an introduction to fatigue testing equipment, test setup...
TRANSCRIPT
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An Introduction to Fatigue Testing Equipment,
Test Setup & Data Collection
Lisa Goodwin Servohydraulic Sales Specialist & Market Manager - Instron
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Themes..
• Certainty of Measurement • Repeatability of Measurement • Safety & Legislation • Usability & User Experience
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Things to cover...
• Fatigue Testing Basics: • Why Servo-Hydraulic? • The key components of a servo-hydraulic system. • The working principle behind an actuator. • Factors which effect performance. • Sensors and control. • User Interfaces.
• Test Setup & Data Collection: • Grips and fixtures for fatigue. • Data collection and processing. • Advancements. • Alternatives to Servo-Hydraulics for fatigue
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Servohydraulic System Setup
Hydraulic Power Unit (HPU)
Controller
Manifold + Servo-Valve
Actuator & LVDT
Load Frame
Flexible Hoses
Load Cell
User Interface PC/Software
Test Area
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Why Servohydraulic(SH)? • Low compressibility allow for a stiff and dynamic actuator
system. • Very smooth and efficient for linear movement. • Provide a ‘compact’ way of achieving high forces. • Versatile performance just by configuring the system
components. • Reliable test machines which can be in use for 30 years or
more! • Good for Fatigue testing, particularly metals, where we want
to test many cycles usually at high frequency.
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Standard SH System
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Hydraulic Power Supply • Responsible for providing High pressure(207 bar) oil for the
test system • Characterised mainly by the flow of oil they can provide in
litres/min. • Pressurised fluid energy generates heat
– requires cooling • Power Consumption – 3 phase
• Notes:
• Cooling - Air or Water • Acoustic Attenuation • Pressure Accumulation • Flexible Hoses • Filtration & Oil Maintenance
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Actuator, Servo-valve & Manifold
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Hydraulic Actuators
• A simple piston with two chambers.
• Actuator movement is caused when the oil pressure in the two chambers is not equal.
• Controlling the flow/pressure of oil in each chamber controls the actuator movement.
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Bearing Types Labyrinth or ‘Plain’
Hydrostatic
•Standard for many suppliers •Mechanical Movement draws lubrication in •Can be damaged by sideloads!
•Uses 4 ‘pads’ of hydraulic oil keep the piston rod central and lubricated inside the bearing. •Increases in sideload result in increased resistance from pressure pads. •Less friction in the bearing
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Hydraulic Manifold
• A hydraulic ‘circuit’ machined from a single block.
• Allows hydraulic components to be attached easily. Most commonly, SVs, Accumulators and Hoses.
• Simplifies build process. • Reduces build time. • Gives predictable performance.
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Servo-Valves
• 5 l/min •10 l/min •20 l/min •40 l/min •65 l/min
•Dual Servo-Valves!
•Control the quantity and direction of fluid flow into the actuator. •Controlled by a small electrical voltage generated by controller. •Characterised by the amount of oil that can flow through them.
•‘Big’ (high flow)SVs : Good for high frequency / large amplitude •‘Small’(low flow) SVs: Better resolution for small amplitudes
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Hydraulic Actuator Operation
Bearing Assemblies
Piston Rod Piston Seal
Piston
Effective Area
Manifold
“Servo-Valve”
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Achieving Higher Forces & Performance?
• In our systems we assume the pressure of the oil is constant, normally 207Bar
• If we want to achieve higher forces then we have to increase the ‘effective area’ of the actuator.
• Increasing the piston area means we need more oil flow to maintain the same performance.
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Oil Flow, Pressure & Performance
• To move the actuator quickly, we need more oil flow • Oil flow is measured in litres/min e.g. 48l/min HPU • Flow can be limited by HPU, hoses, manifold or SV.
• Pressure is measured in Bar/Psi e.g. 207Bar/3000psi HPU
• We ‘assume’ pressure is constant. We said that we need more piston area to achieve higher forces.
• When a lot of oil is flowing, pressure drops can occur between the HPU and the actuator.
• Predicting Performance • There is a trade off between frequency, amplitude and force! • Performance Plot!
