Rajkumar Project Report

A Project Report Entitled
Design, Optimizationand Calibration of 6-Component External

Wind Tunnel Balance
Submitted to
VISVESVARAYA TECHNOLOGICAL UNIVERSITY, BELGAUM

In partial fulfilment of requirements for the award of the degree of
MASTER OF TECHNOLOGY
In
MACHINE DESIGN
By
RajkumarKhot
(USN: 1BM13MMD10)
Project work carried out at
Indian Institute of Science

Bangalore 560012
Under the guidance of
Internal Guide
Dr. J. SharanaBasavaraja
Associate Professor
Dept. of Mechanical Engineering
BMS College of Engineering
Bangalore
External Guide
Dr. S B Kandgal
Principal Research Scientist
Dept. of Aerospace Engineering
Indian Institute of Science
Bangalore
POST GRADUATE AND RESEARCH CENTRE

DEPARTMENT OF MECHANICAL ENGINEERING
B. M. S. COLLEGE OF ENGINEERING
BANGALORE- 560019
July, 2015
POST GRADUATE AND RESEARCH CENTRE

DEPARTMENT OF MECHANICAL ENGINEERING
B. M. S. COLLEGE OF ENGINEERING
BANGALORE- 560019
July, 2015
CERTIFICATE
Certified that the project work entitled Design, Optimization and Calibration of 6-
Component External Wind Tunnel Balancecarried out atIndian Institute of

Science, Bangaloreby Mr.RajkumarKhotbearing the University Seat Number
1BM13MMD10, a bonafide student of B M S College of Engineering is in partial fulfilment
for the award of Master of Technology in Machine Design of Visvesvaraya Technological
University, Belgaum during the year 2014-2015. It is certified that all correction/suggestions
indicated for the internal assessment have been incorporated in the report deposited in the
departmental library. The project report has been approved as it satisfies the academic
requirement in respect of project work prescribed for the said Degree.
Dr. L Ravikumar
Professor and Head
Bangalore -560019
Dr. J. SharanaBasavaraja
Associate Professor
Bangalore -560019
Dr. K MallikarjunBabu
Principal
Bangalore -560019
External Viva
Name of the Examiner
1.
2.
Signature with date
DECLARATION
I, RajkumarKhot (1BM13MMD10), student of IV semester M.Tech Machine Design, B

M S College of Engineering, Bangalore, hereby declare that the work being presented in the
dissertation entitled Design, Optimization and Calibration of 6-Component
External Wind Tunnel Balancesubmitted to the Visvesvaraya Technological

University during the academic year 2014-15, is an authentic record of the work done under
the academic guidance of Dr. J. SharanaBasavaraja, Associate Professor, Department of
Mechanical Engineering, B M S College of Engineering, Bangalore. This project work is
submitted in partial fulfilment of the requirements for the award of the degree Master of
Technology in Machine Design. The work contained in thesis has not been submitted to any
other University or Institute for the award of any degree.
Place: Bangalore
Date:
(RajkumarKhot)
ACKNOWLEDGEMENT
While bringing out this thesis to its final form, I came across a number of people whose
contributions in various ways helped my field of research and they deserve special thanks. It is a
pleasure to convey my gratitude to all of them.
First and foremost, I would like to express my deep sense of gratitude and indebtedness to my
supervisors Dr. S B Kandagal(External guide) Principal Research Scientist,Dept. of Aerospace
Engineering,IISc, Bangalore and Dr. J. SharanaBasavaraja(Internal guide)Associate
ProfessorBMS College of EngineeringBangalore. And for their invaluable encouragement,
suggestions and support from an early stage of this research and providing me extraordinary
experiences throughout the work. Above all, their priceless and meticulous supervision at each
and every phase of work inspired me in innumerable ways
I specially acknowledge them for their advice, supervision, and the vital contribution as and
when required during this research. Their involvement with originality has triggered and
nourished my intellectual maturity that will help me for a long time to come. I am proud to
record that I had the opportunity to work with an exceptionally experienced Professors like them.
I am highly grateful to Dr. S B Kandagaland Dr. D. Ghose, Chairman, Aerospace Engineering
Dept. IISc Bangalore for giving me opportunity to carry out my thesis work at this reputed
institute, which has given me exposure various methodologies of research. I also thank Mr. V
Surendranath and Staff of OCWT, IISc, Bangalore for giving their valuable suggestion and
time whenever asked for.
I am greatly indebted to Dr. B. S. Suresh, Professor and Co-ordinator, PG (Machine Design),

B. M. S. College of Engineering, Bangalore for theencouragement he has given during the
course of this project work.
I wish to express my sincere thanks to Dr. L Ravi Kumar, Professor & Head, Department of
Mechanical Engineering, B. M. S. College of Engineering, Bangalore for supporting throughout
the duration of project.
I take immense pleasure in thanking Dr. K. MallikharjunaBabu, Principal, B. M. S. College

of Engineering, Bangalore, for providing the right kind of milieu.
I
extend
my
thanks
to
my
friendsManjunathMelagiri,
Vishal
G.P,
Ramesh
Sarangamath,Guru Brahmam, Shiva Shankar, Guru Raja, at Vibration and Acoustics lab,
Aerospace department, IISc, Bangalore, for supporting and tolerating me for the past one year
Finally, I extend my thanks to the entire faculty of the Department of MechanicalEngineering,
BMSCE, Bangalore, for their continued co-operation and support during the tenure of this
project work.
RajkumarKhot
ABSTRACT
A six component platform balance was designed and fabricated in the dept. of Aerospace
Engineering, IISc, Bangalore, for measuring aerodynamic forces and moments on models. This
balance utilizes load cells for transducing forces into electrical signals. The platform balance
consists of a leveled platform constrained by six load cells for measuring forces in vertical, axial
and sideward directions. The project work includes the detailed study of wind tunnel balance
types, mounting methods, design concepts, materials used for fabrication of external strain gauge
balances, derivation for calibration, transformation and user matrices.
Project work also includes the FEM analysis of 6-component external force balance,
optimization of force measuring elements and load cells. To study the static and dynamic
coupling of balance when model is attached to force balance by studying individual and coupled
behavior and finally Validating the dynamic characteristics in wind tunnel for a typical model
and study the error in responses of individual components with increased loads. The present
study uses the CATIA to modeling the force balance configuration, Finite Element Analysis
(FEA) extensively to find forces developed in the load cells and optimization of force measuring
elements. MATLAB used during the generation of calibration, transformation and user matrices.
CONTENTS
List of Figures
List of tables
Notations
1
Introduction ............................................................................................................................. 9
1.1
Wind Tunnels ................................................................................................................... 9
1.2
Working method of Wind Tunnel .................................................................................... 9
1.3
Types of Wind Tunnel.................................................................................................... 10
1.3.1
Based on Flow Speed .............................................................................................. 10
1.3.2
Based on Shape: ...................................................................................................... 11
1.4
Balance Types ................................................................................................................ 13
1.4.1
External balances .................................................................................................... 13
1.4.2
Internal balances ..................................................................................................... 15
1.5
Advantages of external balance over internal balance ................................................... 16
1.6
Drawbacks of external balance over internal balance .................................................... 16
1.7
Model Mounts ................................................................................................................ 16
Literature Review .................................................................................................................. 19
Platform Balance Description ................................................................................................ 22
Load Cell ............................................................................................................................... 24

