injection-moulded test specimen, polypropylene (bumper ... · development of improved material...

1Materials and ChemistryErik Andreassen 2008-04-08

High-speed tensile testingInjection-moulded test specimen, polypropylene (bumper grade)

Crosshead accelerated to speeds up to 10 m/s before gripping test specimen

2Materials and ChemistryErik Andreassen 2008-04-08

True stress-strain

3Materials and ChemistryErik Andreassen 2008-04-08

High-speed tensile testing

5 m/s1 m/s500 mm/min

5 mm/min

5 m/s1 m/s500 mm/min

5 mm/min

4Materials and ChemistryErik Andreassen 2008-04-08

Different responses in tension and compression, modified Mises criterion

5Materials and ChemistryErik Andreassen 2008-04-08

Material models for simulating impact response

0

500

1000

1500

2000

0 0.005 0.01 0.015 0.02

Deflection [m]

Forc

e [N

]0.7 m/s 0.7 m/s simulation1 m/s 1 m/s simulation2 m/s 2 m/s simulation4 m/s 4 m/s simulation

Validation of models:Comparing results from impact testing with simulations

6Materials and ChemistryErik Andreassen 2008-04-08

Material models for simulating impact responseValidation of models:Comparing results from impact testing with simulations

0

100

200

300

400

500

600

700

0 0.005 0.01 0.015 0.02

Displacement [m]

Forc

e [N

]4 m/s 4 m/s simulation1 m/s 1 m/s simulation500mm/min (const) 500 mm/m simulation5mm/min (const) 5 mm/min simulation

7Materials and ChemistryErik Andreassen 2008-04-08

Unloading response

0

5

10

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25

0 0.05 0.1 0.15Strain [-]

True

stre

ss [M

Pa]

Tensile loading and unloading, 800 mm/min

8Materials and ChemistryErik Andreassen 2008-04-08

New mould for injection moulding test specimensPartly funded by ISI

80 x 80 x 4 mm3 plate80 x 10 x 4 mm3 bars can be machined for

High-speed testing (ISO 18872, large strains)Bending, Charpy etc

Other specimen geometries for shear, compression etcSpecimens can be cut parallell and perpendicular to flowExchangable gate inserts:

Film gatePoint gates at two corners (producing a weld line with varying strength)

Also a cavity for a 80 x 80 x 1.5 mm3 plateCombined pressure and temperature sensor in each cavity

9Materials and ChemistryErik Andreassen 2008-04-08

Gate block B

Ejectors

Cavity 281 x 81 x 1.51 mm3

Cavity 181 x 81 x 4.05 mm3

Tempering fluid in/out

A, B, C and DExchangable gate blocks

Gate block A for cavity 1 Gate block C for cavity 2 Gate block D for cavity 2

10Materials and ChemistryErik Andreassen 2008-04-08

Small milling machine for making test specimensPartly funded by ISI

11Materials and ChemistryErik Andreassen 2008-04-08

Shear etc

12Materials and ChemistryErik Andreassen 2008-04-08

Iosipescu shear test (ASTM D 5379)

13Materials and ChemistryErik Andreassen 2008-04-08

Iosipescu shear testing (Xiang and Sue, J. Appl. Polym. Sci., 2001)

Effect of temperature?

14Materials and ChemistryErik Andreassen 2008-04-08

V-notched rail shear test (ASTM D 7078)

15Materials and ChemistryErik Andreassen 2008-04-08

Digital image correlationFull-field displacement and strain measurements

Vertical displacements

Shear strain distribution across specmen (horisontally)

16Materials and ChemistryErik Andreassen 2008-04-08

3D digital image correlationEquipment (hardware and software) will be bought by SINTEF (not funded by ISI)

17Materials and ChemistryErik Andreassen 2008-04-08

New striker for 3-point bendingimpact test (work in progress)

New force senssor (Kistler 9301B) will be mounted close to striker head

New striker head and striker shaft of titanium alloy

18Materials and ChemistryErik Andreassen 2008-04-08

PhD workMain objective: Development of improved material model(s) for impact loading

Injection moulded parts, with and without fibre reinforcementTesting and numerical simulation (LS-DYNA)

Suggested topics:Improve test procedures

True stress-strain for tension, compression and shearReliable data from testing of components

Improve or develop material models, and establish robust simulation methodsIn-depth study of deformation, damage and fracture

Material type (MWD etc), recyclingLoading temperatureState of stress (tension/compression, multiaxial, ...)Process-induced anisotropy and inhomogeneity – Numerical simulation of injection moulding to get input for local mechanical properties to LS-DYNA

19Materials and ChemistryErik Andreassen 2008-04-08

Summary

Various tests (high-speed tension, shear, compression) in development for obtaining better input to material models Digital image correlation for full-field strain measurementsNew mould for assessing processing effects, anisotropy etcPhD student

20Materials and ChemistryErik Andreassen 2008-04-08

Background info

21Materials and ChemistryErik Andreassen 2008-04-08

Expertise of the Polymer and Composites groupIn the field “mechanical response”

Knowledge of the characteristics of different polymer materialsCompetence on the micro-mechanics (yield, fracture) of some polymer materials

Effects of morphology/processingCharacterisation by microscopy etc

Experience with testing polymersInstruments designed/modified for polymers (high-speed tensile tester, instrumented falling weight)Special rigs, instrumentationSpecial tests for composites

Some experience with numerical simulation (mainly ANSYS)

22Materials and ChemistryErik Andreassen 2008-04-08

Equipment for mechanical testingZwick – quasistatic (load cells 10 N – 250 kN, up to 0.5 m/min)Schenk Trebel – quasistatic (100 kN, temp. from -150 to 250 °C)Instron – fatigue (250 kN)Schenk/Instron – high-speed tensile testing (up to 10 m/s) and fatigue (100 kN, but also possibilities for other load cells) Imatek/Rosand – Instrumented dart drop (up to 12 m/s, up to 650 J)

23Materials and ChemistryErik Andreassen 2008-04-08

Mechanical testing (cont.)

Autoclaves for chemical and thermal exposure, pressure testing etcDynamic mechanical thermal analysis (DMTA)Mini tensile tester (can be placed in a microscope)Rig for creep testing (under development)Measurement of linear thermal expansionExpertise on strain gauges and loggingExperience with high-speed video