CRACKTRONIC. Resonant testing machine as table model for dynamic bending load applications testing frequencies Hz

Transcription

1 CRACKTRONIC Resonant testing machine as table model for dynamic bending load applications testing frequencies Hz RUMUL RUSSENBERGER PRÜFMASCHINEN AG

2 CRACKTRONIC Dynamometer Torsion rod Specimen Armature of the exciting magnet General Mainly two observations in dynamic material testing were the reasons to develop the CRACKTRONIC A high number of tests are done with low loads For bending load tests instead of axial loading (tension/compression) such a small and low cost machine is favorable. In addition a lot of tests are to be done on small specimens. Evaluations of fatigue crack growth rates are comfortably done with our crack length measuring system FRACTOMAT and our SOFTWARE. Functional description The kinematic conditions allow a pure bending between the gripping heads. An electromagnetic driven resonator, built as a rotary oscillator, creates an appropriate bending moment. Independent to the dynamic drive a static moment is possible to be applied to the specimen via a torsion rod. Main applications Fatigue tests / S/N-diagrams Fatigue crack growth / da/dn-curves Precracking of fracture mechanic specimens also in «hot cells» manufacturing quality control in connection with special customtailored devices

3 CRACKTRONIC Machine design The CRACKTRONIC is used for many different testing applications where an easy and fast change of mounted gripping heads is essential. Due to a conceptual separation of the testing machine into a basicmodule with all drives and easily mountable gripping heads for the specimens a change of the gripping head can be done within a few minutes. Each gripping head contains a complete fixation with an adequate sensor and measuring preamplifier. Control conception The RUMUL control unit CREDO is designed as a compact adaptive testing system. The twin computer concept allows a consequent separation in functions. The operating system runs under WINDOWS. All measuring data are processed on-line by the main control program in the process computer. Essential features of the mechanical conceptions are beside the modular design the adjustable magnet which gives much more flexibility for testing soft specimens and to realize custom-tailored solutions at cost-saving conditions (for components, hot cell, corrosion, etc.). The CRACKTRONIC is equipped with the control unit CREDO and a PC workstation to operate the easy to use RUMUL software. Gripping head for «hot cell» Gripping head for sheet metal tests Examples of specimens Gripping head for customer designed specimen

4 CRACKTRONIC SOFTWARE-PROGRAMS Fatigue tests Due to the low power consumption (approx. 5 W) and the high testing frequencies the CRACKTRONIC is well suited for fatigue tests. In connection with the RUMUL SOFTWARE different evaluation methods are available; arc sin p Transformation Weibull procedure Perlschnur (regression) stair case method Arc sin p Transformation There are integrated diagram-functions as well as ASCII-files for customer made evaluation software available. History-record frequency drop Precracking If fracture mechanics specimens need a fatigue crack (precrack), the CRACKTRONIC is the best solution for precracking of small specimens. The RUMUL SOFTWARE supports the precracking procedure efficient and reliable. The SOFTWARE takes care to reach the final cracklength in several loadsteps to make sure that the procedure is in accordance with standards. Frequency drop / load adjustment

5 CRACKTRONIC SOFTWARE-PROGRAMS Fatigue crack growth The CRACKTRONIC, appointed as a cyclic load system for bending specimens, combined with KRAK GAGES and the crack measuring system FRACTOMAT are an ideal configuration for receiving da/dn data. The machine is able to be controlled manually via the cracklength indicated on the FRACTOMAT. In connection with a PC and the RUMUL SOFTWARE an automated testing procedure (i.e. Threshold) is on disposal. The operator is free to change test modes at any time in order to receive new stress intensity values. The current da/dn curve is on display during the test. FRACTOMAT Applied KRAK GAGE da/dn diagram Examples for KRAK GAGES

6 CRACKTRONIC Bending tests mounted gripping head for specimens up to 10x10 mm 160 Nm mounted gripping head for specimens up to 12x24 mm Bending tests on metal sheet Tension/compression tests mounted gripping head for specimens CT 1 4 Torsion tests mounted gripping head for torsion tests

7 CRACKTRONIC Mini-Charpy specimens adapter pieces for mini specimens 3x4x27 mm or customized shapes Technical specifications max. bending moment: 160 Nm max. dyn. bending moment: 160 Nm max. stat. bending moment: 100 Nm max. tension load (with tension/compression module): 8 kn max. testing frequencies (depending on the mounted head): max. oscillating angle (depending on the mounted head): max. specimen dimensions for bending: up to 250 Hz, in steps ± 3, adjustable 24x12x120 mm Dimensions: BxHxT machine: 50x20x32 cm control panel: 50x32x37 cm Weights: machine: 50 kg control panel: 30 kg Power supply: 230 V / 6 A Options: gripping heads for bending up to 160 Nm device for torsion tests on round specimens (clamping 14 mm / 24 mm) or square shapes gripping head for tension/compression up to 8 kn machine controlled by the oscillation angle (analogous to stroke control mode in tension/compression tests)

