenneth Kalv g http fatigue testresources net us axial fatigue testers 104 810le516 modular fatigue tester 8500 Ib 15 hz Standard ASTM e606 04 http www coastpneumatics com metric valves EVS Series Valves pdf http content2 smcetech com pdf VS7 6 8 EU pdf http content2 smcetech com pdf VS7 6 8 EU pdf http content2 smcetech com pdf CS1 EU pdf http content2 smcetech com pdf T EU pdf http content2 smcetech com pdf KQ2 EU pdf http biltema no no Verktoy Try
53. ad safety factor 5 Ka x Bj Sy uim da XhxL n TO LOADING TRAIN T X Gy SPECIMEN CLAMP 3 5 x 10450 x3x5 FLAT ANVIL AND SPECIMEN END FOR ALIGNMENT bn 355 x 1 x 33 252 x 2 7 L 5 48mm M20 Thread safety factor 5 P THREADED 3 5 x10450 x 1 25 x 5 CYCLIC FORCE SPECIMEN bn 355 x x x 12 912 x 1 088 c THREADED SPECIMEN FIXTURE La 14 59mm Figure 4 This concept was made out from a fixture design taken from ASTM e606standard which shows threads on the test specimen and a threaded bolt from the top By turning on the fixture it will screw itself on both fixture bolt and test specimen This bolt you can tighten against the test specimen to make sure the test specimen is fastened properly On both concepts 1a and 1b there will only be needed 5 48mm threads M36 on the tightening bolt and 14 59mm threads M20 on test specimen with a safety factor of 5 This is not much and will not take up a lot of space This concept is made simple to use easy to make and would spare materials as well as costs But this type of fixture can in some cases shake loose and that could result in slack The threads do also produce a threat of fracture points which could result in fracture at the wrong area An FIR HOGSKOLEN i Buskerud Fatigue Test Rig Concept round 1 rev 2 0 6 2 Idea 1b Thread fixture design von Mises Nimm 2 Yield strength 351 6 Figure 5 This concept did also follow ASTM e606 stan
54. chosen PLC Input o E TN x DC 17 18 m 12 ooy oa Speer A ac A 196 H rn e H uti WA SCH Figure Eaton PLC EASY 819 at the left and Siemens PLC LOGO 230RC to the right 24 25 The PLC is a programmable logic controller and can manage the signals given to it When programmed it can logically control the signals with logical components When choosing a PLC for our control system the two different choices were Eaton PLC EASY 819 and Siemens PLC LOGO 230RC Both of the PLCs have a display which is needed for the cycle counter The Eaton PLC has 12 inputs and 6 outputs and the total cost for this PLC is Ant Artnr Elnr Type Tekst Pris stk Netto stk Bel p 1 256269 4520956 EASY819 DC RC 12DI 4A 6DO RELE STD 24VDC 2 970 00 2 970 00 2 970 00 POWERSUPPLAY 1 212319 4520907 EASY 400 POW 230VAC 24VDC1 254 801 00 801 00 801 00 Pris netto kr 3 771 00 Table 2 The cost of Eaton PLC FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 The Siemens PLC has 8 inputs and 4outputs and the total cost for this PLC is gt um Listepris nettopris Pos nr Artikkelnummer Alternativer El nr Antall Beskrivelse NOK Prisenhet Rabatt NOK r LOGO USB PC CABLE FOR PROGRAM TRANSMITTING r FROM PC TO LOGO AND VICE VERSA DRIVER ON CD 4 6ED1057 1AA01 0BA0 4504115 1 ROM INCLUDED 685 00 1 685 00 LOGO SOFT COMFORT V7 SINGLE LICENSE 1 r INSTALLATION E SW SW AND DOCU ON
55. ction criteria of zc gives a deflection limit of 2 5mm in the beam 2 To make the rig as stiff as possible the group has chosen that the beam has to obtain a maximum deflection value of 0 1mm The stress analysis shows a deflection of 0 017mm which satisfies requirement ref R28 Requirement Specification rev 1 4 7 3 Lower frame Figure 7 Lower frame After the project decided to go with a hydraulic cylinder with a continuous rod the group could not benefit from the design strength towards bending in the H beam profile The final design included the use of a rectangular tube that allows the piston rod to move through the lower frame The rectangular tube has the dimensions 160x85x500mm A FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 Calculations Bending M 5500N 0 25m 1375Nm 5 67 10 95m 8 M C 8 1375Nm 0 0425m e A cq am 5 67 10 6m j Deflection FxL 11000N 500mm P TT N 200000 5668333mm 48 mm 25 26 x 10 mm The deflection calculation shows a deflection of 0 0253mm which satisfies requirement ref R28 Requirement Specification rev 1 4 N 12 H GSKOLEN i Buskerud EZ FIR Fatigue Test Rig Technical document rev 1 0 FEM analysis Stress SY NAmm 2 MPa 144 116 Figure 8 Stress analysis lower frame 11kN The figure above show the bending stress
56. dard for test specimen fixture This concept is only another version of concept 1a This was a bigger version and you would also need a ratchet wrench to tighten the bolt against test specimen This concept would also need more material to produce With this fixture you would only need one tightening point With left hand thread at the bottom and ordinary threads at the top of the test specimen you would only need to screw the test specimen into the fixture and tighten with the tightening bolt at the top with the ratchet wrench This also have the disadvantage that the test specimen can shake loose resulting slack The threads can also here produce fracture points on the wrong area because of the threading An FIR HOGSKOLEN i Buskerud Fatigue Test Rig Concept round 1 rev 2 0 6 3 Concept 1 Collar fastening CLAMPING FORCE t BUTTON HEAD OR EFFICIENCY CONICAL BUTTON HEAD tr SPLIT SPECIMENS CYCLIC FORCE COLLAR Figure 6 4 This Fixture is made out from a fixture method used in ASTM e606 standard There is a conical split collar of 4 parts per fixture To fasten the test specimen the collars need to be taken out the test specimen is placed in the fixture and the collars are placed around the test specimens button head Then there is a cup placed on the collars and test specimen The clamping force will be made by a bolt screwed in from the top of the bottom head This force on the test specimen and on the collars w
57. dle section 20mm Thickness upper section 30mm Thickness cylinder bracket 32 5mm Height cylinder bracket 70mm Diameter cylinder fixture 40mm A z FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 FEM analysis Stress Node 19603 X Y Z Location 37 5 192 19 9 mm Value 6 8 N mm 2 MPa von Mises Nimm 2 MPa 124 11 1 9 1 84 74 6 1 5 1 40 3 0 PY RITIT ft 16477 Node X Y Z Location 35 5 134 37 1 mm Yield strength 355 0 Value 121 Nimm 2 MPa Figure 24 11kN axial stress Stress analysis of the lower specimen fixture show a stress of 12 1 Mpa The maximum stress is located in the lower left corner of the upper section The stress in the fixture meets the requirement ref R15 Requirement Specification rev 1 4 A FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 Displacement Node X Y Z Location 17 5 216 26 7 mm SO Value 5 635e 003 5 166e 003 4 696e 003 4 226e 003 3 757e 003 3 287e 003 2 81 8e 003 2 348e 003 1 878e 003 1 409e 003 9 392e 004 4 696e 004 1 000e 030 Figure 25 Displacement 11kN axial stress The displacement of the lower specimen fixture has a displacement of 0 005635mm The maximum displacement is located at the upper part of the bracket The displacement analysis satisfies requirement ref R28 Requirement Specification rev 1 4 7 10 Cylinder bracket
58. e area on both sides of the cylinder ref Force E 16 A FIR HOGSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 9 2 Hydraulic valve H5909 Figure 61 Bosch Rexroth 4WE 6 J6X EG24K4 directional valve 17 A B Electrical side A p T Elektrical side B Figure 61 4 3 valve spool The valve is a hydraulic 4 3 valve The valve is a directly operated directional spool valve with solenoid actuation The valve function is to distribute and stop flow in hydraulic systems It has two inputs and two outputs for hydraulic lines The valve is assembled together with an ng6 Cetop sub plate Lines A and B is to each side of the hydraulic cylinder P is for the pressure in from the hydraulic pump and T is to the fluid reservoir The electrical side A and B is connected to the PLC The magnets on each side react when they gets a signal of 230V and switch to the desired position If the magnet spool a on the left of the picture gets 230V voltage it switch the slide inside to open fluid output A and opens fluid output B when magnet spool b on the e a FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 right side of the picture gets 230V voltage 19 The center position is open between the lines to the cylinder and to the reservoir which is desirable P Type 4WE 6 E6X E Figure 62 Internal view Bosch Rexroth 4WE 6 J6X EG24K4 directional valve 17 9 3
59. e deviation to these calculations which is caused by the fastening points of the beam in the computer simulation The group chose to use fixed geometry to simulate the beam being welded together with the channel bars in the top of the frame The application of the forces in the FEM analysis might also be a factor for the deviations H GSKOLEN i Buskerud FIR Fatigue Test Rig Technical document rev 1 0 FEM analysis Stress Node i509 X Y Z Location 2 02 80 1 05 mm Value 5 5 Nimm 2 MPa Figure 5 Stress analysis H beam 11kN The stress analysis for the beam conducted in SW shows a maximum bending stress of 3 9 MPa on the edge of the beam This corresponds with the theory that states that the highest level of stresses occurs at a point furthest away from the neutral axis On the tension side the highest bending stresses appears on the tensile edge of the beam while on the compression side the highest compression stresses occur on the compression edge of the beam 2 A FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 Displacement 286 on 80 80 0 234 mm 1737 002 mm Figure 6 Displacement analysis H beam 11kN The FEM analysis has some deviation compared to the manual calculation which stated earlier is a result of the fixed geometry in the end of the beams The manual calculations are based on a simply supported beam According to standard defle
60. e supervisor has been absent for 2 weeks In this period the group was unable to contact the supervisor but decided to work with subjects in which they required no help or advice 7 7 Lack of knowledge During the project the group has had some challenges with some aspects of the project work The group has had a challenge in finding the necessary force that had to be applied to the wedges creating enough gripping force to hold the test specimen There has also been a challenge for the group to acquire knowledge about the control system of the rig During the work with the project the group realized that the system had to have in some extent an electrical control system This lead to a delay and caused the group to come behind schedule The project plan was to some extent staggered 8 0 Follow up During the examination period the group was occupied with various subjects which lead to less work with the project The group was not as much in contact with the client as scheduled This meant that the client did not get as much update on the project progress as intended in the requirements set by the client The group was late to confront the client on the fact that building a prototype was put on hold During the project process the group has learned a lot about working together as a team to achieve a goal There has been educational for each group member to work with this project Each group member has acquired experience in planning a project from
61. e sure the implementation of the various components is as smooth as possible To avoid getting a single tracked mind and get stuck on a concept the group has been disregarding earlier ideas and thought of alternative solutions for the problem The new ideas are discussed with the client and the best solutions will be analyzed further O FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 7 0 Theory and appropriation The tools used and theories in round 2 of the project are e Solid Works e FEM analysis e Material technology and manufacturing techniques e Construction technology e Hydraulic constructions e Digital technology There are many challenges that need to be solved Knowledge within digital technology construction technology and hydraulic constructions need to be studied to acquire further knowledge The level of knowledge in the group is improving and the development of different components are increasing A FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 8 0 Final test specimen concept 8 1 6 35mm The ASTM E606 standard operates with a minimum diameter of the test area on the test specimen of 6 35mm By using this as a guideline for processing the test specimens an estimation of the force needed for carrying out the test will only be around 11000N Calculation 10mm A mr A m 0 005 A 0 00007853m P Omax A P
62. e test specimen being taken out out from the test specimen fixture e FIR H GSKOLEN 14 i Buskerud Fatigue Test Rig User manual rev 1 0 5 9 Step 9 When the test specimen has been fractured and broken the cycle count is readable on the PLC display This cycle count and the given force from the pressure form after several tests a SN curve which is plotted manually The SN curve will after several tests show the fatigue limit of the material Press the reset button to reset the counter U N H I IS 14 I5 16 I 18 E 1 1 KEE AC DC 115 240v INPUT amp xACIDC SIEMENS E EN gt stress amplitude S Be ponga SOROR fatigue strength at N cycles we mm mm mm mm mm zm mm zm mm ooo 103 104 fatigue life 107 Ny 108 10 1010 EE cycles to failure N logarithmic scale The cycle counted to failure are put in the x direction and stress in the y direction e FIR H GSKOLEN 15 i Buskerud Fatigue Test Rig User manual 6 0 Technical data the Fatigue Test Rig rev 1 0 Fatigue Test rig Specification Weight 137 Kg Work pressure 0 75bar Work frequency 3Hz Tests test specimen of 6 35mm in diameter with gripping diameter of 12 7 mm Voltage 230V Dimensions 570mm w 619mm h 900mm Starting device Start button 7 0 Wiring diagram
