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Team bender

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1. The document describes the design of a test stand for conducting strain tests on various materials up to 150 lbs of force. 2. It evaluates different design concepts and selects a hybrid design with an aluminum frame, pneumatic cylinder for force application, dial gauge for measurement, and four jaw chuck for sample holding. 3. Key calculations are shown to determine the minimum bore size of 2 inches for the pneumatic cylinder to apply up to 150 lbs of force given an input pressure of 60 psi.

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Team Members: Doug Bradley Dan Ehlke
Strain Test Stand Finite Element Analysis (FEA) vs Physical Testing School of Technology Lab Cheaply Load of up to 150 lbs Various length/geometry test specimens
Aluminum Frame Force Application: weights Plexiglass cover Clamping system: standard clamp Electronics: amplifier unit. Data Output: Digital display of voltage Signal Conditioning: Tare function to exclude the influence of preloads. Test Specimens: tensile test rods, in aluminium, copper and brass Force measurement: manually add weight values
Determined the most important aspects of the design Accuracy/Precision User-friendliness Safety Functional decomposition identified key parts
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Closest to current SofT design Leverage based sample holding system Hanging weights apply force Dial gauge measures displacement Internal electronics for strain gauges
More stable frame design Uses clamping system to hold sample Hydraulic cylinder applies force Dial gauge measures displacement Internal electronics for strain gauges
Lighter frame design than concept 2 Uses chuck assembly to hold sample Electronic linear actuator applies force Dial gauge and internal electronics hookups not shown
Based on the important qualities determined by the QFD Identified concepts 2 and 3 as best
Uses the stable U-frame (Concept 2) Chuck assembly used for sample holding (Concept 3) Pneumatic cylinder for force application (Concept 2) Dial gauge and internal electronics as standard
Frame is load-bearing A500 Steel Tube 6 in X 4 in, .25 in thick Top bar for stability Under smaller loads Steel barstock 1 in diameter Free
Assumptions: ≤ 0.5 in deflection of sample Calculated bore size ≥ 1.8 in Next highest pneumatic size: 2.0 in 60 psi pressure source is unreliable, as is pressure gauge Alternatives KNOWN SOLVE FOR DIAMETER F = Force P = pressure A = Surface area of pneumatic cylinder bore D = Minimum Cylinder Bore Diameter F= 150 lb (10 lb increments) P= 60 lbs/in 2 A = ? D = ? F=pA 150 lb = (60 lbs/in 2 ) * A A = 2.5 in 2 A = ? r 2 Determine r 2.5 in 2 = ? r 2 r = 0.89206 D = r*2 D = 1.784124
Screw Jack Control Constant Load Cell Precise Measurement Automatic logging
4 jaw chuck
Steel frame Force Application: Screw jack Adjustable jack Placement Clamping System: Four jaw chuck assembly Adjustable chuck height Internal Electronics: NI-DAQ 9237 Signal Conditioning: NI-DAQ 9237 & Labview Software Data Output: Graph of Strain / Force in LabView Test Specimens: 3 crowbars Dimensions: 42” x 30” x 6 Force measurement: Honeywell Model 53 Load Cell
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Team bender

  • 1. Team Members: Doug Bradley Dan Ehlke
  • 2. Strain Test Stand Finite Element Analysis (FEA) vs Physical Testing School of Technology Lab Cheaply Load of up to 150 lbs Various length/geometry test specimens
  • 3. Aluminum Frame Force Application: weights Plexiglass cover Clamping system: standard clamp Electronics: amplifier unit. Data Output: Digital display of voltage Signal Conditioning: Tare function to exclude the influence of preloads. Test Specimens: tensile test rods, in aluminium, copper and brass Force measurement: manually add weight values
  • 4. Determined the most important aspects of the design Accuracy/Precision User-friendliness Safety Functional decomposition identified key parts
  • 5. ?
  • 6. Closest to current SofT design Leverage based sample holding system Hanging weights apply force Dial gauge measures displacement Internal electronics for strain gauges
  • 7. More stable frame design Uses clamping system to hold sample Hydraulic cylinder applies force Dial gauge measures displacement Internal electronics for strain gauges
  • 8. Lighter frame design than concept 2 Uses chuck assembly to hold sample Electronic linear actuator applies force Dial gauge and internal electronics hookups not shown
  • 9. Based on the important qualities determined by the QFD Identified concepts 2 and 3 as best
  • 10. Uses the stable U-frame (Concept 2) Chuck assembly used for sample holding (Concept 3) Pneumatic cylinder for force application (Concept 2) Dial gauge and internal electronics as standard
  • 11. Frame is load-bearing A500 Steel Tube 6 in X 4 in, .25 in thick Top bar for stability Under smaller loads Steel barstock 1 in diameter Free
  • 12. Assumptions: ≤ 0.5 in deflection of sample Calculated bore size ≥ 1.8 in Next highest pneumatic size: 2.0 in 60 psi pressure source is unreliable, as is pressure gauge Alternatives KNOWN SOLVE FOR DIAMETER F = Force P = pressure A = Surface area of pneumatic cylinder bore D = Minimum Cylinder Bore Diameter F= 150 lb (10 lb increments) P= 60 lbs/in 2 A = ? D = ? F=pA 150 lb = (60 lbs/in 2 ) * A A = 2.5 in 2 A = ? r 2 Determine r 2.5 in 2 = ? r 2 r = 0.89206 D = r*2 D = 1.784124
  • 13. Screw Jack Control Constant Load Cell Precise Measurement Automatic logging
  • 15. Steel frame Force Application: Screw jack Adjustable jack Placement Clamping System: Four jaw chuck assembly Adjustable chuck height Internal Electronics: NI-DAQ 9237 Signal Conditioning: NI-DAQ 9237 & Labview Software Data Output: Graph of Strain / Force in LabView Test Specimens: 3 crowbars Dimensions: 42” x 30” x 6 Force measurement: Honeywell Model 53 Load Cell
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