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Robert Metz PCB Piezotronics, Inc. Automotive Testing Expo, North America Novi, MI, USA October 26, 2006
Overview
Reasons for Impact Testing Energy and Impact Force Relationship Between Force and Distance Relationship Between Force and Time Drop Test Example Selecting a Force Sensor ICP Force Sensor Configurations Conclusions
Determine energy absorbed or required to damage UUT Validate design & ensure that it meets product durability & safety requirements Safety critical components: Automotive bumpers, protective sports equipment, headform testing of hardhats/helmets Various SAE, MIL, ANSI or ASTM test specifications Destructive impact testing performed to document strength or durability of non-safety critical items for industrial use
Work-Energy Principle
Ave. impact force x distance traveled = change in kinetic energy Reduce impact force by extending stop distance via crumple zones.
Conservation of energy - potential energy before event must equal kinetic energy after event PE = KE Drop test conservation of energy equation is mgh = mv2 Impact velocity independent of mass, neglecting drag caused by air resistance, velocity is calculated from: v = 2gh
Steel
4.5
44.1
0.0001
99,137
441,000
Plastic
4.5
4.427
44.1
0.1
99
441
Foam
4.5
4.427
44.1
h d
Do not confuse acceleration due to free fall gravity (g) used in impact velocity calculation with the impact acceleration Impact force is then calculated from Newtons 2nd law F = ma Pulse width, and acceleration, vary as penetration distance varied. Softer impact surfaces have lower impact force Soft surface slows down the impact, spreading pulse width
Pulse Width
Material
h (m)
m (kg)
v final (m/s)
KE (J)
t pulse
F (lbs)
F (N)
Steel
4.5
4.427
44.1
0.0005
18,050
80,294
Plastic
4.5
4.427
44.1
0.002
4,513
20,076
Foam
4.5
4.427
44.1
0.100
90
400
Bumper
[85.7 g peak]
Crosshead supported by 4 ea. PCB model 203B ICP force rings Each having a 20 klb (90 kN) compression rating Total impact range 80 klb (355.9 kN)
Cross check the math with displacement Use work-energy principle derived earlier Displacement of bumper after impact was 1.5 in (0.038 m)
Estimate average force from curve 19,108 lbs (85 kN) Energy is: Wnet = F * d = 19,108 lb * 1.5 in = 28,662 in-lb = 3,238 N-m = 3,238 J
Quartz Piezoelectric force sensors react to stress, not large displacements 1E-6 in (0.2 m) Few orders of magnitude stiffer than strain gage load cell of equivalent measuring range Depending on physical shape, stiffness 6 to 100 lbs/in
Additional benefits of high stiffness small size low mass overload protection
100000
Force (Lbs.)
80000
60000
40000
20000
208C05
205C
200C50
208A22
260A11
ICP impact force sensors supplied with specially designed impact caps Convex surface transmits impact loads evenly
Better measurement results Preventing sensor damage
Caps also compensate for misalignment of UUT or drop mass Provides replaceable wear surface if damaged
4500 4000 3500 3000 Force (lb) 2500 2000 1500 1000 500 0 -500 0.00 0.25 0.50 0.75 Time (ms) 1.00 1.25 1.50 60 mph 90 mph
Base Plate
Impact force simultaneously in 3 orthogonal directions PCB ICP 260 series, 3-component force ring Each x-y-z axis provides independent output signal Summing 4 in series provides 6 DOF
Fx,y,z and Mx,y,z
e os Cl o up so en fs g in nt ou rm
Conclusions
Impact force measurement is a proven way to document that proper energy obtained during impact test Selection of force sensor measuring range possible by
Using conservation of energy and estimate pulse width for the planned test Use of Newtons 2nd law