63. e use drop box folder that can be opened from the Internet by any member of the group We need to back up our own work on our own computer and also back up the contents of the drop box folder and also take precautions against viruses Medium risk High consequences 6 3 Short term illness Short term illness is something that almost every project group is prone to suffer If this happens the other members on the group will have to take on some extra work in a short time period Or in case this will not work the activity have to be postponed ahead High risk Low consequences En H GSKOLEN i Buskerud Fatigue Test Rig Project plan rev 2 0 6 4 Long term illness If this occurs the project group will need to distribute the work on other members of the group This can make it difficult to complete the project as planned and a possibility will be that project will have to be scaled down from its original plan Low risk High consequences 6 5 Lack of components If the University lacks some of the needed components or the delivery of a component is going slow the production of a prototype can be in peril The project group is bound by its deadline and has very limited economical resources The group will need to either come up with a better solution for components or have to wait for delivery of the component This will delay the project Medium risk Medium consequences 6 6 Client changes If the client changes the requi
64. ea were not satisfying It was over dimensioned and there was only one on each side It was used a square beam in the last one and was not needed The support legs which are used in this concept is small takes little space and it is not in front of the operators work area It is 4 support legs each in a corner which supports the rig from tilting A i FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 10 0 Test specimen fixture design 10 1 Ideas 10 1 1 Idea Quick lock device Figure 18 Quick locking device with handle This concept came up as an idea from a cartridge reloading press In this mechanism a simple coupling that makes it easy to fasten and unfasten the test specimen What the press essentially does is to hold the specimen and eventually reload the testing machine with a new specimen and at the same time provides the mechanical leverage that allows the operator to easily accomplish these tasks The major disadvantage of this mechanism is that it cannot be used on the bottom side fixture and thus another solution has to be developed On the other hand it is relatively complex structure with many moving parts that will be exposed to fatigue A i FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 10 1 2 Idea Hydraulic jack on top Figure 19 Hydraulic press at the top In this concept a hydraulic press fastened vertically at the top of the frame crea
65. ect the group was attracted to jump on to the task at hand right away And as the group already had a thought in mind for how the test rig would work we would need to clear our heads to think of different solutions which could work for the test rig The group purpose is to be innovative and to find the best solution When starting on our concepts we took 15minute of brainstorming on each of our components and on subsystems to make sure all components are the best and that subsystem are fit together The group wants to find good solutions and good ideas in each round and the best ideas are taken into the next round The solutions might be modified but the best is brought on LAA H GSKOLEN i Buskerud Fatigue Test Rig Concept round 1 3 0 Abbreviations BUC Buskerud University College SW Solidworks FEM Finite Element Method FTR Fatigue Test Rig F S Factor Of Safety rev 2 0 Vt 6 H GSKOLEN i Buskerud FIR Fatigue Test Rig Concept round 1 rev 2 0 4 0 Test specimen Dimension Concept 1 The test specimen dimension is important and affects every aspect of our fatigue test rig Because our test specimen defines how much force the test rig will have to withstand When searching for a dimension that is mostly used we came over some sites on the internet and design books that mention that the dimension of the test specimen have to be 10mm when doing a fatigue test 1 We chose to use 10mm The forces
66. een the wedges and to fasten it it is needed a torque of 8Nm on the bolt to fasten the test specimen Upper test specimen fixture Figure 9 How to fasten the test specimen in the upper fixture frame Illustration 1 and 2 shows that the test specimen must be placed between the wedges Illustration 3 shows that the power passing needs to be placed between the wedges and the bolt Illustration 4 shows how much the bolt needs to be screwed to supply enough gripping force on the test specimen Lower test specimen fixture FIR H GSKOLEN 11 i Buskerud Fatigue Test Rig User manual rev 1 0 Figure 10 How to fasten the test specimen in the lower fixture frame Illustration 1 and 2 shows that the lower frame needs to be placed around the tests specimen Illustration 3 shows that the power passing needs to be placed between the bolt and the wedges Illustration 4 shows that the needed torque is 8Nm to ensure enough gripping power of the test specimen 5 4 Step 4 For a safe use of the test rig the plexi glass door needs to be closed The magnet on the door will keep it closed Use the handle to close 5 5 Step 5 The hydraulic pump needs to be started and configured When pushing the start button on the hydraulic pump the pump starts and there is a need to configure how much pressure the pump shall give The pressure from the hydraulic pump should be the same as the pressure configured on the pressure sensors The pump
67. ept Binary counter In the project the group has considered using PLC in the control of the machine If there is used PLC a digital counter can count every 1 signal given by SR flip flop JK flip flop or other logically devices The use of a counter of this matter would work better and more reliable than a mechanical counter i FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 18 0 The machine control system The system which controls the Fatigue test rig has to be reliable and should have all commands covered There is going to be used switches buttons counter and emergency stop devices The group wanted to look at 2 different types of controlling the machine where in one control method there is only used mechanical components and in the second one the controlling is done through PLC with different switches 18 1 Idea 1 Mechanical control of the system If it is used mechanical controlling of the machine every component used is mechanical and manual The switches and counters will work with mechanical and manual labor To control the start and stop there is switches going directly to the hydraulic pump To adjust the force on the test specimen the operator has to adjust the pressure on output from the pump The emergency stop devices will also need to cut the power directly to the hydraulic pump The use of all mechanical and manual components would reduce the quality of our rig and some compo
68. er The task of the cover is to make sure the POM is held in place during operation The dimensions of the POM cover is 50x30x5mm outer diameter x inner diameter x thickness There are drilled four holes M3 in the cover for mounting on the stabilizer bar 7 22 H beam covers Figure 55 H beam covers The H beam covers have no other task than to create a more appealing appearance to the FTR A steel plate with an engraved logo is welded to the one side of the H beam while the other side has a smooth surface The dimensions of the plates is 500x5x160mm length x width x height A FIR HOGSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 7 23 Door handle Figure 56 Door handle The group decided to use a simple door handle provided by Erwin Halder KG The handle has two holes M6x1 for mounting on the door bore for cylinder head stud ISO 4762 M6 Figure 57 Dimensions of door handle 11 Dimensions b 11 12 a d h1 h2 r g 26mm 164mm 178mm 17mm 6 4mm 57mm 17mm 17mm 196g Table 5 Dimensions of handle 11 A HOGSKOLEN i Buskerud FiR Fatigue Test Rig Technical document rev 1 0 8 0 Choice of materials 8 1 Frame Upper frame The material used for the upper frame is 355J2G3 carbon steel with yield strength of 355MPa and E module of 210GPa 12 Lower frame The material used for the frame is
69. era FEM analysis Stress Figure 14 Stress analysis cylindrical guide rod Analysis shows that a unexpected force of 100N to the beam will generate a stress of 32 8 MPa The maximum stress occurs at the middle of the rod A i H GSKOLEN i Buskerud FIR Fatigue Test Rig Technical document rev 1 0 Displacement ao 1 805e 001 Figure 15 Displacement analysis guide rod The figure above shows the displacement of the guide rod The maximum displacement is 0 18mm 7 6 Stabilizer bar Figure 16 Stabilizer bar The figure above shows the stabilizer bar To ensure the application of the force onto the specimen is completely axial the project came up with the idea of using a stabilizer bar The bar is attached to all four of the guide rods and clamped to the lower test specimen fixture in the center of the structure This provides a support structure to ensure that the lower test specimen fixture is not able to have a horizontal movement A FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 FEM analysis Stress Figure 17 Stress analysis stabilizer bar 0 1kN A FEM analysis shows that an unevenly distributed load from the lower specimen fixture of 100N would generate a maximum stress of 17 846 MPa in the center bracket of the stabilizer bar Displacement Figure 18 Displacement stabilizer bar at 0 1kN The figure above shows how the displacement is dis
70. etil Haugmoen Kj ndal Internal Supervisor Jamal Safi Date 26 05 2012 We confirm that the submitted assignment is entirely our work Espen Kolberg Kjetil Kj ndal Fatigue Test Rig Vision document rev 2 0 Table of contents Document AiO Meine 3 Fatigue Test ig iius EG ati 4 Project group imetmbers reiten debeo ce ona rus bez od agFeadban Sens tie caysoeanengereseeceeendecedeetee 4 Project organizing and responsibility cccseessssececececsesesseaecececesesseseaeeeeecssesseeeaeeeeecesseseseaeeeeeeseesees 5 i re C 5 The Assjenment EE 6 Introduction aars 6 Situation ida 6 Main objective Of the porolect een ennn nnne nhan en nnns sn en nhan ss sn na asserta dass sena das 7 Fatigue Theory cec ertet ceat ie deduce rl e eos aske pa cerra a 7 FIR H GSKOLEN 2 i Buskerud Fatigue Test Rig Vision document rev 2 0 Document history 20 12 2011 0 1 First draft 08 01 2012 0 2 English check spell check 10 01 2012 1 0 English check 23 03 2012 1 1 Change participants change responsibilities 09 05 2012 1 2 Spell and grammar check 09 05 2012 1 3 Adding risk analysis and outcome 22 03 2012 Fatigue theory 26 05 2012 2 0 Grammar and spell check Finalized document Table 1 Document history A FIR H GSKOLEN 3 i Buskerud Fatigue Test Rig Vision document rev 2
71. ev 2 0 Table of contents 1 0 Document history src id a E aaas 3 PAD ARENAS T SNT 3 TNS 3 Eat 4 5 0 Test PENANG kake 5 5 1 Test of functional requirements aa 5 5 2 Test of system requirements ri 6 53 Fet or ee PEN EN iaa 7 5 4 Test of environmental requirements cri las 8 5 5 Test Of other requirements EN 8 i Buskerud Fatigue Test Rig Test Specification rev 2 0 1 0 Document history 29 12 2011 0 1 Started and edited 03 01 2012 0 2 Edited hierarki 06 01 2012 0 3 Edited requirements 08 01 2012 0 4 Added Introduction and edited test specs 10 01 2012 1 0 Finalyzed document 23 03 2012 1 1 Edited requirements layout and test strategies 29 05 2012 2 0 Finalized document Chart 1 2 0 Abbreviations BUC Buskerud University College 3 0 Introduction This task is given by BUC which is located in Kongsberg The need for a replacement of a fatigue machine is the background for the project The existing machine does not fulfill the demands of a reliable machine to be used by the students It consists of an electromotor which delivers the power to rotate the test specimen The specimen is held in place on the one side of the axle while it s subjected to load on the other side This circular type of motion will make the test specimen exposed to both tension and compression forces The main goal of this project is to make a prototype of a fatigue machine which uses linear forces
72. ever that produces enough clamping force to grip and fix the specimen An advantage is that the jack is readily available and little manufacturing is needed for the clamps It is also easy to handle manually However this idea has some disadvantages concerning inability to control or adjust the applied clamping force A i FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 10 2 Final concept test specimen fixture design 10 2 1 Collar fastening CLAMPING FORCE BUTTON HEAD OR EFFICIENCY CONICAL BUTTON HEAD tr SPLIT SPECIMENS drcit FORCE COLLAR Figure 21 Collar fastening 6 This Fixture is made out from a fixture method used in ASTM e606 standard There isa conical split collar of 4 parts per fixture To fasten the test specimen the collars need to be taken out the test specimen is then placed in the fixture and the collars are placed around the test specimens button head On the top of the collars a cup is placed A bolt screwed in from the top of the bottom head will make the clamping force This force on the test specimen and on the collars will make the collars grip the test specimen when exposed to tensile force and the force on the button head will make sure it stays in place when exposed to compression force This fixture will provide a good fastening of the test specimen the coarse fine threaded bolt is supporting tightly the test specimen and the fixture is robust On the bottom