4.1
What is a Load Cell? ...................................................................................................... 24
4.2
Working of Load Cell .................................................................................................... 25
Load Cells - How They Work?.............................................................................................. 25

5
Calibration of the platform balance ....................................................................................... 27

5.1
Objectives of the calibration .......................................................................................... 27
5.2
Force and moment concepts ........................................................................................... 31
5.3
Calibration procedure ..................................................................................................... 32
5.3.1
Negative normal force: ........................................................................................... 32
5.3.2
Positive rolling moment: ......................................................................................... 32
5.3.3
Negative axial force: ............................................................................................... 33
5.3.4
Positive pitching moment: ...................................................................................... 33
5.3.5
Positive side force: .................................................................................................. 34
5.3.6
Positive yawing moment: ........................................................................................ 34
6 Derivation of Calibration Matrix, Transformation Matrix and User matrix of the platform
balance .......................................................................................................................................... 36
7
Balance calibration data and errors ....................................................................................... 40
The Concept of I-Beam and Spring Element......................................................................... 43

8.1
I-Beam ............................................................................................................................ 43
8.2
FE Analysis of Force Measuring element without and with I-beam.............................. 44
8.3
Spring Element in place of Load cell ............................................................................. 45
FEM analysis of external force balance ................................................................................ 46

9.1
Normal Force, Rolling moment and pitching moment measurement ............................ 46
9.2
Side Force and Yawing moment measurement .............................................................. 47
9.3
Axial Force Measurement .............................................................................................. 48
9.4
Combined forces and Moments: .................................................................................... 49
9.5
Stress and Deformation plot ........................................................................................... 50
10
Conclusions and Recommendations .................................................................................. 51
10.1 Conclusions .................................................................................................................... 51

10.2 Recommendations .......................................................................................................... 51
11
References .......................................................................................................................... 52
12
Appendix ............................................................................................................................ 54
12.1 Appendix A .................................................................................................................... 54
LIST OF FIGURES
FIGURE 1-1SCHEMATIC REPRESENTATION OF A WIND TUNNEL....................................................... 10
FIGURE 1-2SCHEMATIC REPRESENTATION OF AN OPEN CIRCUIT WIND TUNNEL ............................. 11
FIGURE 1-3SCHEMATIC REPRESENTATION OF A CLOSED CIRCUIT WIND TUNNEL............................ 12
FIGURE 1-46-COMPONENT EXTERNAL BALANCE AND SUPPORT SYSTEM AT IISC OPEN CIRCUIT
WIND TUNNEL. ........................................................................................................................ 13
FIGURE 1-5TYPICAL SCALED MODELS INSIDE THE WIND TUNNEL ................................................... 14
FIGURE 1-6TYPICAL INTERNAL BALANCE USED IN LOW SPEED WIND TUNNELS .......................... 15
FIGURE 1-7STING AND STRUT MOUNTING METHODS ...................................................................... 16
FIGURE 1-8TYPICAL MODELS INSIDE THE WIND TUNNEL TEST SECTION ......................................... 18
FIGURE 3-1DIFFERENT VIEWS OF PLATFORM BALANCE .................................................................. 22
FIGURE 4-1TYPICAL LOAD CELL USED IN PLATFORM BALANCE AT IISC OPEN CIRCUIT WIND TUNNEL
............................................................................................................................................... 24
FIGURE 4-2SPECIFICATION OF LOAD CELL ..................................................................................... 25
FIGURE 4-3WHEATSTONE BRIDGE NETWORK ................................................................................ 26
FIGURE 5-1PLATFORM BALANCE WITH CALIBRATION SETUP (A) .................................................... 28
FIGURE 5-2PLATFORM BALANCE WITH CALIBRATION SETUP (B).................................................... 29
FIGURE 5-3AXES SYSTEM .............................................................................................................. 30
FIGURE 5-4FORCE AND MOMENT CONCEPT .................................................................................... 31
FIGURE 5-5CALIBRATION FOR NF AND RM .................................................................................... 32
FIGURE 5-6CALIBRATION FOR AF AND PM..................................................................................... 33
FIGURE 5-7CALIBRATION FOR SF AND YM..................................................................................... 34
FIGURE 6-1FORCE AND MOMENT VECTORS AT CC AND BC ........................................................... 38
FIGURE 8-1CONCEPT OF I-BEAM.................................................................................................... 43
FIGURE 8-2FORCE MEASURING ELEMENT WITHOUT AND WITH I-BEAM .......................................... 44
FIGURE 8-3FE ANALYSIS OF FORCE MEASURING ELEMENTS ........................................................... 44
FIGURE 8-4FE ANALYSIS OF FORCE MEASURING ELEMENT BY REPLACING SRING INPLACE OF LOAD
CELL ....................................................................................................................................... 45
FIGURE 9-1NF, RM, PM MEASUREMENT ......................................................................................... 46
FIGURE 9-2SF, YM MEASUREMENT ............................................................................................... 47
FIGURE 9-3AF MEASUREMENT ....................................................................................................... 48
FIGURE 9-4COMBINED FORCES AND MOMENTS MEASUREMENTS ................................................... 49
FIGURE 9-5STRESS AND DEFORMATION PLOT ................................................................................ 50
LIST OF TABLES
TABLE 3-1 THE RATING OF THE BALANCE IS GIVEN IN THE ABOVE TABLE. .................................... 23
TABLE 7-1CALIBRATION DATA (1)
TABLE 7-2 CALIBRATION DATA (2) ......... 40
TABLE 7-3 CALIBRATION DATA (3)
TABLE 7-4CALIBRATION DATA (4) ......... 41
TABLE 7-5CALIBRATION DATA (5)
TABLE 7-6 CALIBRATION DATA (6) .............. 42
TABLE 9-1NF MEASUREMENT ........................................................................................................ 46