8 Other well proven RUMUL products Resonant System SWINGER efficient equipment for alternating bending load Resonant Testing Machine TESTRONIC 50/100/150/250 kn Crack Length Measuring System FRACTOMAT for measuring cracks in fracture mechanics Resonant Testing Machine MIKROTRON 5/20 kn RUMUL RUSSENBERGER PRÜFMASCHINEN AG Gewerbestrasse 10/Rundbuck CH-8212 Neuhausen am Rheinfall Switzerland Telephone Telefax Homepage

9 MIKROTRON MIKROTRON resonant testing machine Resonant Pulsator MIKROTRON for loads up to 20 kn dynamic stroke up to 4 mm and operating frequencies up to 250 Hz

10 MIKROTRON General The MIKROTRON testing machine combines a simple and well thought-out design with a modern and user-friendly control system. Many decades of experiences in the design and manufacturing of resonant systems and also the knowledge of the requirements of our customers allow to achieve a high level of reliability in a wide field of applications. Due to the unique resonant system, the pulsator is able to work in an operating frequency range between 50 and 250 Hz in consuming a significant low power of less than 0,5 kw. The MIKROTRON is well established in R&D, quality control and other testing fields. Characteristical features of all the resonant type testing systems are: High reliability No maintenance for valves, pumps or cooling Easy operation Fast testing procedures due to high operating frequencies Low energy consumption Software with many practical and user-friendly functions Legend 1 Magnet for dynamic drive 2 Cross head 3 Oscillating springs 4 Oscillating mass 5 Columns 6 Specimen / component 7 Load cell 8 T-slotted table as counter mass 9 Gear drive for static load 10 Ball screw spindle Function The diagram shows the drive for the static load in the lower machine frame and the dynamic drive (magnet) in the upper part of the machine. The effective load on the test piece is generated by the two drive systems, controlled and adjusted independently. The unique design of the MIKROTRON resonant system results in an outstanding large oscillating stroke of +/- 2 mm and still a light machine which does not require special foundations. Control concept The well established dual computer approach ensures a clear and easy to understand Windows-based user environment, while the embedded device is running a powerful and robust Linux operating system to control all machine tasks in parallel. Latest technologies like digital signal processing, FPGA integration (Field Programmable Gate Array) etc. have been used to achieve a most reliable control system with best long-term stability. The new and comprehensive self-diagnostic function informs the operator about unusual events or inappropriate manipulations and therefore helps to avoid damages. If necessary the user can individually adjust all control parameters. This is especially useful with complicated or difficult measurement setups. The RUMUL application programs running on the Windows computer use a RS 232 or an Ethernet (TCP / IP) link to communicate with the machine. Networking features like remote access, remote maintenance etc. are prepared. Frequency response The diagram shows the frequency behaviour of the MIKROTRON, 20 kn version, depending on the stiffness of the specimen. In order to vary the frequency within the drawn range, the oscillating mass (4) needs to be changed. RUSSENBERGER PRÜFMASCHINEN AG Gewerbestrasse 10 info@rumul.ch CH 8212 Neuhausen am Rheinfall Tel Fax

11 MIKROTRON Applications The main applications for resonant testing machines are tests with a large number of load cycles. The machine is designed to run dynamic loads at frequencies up to 250 Hz in consuming power below 0.5 kw. This is a fraction of power compared to servo-hydraulic systems. No maintenance for pumps, valves and cooling results in a most economical solutions for: fatigue tests in R&D and quality control fatigue crack growth investigations (fracture mechanics) K-Threshold determinations (fracture mechanics) precracking of fracture mechanics specimens Two-masses-system (simplified view) Resonance curve Dynamic drive (Resonant) The dynamic part mainly consists of the mass m 1 (4), the counter mass m 0 (8), the elasticity c of specimen (6) and all other elasticities and masses within the dynamic load flow. These parts form the oscillating system which is controlled and excited with MAGNODYN in its resonant frequency. Static drive The static load (mean load) is applied by a ball spindle with a preloaded doublenut, which is driven by a low-backlash gearbox and a servomotor. Load measurement The load is measured by means of RUMUL load cells which have proved their reliability over many years. Their features are very high stiffness to tensile, compressive, bending, shearing and torsion loads. The load cells may be fixed either on the upper cross beam or on the T-slotted table. The lower position may be of advantage in using a high temperature furnace, while the upper position is preferred when testing components. They are fitted with a built-in acceleration transducer for the compensation of the inertia forces resulting from oscillating gripping devices. RUSSENBERGER PRÜFMASCHINEN AG Gewerbestrasse 10 info@rumul.ch CH 8212 Neuhausen am Rheinfall Tel Fax