73. f zii d b 227575 748 75b P 12210 7 1147 10 gt Sei Figure 59 Function of cylinder with double rod 16 Force calculation ms S d m 5 ep 1472cm Piston force F A p 10 F A p 10 14 72 75 10 11004N F A p 10 14 72 75 x 10 11004N As can be seen from the calculations above the cylinder is capable to provide the same force in both directions due to the equal area on both sides of the piston 16 5 FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 Hydraulic circuit for the double rod cylinder Pressuretransmitter 100 Pressuretransmitter 100 Figure 60 Hydraulic circuit drawing The circuit above show the double rod cylinder connected with the various components of the system The T symbol in the circuit illustrates the oil reservoir and the P shows the connection to the power source Between the tank and the pressure source there is a 4 3 directional solenoid valve with 4 inlets and 3 positions ref chapter 9 2 that directs the hydraulic fluid to either side of the cylinder When the valve is in the leftmost position the fluid flows into the right chamber of the cylinder pushing the piston to the left The system is monitored by pressure transmitters that make the oil flow switch direction at a given pressure As can be seen on the circuit drawing the power transfer will be equal on both sides of the piston due to the sam
74. f the leg 7 16 Vibration absorption Figure 48 Rubber pad vibration damper The vibrations that are generated from the test rig have to be reduced to a minimum During the earlier stages of the project process the group thought of bolting the machine directly on the floor in the room where the machine is to be used This would transfer all the machines vibrations into the surrounding structures The might also cause problems related to resonance After doing some research the group came up with an idea of using a silicon rubber pad on all contact surfaces of the rig The dimensions of the rubber pads are 205x50x10 mm A FIR HOGSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 Temperature dependence of vibration absorption of rubbers Vibration absorbing silicone rubber SEP rubber Loss modulus tan 8 General purpose silicone rubber Loss modulus tan is expressed by the following equation KE 951 e NG tan Gi G1 storaga modulus G2 loss modulus The larger the value of tan 5 the greater the ability of a particular matarial to absorb energy vibration etc 40 0 50 100 Temperature C Figure 49 Vibration absorption of different rubber compounds 7 The ability to absorb vibrations is generally low for silicone rubber A rubber compound with enhanced vibration absorption performance has the capability to absorb vibration consistently over a wide temperature range f
75. f this round the concepts presented is the final decisions made in this round A FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 6 0 Planning The project model used by the group is based on incremental development The project is divided into increments and we chose to start with the most demanding increments and do the easier increments at the end We come up with a solution for each increment evaluate the solution and work with it over and over until we are satisfied By doing this we ensure that we get the best possible solution It is also important to bring on the useful information and solutions from the previous round to improve components The previous concept and ideas let us think of new solutions based on the experiences that were achieved during the first round When working with a project it is easy to get stuck at one solution so the group has to be innovative and look for alternative solutions There are limited amount of time and the group has to decide which solutions that should be further developed in the next round To be able to achieve the goal set for the project it is important to be rational with the disposal of time regarding what to work on and what to throw away To make sure the final product corresponds with the requirements set from the client the group continuously work towards the requirements defined by both the group themselves and the client This will also mak
76. g forces applied 7 3 Concept Pneumatic Pneumatic systems are commonly used in tests which require a small amount of force That is because air as a drive medium not provides a large amount of forces without having a very large cylinder which also requires more room Besides that air as a drive medium is compressible this could lead to deviation in the test results A system driven on pneumatic requires a large amount of air supply which has to be delivered by a compressor and an external pressure vessel Advantages e Possible to let excess pressure in the air e No harmful vapors e Not flammable e Environmentally pleasant e Ability to regulate forces applied Disadvantages e Requires large equipment in terms of forces needed e No expertise at school e o FIR HOGSKOLEN i Buskerud Fatigue Test Rig Concept round 1 rev 2 0 7 4 Decision The ideas were presented to the client The electro motor based system was decided to be dropped because of the many gearings that would occur by using it which could lead to a lot of deviations in the results The hydraulic and pneumatic systems were decided to be done more research on before making a decision for which system to choose The client wanted to be absolutely certain and the group agreed But there was chosen pneumatic as a starting point because of the cheap and small equipment to use LAA H GSKOLEN i Buskerud FIR Fatigue Test Rig Conce
77. g need supporting legs to make sure it does not tip over when in use The group added one square tube at each side of the lower frame The support legs are welded on the side of the lower frame The legs has a outer dimension of 300x100x100mm length x width x height A i FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 9 3 Final frame concept This is the last concept the group has made and a lot from previous ideas and concept are used further in this concept The group has thought of dimensioning it to real dimensions since the FTR is not going to be produced The group thought of a solution for the possibility to change parts quite easily This was not considered that much in the previous concepts but has been an important key in this new concept Figure 12 Final frame concept A i FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 9 3 1 Upper frame Figure 13 Upper frame HE160B The final frame concept includes a much leaner H beam profile as well as a much more compact lower frame The redesigned upper frame consists of a HE160B profile beam 9 3 2 Lower frame Figure 14 Lower frame Rectangular tube Like the previous idea there is going to be used H beam as upper frame and a rectangular beam as a lower frame These comply with our need for stiffness and can be dimensioned for fatigue with small modifications The lower frame is reinforced with a th
78. ge E TEE 10 A E A SER 10 TO Poet PN a 11 LO Elte EE 13 amp FIR H GSKOLEN i Buskerud Fatigue Test Rig Project plan rev 2 0 1 0 Document history 30 12 11 0 1 Started and edited 04 01 2012 0 2 Added activity plan and project plan 08 01 2012 0 3 Added Risk analyses 10 01 2012 0 4 Added project plan 10 01 2012 1 0 Finalized document 29 05 2012 2 0 Added Risk outcome grammar and spell check Finalized document 2 0 Abbreviations BUC Buskerud University College i FIR H GSKOLEN i Buskerud Fatigue Test Rig Project plan rev 2 0 3 0 Introduction This project has an objective and purpose to increase the students knowledge and to give them an understanding of being an engineer The students who participate in the project will learn to cooperate execute and to lead through a project It is important for the students to get to know how an engineer works and completes a project It is important to do a good job and to show that we can work effectively and efficiently in a group This group aims at making a project worth using as a recommendation applying for a future job A project could be just as important as a character chart to show future companies when applying for a job Every student needs to have a full understanding of all aspects of the project throughout and therefore it is necessary to assign different work areas to every student
79. hannel bar 5 5 kN The axial force indicated by the pink arrows is set to 5 5kN to illustrate the forces that are applied from the upper frame The FEM analysis show that the maximum stresses in the channel bar is 6 7MPa and is located in the transition to the lower frame This stress is well within the acceptable limit the client has set for the frame ref R15 in the Requirement specification rev 1 4 e FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 Displacement se Max 2 0368 0017 D Figure 12 The figure above shows the displacement of the channel bar of 0 2mm The maximum displacement is located at the very top of the bar According to the requirement for deflection of the frame the displacement satisfy requirement ref R28 Requirement Specification rev 1 4 7 5 Cylindrical guide rods Figure 13 Cylindrical guide rod The cylindrical guide rods are used to ensure that the force from the cylinder is evenly applied onto the test specimen The guide rods are not subjected to any significant load and are designed to operate only as guides To make sure the rods will cope with an unexpected scenario where the cylinder apply the forces uneven a FEM analysis is carried out A FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 Calculations M 100N 0 45m 22 5Nm 7 85 a 10 m 8 Mast 8 22 5Nm 0 01m 38 gave 7771 785 109m
80. he electrical power to the pump is breached A FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 Emergency stop devices 24V to 230V to PLC Hydraulic pump contactor A mm Emergency 2 push button Figure 71 Emergency stop devices 25 27 An emergency stop switch has two circuits The function of an emergency stop switch is to cut off any electrical power The electrical lines will have to be connected to the desired device to stop The switch acts when pushed A FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 Start button i start button Figure 72 Start button The start button has one simple function When pushed the start button connects the circuit Transformer 230V Figure 73 Transformer The transformer for the 230V AC to 24V DC is put together by a transformer a rectifier and a capacitor The transformer consists of two spools that have a relation of ca 10 1 The transformation in a transformer is from 230V DC to 23V DC The spool that has 230V has 1000 windings and the spool to the right in the picture has 100 windings To rectify the voltage there is used a rectifier but from the rectifier there is a pulsating DC To even the pulses out there is used a capacitor A a FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 Pressure switch Type DG 1 DG 8 F Figure 74 HAW
81. horizontal force since wedges will work as self locking mechanisms increased by increasing the tension force This will bring us back to use a standard manufactured specimen that is easier to produce e FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 11 0 Bearing of guide rods 11 1 Idea 1 Linear ball bearings The bearing of guide rods is important If there are not any bearings the stabilizer bar can get lodged up against the guide rods This can lead to serious consequences where components can get damaged When there is used bearing the stabilizer bar can travel freely on the guide rods There are two options the group has looked at Figure 22 Linear ball bearings The linear ball bearings provide an adequate sliding on the guide rods It consists of a housing that is in this case press fitted on the stabilizer bar and balls to roll on the guide rods The lubrication used is grease lubrication for spindle bearing arrangements There are only needed small amounts of grease to maintain the lifetime of the bearing 7 When the bearing is attached to the stabilizer bar it can roll on the balls with little friction Because the balls are rolling they have a much lower coefficient of friction than if two flat surfaces were sliding A FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 11 2 Final concept bearing of guide rods 11 2 1 POM Figure 23 POM
82. http www oecinc net products parts circuit breakers 25 05 2012 22 http cnsentai en alibaba com product 52355751 200008492 GMC_Electrical_Contactor html 20 05 2012 23 http www autoshop101 com forms hweb2 padf 24 http www allaboutcircuits com vol_4 chpt_5 2 html 25 http www hawe de fileadmin content typeman catalog pdf 5 4 D5440 en pdf 27 05 2012 25 http www expo21xx com sensor 2183_st2_magnetic_field_sensor default htm 26 Hibbeler R C Mechanics of materials Pearson 2011 27 http www grabcad com 28 http iamechatronics com notes 78 lessons in instrumentation 263 plc logic programming part 3 29 05 2012 Y OW 2 FIR H GSKOLEN i Buskerud HOGSKOLEN i Buskerud Department of Technology Kongsberg Title of document Test report version 1 0 Course code name SFHO3200 H11 Hovedoppgave med prosjektstyring Group members Espen S tre Kolberg Kjetil Haugmoen Kj ndal Internal Supervisor Jamal Safi Date 29 05 12 We confirm that the submitted assignment is entirely our work Espen Kolberg Kjetil Kj ndal Fatigue Test Rig Test report rev 1 0 Table of Contents 1 0 Docuimernt hISEOLy EE 3 i18 ade a aE 4 2 0 INTO L 51 0 ns 5 BREET 5 OLMOS cds 5 BO EXGCUbON Of tes EE 5 Bil EEE RE 5 MICI a A Dee AEN 6 6 1 Critical failure veian a cia 7 Olne H 6 3 Ee le TT EE
83. hurt the end product are recognized under the testing 6 2 Roles Kjetil Haugmoen Kj ndal Responsible for the test Espen S tre Kolberg Responsible for execution of test 6 3 Equipment The test is done on the computer and with the use of Solidworks e FIR H GSKOLEN i Buskerud Fatigue Test Rig Test report rev 1 0 6 4 Evaluation The test is executed easily but not on a physical machine It shows that every component is in line and should apply the load axially on the components Since the physical machine not is produced we have to rely on measuring in solidworks Based on this the test is approved But when the physical machine is up and running there should be made another physical measure test to ensure that every component is according to drawings and matches E 2 F R H GSKOLEN i Buskerud Fatigue Test Rig Test report for T10 i Buskerud Fatigue Test Rig Test report rev 1 0 7 0Introduction This test will be taken to ensure that the floor where the machine is located will be resistant to the load of the machine If the load from the machine is too large relative to the floor s capacity this would be a risk factor 8 0 Abbreviations SW SolidWorks qk Uniform distributed load 9 0 Limitations The exact floor construction in the lab where the machine is located is not known 10 0 Execution of the test 10 1 What is tested This test looks at T10 from the test specification