TABLE 9-2SF MEASUREMENTS ....................................................................................................... 47
TABLE 9-3AF MEASUREMENT ........................................................................................................ 48
TABLE 9-4COMBINED FORCES AND MOMENTS MEASUREMENTS..................................................... 49
TABLE 9-5EN24 STEEL PROPERTIES ............................................................................................... 50
NOTATIONS
E..Youngs modulus
G..Shear modulus
..Poissons ratio
x, y, z Cartesian coordinates
Fx, Fy, Fz Forces in Cartesian coordinate system
Mx, My, Mz Moments in Cartesian coordinate system
AF.Axial force
NF.Normal force
SfSide force
Mx..Rolling moment
My..Pitching moment
Mz .Yawing Moment
Stress at a point
Strain at a point
M ............Mach number
[C].Calibration Matrix
[T].Transformation matrix
[U].User Matrix
RPerpendicular distance between CC and BC
CC.Calibration centre
BC....Balance centre
a..Eccentricity
F.....Force
Design, Optimization and Calibration of 6-Component External Wind Tunnel Balance
1 Introduction
The aim of wind tunnel tests is the simulation of the flow around bodies or their scaled models.
In aeronautical applications, the measurement of aerodynamic loads in a wind tunnel, forces and
momentums, is a very difficult task due to the required accuracy. The wind tunnel balances,
comprised by several hardware and software components, provides directly the pursued
measurements, with high accuracy and reliability. For these reasons, among others, wind tunnel
balances have become a common tool in testing facilities.
1.1 Wind Tunnels

Wind tunnel is a physical instrument used to test scale models of aircraft and spacecraft. Wind
tunnel is used to predict the amount of forces and moments generated by the solid objects. This
helps designers to choose the proper size for things such as wings, spoilers, and parachutes.
Information obtained in wind tunnels is used to improve the design of anything affected by wind.
In the tunnel; the engineer can carefully control the flow conditions which affect forces on
the aircraft. Some wind tunnels are big enough to hold full-size versions of vehicles. Typically,
there are sensors and instruments inside wind tunnels that give scientists hard data regarding an
object's interaction with wind. And often, there are windows that let those same scientists
observe experiments visually. With those data and observations, engineers grapple with variables
of aerodynamics such as pressure, velocity, temperature and density. In addition, these tunnels
can help engineers figure out how wind interacts with stationary objects, such as locomotives,
buildings, missiles, spacecrafts and bridgesand find ways to make them stronger and safer.
1.2 Working method of Wind Tunnel

Most of the time, powerful fans move air through the tunnel. The object to be tested is fastened
in the tunnel so that it will not move. The object can be a small model of a vehicle. It can be a
full-size aircraft or spacecraft. The air moving around the still object shows what would happen
if the object were moving through the air. How the air moves can be studied in different ways.
Department of Mechanical Engineering, B M S College of Engineering, Bangalore.
Page 9
Smoke or dye can be placed in the air and can be seen as it moves. Threads can be attached to the
object to show how the air is moving. Special instruments are often used to measure the force
and moments of the air on the object.
1.3 Types of Wind Tunnel

Wind tunnels are designed for a specific purpose and speed range. Therefore, there are many
different types of wind tunnels and several different ways to classify wind tunnels.
1.3.1 Based on Flow Speed
Figure 1-1Schematic representation of a wind tunnel
1.3.1.1 Subsonic or low speed wind tunnels

Maximum flow speed in this type of wind tunnels can be 135m/s. Flow speed in wind tunnels is
generally preferred in terms of Mach number which comes out to be around 0.4 for this case.
These types of wind tunnels are most cost effective due to the simplicity of the design and low
wind speed. Generally low speed wind tunnels are found in schools and universities because of
low budget.
Page 10
1.3.1.2 Transonic wind tunnels
Maximum velocity in test section of transonic wind tunnels can reach up to speed of sound i.e.
340m/s or Mach number of 1. These wind tunnels are very common in aircraft industry as
most aircrafts operate around this speed.
1.3.1.3 Supersonic wind tunnels
Velocity of air in test section of such wind tunnel can be up to Mach 5. This is accomplished
using convergent-divergent Nozzles. Power requirements for such wind tunnels are very high.
1.3.1.4 Hypersonic wind tunnels
Wind velocity in test section of such type of wind tunnels can measure between Mach 5 and
Mach 15. This is also achieved using convergent - divergentnozzles.
1.3.2 Based on Shape:

1.3.2.1 Open circuit wind tunnel:
Figure 1-2Schematic representation of an open circuit wind tunnel
This type of wind tunnel is open at both ends. The chances of dirt particles entering with air are
more so more honeycombs (mesh to clean incoming air) are required to clean the air. Open type
wind tunnels can further be divided into two categories:
Page 11
A) Suck down tunnel

With the inlet open to atmosphere, axial fan or centrifugal blower is installed after test section.
These types of wind tunnels are not preferred because incoming air enters with significant swirl.
B) Blower tunnel
A blower is installed at the inlet of wind tunnel which throws the air into wind tunnel. Swirl is a
problem in this case as well but blower tunnels are much less sensitive to it.
1.3.2.2 Closed circuit wind tunnel
Figure 1-3Schematic representation of a closed circuit wind tunnel
Outlet of such wind tunnel is connected to inlet so the same air circulates in the system in a
regulated way. The chances of dirt entering the system are also very low. Closed wind tunnels
have more uniform flow than open type. This is usually a choice for large wind tunnels as these
are more costly than open type wind tunnels.
Page 12
1.4 Balance Types

Balance types are distinguished by the number of force/moment components which are measured
simultaneously one to six are possible and the location at which they are placed. If they are
placed inside the model they are referred to as internal balancesand if they are located outside of
the model or the wind tunnel, they are referred to as external balances. And rotary balances are
used for propellers, helicopter blades and other rotating models.
1.4.1 External balances
Figure 1-46-component External Balance and Support system at IISc Open circuit wind tunnel.
Page 13
Figure 1-5Typical scaled models inside the wind tunnel

They are placed outside the model, inside or outside the wind tunnel chamber test section, there
are two types of external balances exist. The first is the one-piece external balance, which is
constructed from one single piece of material and which is equipped with strain gauges. Such
balances are also referred to as sidewallbalancesas used in half-model tests. The second type of
external balance comprises single force transducers which are connected by a framework. Such a
design can be built very stiff but needs more space compared to the one-piece design. However,
there is usually plenty of space available around the wind tunnel for such a balance, and so the
construction can be optimized with respect to measurement requirements, such as optimized
sensitivity, stiffness and decoupling of load interactions. But they always introduce some
interference in the wind flow. However the possibility to change test models with almost no
effort provides a high flexibility to the wind tunnel facility. There are several degrees of
complexity for these balances, depending mainly on the number of measurement channels, which
can vary between 1 and 6.
Page 14
1.4.2 Internal balances
Figure 1-6Typical Internal Balance Used in Low Speed Wind Tunnels
They are placed inside the model, thus no interferences are introduced in the wind flow by the
balance components, but a mechanical support for the model is always needed to maintain it in
the test chamber and change the model orientation if desired. There is limited space inside the
model itself, so internal balances have to be relatively small in comparison to external balances.
There are two main types of internal balances. The monolithic type, in which the balance body
consists of a single piece of material, is designed in a way such that certain areas are primarily
stressed by the applied loads. The other internal balance type uses small transducers which are
orientated with their sensing axes in the direction of the applied loads. Such a balance is
combined into a solid structure. A balance measures the total model loads and therefore is placed
at the center of gravity of the model and is generally constructed from one solid piece of
material. The number of measured components can also vary between 1 and 6. Above Figure
shows an example of internal balance.
Page 15
1.5 Advantages of external balance over internal balance

