Multiaxial high cycle fatigue test system
Contents
1. AJIA 3915 IHSI AATA T ac LOS end OU SEE Oe a an 3903 duvHS ESTA GET IN3ALV3NL 301 MOVIE V 3A139389 OL 51 W3L ONINIHOVN 314Y H9V3 40 ALILNYNO 133415 031108 9100 38 OL S S310N uo NCHS ve 107 ONA iN Nov 7 2002 US 2002 0162400 A1 38 v 910 431W Lb 2 6 IHd E MESA V ad HONViS3M SW3lSAS H231GV NOV 313388 ios 0 n SIWY 5784034 1309 Wi V SNOIGHISATG 031419345 ISAO 3078 A Vdv S338930 09 30974 j d33d 01 S1v14 HON3HM LNI N MING JOVIS L AS ShlOVH EO vZ 8 gt d33g OZ Z OV3HHL l l 3SVHO d33G azz 291 91 3808 S39G3 77 3AOW3M 43 41 MOVIE 38 OL SI HOV3 Z 40 ALIINVOO 7133458 9377104 0109 38 S TVIM3LYW S3LON es 25 s5 sys eer v 2s Lau us oud Nov 7 2002 US 2002 0162400 A1 39 V LV0 JLVIN DH Dag SUE TON oa i 5 S WALO3O TRV BIJU2. Lavd 081 Z dALV NMOHS SV N di3 40 4913 HON3HM 1055 i L JAL DHL FE R C V 20 Q3d xo 38 Ol 3NV SLYVd ONINIHOWN Malay 2 30 ALIANYND Vad LS 0371104 0109 38 OL SI S3310N SONJ HLOH N 017 H33AVHO Nov 7 2002 44 US 2002 0162400 A1 r t 40 1 31738 10 500 iii 675 927 266 SWALSAS HO310V saam SEED 931445345 35103410 NN WMOHS SY Z 4330 OZO X HialMA FO LOIS NIY dVNS 53903 dMVHS VIY 3AOW3M ETENI TETEN HOV3 Z 40 ALILNYND 1331s 0 SALON Nov 7 2002 US 2002 0162400 A1 45 M35N3AVOS 815879092108 HONV3S3M SWilSAS H2310V NMOHS SY 30V1d L 9 WIG 3408 0 NMHL 82 77189 NMOHS SV S39V1d v dah NAHL OZ v l dvi 43180 SH3NHUOJ3 dHVHS 77 3AOW3M q3d xo 38 51 H3L3V HOV3 L 30 ALILNYNO 7331S 031108 0100 38 04 51 1VIH31VW SALON omen Nov 7 2002 US 2002 0162400 A1 46 FZO 6
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8. 1961 0 14330 9511 N aug Ur 1 70005 OL STIVA aalE TaNvd IHL HLIM ONY TAY Wavd 38 Di 3uY SITK 4018 Hio8 dol 394 SNOISN3MIO 1015 3I N 51075 ONY 80 SISTI Mad gt ans 885010 Ed IT Fags tos Co i9 000 2 339 8 W101 v 30 4 8 ROLLOS Oy dol 3Hi NO S310H 403 dil ig330 DU 8152 1 dvi daag Nov 7 2002 US 2002 0162400 A1 25 GE wy EEN MEE RE V 9000701 Eun 2 Nos Sv B30Vld dAL 4330 SZ0 BE 3408 9 zig4 SY S30V1d r dhl 14339 00 83 271 avi daad i 09 18 SMANMOO ONY 53903 duvHs Z00 SSANMOIHA 733421N ONINIHOVW 13149 SN11V1d HSV1J 3A1303M OL 51 T3NVd HOVE 1 40 ALILNYND 713315 QUVHONV E 38 OL S STVIM3LYA S310N 000 627 510 LiM 3Nvd JO 30 nou rog OER SY Sadvid DC SE 1005 NIHLIM OL STIYM 3015 T3NYd HLiM T3T1VBVd ONV 1NOM4 E au MI Eo Greco dOL AT WuYd 38 OL STIVA 1015 5101
9. Z 2 0 dvi wug2 ONY Nov 7 2002 34 06 2002 0162400 1 sss dOl 3iVld did X INVG ofS ESE HONV3S3H 5831645 HO311GY F su ISiT ua i raar Fun gi pens ERI e xv 3015 AJLA INCU 0 534 sv aom sv T tht 1 Hy q 4M 40 9y ty qozu o00 ei EN AR om wa eani na SOME 1 51544 30170 ONITIVISNI OL 4 YOVI V 3A1303M 01 51 31V3d 03553934 A11Hg 18 DOL 38 LSNN 31ivld 3 40 30VAMNS 3001059 10 ISAK 51509 3d n9 537109 ONIONOdS3NO0 NI SLSOd 3GIND v 114 85309 L NMOHS SY 6310 3MOH O TV ONY ITOH M31N32 mu e VIO S310H 1 Z 1 dvi HOVE BLVId L 40 ALLINVRD V 7 13315 0204 SI CWIN31VA W3WOlSQO EA OL 4 TUM 31V d 311 8310N 401 HORE w avwa EI 3 Nov 7 2002 US 2002 0162400 A1 M ES i MTN sa gu HSINI 3 300XO V 3A1303M d NOLLVTIVISN 3139 SONIHSNA ONY 3iV d H 38 SONIHS
10. Attack Hold Stops all waveform action on all axis that have the box labeled Include Axis in Master Waveform Control checked All axis will be stopped at the point where they are located within their respective cycle when the button is hit Reset Stops all waveform action on all axis that have the box labeled Include Axis in Master Waveform Control checked All axis will be stopped within the time frame specified in Decay and all axis will return to their respective starting point when the cycle begins 06 2002 0162400 1 Nov 7 2002 16 s 3 s H nye isses ge E E l pros AMT antes ae ct NER ol es Figure 3 2 06 2002 0162400 1 Nov 7 2002 17 6 Select the Axis 3 tab and confirm that the box labeled Include Axis in Master Waveform Control is NOT CHECKED This axis will not have a cyclic waveform generated through it All other parameters found within this tab can be left as they are 7 described above in section 3 4 1 selecting the large start button will start the Cyclic Waveform Generator 8 Tostop a waveform the operator has two options either select the large Hold or Reset buttons located at the top of the waveform generator s screen Their individual functions are described in Section 3 3 1 06 2002 0162400 1 Nov 7 2002 d 1 4 2 18 SYSTEM SHUTDOWN CONTROL
11. SYSTEM UNLOAD 1 Upon completion of a test at anytime the operator wants to dismantle the test setup the waveform generation should be stopped by selecting the Reset button This allows the actuators on Axis 1 and 2 to return to a unloaded position Axis 3 however will remain loaded since it was not included in the waveform function Before proceeding check for any component or test fixture failure as this may dictate how the test frame should be unloaded Remove the couplings that are gripping the component on Axis 1 and 2 If needed Axis 1 and 2 can be retracted using the Jogging Handsets However remember to disable the Stroke Limits that may have been set on Axis 1 and 2 first If no failure is noted select the Load Cell button for Axis 3 and go to the Limit tab and uncheck the enabled button for the Lower Sensor Limit The Upper Sensor Limit should be left enabled for safety Select the Setpoint Control button and input a new lower target load for Axis 3 of around 20 Ibs tension and hit Enter Select a new Ramp time of approximately 10 sec and hit Enter Select the Start button and the load on Axis 3 should reduce to the target load over the 10 sec time period The system can be stopped by selecting the small square stop button within Test Group 1 or by hitting the Emergency Stop button on the Labtronic 8800 At the test frame release the hydraulic grip pressure that is holding the strap By allowing 20
12. and specimen were mounted on the bottom movable die plate attached to the vertical actuator 14 As a result the position of the specimen relative to the transverse actuator changed whenever the vertical actuator moved and whenever the hydraulic power was switched off In the new multiaxial test frame the hydraulic grip is mounted on the bottom movable die plate attached to the vertical actuator The broach block and the specimen are mounted on the top fixed die plate This ensures that the relative distance between the specimen and the transverse actuators remains undisturbed by the move Nov 7 2002 ments of the vertical actuator This also enables quick change over from one test to another on same or similar blades by eliminating changes in the critical locating dimensions 0057 load cell of 2000 Ib capacity supplied by Sen sotec is mounted on the piston rod of each transverse actuator using an adapter A clevis is attached to the load cell The clevis is connected to the grip pin using two rod end bearings The grip pin extends from one end of the grip to the other end When the piston rod of a lateral actuator moves forward it pushes one end of the grip pin forward via the clevis and the rod end bearings This results in the application of a force to the specimen in the direction of the actuator movement The rod end bearings and the clevis joints allow movement of the grip in the vertical direction to a certain extent A