84. ich can help with the use of the rig Only by doing so will teach you how to use the Fatigue Test Rig in a safely manner NA Ignoring these instructions can be dangerous to life and limb CAUTION Ignoring these instructions may damage parts of the test rig Figure 1 Warning and caution This manual is an important part of the Fatigue Test Rig and should be passed on to any subsequent owner if the test rig is sold or given away 2 1 Intended Purpose The intended use of the Fatigue Test Rig is to safely and reliable do a fatigue test on a test specimens of steel and aluminum with yield strength from 0 355MPa The Fatigue Test Rig is an instrument to find the fatigue strength of different aluminum and steel types 2 3 Spare parts To safely replace parts make sure to order from the part list in this document Any other products may affect the reliability and results of the test rig When replacing parts the guide rods are needed to be taken out when this is done most of the parts should be able to be replaced with some disassembling h e FIR H GSKOLEN i Buskerud Fatigue Test Rig User manual rev 1 0 2 4 Transport When transporting the test rig make sure the door on the rig is closed and that the test rig is disassembled from the hydraulic pipes To run the test rig away from the intended work space make sure to bring the control system and ensure that the new work space has a hydraulic pump
85. icker wall on top of it to withstand the forces applied A i FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 9 3 3 Cylindrical guide rods Figure 15 Guide rod As a solution to make the rig more maintainable and to easily change parts the cylindrical guide rods have now only one function This function is to guide the stabilizer bar and make sure this is horizontal to apply forces directly axial When giving the guide rods only one function and using another bar set as a frame to hold upper and lower frame together the guide rods can be taken out from the rig which make changing parts much easier When using guide rods for one purpose the rods can be dimensioned to a smaller diameter A i FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 9 3 4 Channel bars Figure 16 Channel bar In this last concept there are used channel bars to hold the frame together The channel bars are stiff and can be dimensioned for fatigue The bars have one function It has to withstand the forces applied and the weight of the upper frame The rig needs to have an easier solution to change parts if needed The channel bars will replace the earlier function to withstand forces of the cylindrical guide rods And the guide rods can be taken out and there will be easier to reach the other components 9 3 5 Support legs Figure 17 Support legs The support legs in the earlier id
86. ided to continue with two members instead of three The project group reorganized and divided responsibilities and task between them The demands of the project were scaled down but still a group of two instead of three may influence the final results 7 2 Loss of data In this project some challenges have occurred There has been a computer crash and a virus infection in both computers which also infected the drop box The virus was an encryption infection which attacked one of the computers running an older java version All files on two computers and the drop box were encrypted The group had taken precautions and had backed up the work on other devices No documents were lost 7 3 Illness So far has no one in the group suffered neither short term nor long term illness 7 4 Lack of components There have been difficulties in providing different components for the making of a prototype The group has tried to collect and manufacture necessary parts both from BUC and from different firms and companies After discussing with the supervisor in April the project group realized that making a prototype would be too time consuming Instead the aim was to complete a thorough description of the prototype ready for manufacturing En H GSKOLEN i Buskerud Fatigue Test Rig Project plan rev 2 0 7 5 Client changes There have been no major demands of alteration or changes except that of stated above 7 6 Supervisor absence Th
87. ield strength of 355MPa and E module of 210GPa 12 Locking bolt The locking bolt is made out of 355JO steel with yield strength of 355MPa and E module of 210GPa 12 Vibration absorption The vibration absorption is made out of silicon rubber with a tensile strength of 10 5MPa 8 Door The door is made out of PMMA with a tensile strength of 74MPa and E module of 3GPa 9 Rear cover The rear cover is made out of PMMA with a tensile strength of 74MPa and E module of 3GPa 9 Magnet The magnet is made out of Neodymium with a tensile strength of 75MPa and E module of 1768MPa 10 Hinges The hinges are made out of R304 steel with yield strength of 290MPa and E module of 190GPa 14 POM cover The POM covers are made out of S355J0 steel with yield strength of 355MPa and E module of 210GPa 12 5 FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 Front and rear H beam cover The front and the rear H beam cover are made out of S355J0 steel with yield strength of 355MPa and E module of 210GPa 12 Door handle The door handle is made out of 1060 Aluminum with yield strength of 28MPa and E module of 69GPa 14 9 0 Hydraulics 9 1 Hydraulic cylinder Figure 58 HM85 cylinder illustration Name Description Operating pressure max 250 bar Testing pressure max 375 bar Hydraulic Piston Velocity max 0 5 m s Cylinder h
88. ient is not interested in how the frame is designed the group had a group meeting In this group meeting the concepts were discussed With the qualifications that concept 4 holds that it only uses only one cylinder has the most stable axial loading and has a great amount of stiffness due to the H beam the group means this is the one to use as a basis point Concept 1 is used to develop further since it has the best qualities of the four of them A FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 1 rev 2 0 6 0 Test specimen fixture design The test specimen fixture is an important part of the system and there was researched for different types of fixture The fixture that has to be decided will have to hold the specimen tight It has to be a simple applicability which is easy to understand and use There were a lot of ideas floating both in our heads and from the industry There was used time to consider industry fixtures both from the use of internet machine parts book and standard ASTM e606standard and on a trip to Gj vik where we saw some different fixture methods The concepts we have been working on in concept round 1 is the first ideas that we came up with after going through idea rounds of 15 minutes each There was discussed what was the best ideas to work with T FIR HOGSKOLEN i Buskerud Fatigue Test Rig Concept round 1 rev 2 0 6 1 Idea 1a Thread fixture design M36 thre
89. ign and construction are made for the customer to test and then to have a feedback from the customer This method is more appropriate for software based development There are some pros and cons with this model as well There are not much time for design and might lead to mistakes during the process 4 3 Evolutionary The evolutionary model includes the customer in the development process There are several small waterfall models This leads to a common understanding of the product to be made Working with this model makes it difficult to predict the time needed to finish the work 4 4 Incremental Incremental development allows the main goal of the project to be finished even with a limited number of people The product could operate with less functionality Difficult parts that occurs during the project could be postponed to allow to start at the easier parts of the task 1 H GSKOLEN i Buskerud Fatigue Test Rig Project plan rev 2 0 5 0 Incremental development The group have chosen a model that is an adapted version of the waterfall method In this method we run trough the waterfall method faster than originally and then repeat the process First the analysis is done and the requirement specifications are set This will give us knowledge of what are the project needs and a base from where we start further work with our project The project is divided into increments and we chose to start with the most demanding incremen
90. igue Test Rig Concept round 1 rev 2 0 7 0 Drive Medium 7 1 Idea 1 Hydraulic Hydraulic is widely used in the industry because of its ability to apply large forces and to achieve a great accuracy in testing Use of the hydraulic system is suitable to achieve a soft startup of the system and will lead to a smooth transition when the machine alternates between tension and compression cycles This will avoid backlash or sudden changes which can lead to deviation in the test results Due to the drive medium of hydraulic it is self lubricating and does not require any external maintenance as long as the oil is kept clean Advantages e 3 5 Hz up to 10 15Hz depends on stroke design costs 2 3 e Low maintenance e Ability to regulate forces applied e Smooth transitions between load cycles e School has hydraulic pump to run the system Disadvantages e Low Hz leads to longer test times H GSKOLEN i Buskerud gt FIR Fatigue Test Rig Concept round 1 rev 2 0 7 2 Idea 2 Electro The use of an electromotor as a power supply for the system is often used when there is a rotating system This is an effective method to get a high amount of cycles and it is a cheap construction The uses of electro in linear test rigs are often a servo electric solution which is complex systems Advantages e High frequency e Quiet system Disadvantages e Not suitable for applying large forces e Not so good in terms of controllin
91. ill make the collars grip the test specimen when exposed to tensile force and the force on the button head will make sure it stays in place when exposed to compression force This fixture will provide a good fastening of the test specimen the coarse fine threaded bolt supports test specimen very good and the fixture is robust On the downside there will be some manufacturing with the collars in mind There will possibly be used some time on the test specimen assembly And there is a possibility that the bolt may shake loose after a period of time 6 4 The decision The group arranged a meeting with the client to decide which specimen fixture that was the best solution The client and the group went through the various concepts the group had come up with and it was determined what the client wanted to go for There was also An i FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 1 rev 2 0 discussion around changes to the tightening of the specimen The group came up with a couple of suggestions for possible changes The internal supervisor asked us to investigate whether it was possible to make use of hydraulic attachments after the meeting When deciding there were made clear that threads on the test specimen were something that was not wanted The choice from the client was concept 2 but he wanted to look for other tightening options than the screw clamping force A E 15 F R H GSKOLEN i Buskerud Fat
92. in the lower frame Stress analysis show a maximum stress of 14 1 MPa at the edge of the beam There was also a stress of 12 7MPa in the middle of the beam These stresses fulfill the requirement ref R15 Requirement Specification rev 1 4 Displacement URES mm 3 539e 002 3 244e 002 2 949e 002 2 654e 002 2 360e 002 2 065e 002 1 770e 002 1 475e 002 1 180e 002 e 3 539e 002 88486 003 5 899e 003 e 2 949e 003 1 000e 030 fin 1 000e 030 Figure 9 Displacement analysis lower frame 11kN Displacement analysis shows a deflection of 0 03539mm The group aims to limit the maximum displacement as much as possible and has set a requirement of 0 1mm as a maximum deflection The lower frame meets the requirement ref R28 Requirement Specification rev 1 4 A FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 7 4 Channel bar Figure 10 Channel bar The final edition of the rig contains the mounting of two U shaped channel bars that is welded together with the upper and lower frame This will ensure a stiff frame for the rig Earlier concepts made use of cylindrical rods that served both as a framework and guidance for the cylinder By using the U channel for the bearing structure the rods will only ensure that the force is applied axially on to the specimen and will not be subjected to any loading FEM analysis Stress Figure 11 Stress analysis c
93. ion The group discussed the differences both individually and with the supervisor forth and back There was then held a meeting with our client where we went through the concepts for drive medium and the up and downsides of each drive medium It was made a decision to go for the hydraulic system This was because it will provide enough force as little deviation on the results the compression of fluid and the fact that BUC can provide with a lot of equipment to hold the costs low A i FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 13 0 Hydraulic valves 13 1 Idea 1 Olsen valve The group has looked at different valves which can provide the needed function It has to have 3 positions where position one has as function to provide pressure to lower end of the hydraulic cylinder and that fluid from upper end in the hydraulic cylinder goes into the reservoir Position two contains a function that drains fluid from the hydraulic cylinder to the reservoir And position three will provide a function that sends pressure into the upper end of the hydraulic cylinder while the lower end drains into the reservoir Figure 24 Olsen valve 15 A valve at University premises is an Olsen Valve which is a pre guided spool valve A pre guided spool valve is a valve that contains a directional valve on top The main component is hydraulically connected to a directional valve that controls the main valve The valve
