PB 765 2.0315

Dynamic and Fatigue Testing Systems

Intelligent testing

1 Zwick – with passion and competence Contents

Page

1

2

The Zwick Roell Group

2.1 Servo-hydraulic testing machines

4

2.2 Vibrophores

9

2.3 High-speed testing machines

12

3.1 testControl II control electronics and testXpert R testing software

13

3.2 Control Cube control electronics and Cubus testing software

17

4.1 Modernization of servohydraulic testing machines

19

4.2 Materials Testing Laboratory

19

Dynamic testing machines by Zwick

2

For over 160 years the family-run concern of Zwick Roell has stood for outstanding technical achievement, innovation, quality and reliability in materials and component testing. Zwick is the world leader in static materials testing; Zwick testing machines are used in R&D and quality assurance in more than 20 different industries. Zwick can also look back on a long tradition in the field of dynamic testing technology. It is hard to imagine a laboratory engaged in fatigue testing which is not equipped with Amsler resonance testing machines. Our servo-hydraulic portfolio is similarly being expanded step by step, while product development has embraced new technologies such as electric linear drives; all part of the significant growth in dynamic testing which Zwick has experienced over many years.

With over 1,200 employees, production facilities in Germany, the United Kingdom and Austria and branches in France, the UK, Spain, the USA, Brazil, Turkey, Singapore and China, together with agencies in 56 countries around the world, the Zwick brand is a guarantee of the highest product and service quality.

Our ‘all-purpose’ servo-hydraulic testing machines can be used for both static and fatigue loading. There is also a range of machines for high speed testing up to 20 m/s. Their unitary modular design includes testing systems up to 2,500 kN (even higher in special versions).

Dynamic testing machines at Zwick At Zwick we use various physical drive principles for our dynamic testing machines. Each has its own special advantages and areas of application, allowing us to find the optimum solution for your testing situation in line with your requirements. Vibrophores employ an electromagnetic resonance drive. This enables high testing frequencies, giving short testing times with minimal use of energy. Vibrophore resonance testing machines are available for test loads up to 1,000 kN.

3

2.1 Servo-hydraulic testing machines HA series: 50 to 500 kN Standard versions of the HA load frame in the 50 to 500 kN range have the testing actuator mounted in the lower crosshead, below the test area. They are especially suitable for test arrangements which require temperature chambers or furnaces to be installed in the test area. The position of the actuator means that it is unaffected by the rising warm air; it also prevents oil drips into the heated test area. Features • 4 standard nominal capacities from 50 kN to 500 kN • actuator recessed into the lower crosshead to minimize piston rod length • ergonomic working height • particularly suitable for integration of a high-temperature furnace or chamber • hydraulic clamping and adjustment for easy positioning of upper crosshead • safety guard to comply with EC Machinery Directive, depending on application Fig. 2: Easy change between static and dynamic test arrangements

Fig. 1: HA 100 servo-hydraulic testing machine for static tensile tests

4

Fig. 3: HA 100 for low-cycle fatigue (LCF) tests at high temperature (sample temperatures up to 1,000 °C )

HB Series: 50 to 2,500 kN Standard versions of the HB load frame in the 50 to 2,500 kN range have the testing actuator located above the test area, allowing the use of an optional T-slotted platform on the lower crosshead. This makes the HB models particularly suitable for dynamic testing of components. Features • 6 standard nominal ratings from 50 kN to 2,500 kN • convenient working height • hard-chromed columns for precise guidance of upper crosshead • hydraulic clamping and adjustment for easy positioning of upper crosshead • safety housing as required by CE Machinery Directive, depending on application • version with integrated T-slotted platform especially suitable for fatigue tests on components Fig. 2: Fatigue test on metal specimens using an HB 100

Fig. 1: HB 250 for testing elastomer panels, with temperature chamber

Fig. 3: HB 1000 for fracture mechanics investigations on aluminium with crack-propagation extensometer (inset) 5

HC Series and HC Compact: 10 to 25 kN While the HA and HB ranges are floor-standing, enabling equipment assembly at an optimum operating height, the HC range (10 to 25 kN) are table-top models and can also be positioned on a workbench, for example. A concrete base can optionally be supplied as a support. With all HC models the actuator is positioned above the test area, which is equipped with a T-slotted platform. A special feature of the HC series is the HC Compact. In this model the hydraulic power-pack is incorporated into the machine support, reducing the system footprint to a minimum. With a flow rate of 12 liters/min, special sound insulation for the hydraulic power-pack and a minimal footprint, the HC Compact is ideal for laboratory operation.