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Sensors & Control
Force Position
Loadcell LVDT
Strain
Extensometer COD Gauge
Strain Gauges
Compliance Strain
Application Specific – Analog 0-10V System Supply
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Sensors & Control Digital Control System
• Expandable or fixed architecture • Safety circuits
• Signal Conditioning • Automatic Transducer recognition & calibration • Transducer signal conditioning
• Waveform Generation • Data Acquisition
• 5/10kHz • Control System
• Closed loop control • Advanced control techniques • 5/10kHz loop closure and update
output
PID Machine Command Error drive
Feedback
+ -
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Load Frames Load Reaction Frame • Frame designs based on their dynamic load rating • Frame stiffness is important! • Actuator position is configurable (base or crosshead)
• Handset for test setup and specimen
installation • Hydraulic crosshead lift – adjust Test space • Actuator jog • Emergency stop button
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Principle of Operation
Hydraulic Pump Test Frame
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Principle of Operation
Hydraulic Pump Test Frame
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Principle of Operation
Hydraulic Pump Hydraulic Actuator Servo Valve & Manifold
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Principle of Operation
Hydraulic Pump
Hydraulic Actuator
Servo Valve
Control Unit, closed loop control
LVDT feedback
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Principle of Operation
Hydraulic Pump
Loadcell feedback
Servo Valve
Control Unit, closed loop control
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Principle of Operation
Hydraulic Pump
Extensometer feedback
Servo Valve
Control Unit, closed loop control
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User Interface - Software
• System Setup Software • Sensor Calibration • Loop Tuning • Sensor Limits
• Live Sensor Feedback
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Application Software • Application Specific Software
• General Purpose Static & Fatigue • Fracture Mechanics – da/dN, JIC, KIC, R-Curve, CTOD • LCF, TMF etc
• Waveform Generation, Test Control & Monitoring
• Stress-Life or Strain-Life Data Crack Growth & Fracture Toughness
0
10000
20000
30000
40000
50000
60000
0 0.5 1 1.5 2 2.5 3
COD (mm)
Load
(N)
0
2
4
6
8
10
12
14
16
18
20
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
Load Line Displacement (mm)
Load
(kN)
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Servohydraulic System Setup
Test Area
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Test Setup & Data Collection
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Grips & Fixtures for Fatigue • Standard attachments sized for actuator capacity
• Pre-load for reverse stress testing
1000°C Split Furnace
Reverse Stress Pullrods
1000°C Extensometer
High Cycle Fatigue (HCF) Low Cycle Fatigue (LCF)
Alignment Fixture
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Grips & Fixtures for Fatigue • Fracture Mechanics
SENB Bend Specimen Setup
CT Specimen Setup
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Test Setup & Run Procedure
1 Install Appropriate Grips/Fixtures - Pre-load (reverse stress) - Alignment checks
2 Calibrate & Balance Sensors – Load & Strain
3 Install Specimen
4 Loop Tuning - PID - All channels used in the test
5 Set Test Limits - Protect travel of sensors - Appropriate for test conditions
6 Program Test Method
7 RUN TEST
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Live Test Monitoring • Live graph editing – freedom to edit at any time • Progress indicators – instant status feedback
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Intelligent Data Processing
Raw Data
Data Processing
Enable
Vector of data Position Load Strain Cycle count
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Intelligent Data Processing
Raw Data
Data Processing
Enable
Trend
Track
Peaks Vector of data Position Load Strain Cycle count
Discarded Vectors
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Calculating Additional Test Data
• Additional Calculated ‘channels’
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Advanced Control Modes • Run tests not previously possible..
• Use calculated channels as control targets
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Alternatives to SH Actuator Drive Systems • Pneumatic Actuators
• Air is very compliant/compressible • Limited to static or low force, slow cyclic
• Resonance systems • Sinusoidal waveforms only • Short Stroke • Fixed Frequency – capable of high frequency • Essentially open loop control
• Preloaded Ballscrew Actuator • High precision low speed static, slow cyclic
• Direct Drive Linear Electric Motors • Long stroke • Closed loop control • Cyclic testing • No oil!
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Linear Electric Motor Fatigue System
Controller
Actuator & LVDT
Load Frame
Load Cell
User Interface PC/Software
Test Area Power Amplifier
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Drive System Comparisons Drive Applications Pros Cons Servo hydraulic HCF
Static LCF & TMF Fracture 5kN to +10MN
Highly configurable Tried & tested Long life
High Energy consumption Maintenance costs
Pneumatic Low Force Low cost Clean & quiet
Air is compliant/compressible Control challenges
Resonance Drive HCF Fracture Sinusoidal only <1MN
Low Energy consumption Very high frequency
Short stroke Fixed frequency Low accuracy Sine waveforms only
Direct Drive ServoElectric Ball Screw
LCF TMF Static <250kN
High Precision Slow Speed Control Low Energy Consumption
Limited to slow speed tests only
Direct Drive Linear Electric Motors
HCF Static Fracture <15kN
No Oil Low maintenance Quiet Easily relocated
Low force Control challenges
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Wrap Up..
• Fatigue Testing Basics: • Why Servo-Hydraulic? • The key components of a servo-hydraulic system. • The working principle behind an actuator. • Factors which effect performance. • Sensors and control. • User Interfaces.
• Test Setup & Data Collection: • Grips and fixtures for fatigue. • Data collection and processing. • Advancements. • Alternatives to Servo-Hydraulics for fatigue
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Questions?