1. They are placed outside the model, inside or outside the wind tunnel chamber test section.
2. High flexibility to the wind tunnel facility.
3. Multi-purpose test facility (Aircrafts, automobiles, locomotives, Buildings etc.).
4. The external balance placed outside the wind tunnel test chamber so, their dimensions
and weight are not important.
1.6 Drawbacks of external balance over internal balance

1. Drawback is always introduces some interference in the wind flow, interference problem
doesnt arise in internal balance as the balance placed inside the model.
2. Aerodynamic interference between the model support system and the model itself
3. Interference between tunnel and model.
4. Inertia loads on the balance.
1.7 Model Mounts
Figure 1-7Sting and strut mounting methods
Page 16
There are several different methods for mounting the model inside the test section. The choice of
mounting system in a particular wind tunnel is often driven by the type of balance being
employed. For an external balance, measuring devices are located outside of the model and the
tunnel. For an external balance, the mount must transmit the aerodynamic loads on the model to
the external balance, and hold the model securely at the desired flight condition of angle of
attack and angle of yaw. For an internal balance, the measuring devices are located inside the
model. The mount does not have to transmit forces, but must provide a path for information to be
passed from the model to data recording devices.
On the above figure, four different methods for mounting a fighter aircraft model in a tunnel and
for all of the mounting systems, the struts are normally shielded from the air in the tunnel so that
the drag of the struts themselves is not included in the drag of the aircraft. At the upper right, we
have a three strut mount that connects to the model near both wing tips and at the aft end. The
three strut mount is used most often with external balances; the bottom of the three struts
connects to a platform that is instrumented with strain gages. With three movable struts,
the angle of attack and roll angle can be accurately set and sustained while yaw is provided by
turning the model on the circular section of the platform. The disadvantage of this system is the
expense, complexity and maintenance for three movable struts. Aerodynamic interference
between the struts and the model and flow blockage in the tunnel are also concerns for a three
strut mount. Less expense, interference, and blockage can be obtained by the two strut mount at
the upper left. But the two strut mount is less rigid than the three strut in pitch and roll. Even less
expensive and with a minimum of interference and blockage is the single strut mounting system
shown at the bottom. The single strut can be attached to the top or bottom of the model as shown
at the left bottom, or it can be attached to the rear of the model, as a sting mount, as shown at the
right bottom. The sting mount has less interference with the model flow field than the one strut
mount, but the aft end of the model may be distorted to accept the sting mount. Single strut
mounts are less rigid than multiple strut mounts. The single strut mounts works very well with
internal balances and flow diagnostics.
Page 17
Figure 1-8Typical models inside the wind tunnel test section

We now focus our attention in the 6 components external balances, as they provide 3 forces and
3 momentums measurement and a high flexibility for a multi test wind tunnel.
Page 18
2 Literature Review
Miguel A. Gonzalez, Jose Miguel Ezquerro, Victoria Lapuerta, Ana Laveron,
and Jacobo Rodriguez [1]
This paper gives the general description of wind tunnel balances. The number of measuring
components and the position of the balance with relation to the model and wind tunnel chamber
determines the wind tunnel balances designs. The most flexible ones in terms of usability are the
six components external balances, so these will be referenced for introducing the calibration
process; this is one of the key points to achieve the required aerodynamic tests results accuracy
and reliability. Because of its influence on the drag measurement accuracy, the coupling effect
between lift and drag measurements is analyzed very deeply as well. The analysis of the nonstationary effects are finally done taking into account the wind tunnel balance requirements and
constraints, with special attention on an issue not commonly mentioned, the inertia forces
generated on the balance by the model vibrations, and their influence on the aerodynamic forces
to be measured. Several mentions to signal processing and acquisition are done, as this is the
other key point on the measurements accuracy. However, it is easy to extrapolate these
procedures to other types of balances, as the main intention is to shows which are the critical
points that make wind tunnel balances such a special and complex hardware. They do not intend
here to describe the design and calibration procedures of the industrial manufacturers. This is the
result of a work done in the University Polytechnica de Madrid (UPM), and the
InstitutoTechnologico y de EnergiasRenovables (ITER, Tenerife, Canary Island, Spain,
www.iter.es).
AnkitSoni&PankajPriyadarshi[2]
The important design principles were learnt during the study of this paper, which are described in
this paper. Measurement of forces and moments on aerodynamic models has always been an
important part of wind tunnel experiments. A study was carried out on various beam type load
cells using Finite Element Analysis. It was found that a parallelogram beam type load cell met all
Page 19
requirements and was found to be sensitive only to the normal loading and insensitive to all other
loads and moments. The final configuration of the load cell was arrived at by carrying out a nonlinear constrained optimization of the configuration parameters for two materials, namely
Aluminum and Stainless Steel. These load cells were used to configure different designs of six
components External Strain Gauge Balance. Static FE analysis of the complete assembly was
carried out. An attempt was made to reduce the coupling between various forces & moments and
to make the components sensitive only to their respective normal loads.
HosseinNabipour[3]
This paper aims to fully put the wind tunnel of Memorial University back into service which
requires equipping the tunnel with its old force balance and flow visualization equipment. The
major part of the project will be the calibration and modernization of the force balance for force
and moment measurements on the test model. The balance will be equipped with a data
acquisition system and a computer to monitor and analyze the test results simultaneously. Also
there will be some flow measurements across the test section and finally the smoke generator
needs to be prepared and installed in the tunnel.
Marin SANDU, Adriana SANDU [4]
This paper describes the design of a six-component force/moment sensor which is compact, has
high measuring sensitivities, and can be used either as internal or as external balance in the
aerodynamic testing. The measurement of steady and fluctuating forces acting on a body in a
flow is one of the main tasks in wind-tunnel experiments. Usually, a multi-component strain
gauge force and moment sensor (also known as balance) is used to generate signals which are
processed by means of an adequate instrumentation. To design a wind-tunnel balance, the
specifications of the load ranges and the available space (for the placement of the balance inside
or outside the model) are required. The main challenge is to conceive the elastic element of the
sensor as a monolithic part with a relative simple geometry and to identify the adequate
Page 20
placement of strain gauges to maximize the measuring sensitivities and to diminish the interinfluence of the components.
S. M. GORLIN and I. I. SLEZINGER [5]

Some of the measuring techniques and instruments are described in this book. In this textbook
for advanced measuring techniques and instruments are described. R. C. Pankhurst and D. W.
Holder discuss a wide range of experimental problems in their textbook "Wind -Tunnel
Technique" (1952), but the treatment is general and sometimes superficial. Since the publication
of these works the technology of aerodynamics has advanced greatly. In this book systematically
certain modern techniques of aerodynamic measurement are described. They have made wide
use of experience in the USSR and abroad, selecting material to enable readers with knowledge
of theoretical aerodynamics to become familiar with experimental practice and with the
instruments and apparatus used in practice. The book is intended mainly for experimentalresearch works in aerodynamics and for those using their results and also for students of fluid
dynamics. This book is useful for engineers and technicians designing and constructing
aerodynamic installations, and developing measuring equipment.
Tropea C, Yarin A L, Foss J F [6]