13. enabled the machine to apply not only bending loads but also torque to the blade The application of bending and torsion loads to the blade is explained in detail in Section 3 1 Nov 7 2002 0036 2 0 Prototype Test System with Biaxial Loading Capability 0037 2 1 Design of a Biaxial Loading Test Frame 0038 In Phase I an existing four post test frame was modified to test a gas turbine engine fan blade under biaxial loading A four post die set was designed and fabricated It was placed between the top and bottom platforms and was mounted on the load train A vertical plate 10 was mounted on the side of the die set 12 12 on which a second hydraulic actuator was mounted FIG 2 1 shows the schematic of the biaxial loading machine FIG 2 2 shows a photograph of the completed biaxial loading machine The vertical actuator 14 was used to apply the steady radial load to simulate the actual centrifugal load on the blade The horizontal actuator 16 was used to apply the fatigue loading to simulate the actual vibratory load Both actuators were controlled by an Intelaken DDC4000 controller The load and time data were collected in a computerized data acquisition system Labtech Notebook was the data acquisition and analysis software used 0039 gripping system 20 was designed and manufac tured to apply the biaxial loading to the blade A schematic of the gripping system is shown in FIG 2 3 Transverse fatigue loading was applied t
14. in a horizontal position Instron Servo Hydraulic Actuators Model PLF7D Load rating 5 2 kN Stroke 20 mm Identification Axis 2 is located on the Right Test Frame Wall mounted in a horizontal position Instron Servo Hydraulic Actuator Model 1287 3010 Load rating 50 kN Stroke 150 mm Identification Axis 3 is located on the Lower Test Frame Wall mounted in a vertical position 1 LABTRONIC 8800 Hydraulic Manifold Controller ELECTRONIC CONTROL SYSTEM The Control System is comprised of the following components w Instron RS Console Control Software Instron RS PLUS 32 Data Acquisition Software Instron Remote Jog Handset 400 MHz CPU 64 MB RAM Dell Computer and monitor 06 2002 0162400 1 Nov 7 2002 13 MECHANICAL SYSTEM The Mechanical System is comprised of the following components 4 4 Thick Cold Rolled Steel nickel plated panels 4 Post Danly Die Set Model 647 Hydraulic Wedge Grip Mounted on 2 Steel Gusseted Beams 06 2002 0162400 1 Nov 7 2002 2 1 2 2 2 2 1 SYSTEM PREP AND START UP HYDRAULIC SYSTEM START UP Initiate start up of MTS 506 Hydraulic Compressor located in Bldg 4252 Room 25227 Start up instructions are shown below and are located on the front of the control panel to the compressor MTS HYDRAULIC PUMP START UP 1 Check that chilled water is on South side of Bldg 252 top white tank temp of 60 F or lower 2 Ch
15. lbs of tension as explained in Step 2 this should allow a slow descent of the ram on Axis 3 HYDRAULICS SHUTDOWN 1 Prior to deactivating the hydraulics an examination of the test frame is important to ensure that there is nothing to interfere with the possible movement retraction of the three actuators US 2002 0162400 A1 Nov 7 2002 19 2 All hydraulic flow to the actuators is controlled through the Labtronic 8800 and can be stopped by selecting each actuators Off button located beneath the Hydraulics 1 2 and 3 control panel 3 Close all of the RS console software windows and completely exit off of the computer 4 Deactivate the Labtronic 8800 by reversing the procedures set forth in Section 2 2 1 5 Shutting down the main hydraulic compressor can be done at the compressor itself by turning the Main Pump switch to low and hitting the large Stop button 6 Shutting down the main hydraulic compressor can also be done at one of the Emergency Shutoff buttons that are located at the exit doors above the 6 level in rooms 25220 25222 25223 and 25224 The operator should note their locations prior to starting the hydraulic compressor APPENDIX DRA WINGS 06 2002 0162400 1 Nov 7 2002 21 Nov 7 2002 US 2002 0162400 A1 22 LE E Nov 7 2002 US 2002 0162400 A1 23 EER ON HoMVaS3M 5021545 HO3LOV 301 1HOTM 53003 01109 ANV 901 u
16. position and hit the Start button With Span finished and waiting for the Fine Balance change Cal Relay to the open position and hit the Start button to finish the calibration procedure Upon completion of the calibration you will be given an opportunity to save the calibration data to a file that can be recalled at a later date or you can select Finish Finally select to close out of the Sensor Properties window COMPONENT ATTACHMENT POSITIONING ACTUATORS Select the Setpoint control button located within Test Group 1 see Figure 3 1 1 Select the Group Setpoint control tab This allows complete control of all actuators including the ramp time mode of control stroke or load and your desired target position for all actuators 06 2002 0162400 1 Nov 7 2002 14 Select Position control for all Axis 1 thru 3 located beneath the Mode column Located at the test frame are three Remote Jogging Handsets one for each axis actuator Each Handset has the capacity to extend or retract each actuator at either a slow or faster rate depending upon which buttons are pushed Insure that all mechanical connections are tightened as needed Using the Handsets extend each actuators ram taking care on proper alignment of gripping devices and the component so that all Axis 1 and 2 couplers are aligned with the gripping device located on the component DO NOT MAKE THE FINAL ATTACHMENT TO THE COMPONEN
17. three dimensional model of the transverse loading mechanism is shown in FIG 3 5 A photograph of the GE F110 gas turbine engine fan blade subjected to multiaxial loading using the gripping system is shown in FIG 3 6 0058 3 3 Hydraulic Components and Control System 0059 The hydraulic control system and the actuators were procured from Instron Schenk Testing Systems Lab tronic 8800 multi axis digital control console manufactured by Instron is used to control all the three actuators It monitors the load and displacement conditions while per forming high speed data acquisition Labtronic 8800 has multi station capability The Labtronic 8800 control console is connected to a personal computer running Windows NT A software called RS Console is used for interacting with the Labtronic 8800 control console RS Console can be used for set up waveform generation and setting of limits It uses a wizard to provide simple easy to use instructions for com plex operations The software also includes multiple live displays for digital readout of data RS Console has function generators that can be interlocked with phase control This enables the maintenance of phase relations between the actuators during cyclic loading 0060 The two lateral actuators are of type PLF7D sup plied by Instron Each actuator has a capacity of 1 100 Ib 5 2 kN and 20 mm stroke These actuators can apply high frequency loading up to 400 Hz Standard fatigue rated a