94. k the circuit in the contactor and break the electrical power to the hydraulic pump The counter gets signal 1 from Q on SR1 in to CU on the counter CV the counted cycles on the counter is shown on the display To reset the counter to start counting from O press the reset button TN FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 11 0 Price estimate Priceestimate Priceestimate w parts from BUC Description B Cost per item 11 0 HE160B 5355J0 upper frame 1 300 Cutting 300 12 0 Channel Bar side frame 2 300 600 13 0 Cylindrical guiderods availible from BUC 4 8 0m 0 14 0 Cylinder bracket 4 100 400 15 0 Squarebeam lower frame 5355J0 160X80X10 MM 1 300 Cutting 300 16 0 Power transfer 1 kg 23 17 0 Doubleacting Cylinder HM85 FFL GV K 1 2500 pc 2500 18 0 Fixture bolt 10 pcs 20 19 0 Upper specimenfixture 5355J0 0 1m3 7 8 30 kg 234 10 0 Wedges z 5 kg 10 111 0 Lower specimenfixture 835530 E 30 kg 270 12 0 Stud bolt 1 30 kg 30 13 0 Hydraulic hoses m 0 14 0 Vibration absorption 4 75 pcs 300 115 0 OlsenDirectional valve 1 pc 0 116 0 Plexiglass front 1 200 pc 200 118 0 Plexiglass rear 1 200 pc 200 19 0 Gliding bushings POM 4 70 m 280 20 0 POM cover 8 8 kg 64 121 0 Support legs 4 100 Cutting 400 122 0 Magnet 1 40 pc 40 123 0 Testspecimen 10 8 33 pcs 83 3 124 0 Hinges 2 50 pcs 100 125 0 Counter Dayton 6X596 1 750 pc 750 126 0 Steel plate 1 69 kg 69 127 0 Emergency stop Rope Pull
95. kkluft Kompressorer Kompressor 55B 90 17659 D FIR HOGSKOLEN i Buskerud PE E CE HOGSKOLEN i Buskerud Department of Technology Kongsberg Title of document Concept round 2 version 2 0 Course code name SFHO3200 H11 Hovedoppgave med prosjektstyring Group Members Espen S tre Kolberg Kjetil Haugmoen Kj ndal Internal Supervisor Jamal Safi Date 29 05 2012 We confirm that the submitted assignment is entirely our work Espen Kolberg Kjetil Kj ndal Fatigue Test Rig Concept round 2 rev 2 0 Table of contents 1 0 Klee iv Ge A 2 O ADDEVIALIONS NS 4 EAU AAA On 4 AO vk deele Le TEE 5 5 0 Ideas e 5 COPIAN NE ia idad 6 7 0 Theory and appropriation cccccccsssssssscecececessesseeseceeeceeseeaeseceesceusesaeaeseeeesseesesaeaeeeeecesseseaeaeeeesens 7 8 0 Final Ee El Ee ul e 8 8 16 35MM EE 8 SD Frame O tad 9 LET 9 93 Finaldr me concept nr ere 20 10 0 Test Specimen fixt re dei iii cada 24 10110 24 10 2 Final concept test specimen fixture desen 27 11 0 B aring of puide rod EE 29 11 1 Idea 1 Linear ball bearings nn nn neris nnn nnn 29 11 2 Final concept bearing of guide rods oooccconocnncconocnnonononnnonononnncnnnonnnnnnnnnnncnnnonnnnnnnnnnnnnnnncnnnnnnnnns 30 12 0 Drive Medium cei eret pterea tia eee eo rate 31 12 1 Idea 1 Premiati Rm 31 12 2 Final concept drive medium 32 13 0 Hyaraulic valve S sorten petto deseo cute tate a
96. les e School has hydraulic pump to run the system e School has a resource person to ask for advice within hydraulic Cons e Low Hz leads to longer test times h FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 17 2 Discussion After having been in contact with several companies including SMC Lautom and Bosch Rexroth we have come up with that we could be able to have a pneumatic system capable of carrying out 2 3 cycles per second with a max load of 20kN That is in a total reversed load cycle The air supply from a reasonable priced compressor like the model 55B 90N 13 at 490 In min is not sufficient With the use of magnet valve EVS7 10 FG D 3DOB XSE647 14 with a flow of 4905 In min it requires the use of an external pressure vessel Using an electro based system will not meet the requirements of the forces needed to conduct a test By using an electromotor there would be a need for having a form of gearing that is exposed to slack during a period of time Having made contact with several industrial hydraulic companies and BUC s internal expert on hydraulic the group has the perception that a hydraulic system would be the best solution regarding forces needed as well as getting as little deviation in the results as possible This decision is also based on the fact that there is a goal to use as much equipment as possible from BUC in that way the project costs will decrease 17 3 The Decis
97. lly inspect the counter to 29 12 2011 T1 BUC A check if it s counting 5 1 2 User Turn on the machine use the 06 01 2012 T2 BUC A operated emergency mechanism to check if emergency the machine stops stop 5 1 3 Test Ensure that the test specimen is 06 01 2012 T3 BUC A specimen held tight and inspect that the fixture forces in the fixture is adequately 5 1 4 Movement of Perform measurement in SW and 06 01 2012 BUC test rig physically measurement on the A machine T4 Visually check and measure that B the movement is from 0 to to 0 to T5 to0 5 1 5 Test stop Be present during the testing to see 06 01 2012 T6 BUC B if the machine stops when specimen breaks 5 1 6 Test time Use a timer to control if the system 06 01 2012 T7 BUC B test time exceeds 24hrs sv 3 F HR HOGSKOLEN i Buskerud Fatigue Test Rig Test Specification rev 2 0 5 2 Test of system requirements 5 2 1 Vibrations Check the surroundings for vibrations and or resonance 06 01 2012 T8 BUC 5 2 2 Life cycle durability Simulation of a SW design for the fatigue test rig in a FEM analysis there we test that the non maintainable parts of the rig will hold for at least 3 years in a fatigue simulation 06 01 2012 T9 BUC 5 2 3 Machine weight Check and verify that the total weight of the Fatigue Test Rig does not exceed maximum of the floor capacity 2 06 01 2012 T10
98. lts must be saved on a device 06 01 2012 R18 BUC C HOGSKOLEN i Buskerud FiR Fatigue Test Rig Requirement specification rev 2 0 5 4 Environmental requirements 5 4 1 Testing Operating temperature range must be 06 01 2012 R20 BUC A conditions between 5 30 C 5 4 2 Noise level The rig has to operate at 90dB or less 29 12 2011 R21 Group B at a distance of 1 meter 5 5 Other requirements 5 5 1 Operator Moving parts must be placed ina 06 01 2012 R22 BUC A safety housing 5 5 2 User manual The system must have a user manual in 06 01 2012 R23 BUC A English 5 5 3 User friendly The system must be operable by an 06 01 2012 R24 Group A engineer student after reading the manual 5 5 4 Test There must be produced test 06 01 2012 R25 BUC B specimens specimens 6 35mm dia ASTM 606E A H GSKOLEN i Buskerud FIR Pre EOS H GSKOLEN i Buskerud Department of Technology Kongsberg Title of document Test specification Version 2 0 Course code name SFHO3200 H11 Hovedoppgave med prosjektstyring Group members Espen S tre Kolberg Kjetil Haugmoen Kj ndal Internal Supervisor Jamal Safi Date 29 05 12 We confirm that the submitted assignment is entirely our work Espen Kolberg Kjetil Kj ndal Fatigue Test Rig Test Specification r
99. m length x width x height To make the rig more compact and more suitable compared to the forces applied the group came to the conclusion that the beam could be redesigned The benefits of the H beam profile to resist bending was desirable to bring further in the project process FEM analysis Stress Figure 3 Stress analysis of the HE280B beam 11kN applied normal to the beam The stress is located under the upper flange of the beam and has a maximum value of 8 2MPa A i FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 Displacement 2 7628 002 Figure 4 Displacement analysis of the HE280B beam The analysis of the upper frame show a maximum displacement of 0 0276mm The maximum displacement is located at the edge on the upper flange 9 1 2 Lower frame Figure 5 Square tube lower frame The application of a double rod cylinder led to the desire for a more suitable design of the lower frame The square tube design has a weakness towards bending in contrast to the H profile but makes it possible to mount a double rod cylinder The dimensions of the lower frame is 500x400x200mm length x width x height A i FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 To make the rig more compact the group decided to go further with the square tube design of the lower frame but redesign it to make it more suitable to handle FEM analysis Stress N
100. n top and bottom of the rig with a rope attached to the stabilizer bar both ropes to each automatic emergency rope pull device The device triggers when the displacement of the stabilizer bar is outside its work area This occurs when the rope is pulled and the emergency rope pull trigger the stop The rope pull device automatically stops both the pump and rig i FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 17 0 Counter To cover the requirement to count cycles the group has looked at different counter types It is looked at pure mechanical counters and other types of counters When getting information about the material the cycles done before fracture is essential to get any usable information 17 1 Idea Mechanical counter Figure 33 Mechanical counter Before the electronic counters were used there was used mechanical counters and in all mechanical machines For our test rig this could be an option Totalizes are used in a wide variety of applications where accurate totals are needed Typical applications include counting the number of parts produced amount of material used or the number of machine cycles occurring Totalizes are the simplest and most common type of counter 22 The Mechanical totalize counter is in this case used to count every time the stabilizer bar push the count lever The count is for every time the stabilizer bar is in compression mode 17 2 Conc
101. nd 34 13 1 Idea 1 Olseri valve teer e t rte Robes er rc ease iii 34 13 2 Final concept valve torte tret skrenter das 36 14 0 Choice of el ln EE 37 14 1 Jdea Single rod cylinder rrr te t 37 14 2 Final concept cylinder ie its 39 15 0 Final concept manual switches esses eene eene enne nn nasse seen nana sss sss nr nan 40 16 0 Automatic emergency trigger Switch 40 16 1 Idea Automatic emergency trigger Switch 41 16 2 Concept Automatic emergency rope pull occcnnnnococonnncncnonononannnnnonocanonononnnnnnnocananononnnnnnncnns 41 FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 RER ne 42 17 1 Idea Mechanical COUNTE csi rd ENEE Vasa sadness 42 17 2 Concept Binary COUnter eec ierit A eegen 42 18 0 The machine control system siseses tenetere deiran ieina eda aae eieaa a ie Ea aE da aiaa ia ie 43 18 1 Idea 1 Mechanical control of the system 43 18 2 Concept Digital control of the system 43 19 0 Resources and reterences AER 46 rN F R H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 1 0 Document history 0 1 21 03 2012 Added fixture 1 2 introduction test fixture dimension 1 0 23 03 2012 Added fixture 2 3 concept choice 1 1 30 03 2012 Changed headlines dates 1 2 10 04 2012 Added calculation on specimen 1 3 09 05 2012 Grammar and spell check 1 4 14 05 2012 Added concept and idea layout 1 5 27 05 2012
102. nd inside of the directional spool valve 17 A i FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 14 0 Choice of cylinder 14 1 Idea Single rod cylinder The test rig will need to have a hydraulic cylinder to apply force on test specimen It has to provide approx 11000N and it should have as small dimensions as possible There was also wanted to use as small pressure as possible in the system There was looked at two types of cylinders a single rod cylinder and a double rod cylinder Figure 28 Single rod cylinder 18 The single rod cylinder would have the disadvantage to apply less force when the cylinder withdraws the piston rod than it would when the piston rod is pushed out from the cylinder This is because of the area the pressure works on each side of the piston The single rod cylinder has one side which has a bigger area than the other and the greater the area greater the force Calculation This is illustrated in the following example 18 Diameter of the piston D 5cm Diameter of the rod d 2 5cm Work pressure p 60 bar y OO O la S MET i D2 g 529 52 A ma Tom 14 72cm Figure 29 Inside of a single rod cylinder A i FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 Piston force F A p 10 Ft A px 10 19 63 60 x 10 11778N F Ax p 10 14 72 x 60 10 8832N The cylinder has a plus stroke of 1
103. nd side of the figure shows the section of the bolt which is fixed to the lower specimen fixture These parts is subjected to a maximum displacement of A FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 7 15 Support legs Figure 45 Support leg The test rig has to be steady so it does not tip over during use To ensure a rigid construction the project had to come up with a further development of the earlier support legs The final edition of the FTR includes four bevels cut 200x46mm l beam shaped support legs These four support legs form a firm fastener for mounting on a flat surface FEM analysis Stress Figure 46 Stress of 0 7kN on support leg The stress analysis show a maximum stress of 16 0 MPa in the support leg The analysis simulates the weight of the machine distributed on the two support legs In the software the maximum stress occurs at one of the mounting holes The stress concentration that occurs in the holes may be a source of error The more realistic stress might be on the top of the leg The stress located on the top is 15 69 MPa A FIR HOGSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 Displacement Mex 3 810 002 Figure 47 Support leg displacement at 0 7kN The support leg displacement analysis show a maximum displacement of 0 0381 mm Maximum displacement is located at the very tip o