12 MIKROTRON RUMUL Software Main features of the RUMUL Software: Different procedures in displaying, controlling and storing the relevant data History function for a complete documentation of a test Integration in a local network with additional mail function Extensive On-Line help system Scope function for enhanced monitoring facilities User-friendly and save operation of the testing machine via the graphic display and mouse Automatic adjustment of the machine parameters Automatic compensation of the mass forces generated by oscillating gripping heads Remote control of the machine in set-up mode Practically orientated functions for comfortable operation and test management Integrated process know-how from decades of experiences Different possibilities for data analysis Extended fatigue test A wide range of different data are recorded during a fatigue test. The user can determine the type of data and the intervals for reading data. These data include information related to the damage process of the specimen or component and allow a more extensive analysis than a standard fatigue test. A history function with a graphic display records continuously data and shows to the user the immediate state of the test. All test data are in ASCII-files. Fatigue crack growth The test procedure is based on the standard ASTM E647. The machine is indirectly controlled by the stress intensity continuously calculated from the cracklength. Different standard types of fracture mechanic specimens and several methods of cracklength measuring are supported by the software. Precracking of fracture mechanic specimens The program automatically reduces the load according to the cracklength without additional instrumentation. The precracking procedure is simply to adapt, so all standards can easily be met. Block test The test is basically a fatigue test with different load horizons (blocks) within the test. A sequence up to 100 blocks can automatically be repeated. Universal program ProTest This free programmable software with an optimized command set opens a wide range of features to carry out special tests, e.g. extremly low loading rates, communication with robots, control of corrosion pumps and environmental chambers. A fiberoptical communication interface OPTOTRON is also available. RUSSENBERGER PRÜFMASCHINEN AG Gewerbestrasse 10 info@rumul.ch CH 8212 Neuhausen am Rheinfall Tel Fax

13 MIKROTRON Gripping devices The RUMUL clamping system ensures a clear, nonpositive force transmission and a perfect alignment for the specimen. Threads on 10 or 20 kn loadcells: M22x1 M16x1 M10x1 M10x1.5 Threads on 5 kn loadcell: M10x1.5 M6 M4 Other dimensions on request Specifications Version 5 20 kn Daten Max. peak load: 5 20 kn Max. static load tension or compression: 5 20 kn Max. dynamic load: 5 (± 2.5) 20 (± 10) Operating frequencies: Hz Number of frequency steps: 4 5 Max. stroke: 4 (± 2) 4 (± 2) mm Measuring accuracy Dynamic: < 0,5 % < 0,5 % Static: < 0,5 % < 0,5 % Speed of the static drive: Machine weight: Power requirements: mm / min 600 kg 1x 230 V / 10 A RUSSENBERGER PRÜFMASCHINEN AG Gewerbestrasse 10 info@rumul.ch CH 8212 Neuhausen am Rheinfall Tel Fax

14 MIKROTRON - special tools TESTRONIC - Spezialgeräte Hydraulic gripping heads HYDROGRIP 3-Point-Bending with COD measuring Torsion device ± 350 Nm Fatigue test on elevated temperature (Induction heating) 4-Point-Bending ±100 Nm RUSSENBERGER PRÜFMASCHINEN AG Gewerbestrasse 10 info@rumul.ch CH 8212 Neuhausen am Rheinfall Tel Fax

15 MIKROTRON - applications Fatigue test on a toothed wheel Fatigue test on a component from the car industry Test on saw chain Fatigue test on roller finger follower RUSSENBERGER PRÜFMASCHINEN AG Gewerbestrasse 10 info@rumul.ch CH 8212 Neuhausen am Rheinfall Tel Fax

16 M. Härdi, Gestalter FH / The RUMUL product family CRACKTRONIC bending / torsion pulsator TESTRONIC resonant testing machine Daten MIKROTRON resonant testing machine FRACTOMAT crack length measuring system BRAKE CONTROL brake power measuring instrument SWINGER resonant testing machine UPGRADE of old resonant testing machines RUSSENBERGER PRÜFMASCHINEN AG Gewerbestrasse 10 info@rumul.ch CH 8212 Neuhausen am Rheinfall Tel Fax

17 TESTRONIC TESTRONIC resonant testing machine Resonant testing machine TESTRONIC for loads up to 250 kn, oscillating strokes up to 8 mm and operating frequencies up to 250 Hz, equipped with the unique MAGNODYN excitation system.