18. 3362 UL 399 AHL 20 34 DL uv SHINGO 4330 UV3sHl 11 1 SUE TRUG 31 wig EOE davis TY 3ADH3H 1 ALLINVDO HL SI SALON bur 608 US 2002 0162400 A1 Nov 7 2002 54 APPENDIX C Script for the Multi axial High Frequency Test System Video Scene 1 AdTech logo Scene 2 Title A Multi axiai High Frequency Test System Scene 3 Graphics excerpt from Phase I video a turbine engine disk blade assembly Narrator In a typical turbine engine rotating blades are subjected to both the centrifugal force and the periodic transverse excitation This is a multi axial loading condition also present during operation of many other high performance mechanical systems Scene 4 Excerpt from Phase I video prototype biaxial machine Narrator In 1998 AdTech Systems Research Incorporated of Dayton Ohio successfully developed a prototype biaxial loading test system This four post test frame is capable of applying mechanical loading on perpendicular axes through two servo hydraulic actuators Its purpose was to demonstrate the feasibility of performing multi axial loading simulation tests on turbine engine components Scene 5 Computer and operator zoom in to computer screen finite element model Narrator After the proof of concept demonstration
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20. 5 LH 53943 dHvHS 3AOW3M HOVA Z 40 ALILN S S OZ 38 OL SI Wis aak SHOISIARY vno LYN SALON 8 051 SNIAVEG 31 98 LON 020 050 v m t SHY 7930 SNOl12VILI 138y UI 3HY BABS 231312345 SWEIS STUN MILA LNOM 404 VIO yo dal iad Sni vad NMOHS SV 5 dAL Y A 2 7 2002 Su 37905 od MET ROTH sany 5230 1 920 26 Hd 33J943AY38 5 SW318AS HOaLOY 1304 S32HV13101 SAH Hi 30 SNOISHZ 921315345 25004410 SSIINN 52 1007006 SY Z MAL i 4330 40 X FO 1016 ONTY dVNS Z 40 ALIINVRO 13318 1001 38 51 WIYSLYA 434 9NIANVdAODOV 33 00 Q3N31HOHS 38 Ol SI ONIISIX3 SI LMVd ZION S awa _ 5011410534 anoz SHOISTATA v Lam US 2002 0162400 A1 Nov 7 2002 25 US 2002 0162400 A1 AAS CALON SV HO 900 ON das RENE 18 WHONSIXH WVH ONIMVHG B2EE 92y CTG 8692 2EVSY OIHO NOLAVG HOMUVASdH SWALSAS HALAY ERG T 1005 ui NADHS Sv 5398714 E uve HHL JU GNA DL 315
21. N3LIVW SION SNOISIA3U TEM 5 SIHIN f INY SNOISH341G 031413338 351 552197 Nov 7 2002 US 2002 0162400 A1 49 1 dO isans ezt ozy Z 6 334u0H3AY3H HOYVASSY SW31SAS HO3lQdV uya WOI Ldi UOS SHOISIAIY 31 NIN S31TNV 87 81239 ENON LOVES SHOW JUV SOISN3HIO Q314 934S 3514012110 SSIINN FWS 198 bx d 9411119 Woes 3543 dMYHS QNnOM HOWE 30 ALILNYNO NMOHS SV LYVd 3HL jO Hi9N31 3 ind S S SI lVIN31VNW MOQN3A 3Hl OL GAHSINYNA 38 ONY OSNIISIX3 SI LYYd 31ON SZU Z WIG 9NI1SIX3 Nov 7 2002 US 2002 0162400 A1 50 8741930 sugilovus soom 4 31412145 3842010 831 BEEE BZy 1C8 Hd O1HO X33H983AV3H SW3LSAS 4 v Z HLION31 3LON 094 1 OE SHOISIA38 ONILLIOO JHL 53913 dHVHS HOV3 Z 40 AL NMOHS SV LYVd JHL 40 HI9N31 1n2 S S 20 51 WIMALYW HOON3A IHL OL OAHSINMN4 38 NV ONILSIX SI LYYd ALON i Nov 7 2002 US 2002 0162400 A1 51 62e 9Zv 4 8 Hd OHO 331 3 38 301
22. NA 39 14 NI 3114001 9NIHSNE 38 TVA TIViSNI NMOHS SV 0 ONY 5310 VIV VIHA HOV3 L 40 ALIINVDO V 73318 0201 SI HANOLSNO IHL 01 38 31 14 310 ATINVO S3108 M3TA 081 mew xw 410 BNOISIATH 438 000 1ANOM4 434 000 91 434 000 3 5 0069 008 9 334 00076 GAM 0 09 438 oag s 434 09270 EE VO MIIA 901 l viia HOS 9 d330 PA 18334 GEEL 09725 1174 SV 12310 Aa Nov 7 2002 US 2002 0162400 A1 36 E Er MUM HOHy383H SWiiSAS HO3LOV EN 1191150 Kaye Nu H9V3 40 AliiNVOD 70 TIAMMOOM 9 09 OL 36 2 T3318 631108 0100 38 OL 51 TWINaLYW S310N Shia MMOHS SV 30Vid L dAL goy 40 431435 1207 14330 00 91 80 9336 HiOB dAi SM ava dvi vid 000 000 2 m d vd 8 00 Nov 7 2002 US 2002 0162400 A1 37 V SIO 31VN Le TR KI EN EA EI SOLVAV TTVWS bo HO4V3S3H SW31SAS
23. T Using the Handset on Axis 3 extend the ram to the desired position and hold red emergency stop button is located to the lower right side of the test frame which will deactivate all of the hydraulics to all actuators if needed 3 2 2 ATTACHING ACTUATORS TO THE COMPONENT 1 A strap is used to apply the tension load on Axis 3 Loop the strap over the components grip and while applying an even pull the strap slide it into the hydraulic grip wedges and initiate the grip on Axis 3 Adjust the wedge gripping pressure to sufficiently grip the strap There should be no load on this axis at this time At the Setpoint control within Test Group 1 change Axis 3 to Load control Establish and activate the Upper Sensor Limit settings for Axis 3 this can be found by clicking on Axis 3 s load cell button within Test Group 1 Input your target tension load on Axis 3 and hit enter Enter must be hit after entering any numerical target command Adjust your Ramp time accordingly approx 20 seconds and hit enter Select the start button to initiate Axis 3 s tension load All actuator movement can be stopped by hitting the Stop button located within Test Group 1 or by pushing the Red Emergency Stop knob on the Labtronic 8800 this will dismantle all hydraulic flow to all actuators The operator should be familiar with both before initiating any actuator movement With full tension load applied to Axis 3 carefully us
24. TAANOA INO 40 ALILNYNO SALN 1808 9558 166 XW3 62 5 13 55384 113 55384 TAMDA TAT 1000 6 113 NHL dvi TIADA vId B E ADs NYHL ONY Trad Suge NADOHS SV S3TH NAHL qvi v9 28 ru 114 55384 2 1 O3 Wv3N NV EXP 2000 27 Nov 7 2002 31 US 2002 0162400 A1 30X0 MOVIE 8561 01 90 600 31VN 3X SNI NVHOW 519 3 daVHS TY 3AUW3H 19 INSWLVASL 73315 SI WIMGLYW 1809 97 zee 2 620 920 186 Hd HO NOJAVOG OU HINON 30 ALILNYNO SWALSAS HO3LOV ZION VY NOI 057 y 00 t 1 NAHL 91 61 reu 3ovds ATIVNOS SATOH 9 4334 2960 21808 Jang NAHL TEG 08 TIG DET 200 27 Nov 7 2002 US 2002 0162400 A1 32 Ad 530903 davHS ST3ADU A9074 ATHLODWS 1 NI 30TIS SVH iyd 800 419 94 HOOT HOVOMA M3LAYAY HAIA HOLVW SNOILY907 3 DH
25. US 20020162400A1 a2 Patent Application Publication ao Pub No US 2002 0162400 A1 19 United States Xie et al 43 Pub Date Nov 7 2002 54 MULTIAXIAL HIGH CYCLE FATIGUE TEST SYSTEM 76 Inventors Ming Xie Beavercreek OH US Som R Soni Beavercreek OH US Charles J Cross Centerville OH US Gary E Terborg Englewood OH US Correspondence Address Bernard E Franz 180 Davis Ave Enon OH 45323 1810 US 21 Appl No 10 085 916 22 Filed Feb 28 2002 Related U S Application Data 60 Provisional application No 60 273 134 filed on Mar 5 2001 Publication Classification 51 Int CM Lt GOIN 3 32 52 US Cl assets 73 812 57 ABSTRACT A multiaxial high cycle fatigue test system for testing bending torsion and tension of a test unit comprises servo hydraulic components including a hydraulic service manifold two small high frequency actuators along a first axis and one large main actuator along a second axis The large main actuator is used to apply a radial centrifugal force and the two small actuators are used to apply vibratory loading the two small side actuators being offset indepen dently of each other to enable the machine to apply both bending loads and torque to the test unit The test unit is subjected to torsion loading when the traverse actuators move in phase that is when both actuators move either in or out at the same time The test unit is subjected to b