The aim of this paper is to give an impression of the possibilities, advantages and limitations
offered by the use of piezoelectric balances. Several types of external balances are discussed for
wall mounted models, which can be suspended one-sided or twin-sided. Additionally an internal
sting balance is described, which is usually applied inside the model. Reports are given on
selected measurements performed in very different wind tunnels, ranging from low-speed to
transonic; from short- to continuous running time and encompassing cryogenic and high pressure
principles. The projects span from a wing/engine combination in a low-speed wind tunnel to
flutter tests with a swept-wing performed in a Transonic Wind Tunnel, and include bluff
bodiesin a high pressure and cryogenic wind tunnel, as well. These tests serve as examples for
discussing the fundamental aspects that are essential in developing and applying piezo balances.
Page 21
Platform Balance Description
A six component platform balance was designed and fabricated in the dept. of Aerospace
Engineering, IISc, Bangalore, for measuring aerodynamic forces and moments on models. This
balance utilizes load cells for transducing forces into electrical signals. The platform balance
consists a leveled platform constrained by six load cells for measuring forces in vertical, axial
and sideward directions. Fig.1to Fig. 4 shows the different views of the balance. In Fig.1 two
load cells (H1, H2) are indicated which were used for measuring side force and yawing moment.
In Fig.2 one load cell (H3) is indicated to measure axial force. In fig.3 three load cells (V1, V2,
and V3) are fixed to measure normal force, rolling moment and pitching moment. In Fig.4 all
the six load cells are fixed to form the complete platform balance system.
Figure 3-1Different views of platform balance
Page 22
A hexagonal shaped rigid plate (Fig.4) is used as the metric platform. A circular flange fitting is
bolted at the center of this platform (Fig.4) for the purpose of fixing the model support adopter.
The center of the flange coincides with the vertical center line of the platform balance.
The vertical components of the load on the model are sensed by the three load cells fitted
vertically as indicated in the Fig.3. These loads cells are designated as V1, V2 and V3. For
sensing side force and yawing moment, there are two load cells fitted horizontally. In the same
plane for sensing axial force one load cell is provided. These load cells are designated as H1, H2
and H3. From these six load cells the six-components of forces and moments are obtained.
With the direction of axial force aligned parallel to the tunnel axis, we have the following main
components referred to the balance Centre.
1. Normal Force (NF) = V1+V2 +V3
2. Rolling Moment (RM) = (V1-V2)*a
3. Pitching Moment (PM) = V3*a
4. Side Force (SF) = H1+H2
5. Yawing Moment (YM) = (H1-H2)*b
6. Axial Force (AF) = H3
Where a and b are the corresponding length of the moment arm.
Axial force
136 kg
Side force
250 kg
Normal force
700 kg
Rolling moment
200 kgm
Pitching moment
50 kgm
Yawing moment
70 kgm
Table 3-1The rating of the balance is given in the above Table.
Page 23
4 Load Cell
Load: The word loadwill be used to describe both the applied forces and moments. The task of a
balance is to measure the aerodynamic loads, which act on the model or on components of the
model itself. In total there are six different components of aerodynamic loads, three forces in the
direction of the coordinate axes, and the moments around these axes themselves.
Thesecomponents are measured in a certain coordinate systemwhich can be either fixed to the
model or to the wind tunnel.
4.1 What is a Load Cell?

A load cell is a sensor or a transducer that converts a load or force acting on it into an electronic
signal. This electronic signal can be a voltage change, current change or frequency change
depending on the type of load cell and circuitry used.
Figure 4-1Typical load cell used in Platform balance at IISc open circuit wind tunnel
Load cells or Load sensors as they are commonly called - can be made using resistive,
capacitive, inductive or other techniques. Most commonly available load cells are based on the
Page 24
principle of change of resistance in response to an applied load. This is termed piezo-resistive

i.e. something that changes in response to an applied pressure (or squeezed).
One of the most popularly used types of the load cells is the strain gauge load cell. In fact
amongst all the types of load cells, the strain gauge type ones are used most commonly. These
load cells are used for the measurement of very large compressive and tensile forces. This load
cell is the special application of the strain gauges.
4.2 Working of Load Cell

Load Cells - How They Work?
Load cells are traditionally built using resistive bonded foil strain gauges (as shown in the picture
below). Strain gauges are essentially resistors built using standard semiconductor etching
techniques and are bonded to a metallic member such as a cantilever beam or diaphragm.
Figure 4-2 Specification
of load cell
Page 25
Usually at least four strain gauges are configured in a Wheatstone Bridge configuration with four
separate resistors connected as shown below in what is called a Wheatstone Bridge Network. An
excitation voltage - usually 10V is applied to one set of corners and the voltage difference is
measured between the other two corners. At equilibrium with no applied load, the voltage output
is zero or very close to zero when the four resistors are closely matched in value. That is why it
is referred to as a balanced bridge circuit.
Figure 4-2Wheatstone bridge Network

When the metallic member to which the strain gauges are attached, is stressed by the application
of a force, the resulting strain - leads to a change in resistance in one (or more) of the resistors.
This change in resistance results in a change in output voltage. This small change in output
voltage can be measured and digitized after careful amplification of the small milli-volt level
signals to a higher amplitude 0-5V or 0-10V signal.
Page 26
5 Calibration of the platform balance

The goal of calibration is to minimize any measurement uncertainty by ensuring the accuracy of
test equipment. Calibration quantifies and controls errors or uncertainties within measurement
processes to an acceptable level.
5.1 Objectives of the calibration

1. To determine the interaction components
2. To check accuracy, repeatability and linearity.
3. To determine the calibration constant for each component.
For calibration purpose a vertical tubular column with suitable fittings on its both ends need to
fabricate. One end of the bar will have a flange fitting and will be bolted on the platform balance
to the corresponding holes provided for the purpose. The other end of the bar will also have
flange fitting clamped to the vertical column by a pinch fitting thus permitting rotation about a
vertical axis. This will be used for supporting the loading bar and pans. Fig shows a typical
arrangement made for calibration. The loading bar and pans can be aligned with the axial or
lateral directions to calibrate respective components. This arrangement is used for calibration of
the following components.
Page 27
Figure 5-1Platform balance with calibration setup (a)
Page 28
Figure 5-2Platform balance with Calibration setup (b)
Page 29
Axes System
Figure 5-3Axes system
For the platform balance, we choose the balance centre to be at the centre of the mounting flange
which mates with the model/calibration column. The directions of axes are chosen as follows:
Axial force direction coincides with wind direction and is horizontal (X direction).
Normal force direction is vertical positive upwards (Z direction).
Side force direction is horizontal and at right angle to the tunnel axis (Y Direction).
Page 30
5.2 Force and moment concepts
Figure 5-4Force and moment concept
1. Axial force: The force Parallel to the wind flow and to the tunnels walls.
2. Normal force: Upward/Downward force normal to Drag and Side force.
3. Side force: Applied to the sides of the test model and normal to drag and lift.
4. Yawing moment: Moment caused by Drag and Side force about an axis parallel to Lift
5. Pitching moment: Moment caused by Drag and Lift about an axis parallel to side force
6. Rolling moment: Moment caused by Lift and Side force about an axis parallel to Drag
Page 31
5.3 Calibration procedure