18 TESTRONIC General The concept of the TESTRONIC is based on the latest possibilities in resonant machine engineering. Many decades of experiences in developing and manufacturing of resonant testing systems and also our continuous task to support our customers in their testing needs are the benefit. Characteristical features: High reliability No maintenance for valves, pumps or cooling Easy operation Fast testing procedures due to high operating frequencies Low energy consumption Software with many practical and user-friendly functions Legend 1 Main mass m 1 variable in 8 steps 2 Counter mass m 0 built as a T-slotted table 3 Specimen or component 4 RUMUL load cell, resistant to fatigue 5 MAGNODYN excitation system (original RUMUL) 6 Preload springs for static load 7 Columns of the load frame 8 Precise ball bushings 9 Travelling cross beam 10 Ball screw spindle 11 Spindle drive with servomotor 12 Damping supports (springs) Static load flow Dynamic load flow Control concept The well established dual computer approach ensures a clear and easy to understand Windows-based user environment, while the embedded device is running a powerful Linux operating system. Latest technologies like digital signal processing, FPGA integration (Field Programmable Gate Array) etc. have been used to achieve a most reliable control system with best long-term stability. The RUMUL application programs running on the Windows computer use a RS 232 or an Ethernet (TCP / IP) link to communicate with the machine. Networking features like remote access, remote maintenance etc. are prepared. Qualified functions for self-diagnosis and controller optimization are integrated. Unique features The pure elastic lateral suspension, part of the MAGNODYN dynamic drive, prevents energy-consuming transverse oscillations. Profit: More energy is available to generate the dynamic load. In order to optimize the oscillating masses, tempered aluminium has been specifically incorporated for selective parts. Profit: The frequency range is considerably widen. The design of the machine allows a consequent split of the cables for power and measuring signals. Profit: Increased accuracy of the load measuring (tests are possible in the percentage range of the nominal load). Load, strain, stroke and a combined control mode are possible. Profit: Improved flexibility to adjust the machine for critical test setups. Frequency response The resonant frequency of the machine changes with the stiffness of the specimen or component and the size of the main mass m 1. The main mass can be changed in 8 steps. In order to simplify the diagram only the upper and lower limits are indicated for the 250 kn machine. Adding masses (or reducing the resonant frequency) is done in activating integrated masses by loosening screws or vice versa. RUSSENBERGER PRÜFMASCHINEN AG Gewerbestrasse 10 info@rumul.ch CH 8212 Neuhausen am Rheinfall Tel Fax

19 TESTRONIC Applications The main applications for resonant testing machines are tests with a large number of load cycles. The machine is designed to run dynamic loads at frequencies up to 250 Hz in consuming power below 1 kw. This is a fraction of power compared to servo-hydraulic systems. No maintenance for pumps, valves and cooling results in a most economical solutions for: fatigue tests in R&D and quality control fatigue crack growth investigations (fracture mechanics) K-Threshold determinations (fracture mechanics) precracking of fracture mechanics specimens Two-masses-system (simplified view) Resonance curve Dynamic drive (Resonant) The dynamic part mainly consists of the mass m 1 (1), the counter mass m 0 (2), the elasticity of specimen (3) and all other elasticities and masses within the dynamic load flow. These parts form the oscillating system which is controlled and excited with MAGNODYN in its resonant frequency. Static drive The static load (mean load) is applied by a ball spindle with a preloaded doublenut, which is driven by a low-backlash gearbox and a servomotor. MAGNODYN excitation system This system consists of an electro-magnet and springs (elasticities) which are built-in in the dynamic load flow. Both parts work combined. The magnet needs only a small, but constant air gap, which works independent to the static load system. This allows to run comprehensive tests with independent load variations in the static as well as dynamic loops. The design of the MAGNODYN system allows to generate more active power which is directly used on the specimen or component. Load measurement The load is measured by means of RUMUL load cells which have proved their reliability over many years. Their features are very high stiffness to tensile, compressive, bending, shearing and torsion loads. The load cells may be fixed either on the upper cross beam or on the T-slotted table. The lower position may be of advantage in using a high temperature furnace, while the upper position is preferred when testing components. They are fitted with a built-in acceleration transducer for the compensation of the inertia forces resulting from oscillating gripping devices. RUSSENBERGER PRÜFMASCHINEN AG Gewerbestrasse 10 info@rumul.ch CH 8212 Neuhausen am Rheinfall Tel Fax