104. needed to show the first point on the SN graph would be right up to 2850kg A TXr A r x 0 005 0 00007853mm P Omax 7 A 355MPa x 0 00007853mm 27878N MN FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 1 rev 2 0 5 0 The frame In this section there are different concepts for how the frame of our FTR could look like The different concepts came from idea rounds there we sat down in 15 minutes each time and chose the best one from each idea round These concepts were the first ones to be considered and that we used to work further to find the best possible solution The frame concepts were made out from our own ideas and from solutions taken out from industry used fatigue test machines 5 1 Idea 1 Figure 1 Concept 1 was the first idea to make it to the drawing board This concept came from own ideas from the group The cylindrical rods are there to make sure that the test specimen at all times is straight like it is supposed to be This concept is built with two hydraulic cylinders and two cylindrical guide rods It can be difficult to make sure the two hydraulic cylinders go parallel with each other Here there is the problem with guide rods on one axis this could cause a crooked load on the test specimen There would be more preferred with the four guide rods that cover both x axis and y axis There will also be an economical cost by having two hydraulic cylinders Then we would need
105. nents would be difficult to manage To switch from compression to tension in the cylinder would be hard to control and there would have to be used a timer to send signal to the correct end of the valve for controlling this It may be unreliable because of the time used to fill up and press with one side of the cylinder 18 2 Concept Digital control of the system If there are used digital controls in our system some of the functions would function automatically and it would help the automatic switch between compression and tension PLC Programmable logic controller is an option It is used in industry to automate tasks like production and control of e g levels in a silo The PLC has outperformed in tasks that a lot of relays has done in the past The PLC has as a computer memory and processor which form the basis for all program execution The PLC can be programmed to do different assignments with programs used from a computer connected to the PLC 23 6 FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 Different from a computer the PLC does not have a flat screen and a keyboard Instead it is used electrical inlets and outlets and communicates with the system by electrical signals instead of a screen and keyboard This option would simplify a lot of the trouble with control of the rig The Switches buttons emergency stop triggers and counter would all be included in this system 18 2 1 The
106. nt analysis of the bolt 1 146kN Analysis of the bolt shows a maximum displacement of 0 0006326mm The maximum displacement is located at the bottom of the bolt H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 7 13 Wedge lock Figure 35 Wedge lock To ensure that a tight and firm grip is applied to the test specimen the angle of the wedges is very important as well as the vertical force applied onto the wedges It is crucial that the test specimen is held tight during the execution of a test not only to make sure that the rig don t fail but also to get reliable results As can be seen of the calculation below the optimal angle for the wedges will be 4 028 degrees Calculations Optimal angle of the wedges ew edge of the wedge t test specimen Hew 0 6 Ht 0 7 1 Ht Mew 0 7 a 0 6 o AA 4 02 He ren de EET maa 6 A FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 1 The calculation below takes a look at a a Section of the wedge pew Na 393 6 N 275N O 2nr 2 1 6 35 40mm Force normal to the wedge f _ 11000N n 15714 3N u 0 7 197143 392 85N Ng 40 S e FIR H GSKOLEN i Buskerud EF Fatigue Test Rig Technical document rev 1 0 Axial force along the wedge _11000N 27 Are An Wedge EF EF NA cos 4 Hey NA sin 4 393 6N
107. nt process EE 7 0 The Fatigue Test Rig E R nn E 7 2 UDE MC DL A ES ad AE 23 Lower frame RP oadju MH P 11 7 A Channel bar tr 14 7 5 Cylindrical guid rods iii oa 15 76 Stabilizer TN 17 7 7 POM C guide bushing idad 19 7 8 Upper specimen TIXCUEB oos err Eeer eane aisa PERSE DN aieiaa 20 7 9 Lower specimen BEE 22 740 Cylinder bracket AA 24 7 41 The power transfer Tit e dl A io 26 7 12 The fastener cose eds epp ku EDS qi I DARAN ra 29 7 13 Wedge c Y etalon 33 7 14 Locking bolt Get 37 T A5 SUPPONE pS iR RUPES 41 7 16 Vibration absorption esses eene eene nnne nennt nnns nisse enne ks erne 42 AP H 44 TAG REAL COVER me HP 45 7 19 DOOR Mag MEt E 45 120 He UE 46 AN EENEG M 47 7 22 H beam COVERS ii 47 223 DOF ET 48 8 0 Choice of materials arar 49 A TAN 49 8 2 A edd 49 E ERE REE otitis 51 A H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 9 1 Hydraulic elle DT 51 9 2 Hydraulic valve cccccononoonoccnnonnnonononncnnnnnnnnnnonnononnnnnnnnnnnnnno no nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnos 54 9 3 SUD pl te e nr ied P P e E ER ET ERREUR ERE EE ari 55 10 The machine control evstem ranas 56 10 1 Logic components b e e e RE D EE RR ERR RE EXER E REN EXE RE ERR ERN RR EXE ERA PER ER dead 56 2
108. ode dd il ae X Y Z Location 200 3 64 430 mm 674 Value 279 Nimm 2 MPa S 041 amp Yield strength 355 0 Figure 6 Stress in rectangular lower frame 11kN The software analysis of the lower frame show a maximum stress of 27 9kN at the very center of the square tube H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 9 1 3 Cylindrical guide rods Figure 7 Guide rod The cylindrical guide rods are supposed to ensure the axial appliance of the force on the test specimen In this idea the guide rods are also the bearing structure of the frame After doing research in the workshop at BUC the rods available had a diameter of 60mm The rods will be subjected to a force of 1 428kN plus the weight of the upper frame Calculations 105kg pr meter 2 105 kg 0 5 m 52 5kg 52 5 kg 9 81 515N 10428N 515N 10943 N The rod will then be subjected to a load of approximately 11kN divided on the four guide rods which result in a force rod of 2750N A FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 The cylindrical rod in this idea is 50mm in diameter and we wish to test if it is within the requirement of 2x fatigue F S ref R15 Requirement Specification rev 1 4 2750N 793mm 50mm Figure 8 Force applied on guide rod and Stress in guide rod 50mm Calculations Amr A n25 A 1963mm P dani _ 2750 1963 o 1 4 MPa pe PL AE
109. of friction between bolthead and surface rim the radius that the friction force acts upon Steh r m 4 S wrench width dp hole diameter Total moment M M M M F fp tan s 90 44 F rm F 1146N H4 us 0 20 Ug d 25 67mm Tm S 46mm based on NS 1073 6 1971 d 26 3mm P 1 fn 13 5 u 0 2 t 0 231 13 0 Antes cos a cos 30 e P 1 tan p gt 0 69 T d m 26 3 S da B 46mm 25 67mm 2 ri 17 91mm r m A i FIR H GSKOLEN i Buskerud ER Fatigue Test Rig Technical document rev 1 0 M 1146N m tan 13 0 69 0 20 1146N 0 01791m M 3 67 4 10 7 77 gt 8Nm The bolt has to be tightened with a torque of 8 Nm 5 Stress A mr n 13 19 54656mm JP Ue O mg CA DTM E Elongation Pa 1146N 0 001m 1 04 10 mm AE 546 56mm2 200000MPa i Y FIR HOGSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 FEM analysis Stress von Mises N mm 2 MPa Figure 33 Stress analysis of the bolt at 1 146kN The stress analysis of the bolt shows a maximum stress of 4 0 MPa Maximum stress is located under the hexagonal head of the bolt Displacement URES mm 6 326e 004 5 798e 004 5 271e 004 4 744e 004 4 217e 004 3 690e 004 3 163e 004 2 636e 004 2 109e 004 1 581e 004 1 054e 004 5 271e 005 1 000e 030 Figure 34 Displaceme
110. olt Locking bolt 1 29Kg 1 1 29Kg between lower frame and cylinder piston 15 Support leg 584g 4 2336g 16 Vibration 123g 4 492g absorption 17 Plexi glass Front door of the 2Kg 1 2Kg with holes rig to handle 18 Plexi glass Rear cover of the 2Kg 1 2Kg rig 19 Magnet Door magnet 2 20 Hinges Hinges to the 400g 2 800g door 21 Steel plate H beam rear 3Kg 1 3Kg cover 22 Steel plate H beam from 2 8Kg 1 2 8Kg with logo cover 23 Door handle 190g 1 190g HOGSKOLEN 18 F R i Buskerud Fatigue Test Rig User manual rev 1 0 24 Hydraulic Double rod 10 8Kg 1 10 8Kg cylinder cylinder 25 Hydraulic Direct directional 1 95Kg 1 1 95Kg valve valve 26 Hydraulic Sub plate for the 9908 1 9908 sub plate hydraulic valve 27 PLC 1 5Kg 1 1 5Kg 28 Relay 258 2 508 29 Buttons Start button 1708 1 170g reset button emergency stop button 30 Transformer Transforms from 100g 1 100g 230V to 24V 31 Pressure Manometer with 1 5Kg 2 3Kg switch set knob 32 Bolts M24 hex bolt 336g 12 4Kg 33 Bolts M5 unbrako bolt 3 258 24 788 34 Bolts M3 unbrako bolt 0 978 32 31 04 g 35 Bolts M8 unbrako bolt 14 278 8 114g 36 Rope pull Emergency stop 2008 2 400g switch device with wire Total weight of the 136 6Kg whole test rig A H GSKOLEN i Buskerud 19 FIR
111. omponent has a deflection of less than 0 5mm The test shows that when the frame is assembled the deflection is less than 0 5mm Since all frame tests show a deflection of less than 0 5mm the test is satisfactory The test was successful e CR F R H GSKOLEN i Buskerud H GSKOLEN i Buskerud Department of Technology Kongsberg Title of document User manual Version 1 0 Course code name SFHO3200 H11 Hovedoppgave med prosjektstyring Group Members Espen S tre Kolberg Kjetil Haugmoen Kj ndal Internal Supervisor Jamal Safi Date 29 05 2012 We confirm that the submitted assignment is entirely our work Espen Kolberg Kjetil Kj ndal Fatigue Test Rig User manual rev 1 0 1 0 Document history 1 0 29 05 2012 The user manual is written and done spell check Finalized document Table 1 Document history KA FIR H GSKOLEN 2 i Buskerud Fatigue Test Rig User manual rev 1 0 2 0 Important information This documents intention is to describe the procedure to successfully run a test It easily explains in steps what to do The test personnel do not have to be a qualified tester and a regular engineer student should be able to use the rig with no problems Please read this manual carefully and completely before using the Fatigue Test Rig for the first time The manual contains a great deal of information and advises wh
112. otation is providing a reversible bending moment that eventually causes the specimen to fail Main objective of the project The main objective of this project is producing a complete fatigue test rig We need to consider the concepts out on the market find the best solutions and then design a Fatigue Test Rig with axial force appliance Since the most of the testing machinery and equipment on the market has more test options than we need we have to withdraw solutions and ideas in terms of what our Fatigue test rig needs The group will have to model the whole test rig in Solid Works part by part We do also need to do FEM Finite element method analysis on many if not all parts of the test rig to get the best possible solution for the University and our project but have in mind what the University actually has of parts and equipment After finishing the design and implementations we will need to go through a test period where we test our equipment to be sure that we will get accurate results which can be trusted and used During the work on the project the group realized that to manufacture and assemble a test rig would take more time than the project had The group also realized that the University had not as much equipment and parts as anticipated When discussing this with the client a decision was made to produce a complete basis for production of the test rig This can be a fun and instructive project assignment where we can get
113. ousing St 52 3 DIN 2393 c Ra value max 0 6 my Piston rod Hard chrome 18NV5 Ra value max 0 3 my Operating temperature 30 gr C 100 gr C mineral oil Table 6 Technical specification HM85 FFL GVK 15 Hydraulics was chosen to be force supply in the rig Hydraulic oil is hardly compressible and would lead to little deviation in the test results The client also has good access for the use of hydraulics and this was one of the aspects in the decision During the project the group considered two different options regarding the cylinder for application of the forces Earlier in the project the use of two cylinders with single rods were applied After discussing with an earlier tutor in hydraulics at the BUC the project came to the decision of using only one cylinder mounted in the center of the rig The idea of using a double acting cylinder with a double rod was introduced This would lead to a more cost efficient rig due to the need of less regulation to the system A FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 The double rod HM85 FFL GVK cylinder available from Kolberg Caspary Lautom was the most suitable cylinder for the project both in cost and size With a piston diameter of 50mm and a piston rod diameter of 25mm the cylinder is capable to deliver a force of 11 kN in either directions at 75 bar The highest force needed for the test will be 11 kN which gives a maximum working pressure o
114. over there is a cutout for the hydraulic hoses with the dimension of 30x195x5mm width x thickness x height The rear cover has the dimensions of 630x655x5mm width x height x thickness 7 19 Door magnet Figure 52 Door magnet To make sure the door is held closed during the testing the group chose the strong and powerful Neodymium magnets The dimensions are 10x1mm diameter x thickness A FIR HOGSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 Density Compression Strength Bending Strength Vickers Hardness Hv Tensile Strength Young s Modulus Recoil Permeability Electrical Resistance R Heat Capacity Thermal Expansion Coefficient 0 to 100 C parallel to magnetization direction Thermal Expansion Coefficient 0 to 100 C perpendicular to magnetization direction 7 4 7 5 g cm 110 kg mm 25 kg mm 560 600 7 5kg mm 1 7 x 104 kg mm 1 05 prec 160 u ohm cm 350 500 J kg C 5 2 x 105 C 0 8 x 10 C Table 4 Neodymium characteristics 10 7 20 Hinges Figure 53 Hinge The project decided to for a standard type hinge provided by Elektro import ren AS These are cost efficient and well suited for connection to the door The dimensions of the hinge are 100x80x5mm length x width x thickness HOGSKOLEN i Buskerud 46 FiR Fatigue Test Rig Technical document rev 1 0 7 21 POM cover Figure 54 POM cov