Features • 2-column frame for dynamic tests up to 25 kN • testing actuator located in upper crosshead • suitable for axial actuator, 10 kN and 25 kN • suitable for combined tensile and compression-torsion actuator with a maximum torque of 250 Nm • hard-chromed T-slotted platform and columns for tests in corrosive media • wide accessory range: temperature chamber, compression platens, specimen grips, flexure test kit etc. • optional hydraulic adjustment for easy positioning of upper crosshead

Fig. 1: HC 25 servo-hydraulic testing machine

Fig. 2: HC Compact servo-hydraulic testing machine with integrated hydraulic power pack and temperature chamber

6

Special testing solutions As well as standardized systems, Zwick also designs and produces special dynamic testing systems, so that multiaxial systems, combined tension-torsion systems, testing systems with various environments and largescale testing systems all form part of our product range

Fig. 2: Four-column HB 250 for component testing

Fig. 1: Servo-hydraulic test portal for railroad ties (sleepers)

Fig. 3: Servo-hydraulic test portal for testing aircraft components

7

Accessories for servo-hydraulic testing machines The final element in our dynamic testing product-range is the manufacture of all the required accessories. The range is constantly being expanded through a program of continuous development and the inclusion of new products, allowing us to satisfy our customers' most demanding quality requirements while continually improving the quality of our products.

Fig. 1: Servo-hydraulic testing actuators up to 5,000 kN from Zwick

C mpress Co ssssio ion on platen en

Spec cial ia al fixxtu tures

Hydrrau Hy aulilic c para pa p ara ralllllell gri r ip pss

Hydr Hy Hydr drau a liic wedg au wedg we d eg grrip ps

Fracture mec echa ec hanics fixtures

Flex Fl e ur ure te ure test st kitts st

Hig gh h-t -tem mpe pera atu ture furrna nace c s

Temp Te Temp mper eratu urre c u ch ham amb mberss

Fig. 3: Comprehensive accessory packages for all sectors and applications

Fig. 2: Zwick supplies tbe complete servo-hydraulic infrastructure (distribution units, valves, hydraulic power-packs) 8

2.2 Vibrophores Due to their design, high-frequency pulsators have so far been used exclusively as dynamic materials testing machines for determining the fatigue strength of materials and components with regard to fatigue life and fatigue limit, for example in fatigue tests to DIN 50100 (S-N curve) in the tensile, compression, pulsating load and alternating load ranges. Modern laboratories and institutes in research, training and industry increasingly find themselves confronted with frequent changes in testing requirements. The latest generation of Vibrophores (high-frequency pulsators) from Zwick can for the first time be used as both dynamic and fully-fledged static materials testing machines - and with test loads of up to 1,000 kN. This also makes them an attractive proposition for laboratories which perform predominantly static tests, as well as for those which mainly carry out dynamic tests, with only the occasional static test.

Fig. 1: Vibrophore 100 high-frequency pulsator

The intelligent testControl II measurement and control electronics have a control frequency of 10 kHz, providing rapid response to events during tests combined with a high measured-value acquisition-rate. Together with the 24-bit resolution, this enables very precise measurements. Also new is the high-quality display-equipped remote control unit which shows measurement channels and machine and test status. This simplifies the set-up procedure and enables accurate positioning of the oscillating crosshead without direct use of the PC, offering greater operator convenience, particularly when PC and testing machine are installed separately, for example in an acoustic booth

Fig. 2: Vibrophore 1000 high-frequency pulsator 9

Dynamic tests using the Zwick Vibrophore The operating principle of the Zwick Vibrophore is based on the concept of a mechanical resonator with electro-magnetic drive. The mean force is applied by displacement of the upper crosshead via the lead-screw drive, while the dynamic load is generated through an oscillating system working in full resonance mode. In this way test frequencies of up to 285 Hz are possible, provided specimens are sufficiently stiff. The two drives, for dynamic and for static testing, are controlled separately, so that any stress ratios (R-ratios) are possible. Tests can be force, displacement or strain-controlled. Because testing is in the resonance range, the Vibrophore can in addition detect developing and growing cracks in the specimen at an early stage through minimal changes in the test frequency. The signal form of the dynamic load applied always corresponds to a sine wave. The testXpert Research software provides intuitive test definition, performance and evaluation. Typical applications include fracture mechanics investigations on CT and SEB specimens, material fatigue tests and fatigue tests on standard specimens and on compo-