20 TESTRONIC RUMUL Software Main features of the RUMUL Software: Different procedures in displaying, controlling and storing the relevant data History function for a complete documentation of a test Integration in a local network with additional mail function Extensive On-Line help system Scope function for enhanced monitoring facilities User-friendly and save operation of the testing machine via the graphic display and mouse Automatic adjustment of the machine parameters Automatic compensation of the mass forces generated by oscillating gripping heads Remote control of the machine in set-up mode Practically orientated functions for comfortable operation and test management Integrated process know-how from decades of experiences Different possibilities for data analysis Extended fatigue test A wide range of different data are recorded during a fatigue test. The user can determine the type of data and the intervals for reading data. These data include information related to the damage process of the specimen or component and allow a more extensive analysis than a standard fatigue test. A history function with a graphic display records continuously data and shows to the user the immediate state of the test. All test data are in ASCII-files. Fatigue crack growth The test procedure is based on the standard ASTM E647. The machine is indirectly controlled by the stress intensity continuously calculated from the cracklength. Different standard types of fracture mechanic specimens and several methods of cracklength measuring are supported by the software. Precracking of fracture mechanic specimens The program automatically reduces the load according to the cracklength without additional instrumentation. The precracking procedure is simply to adapt, so all standards can easily be met. Block test The test is basically a fatigue test with different load horizons (blocks) within the test. A sequence up to 100 blocks can automatically be repeated. Universal program ProTest This free programmable software with an optimized command set opens a wide range of features to carry out special tests, e.g. extremly low loading rates, communication with robots, control of corrosion pumps and environmental chambers. A fiberoptical communication interface OPTOTRON is also available. RUSSENBERGER PRÜFMASCHINEN AG Gewerbestrasse 10 info@rumul.ch CH 8212 Neuhausen am Rheinfall Tel Fax

21 TESTRONIC Gripping devices The gripping of specimens as well as other clamping devices with threads can be done on the load cell side as well as on the opposite side. Following thread dimensions are standard: on load cells, sizes of 100 and 250 kn 2 1/2"G M60x2 M16x1 M32x1 M22x1 on load cells, sizes of 10 and 20 kn M22x1 M16x1 M10x1 M8x1 M6x1 Other dimensions on request Specifications Load capacity: kn * 1 Max. static load Daten tension or compression: /250 kn Max. dynamic load: 50 (± 25) 100 (± 50) 150 (± 75) 250 (± 125) Operating frequencies: see diagram on page 3 Number of freq. steps: Max. stroke* 2 : mm Measuring accuracy Dynamic: < 0,5 % < 0,5 % < 0,5 % < 0,5 % Static: < 0,5 % < 0,5 % < 0,5 % < 0,5 % Speed of the static drive: Machine weight: Power requirements: mm / min 3000 kg 1x 230 V / 16 A * 1 higher load capacities on request * 2 optional stroke extension available RUSSENBERGER PRÜFMASCHINEN AG Gewerbestrasse 10 info@rumul.ch CH 8212 Neuhausen am Rheinfall Tel Fax

22 TESTRONIC - special tools TESTRONIC - Spezialgeräte Hydraulic gripping heads HYDROGRIP Corrosion chamber for -25 to 120 C Furnace up to 900 C Corrosion test controlled by RUMUL Software Temperature chamber for -50 to 250 C 4-Point-Bending (alternating) +/- 700 Nm RUSSENBERGER PRÜFMASCHINEN AG Gewerbestrasse 10 info@rumul.ch CH 8212 Neuhausen am Rheinfall Tel Fax

23 TESTRONIC - applications Connecting rod testing HCF testing of a gas turbine blade at ALSTOM (Switzerland) Ltd. Fatigue test on a turbine wheel at MTU Flange system (Quick acting system) Torsion test on a component RUSSENBERGER PRÜFMASCHINEN AG Gewerbestrasse 10 info@rumul.ch CH 8212 Neuhausen am Rheinfall Tel Fax

24 M. Härdi, Gestalter FH / The RUMUL product family CRACKTRONIC bending / torsion pulsator TESTRONIC resonant testing machine Daten MIKROTRON resonant testing machine FRACTOMAT crack length measuring system BRAKE CONTROL brake power measuring instrument SWINGER resonant testing machine UPGRADE of old resonant testing machines RUSSENBERGER PRÜFMASCHINEN AG Gewerbestrasse 10 info@rumul.ch CH 8212 Neuhausen am Rheinfall Tel Fax

25 FRACTOMAT and KRAK GAGES A crack length measuring system for tests in fatigue and fracture mechanics RUMUL RUSSENBERGER PRÜFMASCHINEN AG