5.3.1 Negative normal force:
This is obtained by loading equal weights on both the pans.
5.3.2 Positive rolling moment:

In the negative normal force loading setup, rolling moment is obtained by transferring weights
from one pan to another keeping the total weights same.
Figure 5-5Calibration for Nf and Rm
Normal force = Nf =Fz = F1+ F2

Rolling moment = Rm= Mx= F1*a-F2a
Remaining forces (fx, Fy) and moments (My, Mz) are zero
Page 32
Fz
My

[Nf] = [1 0 0 0 0 0] Mx

Fy
Fx

Mz
Fz
My

[Rm] = [0 0 1 0 0 0] Mx

Fy
Fx

Mz
5.3.3 Negative axial force:

This requires pulley-string arrangement. The loading on the pan gives axial force.
5.3.4 Positive pitching moment:

The loading arm will be rotated by 90 degree to the original position and loading pans will be
hung. Both loading pans loaded equal loads. Now transferring loads from one pan to another,
the pitching moment is obtained.
Figure 5-6Calibration for Af and Pm
Axial force = Af = Fx = F
Page 33
Pitching moment = Pm = My = F*a

Remaining forces (Fy, Fz) and moments (Mx, Mz) are zero
Fz
My

[Af] = [0 0 0 0 1 0] Mx,

Fy
Fx

Mz
Fz
My

[Pm] = [0 1 0 0 0 0] Mx

Fy
Fx

Mz
5.3.5 Positive side force:

This requires pulley-string setup for loading in side direction.
5.3.6 Positive yawing moment:

This is obtained by pulley-string setup, the string being tied to the loading bar at a distance from
the center.
a= 25cm
F
Figure 5-7Calibration for Sf and Ym
Side force = Sf = Fy = F
Page 34
Yawing moment = Ym = Mz = F*a

Remaining forces (Fx, Fz) and moments (Mx, My) are zero
Fz
My

[Sf] = [0 0 0 1 0 0] Mx
Fy
Fx

Mz
Fz
My

[Ym] = [0 0 0 0 0 1] Mx

Fy
Fx

Mz
Page 35
6 Derivation of Calibration Matrix, Transformation Matrix

and User matrix of the platform balance
Before use, any balance needs a calibration to establish the relationship between the balance
output vector in millivolts per volt of excitation and the load vector (forces and moments relative
to a balance centre suitably defined with respect to the balance). For the platform balance, we
choose the balance centre to be at the centre of the mounting flange which mates with the
model/calibration column. The directions of axes are chosen as follows: axial force direction
coincides with wind direction and is horizontal. Normal force direction is vertical positive
upwards and side force direction is horizontal and at right angle to the tunnel axis.
It would be most convenient to calibrate the balance by applying one component of the load
vector at a time and record the balance output vector for each component. However, in this
particular case, it is difficult to apply only a single component of the load vector at a time due to
constraints associated with the balance location. Therefore an alternative scheme using a
generalized loading method is employed and is described below.
Let the balance output vector (written as a row vector for convenience) be associated with a
generalized load vector F. Assuming linearity, we may relate R to F by a calibration matrix C as,
R1
R2
R3
R4
R5
R6
F1
F2
F3
F4
F5
C11
.
F6 .
.
.
C 61
. . . . C16
. . . . .
. . . . .
. . . . .
. . . . .
. . . . C 66
In the above, the calibration matrix is easily obtained by the conventional method of applying
one component of F at a time and recording the balance output vector.
Inverting the above relation, one obtains
Page 36
F1
F2
F3
F4
F5
F6
= R
R2
R3
R4
R5
R6
c11
.
.
.
c61
. . . . c16
. . . . .
. . . . .
. . . . .
. . . . .
. . . . c66
Above equation gives the components of any applied load resolved into generalized forces
1 6 one may transform this to set of forces into forces relative to balance Centre
(Normal force NF, Pitching moment PM, Rolling moment RM, Side force SF, Axial force AF
and Yawing moment YM) by a simple transformation.
We may write
NF
PM
RM
SF
AF YM
= F
F2
F3
F4
F5
T11
.
F6 .
.
.
T61
. . . . T16
. . . . .
. . . . .
. . . . .
. . . . .
. . . . T66
Above equation resolves the generalized forces 1 6 into forces relative to balance
Centre. The transformation matrix [T] is obtained by using equilibrium considerations.
Let CC= calibration Centre, BC= balance Centre; CC and BC are co-linear at a distance of R.
Page 37
R
Figure 6-1Force and moment vectors at CC and BC
Force and moment vectors at CC and BC will be
F = Fxi + Fyj + Fzk;
M = Mxi + Myj + Mzk
Force and Moment vectors at BC wii be
F = Fxi + Fyj + Fzk;
M = Mx i + Myj + Mzk
The procedure to evaluate forces (Fx, Fy, fz) and moments (Mx, My, Mz) at Balance centre is
Cleary explained in calibration procedure chapter.
Fx = Axial force (Af), Fy = Side force (Sf), Fz = Normal force (Nf)
Mx = Rolling moment (Rm), My = Pitching moment (Pm),
Mz = Yawing moment (Ym)
NF
PM
RM
SF
AF
YM
1 0
0 1
0 0
0 0
0 R
0 0
0 0 0
0 0 0 0
1 0 0 0
R 1 0 0
0 0 1 0
R 1 0 a
0
Fz
My

Mx
. (4)
Fy
Fx

Mz
Page 38
R=Column length= 101.4cm
a= eccentricity = 25cm
NF
PM
RM
SF
AF
YM
0
0
0
1
0
1
0
0
0
0
1
0
0
101.4
1
0
0 101.4
0
0
0
4.056 0.04
0
0 0
0 0
0 0
0 0
1 0
0 1
Fz
My

