Periodic Reporting for period 2 - TEST-inn (TEST-INNOVATIVE LOAD APPLICATION MONITORING SYSTEMS)
Période du rapport: 2019-09-01 au 2020-02-29
The main objective of TEST-inn is to reduce product development time risks and costs thanks to the development of a test rig equipped with a combination of state of the art load application system in combination with the innovative monitoring methods proposed for first damage detection, stress-strain events, overloads and hot spot detection and quantification as well as overall deformation measurement. The proposed test configuration will reduce a 33 % the number of tests needed for new product development and a 25 % of recurrent costs saving.
The technical goals are, the development of a test rig equipped with a combination of state-of-the-art load application system in combination with the innovative monitoring methods proposed in order to demonstrate the torsional and bending stiffness of the HLFC Leading Edge configurations by experimental testing an obtain the equivalent beam.
The innovative contributions are the development of the test monitoring system based on novel technologies for specimen control during torsion and bending tests. These are the innovative load application systems with (SMA) Shape Memory Alloys morphing technology to apply tuneable elastic strain. And Innovative innovative SHM Structural Health Monitoring Systems, (AE) Acoustic Emissions for first damage detection, (DIC-3D) Digital Image Correlation for stress-strain events detection and quantification, (FORS) Fibre Optic Rayleigh Scatter for continuous strain measurements for internal areas and (LS) Laser Scanner for overall deformation measurement.
Overall project conclusions:
- A new test rig has been successfully designed, manufactured and assembled for torsion and bending tests and to validate SHM proposed innovative monitoring methods.
- A second test rig dummy structure with representative stiffness of the main torsion box of the stabilizer has been designed, manufactured and assembled for innovative load application method validation.
- SHM innovative monitoring methods proposed have been properly validated.
The technical goals are, the development of a test rig equipped with a combination of state-of-the-art load application system in combination with the innovative monitoring methods proposed in order to demonstrate the torsional and bending stiffness of the HLFC Leading Edge configurations by experimental testing an obtain the equivalent beam.
The innovative contributions are the development of the test monitoring system based on novel technologies for specimen control during torsion and bending tests. These are the innovative load application systems with (SMA) Shape Memory Alloys morphing technology to apply tuneable elastic strain. And Innovative innovative SHM Structural Health Monitoring Systems, (AE) Acoustic Emissions for first damage detection, (DIC-3D) Digital Image Correlation for stress-strain events detection and quantification, (FORS) Fibre Optic Rayleigh Scatter for continuous strain measurements for internal areas and (LS) Laser Scanner for overall deformation measurement.
Overall project conclusions:
- A new test rig has been successfully designed, manufactured and assembled for torsion and bending tests and to validate SHM proposed innovative monitoring methods.
- A second test rig dummy structure with representative stiffness of the main torsion box of the stabilizer has been designed, manufactured and assembled for innovative load application method validation.
- SHM innovative monitoring methods proposed have been properly validated.
A test rig equipped with a combination of state-of-the-art load application and innovative monitoring methods has been developed. The test rig can be assembled in two different configurations. Both configurations have been assembled, verified and the corresponding test cases have been applied using the intended load application methods and the innovative monitoring technologies.
Test case 1, composed of a clamping part and the load application system for the bending and torsion test necessary to obtain the component torsional and bending stiffness by experimental testing an obtain the equivalent beam. In this test rig, conventional monitoring systems like strain gauges, inclinometers. LVDTs, and innovative SHM Structural Health Monitoring Systems were applied, (AE) Acoustic Emissions for first damage detection, (DIC-3D) Digital Image Correlation for stress-strain events detection and quantification, (FORS) Fibre Optic Rayleigh Scatter for continuous strain measurements for internal areas and (LS) Laser Scanner for overall deformation measurement.
For the obtention of the component torsional and bending stiffness, it has been developed an automated procedure Ansys FEM program based.
An additional test was carried out in this configuration, using SMA technology to apply a bending load on the specimen. This test allowed to verify the technology in a lower stiffness configuration than the one presented in test case 2.
For the test case 2, the test rig was set-up to reproduce a real load case representative of in-flight conditions by experimental testing by means of a test loading system based on (SMA) Shape Memory Alloys technology.
It has been developed an innovative load application system based on SMA morphing technology to apply tuneable elastic strains.
For the Innovative SHM systems it has been developed an (AE) Acoustic Emissions technique for the first damage detection. We can detect and locate the first incipient damage in a loaded 3D structure remaining the specimen globally undamaged.
We also have tuned up the innovative SHM systems of (DIC-3D) Digital Image Correlation and (FORS) Fibre Optic Rayleigh Scatter techniques for the stress-strain events detection and quantification during experimental test. More concretely it has been tuned up the DIC system in order to detect and quantify hot spots & stress-strain events for external areas during tests of 3D specimens close to final one to be tested. The set-up has been developed specially for high depth of fields necessary for industrial components when they are tested. On the other hand, it has been tuned up the FORS technology for continuous strain measurements for internal areas. We can detect and quantify hot spots & stress-strain events for internal areas in 3D components difficult to be measured with other techniques.