26 Crack length evaluation unit FRACTOMAT FRACTOMAT General Measuring the crack length is in vast number of tests in fatigue or in fracture mechanics a very important procedure. The test configurations require a high accuracy of the received results. The crack length measuring system FRACTOMAT in combination with the KRAK GAGES offers all this in providing a simple and accurate method. Some experience in bonding strain gages is needed in order to apply the KRAK GAGES in a proper manner. The high signal voltages guarantee a trouble free and stable system. Analog and digital outputs enable setups with any testing machines. Functional description The crack length measuring system works on the basis of the indirect potential drop method and indicates the measuring value continuously. It produces an accurate result of the crack length and can also be used to control the propagation of the crack. The KRAK GAGE is used as measuring transducer. Its structure is based on a constantan layer and an electrically insulating backing. The KRAK GAGES are being bonded as a strain gage onto the specimen and then connected to the FRACTOMAT. The applied KRAK GAGE-materials guarantee a synchronous propagation of the crack in the gage as well as in the specimen. The FRACTOMAT supplies a steady output signal which is proportional to the crack length. The KRAK GAGE is supplied with a constant current. Depending on the crack length, a potential difference of U o + U is being generated. Due to a suited geometry of the gage the relationship between crack length and potential is strongly linear, independent of size, shape and conductivity of the specimen. For the nominal crack length of the KRAK GAGE, the gage output is 100 mv. This value is at least in the order of 100 times higher than the conventional direct potential drop method, in which an enormous current conducts. Significant features Independent of size, shape and materials characteristics of specimen or component No need of electrically insulated grips Linear reference between crack length and potential difference Elevated potential difference, therefore trouble free Same calibration curve for all sizes of KRAK GAGES Continuous measuring and control signal Suitable in corrosive medium Working range from 50 C up to +150 C Analog output for registration or external converters Bonding of KRAK GAGES same as strain gages Clear separation of the functions gives simple and safe handling Elementary diagram 1 KRAK GAGE 2 Source of constant current 3 Differential amplifier 4 Compensating amplifier 5 Compensating voltage

27 FRACTOMAT Specifications Standard version 1:1 KRAK GAGES Number of channels: 2 System output (100%): 10 V Accuracy better than: +/ 1% Resolution: infinite Bonding: same as strain gages Limit detectors: 2, for selectable measured values Dimensions: mm Power: 230 V / 50 Hz Weight: 4 kg Options: BCD output RS 232 Application on RUMUL resonant testing machines Applications on RUMUL resonant testing machines enable direct recording of the crack length or controlling of the load conditions according to the cylic stress intensity continuously calculated from the crack length. * * * * Standard sizes (ex stock) The figure in the type designation A05, A10, B20 a.s.o stands for the nominal crack length (max crack length) of the KRAK GAGES Various KRAK GAGES special versions on request

28 Other well proven RUMUL products Resonant System SWINGER efficient equipment for alternating bending load Resonant Testing Machine TESTRONIC 50/100/150/250 kn Table size pulsator CRACKTRONIC for axial, bending and torsional loading up to 160 Nm. Resonant Testing Machine MIKROTRON 5/20 kn RUMUL RUSSENBERGER PRÜFMASCHINEN AG Gewerbestrasse 10/Rundbuck CH-8212 Neuhausen am Rheinfall Switzerland Telephone Telefax Homepage Stamm 09/2003

29 RUMUL Software for applications on dynamic testing systems RUMUL RUSSENBERGER PRÜFMASCHINEN AG

30 RUMUL Software RUMUL Software Special features in the RUMUL Software with graphic display clearly arranged display structure operating system WINDOWS-NT different procedures in displaying, controlling and storing the relevant data extensive On-line help system integration into network with mailing functions available scope function for enhanced monitoring facilities user friendly and safe operation of the testing machine via the graphic display and mouse automatic setting of the resonant testing machine via program automatic compensation of the mass forces generated by oscillating gripping heads qualified remote control of the machine in set-up mode easy self-installation of program modules various evaluation methods for different tests are available customized or adapted software on request PC configuration Structure of the Software The software provides an easy to use and easy to understand operating surface and guides the user in a dialog through the single program procedures. The user has a number of different possibilities in order to choose and to display the test parameters, to monitor the machine as well as the ongoing test and to define different program reactions. An extensive On-line help system supports the easy use of the program. The data which have been produced are convertible (ASCII-code) and therefore available to work with in customary programs such as EXCEL or WINWORD. The program is structured to calculate and classify the appropriate set values automatically. Function and use of every single program is described in detail on the next following pages of this brochure. The programs offer a wide range of flexibility on the basis of our vast experience in running tests in fatigue and fracture mechanics. In addition, we have incorporated into the basic software a mailing function which allows to connect the system to a network and thus to check the status of the current test from his office. A standard Pentium PC with operating system WINDOWS-NT is used as workstation and communicates with the process computer responsible for measuring data processing. The appropriate configuration will be considered based on customers requirements. RUMUL