26. and the test unit for each test wherein dowel pins ensure that the broach block is returned to the same position as before it was removed from the machine which eliminates the need for setting up the broach block between tests on same or similar blades 7 A multiaxial high cycle fatigue test system according to claim 6 further including a strap which is gripped by a hydraulic wedge grip the hydraulic grip being mounted on the bottom movable die plate attached to the vertical actuator wherein the broach block and the specimen are mounted on the top fixed die plate which ensures that the relative distance between the specimen and the transverse actuators remains undisturbed by the movements of the vertical actuator and which also enables quick change over from one test to another on same or similar blades by eliminating changes in the critical locating dimensions 8 A method of testing a test unit for bending torsion and tension comprising using servo hydraulic components including a hydraulic service manifold two small high frequency actuators along a first axis and one large main actuator along a second axis 06 2002 0162400 1 Nov 7 2002 58 using large main actuator to apply a radial centrifugal actuators move either in or out at the same time and force and using the two small actuators are to apply subjecting the test unit to bending loading when the vibratory loading the two small side actuators being actu
27. ators move out of phase that is one actuator moves offset independently of each other to enable the in when the other moves out or vice versa i to apply both bending loads and torque to the 9 A method according to claim 8 wherein the test unit is est unit turbine blade subjecting the test unit to torsion loading when the traverse actuators move in phase that is when both
28. aulic Flow Initialization 4 2 3 RS Console Test Group 1 stes De D UP 5 3 SYSTEM OPERATION 7 1 see esse ee ee ee ee ee ee se ee ee ee Ge ee ee Ge ee ee 6 3 1 Lead Cell Cala ooi EO e EE OE ha N 6 Load Cell 6 3 2 Component Attachment Ee 7 3 2 1 Positioning 7 3 2 2 Attaching Actuators to Component 8 3 33 Cyclic Waveform Generator Ge H DE UR aai eed 9 3 3 1 Cyclic Waveform Generator Overview 9 3 3 2 Cyclic Waveform Generator Operation 10 4 SYSTEM SHUTDOWN e RE Las 12 4 1 Control System Unload ur ME 12 42 Hydraulics ad 12 06 2002 0162400 1 Nov 7 2002 11 1 2 SYSTEM OVERVIEW HYDRAULIC SYSTEM The Hydraulic System is comprised of the following components gt MTS 506 Hydraulic Compressor located in Bldg 252 Room 25227 The compressor operates at 3000 psi and has a flow rate of 75 gpm Instron Servo Hydraulic Actuators Model PLF7D Load rating 5 2 kN Stroke 20 mm Identification Axis 1 is located on the Left Test Frame Wall mounted
29. ctuators using high pressure rod seals experience a banding problem resulting in early failure When the dynamic stroke is too small to carry fresh oil under the seals the oil film breaks down and results in damage to the rod The PLF7D servo hydraulic actuators are designed built and optimized for high frequency operation Hydrostatic bearings and laminar high pressure seals allow sustained high frequency Short stroke operation The actuator does not have any elastomer seals in contact with the piston rod during opera tion The single rod seal that prevents external leakage when turned off is retracted from the rod when operating A suction pump is used to scavenge the leakage oil during operation 0061 The vertical actuator is a labyrinth bearing pedestal base actuator supplied by Instron The actuator has a dynamic force rating of 11 000 Ib 50 kN and 50 mm stroke The rod diameter is 63 5 mm and the actuator stall force is 63 kN The load in the vertical direction is measured by a dynamic load cell of 11 000 Ib 50 capacity 06 2002 0162400 1 0062 three actuators are connected to servo valves The servo valves are connected to a hydraulic service manifold HSM The hydraulic service manifold is in turn connected to the hydraulic power supply Accumulators are provided in the hydraulic service manifold to enable high frequency operation of the actuators 0063 The procedure for operating the test frame using
30. e the jogging handsets to bring the couplers located on Axis 1 and 2 into alignment with the grips on the component and attach 06 2002 0162400 1 Nov 7 2002 33 3 3 1 13 Axis 1 and 2 will remain in stroke position control for the test and at this time the operator should set their respective Upper and Lower Sensor Limits these can be found by clicking on their Position button square button with the upper and lower arrow heads within Test Group 1 CYCLIC WAVEFORM GENERATOR CYCLIC WAVEFORM GENERATOR OVERVIEW The Cyclic Waveform Generator is capable of controlling each axis individually or it is capable of controlling two or more axis as a group with all axis beginning and ending as a unit The Cyclic Waveform Generator can be located within Test Group 1 and it can be accessed by clicking the square button with the Sine wave symbol The waveform generator can be started and stopped by selecting three of the five large buttons located at the top of the Waveform Generator window They are described by the following see Figure 3 2 1 Start Starts all waveform action on all axis that have the box labeled Include Axis in Master Waveform Control checked Upon selecting this button the operator will receive a confirmation warning showing exactly what actuators will be started and will do so when OK is selected The actuators will then ramp up to the parameters set forth at a rate specified within
31. eck the hydraulic fluid level in pump room fluid gage is located on the right side of pump 3 Check that power is on at breaker in pump room breaker SS H1 4 Make sure that all of the Red Stop and Emergency buttons are out 5 Turn on hydraulic pump Spchg pump auto Source local Main pump Rotate switch to start Back to low for two minutes Rotate switch to high ELECTRONIC CONTROL SYSTEM START UP LABTRONIC 8800 Part of the function of the Labtronic 8800 is the electronic control for the flow of hydraulic fluid to the three Hydraulic Actuators Hydraulic flow is controlled at four different levels Off Pilot Low and High The system has a Main Unit Power toggle switch located on the back and top of the unit Additionally there is an on and off Hydraulic Main switch which is located on the front and left of the unit Once the back Main Unit Power switch has been initiated the unit should be allowed a couple minutes to warm up prior to establishing contagt with the RS Console software 06 2002 0162400 1 Nov 7 2002 10 Figure 2 1 06 2002 0162400 1 Nov 7 2002 2 3 11 Scroll down and select the RS Console option within this application you can set up and control all of the functions of the systems actuators RS CONSOLE TEST GROUP 1 Test Group 1 is the home for all transducer readouts and control system of the three hydraulic actuators When initially opened the Te
32. ed by gussets 0046 3 Auxiliary test frame support including a four post die set 61 62 63 64 and other mounting adaptors 0047 4 Servo hydraulic components including hydraulic service manifold 66 two high frequency actuators 16 1 1 kip 400 Hz and one main actuator 14 11 06 2002 0162400 1 0048 5 Multiaxial digital control and data acqui sition system including the control console and a computer workstation FIG 3 9 See User s Manual 0049 The design features of the above subsystems will be discussed in the following paragraphs 0050 3 1 Concept of Bending and Torsion Loading 0051 Since vibration of turbine engine blades under service conditions include bending and torsion modes two actuators have been designed into the test system to simulate the bending and torsional vibration loading A schematic of the top view of the transverse actuators in relation to the blade is shown in FIG 3 1 0052 The blade is subjected to torsion loading when the transverse actuators move in phase that is when both actua tors move either in or out at the same time FIG 3 2 shows schematic of the torsion loading The blade is subjected to bending loading when the actuators move out of phase that is one actuator moves in when the other moves out or vice versa FIG 3 3 shows a schematic of the bending loading 0053 3 2 Design of the Gripping System 0054 new gripping system was designed and ma