Fig. 1: Vibrophore 100 high-frequency pulsator 10

nents (e.g. connecting rods, crankshafts and threaded connectors), as well as quality control of components which are subjected to oscillating loads in service, such as concrete-reinforcing steel and rebars. Static tests using the Zwick Vibrophore Mechanical clamping of the oscillating crosshead and the deployment of testXpert II software transform the Vibrophore into a fully-fledged static materials testing machine. Generous connecting surfaces and ruggedly dimensioned components ensure high machine stiffness. The combination of this plus precise crosshead guidance ensures that unacceptable mechanical influences on the specimen are minimized. By using suitable additional devices, both static and dynamic testing can be performed under various environmental conditions (temperature, aggressive media), together with torsion and flexure tests. The absence of a central lead-screw allows maximum test-area variability on the new Vibrophore, enabling testing of both very short and very large components.

Fig. 2: The Vibrophore can be used for dynamic (top) and static (bottom) tests

Additional advantages and features: • can be used as fully-fledged static and dynamic materials testing machine • high test-frequencies offer short test times for high specimen throughput • resonance drive has very low energy consumption (approx. 2 % of that of servo-hydraulic testing machines) • stiff 4-column load frame, giving excellent guidance properties • clamping table at convenient working-height (800mm), with ample working area • easy to install - no ancillary units or systems (e.g. hydraulics, coolant) required • no additional vibration damping required from a structural standpoint

• maintenance-free system - wear-free components • safe, reliable operating concept - ideal for research and education • continuously controlled servo motor for fast, accurate mean-force control • high pulse-width modulation resolution (120 MHz) for high control stability and low failure liability • easy to operate via testXpert II and testXpert Research test programs matched exactly to the testing situations • easy 8-step test-frequency change by means of varying weights.

Typical Vibrophore applications

CT T speci c me men nss

Chai Ch ains ns

Ge G ear a wh wheels

Reba ba b a ars

Co onn ne ec ctiting ng rod ods

High Hi igh g -t - empe era ature re spe peci cime m ns me ns

SENB SE NB B spe p ciimens ns

Flat att spe pec ciime enss

Sc crew ws/b bol o tss

11

2.3 High-speed testing machines Strain rate up to 1,000 s-1 - the HTM range of highspeed testing machines are ideal for determining material behavior under crash loading. With a maximum piston speed of 20 m/s (72 km/h), they are even faster than the 64 km/h test speed used in the Euro NCAP frontal impact crash test. The strain rate can easily be varied by means of the piston speed, from quasi-static up to maximum speed. However, it can also be adjusted via the specimen length. The relationship (dependent on specimen length lO and speed v) is as follows:

The HTM 5020 is the most versatile machine in the range. Rated at 50 kN and with a maximum piston speed of 20 m/s, it can be used for testing both plastics and metallic specimens, e.g. sheet metal for automobile bodywork and fiber-reinforced composites. The actuator is mounted on the upper crosshead, enabling component testing in conjunction with the optional Tslotted platform. The machine is also available in an 80 kN version designated HTM 8020. The HTM 16020 is the biggest machine in the range, with a static nominal force of 160 kN. The actuator is mounted on the upper crosshead of the 4-column frame and the baseplate is provided with T-slots, making the machine ideal for component testing. However, tensile tests on larger-dimensioned specimens or belts are also possible. The maximum tensile force at 20 m/s is 100 kN.

Rated at 25 kN and 12 m/s, the HTM 2512 is the smallest machine in the range. The testing actuator is installed below, in the machine table. The HTM 2512 is particularly suitable for testing plastics (polymers, polyurethane) and is often used for puncture tests to ISO 6603-2, together with high-speed tensile tests to ISO 18872.