31 RUMUL Software RUMUL Software Extended fatigue test Fatigue crack growth based on ASTM E 647 The tests are carried out in either load or stress control mode on specimens as well as on components. In case of crack or failure the program acknowledges a number of measuring values, e.g. the frequency drop on a resonant testing machine is a very good indication of a growing crack in the test piece. The permissible increment is chosen by the user to adapt the sensitivity to the test specific requirements. In addition four free choosable measuring channels or calculated parameters can be displayed. The program provides a feature to store intermediate results prior to the final crack. These data consist of information concerning the damage process during the test and allow to analyse the deterioration. To allow the user most universal test conditions a data file with fixed data structure is generated to be used in combination with the RUMUL evaluation software for further data processing as well as a free choosable data structure to run quite customized tests. Evaluation software With the editing function already existing measuring data can be integrated into the evaluation. protocol with project and specimen data results in tabulated or graphical form data printing evaluation based on the arc sin p-transformation with different limits of crack probability evaluation based on Weibull with informations upon the statistical values evaluation in using a regression parabola of higher degree stair case method in transition range; evaluation of Log- Gaussian distribution in fatigue strength range display of probability nets graphics can be copied into WINDOWS office-software Evaluation based on arc sin p-transformation Evaluation based on Weibull Evaluation based on a regression parabola The tests are based on a cyclic stressintensity K control. The program calculates the static and dynamic load based on the current crack length and the required stressintensity. Following methods to measure the crack length are supported by the SOFTWARE: crack length measuring system FRACTOMAT and RUMUL KRAK GAGES any analog signal (0 up to +10 V) with a free eligible calibration function compliance (displaying crack closure at F op ) manually via keyboard The value of the stressintensity is automatically given based on a eligible function which is depending on the fatigue crack growth value (default: exponential function) descending K at a constant R-ratio descending K at a constant K max descending K at a constant K mean ascending K as above constant K constant load F A test based on descending K allows Threshold -procedures. An appropriate selection of the gradient which reduces K exponentially prevents a premature crack arrest due to the plastic zone. The option K max = constant excludes a possible crack closure effect. The SOFTWARE supports six types of specimens: Compact Tension specimen (CT) Three Point Bending specimen (3PB) Round Compact Tension specimen (RCT) Center Crack Tension specimen (CCT) free defined tension specimen free defined compression specimen For the first two types of specimens the geometry functions of ASTM are applicable. All functions to each type of specimen are free to change. In particular the free defined specimens allow a customer specific use of the geometry function. Evaluation of the Paris-Line Evaluation of F op (opening) Evaluation protocols with project and specimen data tabulated results graphical interpretation with dynamic scaling generating measuring results, smoothing of graphs determination of the Paris-line in a eligible window editor to edit diagrams printer/plotter configuration RUMUL

32 RUMUL Software RUMUL Software Block test The block test is basically a fatigue test with different load horizons within the test. A sequence of a maximum of 100 load horizons (Blocks) is automatically repeated. A block is defined by amplitude, meanload and number of cycles or a hold time. Load [ kn ] Blocks Communication interface OPTOTRON The fiberoptical communication interface OPTOTRON is designed to switch electrical loads up to 3kVA directly likewise to trigger digital in/outputs. Inputs specimen informations generating blocks criteria of interrupt Sequence Blocks To control such a variety of different devices, an assortment of applicationboxes is available. Display headings such as date, test or specimen numbers current load (static and dynamic) current block operating frequency number of sequences Evaluation protocol with headings tabulated print-out Precracking of fracture mechanic specimens The operating frequency on a resonant pulsator depends very strongly on the stiffness of the specimen to be tested. The stiffness changes with the propagation of the crack, therefore the frequency change is a value of the crack length. In order to follow the known standards the test is being done in a number of load steps which correspond to the different crack lengths. The single load steps are automatically processed. Running a first precracking test on a specific type of specimen the crack length corresponding frequency drop is being determined. The data will be stored and are again available for later tests. Input test or project number specimen dimensions data on load steps and crack length Load [ kn ] Freq. [ Hz ] Frequency drop/load Crack [mm] Universal program ProTest Free programmable machine program with a reduced and for RUMUL resonant testing machines optimized command set. Easy to use due to self explaining expressions and the same display structure as the program Extended Fatigue Test. The program allows: establishing universal test programs programmable time and load cycle bases support of up to 24 in-/output devices triggering external devices over potentialfree fiberoptical interface OPTOTRON evaluation of test data by RUMUL evaluation software extensive On-line help system Due to the potentialfree galvanic isolation and the noisefree transmission any interferences or transients interfering the system or the connected external devices are avoided. Advantages of the optical fiber are: no transmission of noise or interference signals galvanical potential separation electrical isolation no danger of electrical short cuts flexibility and universal use. Advantages of the new hardware are: modular system subsequently mountable large assortment of application-boxes available integrated signal repreparation of the digitized optical signals. Applications: extended fatique tests corrosion tests involving pumps, fans, heaters, etc. into the test process (corrosion tests) data exchange with external measuring devices. Display headings such as date, test and specimen numbers etc. current load (static as well as dynamic) current load step operating frequency frequency steps (difference) OPTOTRON Fiberoptical communication interface to integrate external devices interactively to the test-procedure