Mx

Fy . (5)
Fx

Mz
In equation (4) and (5) the middle 6*6 matrix is called Transfer matrix [T]
Using above equation we have,
NF
NF
PM
PM
RM
RM
SF
SF
AF YM = R1
AF YM
R2
= R
R2
R3
R3
R4
R4
R5
R5
Here [U] is the user matrix and is obtained by post multiplying
1
R6 C T . (6)
R6 U
. (7)
with [T].
Page 39
7 Balance calibration data and errors
Applied Load
Measured
(NF)(kg)
load (kg)
-20
-20.0185
Applied
% Error
Load (AF)
(kg)
Measured load
(kg)
% Error
-0.0925
-5
-5.0072
-0.144
-40
-40.011
-0.0275
-10
-9.9546
0.454
-60
-59.9901
0.0165
-15
-14.9527
0.3153
-80
-79.9745 0.031875
-20
-19.8777
0.6115
-25
-24.9131
0.3476
-30
-29.853
0.49
-100
-99.9979
-80
-79.9973 0.003375
-25
-25.2144
-0.858
-60
-59.9925
0.0125
-20
-20.2068
-1.034
-15
-15.0998
-0.665
-40
-40.0086
-0.0215
-10
-10.049
-0.49
-5
-5.0138
-0.276
-20
-19.9924
Table 7-1Calibration data (1)
0.0021
0.038
Table 7-2 Calibration Data (2)
Page 40
Applied
Applied Load Measured load
Load
Measured load
(SF)(kg)
(kg)
% Error
(RM)(kg-m)
(kg-m)
% Error
10
10.0333
-0.333
10
10.0333
-0.333
20
19.933
0.335
20
19.933
0.335
30
29.9616
0.128
30
29.9616
0.128
40
39.9879
0.0302
40
39.9879
0.0302
50
49.8957
0.2086
50
49.8957
0.2086
40
40.1149
-0.2872
40
40.1149
-0.2872
30
30.1812
-0.604
30
30.1812
-0.604
20
20.0187
-0.0935
20
20.0187
-0.0935
10
9.9803
0.197
10
9.9803
0.197
Table 7-3Calibration
data (3)
Data (4)
Page 41
Applied
moment
Measured
moment
% Error
Applied moment
(PM)(kg-m)
(YM)(kg-m)
(kg-m)
-2
-1.9638
1.81
-4
-3.934
1.65
Measured
moment
% Error
(kg-m)
1.2
1.1882
0.9833
2.4
2.3997
0.0125
3.6
3.6198
-0.55
4.8
4.8037
-0.0771
-6
-5.9076
1.54
-8
-7.8926
1.3425
6.0227
-0.3783
-6
-5.9025
1.625
4.8
4.8202
-0.4208
-4
-3.9642
0.895
3.6
3.6155
-0.4306
2.4
2.4208
-0.8667
1.2
1.1992
0.0667
-2
-1.9769
data (5)
1.155
Table 7-5
Calibration Data (6)
The calibration data shows that the balance behaves in a linear fashion in the range of loads
applied. The transformation matrix obtained is almost a diagonal matrix as expected. Percentage
error is less than 1% of maximum load in each component.
Page 42
8 The Concept of I-Beam and Spring Element
8.1 I-Beam
Figure 8-1Concept of I-Beam
When an I-beam bends the top of the beam is in compression and the bottom is in tension. These
forces are greatest at the very top and very bottom. So to make the stiffest beam with the least
amount of material you would want the material to be only at the top and bottom sides. However
still need to connect them together or they would just be two separate plates and would not be
stiff at all. So need to put a web in the middle to connect them and make them work together.
The idea is to remove material that is not carrying much load and concentrating the material
where the load is highest. Its an extremely efficient shape for resisting bending.
Page 43
Figure 8-2Force
measuring element without and with I-beam
8.2 FE Analysis of Force Measuring element without and with Ibeam
Figure 8-3FE
analysis of force measuring elements
A study was carried out on various configurations of force measuring elements using Finite
Element Analysis. It was found that an I- beam induced in-between type of force measuring
element met all requirements and was found to be sensitive only to the normal loading and
insensitive to all other loads and moments. Static FE analysis of the force measuring element was
carried out. An attempt was made to reduce the coupling between various forces & moments and
to make the components sensitive only to their respective normal loads and to protect the load
cells.
Page 44
8.3 Spring Element in place of Load cell
Figure 8-4FE
analysis of force measuring element by replacing sring inplace of load cell
The static FE analysis of the complete assembly force balance was carried out by replacing
spring element in place of load cells, because there are no options to create and simulate load
cells like elements in Ansys and some other available analysis softwares. When a spring is
compressed or stretched from its initial position after applying force on an element, the force or
reaction it exerts is approximately proportional to its change in length.
Page 45
9 FEM analysis of external force balance

9.1 Normal Force, Rolling moment and pitching moment measurement
Figure 9-1Nf,
Rm, Pm measurement
The vertical components of the load on the model are sensed by the three load cells fitted
vertically. These loads cells are designated as V1, V2 and V3.
Applied NF (N)
V1 (N)
V2 (N)
V3 (N)
-100
50.98
50.08
0.180
-200
100.29
100.26
0.554
-300
150.15
149.85
0.205
-400
200.20
200.15
0.340
Table 9-1Nf
measurement
Page 46
9.2 Side Force and Yawing moment measurement
Figure 9-2Sf,
Ym Measurement
For sensing side force and yawing moment, there are two load cells fitted horizontally. These
load cells are designated as H1, H2.
Applied SF (N)
H1 (N)
H2 (N)
50
-24.99
24.99
100
-49.99
49.99
150
-74.99
74.99
200
-99.99
99.99
Table 9-2Sf
measurements
Page 47
9.3 Axial Force Measurement
Figure 9-3Af
measurement
In the horizontal plane for sensing axial force one load cell is provided in axial direction and is
designated as H3.
Applied AF (N)
H3 (N)
25
24.99
50
49.99
75
74.99
100
99.99
Table 9-3Af measurement
Page 48
9.4 Combined forces and Moments:
Figure 9-4Combined forces and moments measurements
From V1, V2, V3, H1, H2 and H3 load cells the six-components of forces and moments are
obtained.
Applied
(N)
V1 (N)
V2 (N)
V3(N)
H1(N)
H2(N)
H3(N)
Af
50
-0.00004
-0.0038
-0.0019
-0.0049
-0.00027
49.99
Sf
100
-0.00035
-0.00098
-0.00037
-49.99
49.99
load
0.00022
Nf
200
-100.001
-100.001
0.544
-0.0002
-0.0009
-0.0003
Table 9-4Combined forces and moments measurements
Page 49
9.5 Stress and Deformation plot
Figure 9-5Stress and Deformation plot

The static FE Analysis shows that, stresses and deformations in a designed external balance are
within the limits for specified range of forces and moments.
Material Used: EN24 Steel.
EN24 Chemical composition

Carbon
0.36-0.44%
Silicon
0.10-0.35%
Manganese
0.45-0.70%
Sulphur
0.040 Max
Phosphorus
0.035 Max
Chromium
1.00-1.40%
Molybdenum
0.20-0.35%
Nickel
1.30-1.70%
EN24 Mechanical Properties

Max Stress
850-1000 MPa
Yield Stress
680 MPa
0.2% Proof Stress
665 Mpa
Elongation
13%
Hardness
248-302 Brinell
Table 9-5EN24 steel properties
Page 50
10 Conclusions and Recommendations