Fig. 2: Test device for puncture tests

Fig. 1: HTM 5020 high-speed testing machine

12

Fig. 2 High-speed tensile test with optical measurement system

3.1 testControl II control electronics and testXpert® R testing software The first choice for single-axis standard applications Due to their design, servo-hydraulic testing machines and, in particular, Vibrophores have so far been used exclusively as dynamic materials testing machines for determining the fatigue strength of materials and components with regard to fatigue life and fatigue limit in the tensile, compression, pulsating load and alternating load ranges. By switching from testXpert Research to testXpert II, Zwick servo-hydraulic standard testing machines and the new generation of Vibrophores can be used for both dynamic and static applications. These Vibrophores have therefore been designated 'two in one'. The crucial advantage is that both types of machines can be used as fully fledged static and dynamic materials testing machines capable of using the full scope of Zwick's well-proven testXpert II testing software and our application-specific testXpert Research dynamic testing software.

testControl II measurement and control electronics The first Zwick measurement and control electronics for dynamic testing machines to be developed entirely in-house, testControl II provides a new hardware and software platform for all Zwick testing machines. Users now have access to a uniform testing environment for both static and dynamic testing machines. The intelligent testControl II measurement and control electronics have a control frequency of 10 kHz, providing rapid response to events during tests combined with a high measured-value acquisition-rate. Together with the 24bit resolution, this enables very precise measurements. testXpert® R testing software testXpert Research - the intelligent testing software for fatigue and component testing. testXpert Research provides the user with a uniform operating concept, from sensor calibration, setting PID parameters and specifying set values, right through to the evaluation and report stages. The software's modular design allows easy addition of test programs for specific tests or standardized test sequences as per ISO/DIN or ASTM.

Fig. 1: testControl II and testXpert Research - first choice for single-axis standardized dynamic applications

13

testControl II - powerful modular electronics with state-of-the-art hardware architecture •

24-bit measurement-signal resolution over the entire measurement range for maximum data accuracy

•

synchronous 10 kHz measured-value acquisition-rate delivers precise measurement regardless of number of measurement channels

•

10kHz control frequency for precise control e.g. rapid reaction to spontaneous events

•

proven industry-standard Gigabit Ethernet interface enables very high data throughput to test-bench computer

One testing system for dynamic and quasi-static tests

14

testXpert® R's conveniently laid-out user interface at a glance

Workflow Process-oriented structuring of test definition and performance. Toolbar Key functions at a glance.

Online graphics Synchronous display of the curve graph

Input field All test-related parameters can be input directly in the test layout. Digital display All key measurement channels are displayed clearly. The display is freely configurable.

Sidebar Central control field for all key machine status information. The sidebar is always active and cannot be hidden by other desktop applications.

Status display The status display provides the operator with detailed information on the current test sequence.

Sequencer Individually tailored configuration of a block program.

15

testXpert® R's modern software design simplifies operation and provides support for each individual operation.

testXpert® R - sequencer The freely programmable block program for generating freely definable loading cycles

testXpert® R - fracture mechanics Determination of K1C value as per ASTM E399

®

testXpert R - fracture mechanics K-R curve as per ASTM E561

16

testXpert® R – Low Cycle Fatigue (LCF) For strain-controlled determination of low cycle fatigue as per ASTM E606

testXpert® R - fracture mechanics Pre-cracking for determination of crack progress (K-R curve) as per ASTM E561

testXpert® R – testXpert II Determination of J1C and CTOD as per ASTM E1820. Display of CTOD curve

3.2 ControlCube control electronics and Cubus testing software For single and multi axial testing of components and structures Advantages at a glance: • simple, intuitive and well-structured user interface shortens familiarization times • flexible, modular design allows straightforward system configuration to accommodate both simple and complex testing requirements • easily expanded to up to 32 control channels for multi-channel applications • basic unit available as 1 or 2-channel version • optimized 4 kHz data-acquisition and control frequency for cyclic testing requirements • 19-bit resolution for reliable, highly accurate test data acquisition • reliable PC connection and high data transfer rate via Ethernet • Cubuslight basic software and Cubus testing software for a wide variety of customer-specific testing situations • QuanTiM software package for simulation of actual operating loads