33. embodiment described in the detailed description the test unit is a turbine blade In general the test unit may be any type of complete component or a material sample such as a portion of a component BRIEF DESCRIPTION OF THE DRAWING 0012 FIG 1 1 shows bending and torsion of a gas turbine blade 0013 FIG 2 1 is a schematic of a biaxial loading machine 0014 FIG 2 2 is a photograph of a biaxial loading machine 0015 FIG 2 3 shows a blade gripping system for a biaxial machine 0016 FIG 2 4 is a photograph of biaxial loading of a GE F110 fan blade 0017 FIG 3 1 shows traverse loading in the multiaxial machine 0018 FIG 3 2 shows torsion loading 0019 FIG 3 3 shows bending loading 0020 FIG 3 4 is a three dimensional model of multi axial loading mechanism 0021 FIG 3 5 shows traverse loading of the blade 0022 3 6 is a photograph of a multiaxial loading setup 0023 0024 0025 0026 0027 0028 Appendix A is a User s Manual which contains some computer screen drawings FIG 3 7 shows a multiaxial test frame FIG 3 8 is a photograph of a multiaxial machine FIG 3 10 shows positioning of a traverse actuator FIG 3 11 shows a main chamber and FIG 3 12 shows a four port die set 0029 Appendix B comprises several pages of engineer ing drawings 06 2002 0162400 1 DETAILED DESCRIPTION 0030 1 0 Introduction 0031 Modern gas turbine engines need to ma
34. ending loading when the actuators move out of phase that is one actuator moves in when the other moves out or vice versa 20 NEM Patent Application Publication Nov 7 2002 Sheet 1 of 8 US 2002 0162400 A1 Bending First mode Torsion Third mode Figure 1 1 Bending and torsion of gas turbine fan blade 16 Figure 2 1 Schematic of biaxial loading machine Patent Application Publication Nov 7 2002 Sheet 2 of 8 US 2002 0162400 A1 Figure 2 2 Photograph of biaxial loading machine T i e TE Nylon Strap 1 Pin Contour Surface Rod end Bearing Bonding Plate Figure 2 3 Blade gripping system for biaxial machine Figure 2 4 Photograph of biaxial loading of GE F110 fan blade ra Patent Application Publication Nov 7 2002 Sheet 3 of 8 16 5 Gripping System Transverse 16 Actuator Airfoil Transverse Actuator US 2002 0162400 A1 Figure 3 1 Transverse Loading in the Multiaxial Machine Figure 3 2 Torsion loading Figure 3 3 Bending loading Patent Application Publication Nov 7 2002 Sheet 4 of 8 US 2002 0162400 A1 Figure 3 4 Three dimensional model of multiaxial loading mechanism Figure 3 5 Transverse Loading of Blade Patent Application Publication Nov 7 2002 Sheet 5 of 8 US 2002 0162400 A1 n i EE N Figure 3 6 Photograph of multiaxial loading setup Nov 7 2002 S
35. fferent points with respect to the specimen The base Nov 7 2002 of the lateral actuator slides inside a slot in the actuator fixture and the actuator is bolted to the fixture This allows the actuator to be moved along the slot to a certain extent for quick adjustments The actuator fixture has slots that are used to bolt it to the side frame wall These slots allow the fixture to be moved in the vertical direction to a certain extent for quick adjustments 0068 The main chamber of the multiaxial test frame consists of four frame walls that are 4 inch thick The construction of the main chamber is shown in FIG 3 11 The top and the bottom frame walls have machined grooves The side frame walls have matching machined projections that rest in these grooves This reduces the movement of the side frame walls due to the forces from the transverse actuators This also reduces the transfer of the transverse forces to the bolts holding the walls together A row of threaded holes is provided on the front and back sides of the frame walls to facilitate easy attachment of ancillary equipment such as measuring devices and cameras 0069 four post die set is used in the vertical load train The four post die set is used to minimize the effects of the lateral loading on the piston rod of the vertical actuator The top plate of the die set is bolted to the top frame wall The load cell that measures the load in the vertical axis is bolted to the t
36. heet 6 of 8 US 2002 0162400 A1 Patent Application Publication axial Test Frame 3 7 Multi Figure Patent Application Publication Nov 7 2002 Sheet 7 of 8 US 2002 0162400 A1 D Figure 3 9 Multiaxial machine and operator Figure 3 10 Positioning of the transverse actuator Patent Application Publication Nov 7 2002 Sheet 8 of 8 US 2002 0162400 A1 Figure 3 12 Four post die set 06 2002 0162400 1 MULTIAXIAL HIGH CYCLE FATIGUE TEST SYSTEM 0001 Priority is claimed for provisional application serial No 50 273 134 filed Mar 5 2001 The provisional application is hereby incorporated by reference as though fully set forth 0002 The U S Government has rights in this invention under a development contract with the Air Force Contract No F33615 98 2812 0003 The invention relates to development of a multi axial high cycle fatigue test system BACKGROUND OF THE INVENTION 0004 Modern gas turbine engines need to maintain a balance between high performance affordability and design robustness The rotating components of the turbine engine such as fan blades and turbine blades are subjected to high revolutions per minute during operation As a result one of the most common modes of failure in engine components is fatigue This means that to improve the robustness of components their fatigue behavior would have to be improved 0005 Component fatigue behavior can be improved by improving e
37. igital control and data acquisition sys tem including a control console and a computer work station wherein the large vertical actuator is used to apply a radial centrifugal force and the two small horizontal actua tors are used to apply vibratory loading the two small side actuators being offset independently of each other to enable the machine to apply both bending loads and torque to the blade the blade being subjected to torsion loading when the traverse actuators move in phase that is when both actuators move either in or out at the same time and the blade being subjected to bending loading when the actuators move out of phase that is one actuator moves in when the other moves out or vice versa 2 Amultiaxial high cycle fatigue test system according to claim 1 further including a gripping system to apply the multiaxial loading to the blade a broach block wherein a dovetail of the blade slides into a dovetail of the broach block and the blade is tight ened against the block by two screws from underneath an adapter added to the base of the broach block the adapter being connected to the stationary die plate by a threaded rod the broach block being located on the adapter plate by two dowel pins and attached to the adapter plate by four bolts which facilitates the easy assembly and removal of the broach block and the blade for each test wherein the dowel pins ensure that the broach block is returned to the same posit