33 Other well proven RUMUL products Resonant Testing Machine TESTRONIC 50/100/150/250/350/550 kn Resonant Testing Machine MIKROTRON 5/20 kn Bending/Torsion Pulsator CRACKTRONIC for bending and torsion applications 70/160 Nm Gewerbestrasse 10/ Rundbuck CH-8212 Neuhausen am Rheinfall Switzerland Telephone ++41/52/ Telefax ++41/52/ Crack Length Measuring System FRACTOMAT for measuring cracks in fracture mechanics RUMUL RUSSENBERGER PRÜFMASCHINEN AG 03/2005

34 A Fastener Application RUMUL Users: SPS, LISI, Fontana, Agrati, Brugola etc. Machine(s): Grips: Standard: Frequency: RUMUL VIBRO-Forte 500 kn RUMUL TESTRONIC 250 kn RUMUL MIKROTRON 20 kn RUMUL standard grips for fasteners customer in-house standard between 120 and 180 Hz Load Cycles: 10 Mio load cycles or failure Time per Test: 10 Mio load cycles less than 1 day! Remarks: for internal R + D purposes some tests are performed at low and at high temperatures using a RUMUL temperature chamber from -50 C up to 250 C RUSSENBERGER PRÜFMASCHINEN AG Phone Gewerbestrasse 10/Rundbuck Fax CH-8212 Neuhausen am Rheinfall/Switzerland rumul@rumul.ch IK/bm 05/2006

35 A Conrods Application RUMUL Users: DaimlerChrysler, Georg Fischer, IWK Aachen etc. Machine(s): Grips: Standard: Frequency: RUMUL TESTRONIC 150 kn RUMUL TESTRONIC 250 kn RUMUL standard grips with oil supply for conrods customer in-house standard between 120 and 180 Hz Load Cycles: 10 Mio load cycles or failure Time per Test: 10 Mio load cycles in less than 1 day! Remark: Oil supply depending on customer s requirements to one or both of the conrod eyes. RUSSENBERGER PRÜFMASCHINEN AG Phone Gewerbestrasse 10/Rundbuck Fax CH-8212 Neuhausen am Rheinfall/Switzerland rumul@rumul.ch IK/bm 05/2006

36 A Chains Application RUMUL Users: Wippermann/DE, Rexnord/DE, Reynold Chains/GB, etc. Machine(s): Grips: Standards: Frequency: RUMUL TESTRONIC 250 kn RUMUL TESTRONIC 100 kn RUMUL MIKROTRON 20 kn RUMUL standard grips for chains customer in-house standard between 60 and 120 Hz Load Cycles: 2 Mio load cycles or failure Time per Test: testing of 3 5 chains per day! Remark: frequency drop detection used to stop the test RUSSENBERGER PRÜFMASCHINEN AG Phone Gewerbestrasse 10/Rundbuck Fax CH-8212 Neuhausen am Rheinfall/Switzerland rumul@rumul.ch IK/bm 05/2006

37 A Application Injector Nozzles/Valve Needles RUMUL Users: Bosch, Siemens VDO, etc. Machine(s): RUMUL CRACKTRONIC 8 kn RUMUL MIKROTRON 20 kn Grips: Standards: Frequency: RUMUL special grips for injector nozzles and valve needles customer in-house standard between 80 and 160 Hz (depending on testing system and activated masses) Load Cycles: 10 Mio load cycles or failure Time per Test: 7-14 Mio load cycles per day! Remark: Injector nozzles are tested on the MIKROTRON system in a container filled with oil. RUSSENBERGER PRÜFMASCHINEN AG Phone Gewerbestrasse 10/Rundbuck Fax CH-8212 Neuhausen am Rheinfall/Switzerland rumul@rumul.ch IK/bm 05/2006