115. pt round 1 rev 2 0 8 0 Pneumatic system The actual control system of the pneumatic system is not generated and will have to be more specified and researched Since the decision for drive medium not is set there is not researched into the depth of using a pneumatic system But some components were researched and the components further in this section are the ones preferred to use at this point To get the best as possible frequency the valve needs to be as close to the cylinder as possible and a pressure reservoir is needed to always have pressure ready to control the cylinder SMC pneumatics Norway is the supplier for these components except for the compressor After been in contact with a sales engineer at SMC the following components were chosen for the pneumatic system 8 1Valve Closed centre FHG D F VS7 6 FHG D Figure 7 The valve thought of using is an ISO interface solenoid valve VS7 6 FHG D with a closed centre 6 The airflow to the cylinder controlled by this when the valve initiates the different positions wm e SE LY Figure 8 The sub plate 7 is a plate which has the airflow going through it It has connections to the cylinder to the pressure line from the compressor and to the air reservoir This plate is attached underneath the solenoid valve LA FIR HOGSKOLEN i Buskerud Fatigue Test Rig Concept round 1 rev 2 0 8 2 Cylinder Figure 9 The cylinder thought of using is
116. ptimal regarding size and weight the minimum allowed diameter of the guider rods are calculated 2750N Figure 10 Force applied on guide rod With F S 16 330 Otillatt 16 20 625 MPa P Otillatt A P A Otillatt 2750N 20 625MPa A 133 33mm A mr r 6 51mm HIE When looking at the dimension 13mm with a length of 1200mm there is seen that there could be a possibility of buckling in each of the guide rods The rods have to be designed to A FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 withstand buckling and with these calculations the diameter of the rods will have to be 13 06mm l 1 2m nd 19 212 i Ig EZ lo ei 353 497mm ly 0 51 0 5 1 2m 0 6m d 9212 Geet q 72 lk 600mm i 2 303 260 53 gt 105 Bs n E l m 210000MPa 353 497mm EET 600mm Fg 2 03kN Force applied is 11kN The force is divided on 4 rods One rod should resist 2750N without buckling It should have a safety factor of around 3 The rods should resist a load of 8250N _ Feely Esn lo ndt bal 64 E n ndt 8250N 600 64 210000MPa 72 da 64 d 13 06mm 4 As seen in the calculations the minimal diameter of the guide rods will be 13 6mm 6 i FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 9 2 Support legs Figure 11 Support legs The test ri
117. referred dimensions are chosen from a DIN standard The reason this design was chosen is its ability to withstand large bending forces Calculations Bending HE160B 24 9 x 10 9m M 1375N am C 0 08m Ma 1375N m 0 08m TA ne a Max bending stress 4 4MPa A FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 Deflection F L 8 Exlx48 11000N 500mm 5 7510 mm x 24900000mm 48 Max deflection of the beam 5 75 10 mm Load Type Input Axis 9 Y local axis X local axis Units Inch 9 Metric Stress 4421 221 86495 Section modulus 311 Length 500 Supported at both ends load in middle Lead iff Type of Calculation Deflection 9 Stress Figure 3 Software stress calculation As can be seen at the figure above the computer analyzes software supports the results of the manual calculations regarding bending stress in the beam Load Type Input Axis 9 Y local axis X local axis Units Inch Metric Deflection 0 005752 Modulus of elasticity 200000000000 Moment of inertia 2430 Supported at both ends load in middle Lenath 500 Load 11000 Type of Calculation 8 Deflection Stress Figure 4 Software displacement calculation The figure above show the computer based calculations of the deflection in the beam that concur with manual calculations The FEM analysis has som
118. rements or functions of the product this will lead to reorganization and add to the work of the project group Every member of the group will need to increase their work and if the added workload is too extensive a prototype may be too much to ask for Medium risk Medium consequences 6 7 Supervisor absence If the supervisor is absent when the group needs advice we will suffer a delay relative to the absence If a longer absence of the supervisor should occur it may be necessary to apply for a substitute supervisor Low risk High consequences H GSKOLEN i Buskerud Fatigue Test Rig Project plan rev 2 0 6 8 Lack of knowledge Some of the purposes with this project are to increase the students knowledge and competence in working with projects It may very well be that some aspects of the project need a higher competence and knowledge than the group members can provide The group will in addition to using literature on relevant topics need to seek advice by the supervisor and also by other competent people Failing to find necessary advice or data will of course influence the finished product and an extensive search for relevant help may delay the progress of the project Medium risk Medium to high consequences 7 0 Risk outcome 7 1 Failing exams After the exam results were clear one of the group members had to withdraw from the project After talking to the client and internal supervisor the project was dec
119. rform the calculations the deviation is within an acceptable level To ensure that the frame of the FTR is stiff enough the project has come up with a maximum allowed displacement of 0 5mm for the frame 6 0 Development process In the very beginning of the project the exact dimensions of the test specimen and the forces required to run a test were not completely figured out This led to a slightly over dimensioned frame which later was downsized to a more cost efficient and adequate rig design During the development process the project has come up with several frame designs Discussion with the client and manual analyses led to a need for further development of the previous framework The client has not set any specific requirements for the frame design other than it should obtain a safety factor of 2 against fatigue A typical requirement in designing for fatigue is a F S of 8 1 In order to ensure the frame would withstand the fatigue stresses the group has set the F S of the various parts of the frame to 16 e FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 7 0 The Fatigue Test Rig 7 1 Test specimen Figure 1 Test specimen A test specimen with a straight sided collet grip was chosen for the project The smooth finish surface is cost efficient to produce making it possible for the client to obtain relatively inexpensive test specimens This makes it possible to run multiple te
120. rivetrain design 3 days Mon 23 01 12 Wed 25 01 12 10 EI Power supply 18 days Tue 24 01 12 Thu 16 02 12 m 53 Control system 2 days Fri 20 01 12 Thu 26 01 12 42 Selection concept 1 4day Fri17 0242 Fri 17 02 12 ETE Select concept 1day Fri17 02 12 Fri17 02 12 44 Design phase 1 16 days Mon 20 02 12 Mon 12 03 12 aA 45 Design Solid works 3days Mon20 02 12 Wed 22 02 12 SS FEM analysis Sdays Thu 23 02 12 Wed 29 02 12 LAE E Manual calculation 8 days Thu 01 03 12 Mon 12 03 12 1 mg Documenting Phase 1 2days Tue 13 03 12 Wed 14 03 12 19 Phase 2 Product development 15 days Thu 15 03 12 Wed 04 04 12 EY Easter holiday 3days Thu 05 04 12 Mon 09 04 12 36 F3 Eksamenstid 11days Thu05 04 12 Thu 19 04 12 EN Phase 3 last design 13 days Thu 19 04 12 Mon 07 05 12 Ek Last FEM analysis 12 days Thu19 0412 Fri 04 05 12 S 39 53 Last calculation days Thu 03 05 12 Mon 07 05 12 E 40 E Last equipment choice 2days Fri04 05 12 Mon 07 05 12 D Ea Phase 4 testing 8 days Wed 09 05 12 Fri 18 05 12 43 Phase 5 Finalize documents 7 days Mon 21 05 12 Tue 29 05 12 cei 45 E Final submission of documents O days Tue29 05 12 Tue 29 05 12 o Fa EN Presentation 3 O days Thu 07 06 12 Thu 07 06 12 B LL i Buskerud H GSKOLEN Fatigue Test Rig Project plan rev 2 0 10 0 Sources 1 http www uio no studier emner matnat ifi INF1050 v11 Prosesser INF1050 24 1 2011 2 pr side pdf 12 04 2012 IN a FIR H GSKOLEN i
121. roject is to design a fatigue machine and eventually build an alpha prototype which uses linear forces instead of circular running with bending stresses The machine is to be used by the students at BUC where they can observe the behavior of metal when subjected to variable loadings This document contains the main requirements that are set for our design It will be the guidelines for the group during the development of the testing machine system e FIR H GSKOLEN i Buskerud Fatigue Test Rig Requirement specification rev 2 0 4 0 Requirement definitions The requirements will be divided into groups to give a better overview and to ease tractability There are requirements given by the client BUC and others are constructed by the group out of understanding the need The different subdivisions of requirements are listed below e Functional requirements e System requirements e Result requirements e Environmental requirements e Other requirements All of the requirements are also divided into different categories based on how important those requirements are to be met by the proposed design solution These categories are as follows e A Essential requirements e B Significant requirements e C Requirements that will be done if there is time A FIR H GSKOLEN i Buskerud Fatigue Test Rig Requirement specification rev 2 0 5 0 Requirements 5 1 Functional requirements
122. rom 50C to 100C 8 The group chose the use of silicone rubber rather than natural rubber due to the consistent performance of the silicone rubber A 2 FIR OLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 7 17 Door Figure 50 Door For the rig to be as safe as possible during operation the client set a requirement of placing all moving parts inside housing The group decided to use PMMA as the protective screen between the user and the moving parts of the machine The PMMA is a clear and transparent material and allows the user to inspect the process in a safe matter The door has the dimensions of 510x655x5 width x thickness x height There is extruded holes M8x1 5 to allow mounting of the door handle and M3x0 5 for the fastening of the magnets Characteristics Standard Unit Cast Weight DIN 53479 g cm 3 1 2 Tensile strength DIN 543455 N mm 2 74 Impact resistance DIN 53453 KJ m22 12 E modul DIN 53457 N mm 2 3000 Operation temperature C 10 80 Light transmission DIN 5036 92 Table 3 Characteristics of PMMA 9 A FIR HOGSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 7 18 Rear cover Figure 51 Rear cover To allow the user a good overview of the process the rear cover of the rig is made out of the same PMMA material as the door There is extruded holes M5x0 8 to allow attachment to the frame In the center of the rear c
123. s counter and PLC to control the FTR These switches pressure sensors and relays are connected to the PLC and the PLC is logically programmed to work in relation to these 230V ACin Transformer 24V DC out Start Sa Relay 1 Pressure PLC elay T i Side A of Valve a La s Emergency x2 y1 Stop stop i Relay 2 Side B of valve k E x5 at Pressure ue y F 2av Gnd Reset counter LI Figure 76 How the system works outside of the PLC When the start button is pressed it initiates the cycling in the valve which leads to the hydraulic cylinder The start button gives a signal to the PLC that sends a signal to relay 1 to deliver electrical power to side A of the valve Cycling starts when side A is initiated in the valve The valve cycles between side A and B as the pressure sensors sends signal to the PLC on a given pressure value When the test specimen breaks the rope pull emergency switch will step in and cut power to the relays and hydraulic pump The rig is now safely stopped and has no applied pressure to the system If needed the stop button and emergency stop button has the same function as the emergency rope pull switch FIR E H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 PLC E ro CEN 3 HU N 11 I2 13 14 I5 I6 17 18 a 3 KEE
124. signal out when either or both of the two inputs gets a signal 1 It sends forward a 1 from the output There can be used inverts as the function becomes what is needed 56 F d H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 AND gate Input Output Figure 67 AND gate 20 The AND gate is a gate that gives a signal out when both of the inputs has a signal 1 It sends forward a 1 from the output Counter Signal from SR1 count signal detected R a LY H PV CV Cycles counted Reset push button Figure 68 Counter 20 28 A counter in PLC is an instruction which either increment counts up or decrement counts down an integer number value when a signal in to the counter changes from O to 1 28 The counter used in this project is an up counter The counter counts for every signal 1 into CU The component has a memory and shows counted cycles out from CV The counter will be reset when it gets a signal 1 from the reset button circuit Q gives a signal that a cycle is counted The pre set value of 25 is programmed in the counter and works as a threshold to activate the counters output Q When the pre set value is reached a light or similar can indicate this The counted cycles from CV can be programmed to be shown on the PLCs display s FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 10 2 Electrical components
125. start to finish The process has also involved consulting with several companies regarding components that have been relevant for use in the project At the very start of the project the group decided to write the report in English There was some difficulties regarding the documentation in the beginning but the group is overall pleased that this decision were taken During the process each member of the group has increased their skills in writing a technical document in English FiR HOGSKOLEN i Buskerud Fatigue Test Rig Project plan rev 2 0 9 0 Project plan We have chosen the following milestones for our project e Milestone 1 Presentation 1 13 01 2012 e Milestone 2 Presentation 2 27 03 2012 e Milestone 3 Final submission of documents 29 05 2012 e Milestone 4 Presentation 3 07 06 2012 IN a FIR H GSKOLEN i Buskerud rev 2 0 Project plan Fatigue Test Rig Task Name Duration Start Finish ad EJ ER Presentation 1 Odays Fri13 01 12 Fri13 01 12 2 Ex Develop web site 1 day Mon 16 01 12 Mon 16 01 12 l 3 G Are Bj rnar N ss day Fri13 01 12 Fri 13 01 12 EN Phase 1 Product development 42 days Tue 17 01 12 Wed 14 03 12 EE Coarse concept 23 days Tue 17 01 12 Thu 16 02 12 6 Fixture design 4days Tue 17 01 12 Fri20 01 12 TIE Test specimen design 2days Thu 19 01 12 Sun 22 01 12 8 m Chassis 3days Fri20 01 12 Tue 24 01 12 9 fer D