38. ing performed on a General Electric F110 turbine engine second stage fan blade Two movable side actuators can apply a transverse fatigue loading to the blade At the same time the main actuator can apply a radial loading to the airfoil to simulate the centrifugal force Scene 11 Control system computer and the operator Narrator digital three station control system controls all three actuators monitoring the load and displacement conditions while performing high speed data acquisition Two side actuators on the test frame with 1000 pound capacity each can apply high frequency loading up to 400 Hz while the main actuator has an 11 000 pound loading capacity Scene 12 Overview of the machine then zoom in to one side actuator Narrator The test system can be used to test many other engineering structures under multi axial high frequency loading Two side actuators are movable and can apply loads to different locations of the test specimen Scene 13 Computer screen shot control software Narrator The user friendly control software makes it easy to setup and operate the test System Three servo hydraulic actuators can be controlled individually or as a group Scene 14 Computer screen then overview of the machine Narrator This test system can be used in the design development and analysis of operational gas turbine engine components as well as evaluation of other advanced materials and structures All currently a
39. intain a balance between high performance affordability and design robustness The rotating components of the turbine engine such as fan blades and turbine blades are subjected to high revolutions per minute during operation As a result one of the most common modes of failure in engine components is fatigue This means that to improve the robustness of components their fatigue behavior would have to be improved 0032 Component fatigue behavior can be improved by improving either the material property or the component geometry or both Material characteristics are typically studied by testing coupons The effect of component geom etry is lost in coupon tests Finite element analysis can be used to simulate the actual component behavior to a certain extent The best method would be to test the actual compo nent by subjecting it to conditions similar to the operating conditions 0033 In a gas turbine engine the fan blades and turbine blades rotate at high revolutions per minute during opera tion The blades are subjected to a radial centrifugal force due to this rotation Gas turbines have alternating stator and rotor blades The stator blades guide the gas onto the rotor blades As a rotor blade advances from one stator blade to the next the gas pressure on the blade decreases and increases again This results in the application of a cyclic load to the rotor blade The blade also vibrates at its modal frequency under suitable condit
40. ion as before it was removed from the machine which elimi nates the need for setting up the broach block between tests on same or similar blades strap which is gripped by a hydraulic wedge grip the hydraulic grip being mounted on the bottom movable die plate attached to the vertical actuator the broach block and the specimen are mounted on the top fixed die plate which ensures that the relative distance between the specimen and the transverse actuators remains undisturbed by the movements of the vertical actuator and which also enables quick change over from one test to another on same or similar blades by eliminating changes in the critical locating dimensions 3 Amultiaxial high cycle fatigue test system according to claim 2 wherein the two high frequency actuators provide 1 1 kip in the range of 0 400 Hz and the main actuator operates at 11 kip Nov 7 2002 wherein the system further includes a load cell of 2000 pound capacity mounted on the piston rod of each transverse actuator using an adapter a clevis being attached to the load cell the clevis being connected to the grip pin using two rod end bearings wherein the grip pin extends from one end of the grip to the other end wherein when the piston rod of a lateral actuator moves forward it pushes one end of the grip pin forward via the clevis and the rod end bearings which results in the application of a force to the specimen in the direction of the actuator mo
41. ions These periodic loads result in a vibratory loading on the blade 0034 This vibratory loading causes high cycle fatigue failure in engine blades To study and improve the fatigue life of gas turbine engine blades a new test methodology has been proposed According to this method the blade will be loaded multiaxially during testing to simulate the actual operating conditions prototype biaxial testing machine was proposed and demonstrated in Phase I of this program The biaxial machine had two hydraulic actuators perpen dicular to each other This enabled the machine to apply both a radial load to simulate the centrifugal force and a cyclic transverse load to simulate the vibratory loading The single transverse actuator facilitated the application of bending loads 0035 Vibration of turbine blades include both bending and torsion modes as shown in FIG 1 1 The biaxial machine could not be used to apply torsion loads to the blade as that required two actuators in the transverse direction A multiaxial testing machine was proposed designed and demonstrated in Phase II The multiaxial machine had three hydraulic actuators a large actuator along the vertical axis and two small actuators along the horizontal axis The large actuator was used to apply the radial cen trifugal force The two small horizontal actuators were used to apply the vibratory loading The two small side actuators can be offset independent of each other This
42. ither the material property or the component geometry or both Material characteristics are typically studied by testing coupons The effect of component geom etry is lost in coupon tests Finite element analysis can be used to simulate the actual component behavior to a certain extent The best method would be to test the actual compo nent by subjecting it to conditions similar to the operating conditions 0006 Ina gas turbine engine the fan blades and turbine blades rotate at high revolutions per minute during opera tion The blades are subjected to a radial centrifugal force due to this rotation Gas turbines have alternating stator and rotor blades The stator blades guide the gas onto the rotor blades As a rotor blade advances from one stator blade to the next the gas pressure on the blade decreases and increases again This results in the application of a cyclic load to the rotor blade The blade also vibrates at its modal frequency under suitable conditions These periodic loads result in a vibratory loading on the blade The following patents are of interest Salberg et al 4 802 365 Feb 7 1989 Owen et al 6 023 980 Feb 15 2000 Wu et al 4 875 375 Oct 24 1989 Meline et al 4 607 531 Aug 26 1986 von Marinell et al 3 696 512 Oct 10 1972 Rao 4 748 854 June 7 1988 Detert et al 3 603 143 Sept 7 1971 Ohya et al 4 869 111 Sept 26 1989 0007 These patents relate to fatigue testing or axial and torsion testing Sallberg e