And finally (LS) Laser Scanner technology has been proved for overall deformation measurement. We can measure the overall deformation with accuracy enough in order to obtain the equivalent beam with method proposed.
Regarding the dissemination activities it can be pointed out that the defined roadmap has been followed: A workshop was organized were the innovative load application systems and the instrumentation technologies were analyzed. The consortium members have attended several conferences and events. Press releases with news of the project have been carried out. The web pages of the members have been updated with the latest information, etc.
The potential benefits associated to these results are, to reduce the product development time, risk and costs during the design of new structures, to have new load application system avoiding conventional actuators and to have innovative instrumentation solutions for testing.
Test case 1, composed of a clamping part and the load application system for the bending and torsion test necessary to obtain the component torsional and bending stiffness by experimental testing an obtain the equivalent beam. In this test rig, conventional monitoring systems like strain gauges, inclinometers. LVDTs, and innovative SHM Structural Health Monitoring Systems were applied, (AE) Acoustic Emissions for first damage detection, (DIC-3D) Digital Image Correlation for stress-strain events detection and quantification, (FORS) Fibre Optic Rayleigh Scatter for continuous strain measurements for internal areas and (LS) Laser Scanner for overall deformation measurement.
For the obtention of the component torsional and bending stiffness, it has been developed an automated procedure Ansys FEM program based.
An additional test was carried out in this configuration, using SMA technology to apply a bending load on the specimen. This test allowed to verify the technology in a lower stiffness configuration than the one presented in test case 2.
For the test case 2, the test rig was set-up to reproduce a real load case representative of in-flight conditions by experimental testing by means of a test loading system based on (SMA) Shape Memory Alloys technology.
It has been developed an innovative load application system based on SMA morphing technology to apply tuneable elastic strains.
For the Innovative SHM systems it has been developed an (AE) Acoustic Emissions technique for the first damage detection. We can detect and locate the first incipient damage in a loaded 3D structure remaining the specimen globally undamaged.
We also have tuned up the innovative SHM systems of (DIC-3D) Digital Image Correlation and (FORS) Fibre Optic Rayleigh Scatter techniques for the stress-strain events detection and quantification during experimental test. More concretely it has been tuned up the DIC system in order to detect and quantify hot spots & stress-strain events for external areas during tests of 3D specimens close to final one to be tested. The set-up has been developed specially for high depth of fields necessary for industrial components when they are tested. On the other hand, it has been tuned up the FORS technology for continuous strain measurements for internal areas. We can detect and quantify hot spots & stress-strain events for internal areas in 3D components difficult to be measured with other techniques.
And finally (LS) Laser Scanner technology has been proved for overall deformation measurement. We can measure the overall deformation with accuracy enough in order to obtain the equivalent beam with method proposed.
Regarding the dissemination activities it can be pointed out that the defined roadmap has been followed: A workshop was organized were the innovative load application systems and the instrumentation technologies were analyzed. The consortium members have attended several conferences and events. Press releases with news of the project have been carried out. The web pages of the members have been updated with the latest information, etc.
The potential benefits associated to these results are, to reduce the product development time, risk and costs during the design of new structures, to have new load application system avoiding conventional actuators and to have innovative instrumentation solutions for testing.
For the Innovative LOAD APLICATION SYSTEMS, It has been demonstrated that it is possible to apply tuneable real strain loads, on up to 2-400 µstrains (this is on the order of nominal loading cases); with (SMA) Shape Memory Alloys morphing technology, in real 3D leading edge components.
(AE) Acoustic Emissions for first damage detection has been considered the SHM technology that during the project has shown a beyond state of the art development. We can detect and locate first incipient damage in a real 3D representative structure. Procedure developed match very well with FEM model with strain criteria implemented. After the damage location, the component remains undamaged and is ready to be used for other tests, reducing the number of complex and cost final components.
Moreover, the combination of developed technologies, allows to test components during the development process showing the first damage point, the internal and external hot spot stress concentrations in order to reduce the number of tests needed for new product development and the recurrent costs.
These results have been proved in a similar component of the final HLFC specimen in size, stiffness and materials. From this point until the project is finished it is expected to replicate these results with the final HLFC component.
Also, a new and automated methodology has been developed, such that, from real aeronautical component experimental bending and torsion tests, is possible to obtain the equivalent beam with torsion and bending coupling stiffness.
(AE) Acoustic Emissions for first damage detection has been considered the SHM technology that during the project has shown a beyond state of the art development. We can detect and locate first incipient damage in a real 3D representative structure. Procedure developed match very well with FEM model with strain criteria implemented. After the damage location, the component remains undamaged and is ready to be used for other tests, reducing the number of complex and cost final components.
Moreover, the combination of developed technologies, allows to test components during the development process showing the first damage point, the internal and external hot spot stress concentrations in order to reduce the number of tests needed for new product development and the recurrent costs.
These results have been proved in a similar component of the final HLFC specimen in size, stiffness and materials. From this point until the project is finished it is expected to replicate these results with the final HLFC component.
Also, a new and automated methodology has been developed, such that, from real aeronautical component experimental bending and torsion tests, is possible to obtain the equivalent beam with torsion and bending coupling stiffness.