In addition, everyday use of the testing system is made easier by a multitude of helpful functions. These include automatic optimization of control parameters together with adaptive control which allows control parameters to adapt automatically to changing requirements during the course of the test. There is also a wide range of useful options for data acquisition, measured-value display and export. To interface with the test environment, connections for servo valves, hydraulic supply, remote control and Emergency STOP are available. These are complemented by universal measurement amplifiers and analog and digital inputs and outputs. These can naturally also be retrofitted. Cubus testing software Whether you wish to test a complete product, a component or a single material specimen, Cubus provides professional, highly efficient support. Cubus is a modular software environment specifically developed for single and multi-channel servo-hydraulic testing situations. In a single integrated application Cubus enables full configuration of the test environment, at the same time meeting all the demands placed on modern testbench control systems.

Technical advantages of Control Cube at a glance PC connection Industry-standard Ethernet port

Multi-channel connection Digital I/O connection CNet connects up to 32 Digital inputs and control channels outputs Channel identification LED indicates channel currently configured

System connection e.g. for safety door or flow-limiting valve Interface panel for expansion options Universal measurement amplifier Here for example with two analog For AC or DC sensors (strain gage, outputs and four analog inductive etc.). Fully synchronised inputs data acquisition for control and monitor channels.

Remote control Change to Setup or Testing mode using key switch Jog wheel The jog wheel can be used to change the position of the actuator in the relevant control mode

Channel switching For multi-axis systems user-friendly switching between individual channels is possible

17

Test options cubus test software

Cyclic Pro • Constant amplitude cyclic test • Adaptation, acquisition, trend monitor

Block program • Graphical editor for sequence of test elements • Cyclic, ramp, dwell, digital IO, acquisition etc.

Ramp test • Ideal for structural engineering tests • Failure detection

Dura test • Replay sequence of drive files

Some Controle Cube testing applications

Fig. 1: Multiaxial test bench for simulation tests (Image: © IABG)

18

Fig. 2: Multiaxial test bench (Image: © Ford)

Fig. 1: Modernized servo-hydraulic testing machines

Fig. 3: New ring line for expansion of central hydraulic oil supply

4.1 RetroLine modernization packages for servo-hydraulic testing systems

4.2 Fatigue Testing Laboratory / Contract Testing Laboratory

The modular RetroLine modernization packages for servo-hydraulic testing systems can easily be tailored to individual needs and testing requirements. Modernization of the testing machine usually includes renewal of the measurement and control electronics and the testing software. If necessary the modernization can involve a complete solution with replacement and modification of the hydraulic components. Areas of application range from materials characterization on single-axis materials testing machines to complex component-testing on multiaxial testing systems, for example simulation tests.

The many and varied challenges in the field of dynamic call for long-term experience in this area. From simple material testing to complex component testing, the test engineers in the Zwick Laboratory are always ready to share their experience with our customers and provide support. Our equipment includes testing systems for static and dynamic tests on threaded fasteners, CT specimens, springs, chains, gears, connecting rods and much more. Our customers benefit from our modern testing systems and our laboratory staff's years of experience in fatigue testing.

Fig. 2: Zwick Fatigue and Impact Testing Laboratory, Ulm, Germany

Fig. 4: Selection of specimens used by customers

19

Zwick Roell AG August-Nagel-Str. 11 D-89079 Ulm Phone +49 7305 10 - 0 Fax +49 7305 10 - 200 [email protected] www.zwickroell.com

The Zwick Roell AG group

Zwick GmbH & Co. KG www.zwick.com CaTs³ Limited www.cats3.com

Your local company – worldwide Zwick UK www.zwick.co.uk

Zwick Ibérica www.zwick.es

Zwick Avrasya www.zwick.com.tr

Zwick Korea www.zwick.co.kr

Zwick France www.zwick.fr

Zwick Norge www.zwick.no

Zwick USA www.zwickusa.com

Zwick India www.zwick.co.in

Zwick Belux www.zwick.be

Zwick Sveriga www.zwick.se

Zwick Brazil www.panambrazwick.com.br

Zwick Netherlands www.zwick.nl

Zwick CR, SR www.zwick.cz

Zwick Asia www.zwick.com.sg

Zwick Italia www.zwickroell.it

Zwick Polska www.zwick.pl

Zwick China www.zwick.com.cn