43. nu factured to apply the multiaxial loading to the blade FIG 3 4 shows the three dimensional model of the gripping and loading system developed during the design stage of phase II The broach block used in phase I was used after some modifications The dovetail of the blade slides into the dovetail of the broach block and the blade is tightened against the block by two screws from underneath To access these two screws the broach block has to be removed from the machine every time the blade has to be removed In phase I the broach block was connected to the moving die plate by a threaded rod So the broach block had to be setup again each time as its position moved every time it was removed from the machine 0055 An adapter was added to the base of the broach block in phase II The adapter was connected to the station ary die plate by a threaded rod The broach block was located on the adapter plate by two dowel pins and it was attached to the adapter plate by four bolts This facilitated the easy assembly and removal of the broach block and the blade for each test The dowel pins ensured that the broach block is returned to the same position as before it was removed from the machine This eliminates the need for setting up the broach block between tests on same or similar blades 0056 The strap 24 is gripped by a hydraulic wedge grip 28 In phase I the hydraulic grip was mounted on the top fixed die plate while the broach block
44. o the blade through a rod end bearing 22 connection on the grip surface The rod end bearing was connected to a clevis which was in turn connected to the piston of the horizontal actuator 16 The rod end bearing allows transverse fatigue loading to be applied to the test specimen and at the same time allows small rotation around the gripping This extra degree of freedom will allow the test specimen to bend under trans verse loading 0040 nylon strap 24 was used to connect the fixture to the hydraulic grips The nylon strap served as the flexible connection that prevented interference between the axial and lateral actuators The gripping system had two bonding plates 26 28 whose internal contours conformed to the surface of the blade 30 A photograph of the complete setup is shown in FIG 2 4 0041 broach block was used to hold the turbine blade specimen in place The broach block resembles a part of the turbine rotor disk The dovetail of the blade slides into the block and the blade was tightened against the block by two screws from underneath The broach block was connected to the vertical actuator directly 0042 3 0 Design of the Multiaxial Loading Test System 0043 The multiaxial loading test system includes following subsystems 0044 1 Main test frame 9FIG 3 7 including an enclosed chamber with four side walls 41 42 43 44 0045 2 Main test frame support including two I beam pedestals 50 52 reinforc
45. o4 513771 i u 5 M a 99 s 000 z 3 9 0001 83 105 WW H O i000 M31N32 HO 200 CUI SU 20 xov JNOUJ 51104 at ME ARE 334 SEZL L 00425 33130 5 S3903 dMVHS TIY 3AO0W3M ZOO SSANMOIHL SNINIHOVA M314V 3 HSV14 3 303 OL SI 13NYd HOV3 Z 30 ALIINVOO 1331S ONNOM9 MHL Y 38 OL SI TlM3LYA S3ION FYTYTTTYYYY YTYYT 2 20 25140 05022 4 GOD dt 434 43M oan z e 1NOM4 dol 0055 SNOISN3AIG GN3 NOLLOS NV 901 310N Nov 7 2002 US 2002 0162400 A1 24 6 Lor em ELEK Mode SV HOV3 S3T0H 91 MO4 dAl 4334 S Gl t e dvi 19334 ze iz TUYA NAOHS SV HOY3 dAL 064 Y SH3NNOD i 53903 TV JAONJY I Z00 SS3NXOIHL ONILY Id 1332 N i ONINIHOWA ONILY d HSV13 3413934 OL SI 13NVd HOV3 40 ALIINVDO 3318 HL f 38 OL Sl WIH31VW i S310N s EX aia did 4339 G G N NOS V Said V MMOHS sv 8213 AL N dAL d330 00 19330 0
46. of the prototype test frame AdTech Systems Research continued to develop the multi axial loading test methodology for advanced materials and structures including high cycle fatigue testing of turbine engine blades Scene 6 Graphics bending and torsion modes of a deformed blade Narrator Since vibration of turbine engine blades under service conditions includes bending and torsion modes two actuators have been designed into the test system to simulate the combined bending and torsional vibration loading Scene 7 Animation two horizontal actuators are moving Narrator When they move in phase the blade is subjected to torsion loading When they move out of phase the blade is subjected to bending loading Scene 8 Animation test frame three actuators are being mounted Narrator The new test frame design has three servo hydraulic actuators Two movable small actuators capable of high frequency loading are mounted on the sidewall of the frame and the main actuator is mounted on the bottom of the frame 06 2002 0162400 1 Nov 7 2002 53 Scene 9 Overview of the machine Narrator In September 1999 AdTech Systems Research completed design and manufacture and installed the multi axial test frame in the Air Force Research Laboratory s Turbine Engine Fatigue Facility at Wright Patterson Air Force Base Scene 10 Zoom in to the vibrating blade and gripping Narrator Multi axial high cycle fatigue testing is be
47. op plate The broach block is attached to the broach block adapter plate which in turn is attached to the load cell The hydraulic grip used to grip the strap is mounted to the bottom die plate using a threaded rod The bottom die plate is attached to the piston rod of the vertical actuator When the piston rod of the vertical actuator is moved downwards the strap is pulled resulting in a vertical load on the speci men The four post die set is shown in FIG 3 12 0070 The actual dimensions of the manufactured parts and the materials used to manufacture them are shown in the detailed drawings attached as Appendix B 06 2002 0162400 1 Nov 7 2002 5 APPENDIX A Multiaxial HCF Testing System User s Manual diTech SYSTEMS RESEARCH INC 06 2002 0162400 1 Nov 7 2002 MULTI AXIAL FATIGUE TEST FRAME OPERATIONS MANUAL TABLE of CONTENTS 1 SYSTEM OVERVIE Wa sedes die E u os ede eke oe eke ee vt ERR 1 rein indent 1 L2 CODO N GR L Ya DO Deis ed u a 1 1 3 Mechanical SyStem 2 2 SYSTEM PREP AND START UP 3 2 1 Hydraulic System Start up ese ase ge N EG Ge see De GE 3 2 2 Electronic Control System Start up essere 3 2 2 1 Labtronic 8800 o ed ae um io qe Pa D 3 2 2 2 Test Toolbar RS Console 4 2 2 3 Hydr
48. st Group 1 has 14 control tabs Their descriptions are as follows from left to right and top to bottom 1 STOP Stops all active waveforms 2 SETPOINT Controls movement of the actuators either in position or load control to a given position 3 CYCLIC WAVEFORM Allows the user to setup the operation of the actuators in a detailed format functioning together as a system or to operate each actuator individually See section 5 2 Overview of Instrons Labtronic 8800 Operating Instructions 4 RAMP GENERATOR Allows the user the option of operating the system with various ramp shapes See section 5 2 Overview of Instrons Labtronic 8800 Operating Instructions 5 TRANSDUCER READOUT Displays a readout of the stroke position and load output Along with the load and stroke readouts are the options to read frequency and time Entering the properties of each readout allows the user further control of the readout parameters This is done by placing the cursor over one of the readout windows and hitting the right mouse button The Transducer Readout window can also be docked as shown in Figure 3 1 6 AXIS TABS Each actuator has an Axis Tab that contains a variety of control options for that given actuator Clicking on this tab opens a Controller Properties window displaying those control options 7 DISPLACEMENT TABS Next to the Axis Tabs are the Displacement or Stroke Tabs that allow defined control over the stroke Clicking on this