126. struments there was a demand for a renewal Our Contact at the University who has provided us with the project assignment is Name Kjell Enger Phone number 32869734 E mail kjell enger hibu no te H GSKOLEN 5 i Buskerud FIR Fatigue Test Rig Vision document rev 2 0 The Assignment Introduction Our assignment is given by BUC Buskerud University College BUC have a laboratory department for showing and teaching the students more thoroughly what exactly the different practical methods are The professors want to have instruments to show the students each method and have the possibilities of a practical approach in teaching The instrument most wished for is a fatigue test rig that can be operational and give reliable results The University has asked for an update on old equipment for fatigue testing that is a new Fatigue Test Rig Situation today Load adujstment J Specimen fixture N Counter Rotating axle Figure 1 The old test rig The Fatigue test rig which is operational now does only test fatigue bending stress on a circular test sample This rig has been worn down and is not at its best condition It consists of an electromotor that delivers the power to rotate the test specimen The specimen is held in place on the one side of the axle while it is subjected to bending load on FIR i Buskerud Fatigue Test Rig Vision document rev 2 0 the other side This r
127. sts without excessive costs The smooth finish and the design of the specimen include gradual size of the transitions The test specimen also has no abrupt changes in the surface which again could lead to stress concentrations known as the notch effect The project chose to go with a test specimen dimension which are described in the ASTM e606 standard as the minimum for a test piece The dimension of the test area has the dimensions of 6 35x19 05 mm diameter x length and may be seen in the figure above 1 Processing the test specimen require high accuracy to avoid surface defects or a non uniform shape The area of the test area is 31 6 107 m and the material 355JO which gives us the equation Omax P A P 355MPa x 31 6x10 m 11218N This sets the upper limit for the force needed to conduct the testing A FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 7 2 Upper frame Figure 2 Upper frame During the process of the project there has been made some changes to the different components of the frame The final version of the upper frame consists of a single HE160B H shaped beam with the dimensions of 160x160x500mm The use of this profile ensures the rigidity in the frame as well as being small and compact This leads to a smaller and more rigid setup compared to the earlier versions of the upper frame which is twice the size The beam is made out of 355J2G3 construction steel and the p
128. the wedges to ensure a tight and stable fit during the testing The dimension of the force passing is e Height 20mm e Diameter 23mm e Center cut 13mm Calculations TT ear AT TT I 4 0 0115m Stress The outer diameter of the cup A 415 47mm P 1146N 7714 415 47mm 2 75MPa A FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 Elongation PxL 1146N 0 002m EE fe A E 415 47mm2 200000MPa E M 6 Stress The inner diameter of the cup A 282 73mm P HEN auu AT 28373mm Elongation PxL 1146N 0 0005m 1 009 x 107 mm A E 273 73mm2 200000MPa 0 3 76 10 mm 4 A 27 H GSKOLEN i Buskerud EZ FIR Fatigue Test Rig Technical document rev 1 0 FEM analysis Stress von Mises N mm 2 MPa Yield strength 325 0 Figure 30 Stress in power transfer 1 146kN 62 5 7 5 3 43 4 4 3 9 35 3 0 26 2 1 ee 1 2 0 8 The stress analysis of the power transfer show a stress of 6 1 MPa The maximum stress is located in the bottom face of the extruded cut The stress in the fixture meets the requirement ref R15 Requirement Specification rev 1 4 Displacement Figure 31 Displacement of power transfer Displacement analysis of the power transfer shows a maximum displacement of URES mm 3 488e 004 3 197e 004 2 907e 004 2 61 68 004
129. ting a vertical force downward on a bar which then presses on a cup as shown in the figure above The cup is in contact with the wedge grips as well as with the specimen and when in action this pressing force is holding both the specimen and the wedges in place As the cup presses on the wedges the wedge acts to increase the squeezing pressure applied to the specimen securing it from gliding upwards The major disadvantage of this solution is that it is costly as extra and relatively sized parts have to be manufactured to fasten the hydraulic press In addition specimen in this case will not by standard on the shelf product rather than specifically manufactured to be used on this machine On the other hand handling the specimen in and out of the testing machine is demanding Furthermore this structure cannot be used at the bottom side of the machine A i FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 10 1 3 Idea Hydraulic press from test specimen side 1100kg vekslende Figure 20 Hydraulic press from the side Restricted by the low budget for the project the group started to look for a very simple cheaper and more user friendly fastening mechanism The concept has been adopted from the most used fastening mechanism in fatigue testing that use a hydraulic cylinder The structure contains a simple hydraulic press with a gripping clamp fixed to press cylinder The press is handled manually though a l
130. to run as fast they get another needed signal When this is done the cycle for compression has begun A s FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 Gate Q on SR1 gives signal 1 to the relay to side A on valve When the pressure sensor1 has reached its configured value it gives signal 1 to the AND3 gate and the AND3 gate sets SR2 while it resets SR1 The OR1 and 2 is there to secure that none of the SR NOR gate latches resets the other Now the side B of the valve is initiated and the tension part of the cycle has begun When the pressure sensor 2 reaches its configured value it sends signal 1 to AND2 gate AND2 then have both the needed signals to send signal 1 to set on SR1 and goes through the OR2 gate to reset SR2 The compression part of the cycle starts again This is what happens inside the PLC until either the test specimen breaks or the operator press emergency stop When one of the stop devices is pushed it breaks the circuit to the SR3 gate Since R is inverted the reset is initiated on SR3 and signal 1 is sent out from Q not to OR gate 1 and 2 The OR gates now resets both SR1 and SR2 and the cycling stops It stops because without a signal to one of the sides on the valve the valve is center positioned and no pressure goes to the hydraulic cylinder All of the stop devices are also connected to the contactor which controls the electrical power of the hydraulic pump The stop devices brea
131. tributed in the stabilizer bar Maximum displacement occurs in the lower part of the bracket show on the figure The displacement has a maximum value of 0 05236 mm gt FIR PP ZN H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 7 7 POM C guide bushing Figure 19 POM C guide bushing The POM C in the figure has the task to provide a tight fit along the guide rods that insures that the test specimen is subjected to axial loading only The low friction POM C allows the stabilizer bar to glide smoothly on the guide rods The bushing forms a cylindrical tube with the dimensions diameter x height of 40x80 mm The center of the POM contains an extruded cut of 20mm Properties POM C Standard Unit Value Color Black Weight ISO 1183 g cm 3 1 41 Tensile strength DIN 53455 N mm 2 65 E module DIN 53457 N mm 2 3000 Elongation DIN 53455 D 35 Hardness scale D ISO 1183 81 Operation temperature permanent C 40 90 Operation temperature brief 160 Melting point ISO 3146 C 160 Tolerances expansion ASTM D696 mm m C 0 09 Coefficient of friciton On steel 0 32 Vapor admission at 23 degrees C ISO 1110 0 20 Water admission at 23 degrees C ISO 62 0 25 Table 2 POM C technical data 3 2 A FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 7 8 Upper specimen fixture To be welded on the upper frame Figure 20
132. ts and do the easier increments at the end We come up with a solution for each increment evaluate the solution and work through it again and again until we are satisfied By doing this we hope to see our flaws and correct our mistakes and also improve some aspects of the project Analyses and requirement specification Design FEM analyses and manual calculations Figure 1 Incremental development H GSKOLEN i Buskerud Fatigue Test Rig Project plan rev 2 0 6 0 Risk analysis In a project such as this there are several factors that can jeopardize the progress of the project and the final product It is important to know these factors so that the effects of any risk can be reduced or avoided 6 1 Fail in exams As the project group consists of three students who not jet have passed the necessary exams there is a possibility that one or more of the group members fail and they are not allowed to continue the project If this occurs BUC must decide what action to take Possible solutions may be that either the project can be scaled down to match the remaining group members the project cannot be done or project members have to be placed on other Bachelor projects High risk High consequences 6 2 Loss of data In a scenario there could be a crash in one of the group members computer or on the server or there could be an infection with a virus It is important to back up every document in at least 2 places W
133. ure 39 Stress analysis locking bolt 5 5kN A FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 Min 0 173 Max 16 066 Figure 40 Stress analysis locking bolt 11kN Figure 41 Stress analysis locking bolt 5 5kN The stress analysis of the bolt shows a maximum stress of 16 0 Mpa around the middle of the bolt To ease the analysis in the software the bolt is divided into three parts The analysis illustrates the cylinder pulling with a force of 11kN at the center of the bolt The illustration on the left and the right hand side of the figure shows the section of the bolt which is fixed to the lower specimen fixture These parts is subjected to a maximum stress of 8 2 MPa A FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 Displacement e Max 3 628e 004 Figure 42 Displacement analysis locking bolt at 5 5kN Min 1 000e 030 iz Max 7 575e 004 Figure 43 Displacement analysis locking bolt at 11kN A FIR H GSKOLEN i Buskerud Fatigue Test Rig Technical document rev 1 0 4 es Min 1 000e 030 max 3 628e 004 Figure 44 Displacement analysis locking bolt at 5 5kN The displace analysis of the bolt shows a maximum displacement of 0 00075mm at the middle of the bolt The analysis illustrates the cylinder pulling with a force of 11kN at the center of the bolt The illustration on the left and the right ha
134. xXxp x 10 13 5 x 60 x 10 8100N Figure 32 inside of a double rod cylinder A FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 As shown in the calculations the force is equal If used this double rod cylinder simplifies the hydraulic scheme and there will not be needed a pressure reducer 15 0 Final concept manual switches 15 1 manual emergency stop button Figure 33 Manual emergency stop button 19 The wanted solution for a manual emergency stop button is a standard push and hold button which you turn to unleash It is going to be used as a safety precaution if something happens and the rig needs to be manually stopped 16 0 Automatic emergency trigger switch The automatic emergency stop button is needed to ensure that when the test specimen breaks the whole test rig and hydraulic pump stops The group has looked at different solutions for a emergency stop for this occasion i FIR H GSKOLEN i Buskerud Fatigue Test Rig Concept round 2 rev 2 0 16 1 Idea Automatic emergency trigger switch Figure 32 automatic emergency trigger switch 21 The automatic emergency trigger switch has as purpose to stop the hydraulic pump and rig The switch is triggered when the stabilizer bar hits the trigger It then cuts the power in the pump and stops the rig 16 2 Concept Automatic emergency rope pull Figure 32 automatic emergency ropes pull 21 This is placed o
135. y because of the time spared These tests can detect hidden failures or defects without destroying the material Typical tests of nondestructive testing include x ray magnetic particle inspection ultrasound etc Destructive testing gives an overview of the material properties By using the destructive tests like tensile testing hardness testing or fatigue testing information as strength of material can be known The testing our machine offers is fatigue testing a destructive test where the test specimen breaks off to end the test A FIR H GSKOLEN 8 i Buskerud Pre EOS H GSKOLEN i Buskerud Department of Technology Kongsberg Title of document Requirement specification Version 2 0 Course code name SFHO3200 H11 Hovedoppgave med prosjektstyring Group members Espen S tre Kolberg Kjetil Haugmoen Kj ndal Internal Supervisor Jamal Safi Date 29 05 12 We confirm that the submitted assignment is entirely our work Espen Kolberg Kjetil Kj ndal Fatigue Test Rig Requirement specification rev 2 0 Table of contents 1 0 Document history cidad atacadas 3 2 Q guru DET 4 3 0 INtroquctlo intacto 4 4 0 Requirement definitions csse tc toco ege EAR deed 5 5 0 Requirements eoe teet eere ees beso esu to eei eee ege eed A ertet 6 5 1 Functional requirements c teta rss s 6 5 2 Systemirequiremients seedet edda 7 5 3 Result Dn EE 8 SW dl ell et dE Tt EE 9

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