49. t al have a multi axial fatigue testing machine SUMMARY OF THE INVENTION 0008 The invention relates to a multiaxial high cycle fatigue test system 0009 Vibratory loading causes high cycle fatigue failure in engine blades To study and improve the fatigue life of gas turbine engine blades or other test units such as components Nov 7 2002 or material samples a new test methodology has been proposed According to this method the blade or other test unit will be loaded multiaxially during testing to simulate the actual operating conditions 0010 multiaxial high cycle fatigue test system for testing bending torsion and tension of a test unit comprises servo hydraulic components including a hydraulic service manifold two small high frequency actuators along a first axis and one large main actuator along a second axis The large main actuator is used to apply a radial centrifugal force and the two small actuators are used to apply vibratory loading the two small side actuators being offset indepen dently of each other to enable the machine to apply both bending loads and torque to the test unit The test unit is subjected to torsion loading when the traverse actuators move in phase that is when both actuators move either in or out at the same time The test unit is subjected to bending loading when the actuators move out of phase that is one actuator moves in when the other moves out or vice versa 0011 In the
50. tab opens the Sensor Properties window displaying various control options such as Calibration and Limit Settings 8 LOAD TABS Next to the Displacement Tabs are the Load Tabs that allow defined control over the load Clicking on this tab opens the Sensor Properties window displaying various control options such as Calibration and Limit Settings i US 2002 0162400 A1 Nov 7 2002 12 SENE RT NS Ns Figure 3 1 06 2002 0162400 1 3 2 3 2 1 11 12 Nov 7 2002 13 Select the load cell control button Next select the tab marked Calibration Select the button marked Calibration Confirm that the Auto and Manual calibration option is selected Then hit the Next button Confirm that the Sensor details are correct and select the Next button Confirm that the Sensor Span Point is correct and select the Next button Confirm that either the Auto Calibration or the Course Balance options are selected along with the Open option within the Cal Relay section Select the Start button to begin the calibration On Axis 3 when selecting the start button the software will automatically advance you through steps 9 11 For Axis 1 and 2 you will need to input steps 9 11 manually Within the Status dialog box you will be prompted for the next step e g Course balanced waiting for Span Change Cal Relay to the close
51. the RS Console software and the Labtronic 8800 controller are described elaborately in Appendix A 0064 3 4 Design of the Multiaxial Test Frame 0065 The major structural components of the multiaxial test frame are a main chamber with four side walls two I beam pedestals and a four post die set FIG 3 7 shows a three dimensional model of the multiaxial test frame 0066 photograph of the complete multiaxial test frame is shown in FIG 3 8 The test frame and the hydraulic service manifold are located inside an enclosed test chamber as shown in FIG 3 9 The control system and the personal computer that acts as the interface with the user are located outside the chamber This isolation of the test frame helps to reduce the noise pollution of the surroundings The I beam pedestals of the machine are bolted to a metallic test bed using T bolts This prevents the machine from moving due to vibrations during high frequency tests The I beams are separated from the test bed by neoprene pads The neoprene pads reduce the transfer of vibrations from the test frame to the test bed 0067 The side frame walls of the test frame have three rows of threaded holes The actuator fixtures are bolted to the side frame walls using these holes This is shown in FIG 3 10 The rows of holes allow the actuator fixtures to be moved and positioned both in the vertical and horizontal directions This enables the positioning of the lateral actua tors at di
52. vailable commercial test frames have only uniaxial loading capability This multi axial test system offers many new capabilities and will have important applications in both the research community and industry 06 2002 0162400 1 Nov 7 2002 56 Scene 15 Credits and acknowledgment no narration Principal Engineer and Program Manage Ming Xie Ph D Team Members Bart Bornhorst Mohan Balan and Norman Frey consultant The development of the multi axial high frequency test system was sponsored by the Turbine Engine Division of the Air Force Research Laboratory s Propulsion Directorate at the Wright Patterson Air Force Base Dayton Ohio Air Force Technical Monitors and Support Gary Terborg Bruce Tavner and Charles Cross Ph D Scene 16 AdTech logo 06 2002 0162400 1 57 What is claimed is 1 multiaxial high cycle fatigue test system for testing bending torsion and tension of a gas turbine fan blade comprising the following subsystems 1 main test frame support including an enclosed chamber with four side walls 2 main test frame support including two I beam pedestals reinforced by gussets 3 an auxiliary test frame support including a four post die set and other mounting adapters 4 servo hydraulic components including a hydraulic service manifold two small high frequency actuators along a horizontal axis and one large main actuator along a vertical axis 5 a multiaxial d
53. vement and wherein the rod end bearings and the clevis joints allow move ment of the grip in the vertical direction to a certain extent 4 A multiaxial high cycle fatigue test system for testing bending torsion and tension of a test unit comprising servo hydraulic components including a hydraulic ser vice manifold two small high frequency actuators along a first axis and one large main actuator along a second axis wherein the large main actuator is used to apply a radial centrifugal force and the two small actuators are used to apply vibratory loading the two small side actuators being offset independently of each other to enable the machine to apply both bending loads and torque to the test unit the test unit being subjected to torsion loading when the traverse actuators move in phase that is when both actuators move either in or out at the same time and the test unit being subjected to bending loading when the actuators move out of phase that is one actuator moves in when the other moves out or vice versa 5 Amultiaxial high cycle fatigue test system according to claim 4 wherein the test unit is a component or a material sample 6 multiaxial high cycle fatigue test system according to claim 4 further including a gripping system to apply the multiaxial loading to the test unit broach block having an adapter connected to a station ary die plate to facilitate easy assembly and removal of the broach block
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