10.1 Conclusions
1.
Calibration procedure is explained in detail and data obtained is presented.
2.
The calibration data shows that the balance behaves in a linear fashion in the range of
loads applied. The transformation matrix obtained is almost a diagonal matrix as
expected. Percentage error is less than 1% of maximum load in each component.
3.
The balance can be utilised to determine aerodynamic loads within the specified range
of forces and moments.
4.
The FE Analysis shows that, stresses and deformations of the designed external
balance are within the limits as.
10.2 Recommendations
Recommendations for future works into developing the external force balance include:
1.
Alter the balance so that two or more struts can be used to support models which will
allow for additional stability.
2.
Install vibration isolators that support the force balance to reduce vibration and increase
stability
3.
Create a software program that enables easier calibration, better display, that will reduce
the impact of vibrations on readings
4.
The present work could be extended for developing a design package for complete design
of the balance and preparation of design data that would further help in the design of
actual wind tunnel balances.
Page 51
11 References
[1] Miguel A. Gonzalez, Jose Miguel Ezquerro, Victoria Lapuerta, Components of a Wind
Tunnel Balance: Design and Calibration (2012).
[2] AnkitSoni, PankajPriyadarshi,Finite Element Analysis and Optimization of a Beam Type
Load cell for an External Balance design Aerospace Engg. Dept. Indian Institute of Space
Science and Technology, Trivandrum-695547
[3] HosseinNabipour,Wind Tunnel revitalization project, Memorial University, Mechanical
Engg. Dept. (2006)
[4] M. Sandu, A. Sandu, Analytic-numerical approach in a multicomponent strain gauge
transducer design, Scientific Bulletin of University politehnica of Bucharest, vol67, no. 3,
pp. 37- 44( 2005).
[5] Gorlin S.M &Slezinger,Wind Tunnels and Their Instrumentation, Israel Program for
Scientific Translations, No 1680, Israel Jerusalem (2009).
[6] Tropea. C, Yarin.A.L, Foss.J.F,Force and Moment Measurements, Springer (2007).
Retrived from <http://www.springer.com/978-3-540-25141-5>
[7] Frederick Francois Pieterse, Design and Development of a six Component Strain Gauge
Wind Tunnel Balance, Rand Afrikaans University (2010).
[8] Design of a six component External strain gage balance, NASA Website <www.nasa.gov>
[9] Engler R.H, Klein C, Wind Tunnels and Wind Tunnel Test Techniques, Cambridge, UK,
Paper 43 (1997).
[10] Robinson, M.J. Mee, D.J Tsai, C.Y. Bakos, Measurement of three components of Force on
a large scramjet in a shock tunnel Journal of Spacecraft and Rockets 41(2004).
[11] J.B. Barlow, W.H. Rae Jr and A.Pope, Low-Speed wind Tunnel, 3rd Ed. John Wiley &
Sons, New York (1999).
[12] G. Schewe, Force measurements in aerodynamicsusingpiezo-electric multicomponent force
transducers, Proc. 11th iciasf, 85 Record, Stanford University (1985)
Page 52
[13] Beginners Guide to Wind Tunnels, Glenn learning technologies project, NASA, Retrieved
from <http://www.grc.nasa.gov/www/k-12/airplane/bgt.html>
[14] B. Ewald, Multi-component force balances for conventional and cryogenic wind tunnels,
Meas. Sci.Technol. 11, 8194 (2000)
[15] Tiffany. A, Wind Tunnel Instrumentation, Electronic Engg. Vol 29, No.3, (1957)
[16] Pollok. N, The optimum design of stain gauge sting balance for wind tunnel models,
Report 133, aeronautical research laboratories, Australia (1979)
[16] Levvy .L.E and Saunders.C.G, A modern wind tunnel balance, J.roy.Aero.Soc. vol 57,
512-520 (1953)
[17] Alonpope and John.J.Harpus,Low wind tunnel testing, John Wiley & Sons N.Y (1966).
[18] Reston, Assessment of Experimental Uncertainty with Application to Wind Tunnel
Testing, AIAA S-071A (1999).
[19] G Schewe, Force measurement in aerodynamics using peizo-electric multicomponent force
transducer, 11th ICIASF 85 Record, Stanford University, (1985).
[20] Reston, Calibration and Use of External Strain Gauge Balance with Application to Wind
Tunnel Testing, AIAA R-091(2003)
Page 53
12 Appendix
12.1 Appendix A
The modeling of the external force balance with the required configuration is designed using
CATIA V5 software. The front, top, side and isometric views of the balance is shown in the
following figures.
Page 54
Page 55
Page 56
Page 57

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A Project Report Entitled

Design, Optimizationand Calibration of 6-Component External

VISVESVARAYA TECHNOLOGICAL UNIVERSITY, BELGAUM

Indian Institute of Science

POST GRADUATE AND RESEARCH CENTRE

POST GRADUATE AND RESEARCH CENTRE

Component External Wind Tunnel Balancecarried out atIndian Institute of

Signature with date

I, RajkumarKhot (1BM13MMD10), student of IV semester M.Tech Machine Design, B

External Wind Tunnel Balancesubmitted to the Visvesvaraya Technological

I am greatly indebted to Dr. B. S. Suresh, Professor and Co-ordinator, PG (Machine Design),

I take immense pleasure in thanking Dr. K. MallikharjunaBabu, Principal, B. M. S. College

Wind Tunnels ................................................................................................................... 9

Working method of Wind Tunnel .................................................................................... 9

Types of Wind Tunnel.................................................................................................... 10

Based on Flow Speed .............................................................................................. 10

Based on Shape: ...................................................................................................... 11

Balance Types ................................................................................................................ 13

External balances .................................................................................................... 13

Internal balances ..................................................................................................... 15

Advantages of external balance over internal balance ................................................... 16

Drawbacks of external balance over internal balance .................................................... 16

Model Mounts ................................................................................................................ 16

Literature Review .................................................................................................................. 19

Platform Balance Description ................................................................................................ 22

Load Cell ............................................................................................................................... 24

What is a Load Cell? ...................................................................................................... 24

Working of Load Cell .................................................................................................... 25

Load Cells - How They Work?.............................................................................................. 25

Calibration of the platform balance ....................................................................................... 27

Objectives of the calibration .......................................................................................... 27

Force and moment concepts ........................................................................................... 31

Calibration procedure ..................................................................................................... 32

Negative normal force: ........................................................................................... 32

Positive rolling moment: ......................................................................................... 32

Negative axial force: ............................................................................................... 33

Positive pitching moment: ...................................................................................... 33

Positive side force: .................................................................................................. 34

Positive yawing moment: ........................................................................................ 34

Balance calibration data and errors ....................................................................................... 40

The Concept of I-Beam and Spring Element......................................................................... 43

FE Analysis of Force Measuring element without and with I-beam.............................. 44

Spring Element in place of Load cell ............................................................................. 45

FEM analysis of external force balance ................................................................................ 46

Normal Force, Rolling moment and pitching moment measurement ............................ 46

Side Force and Yawing moment measurement .............................................................. 47

Axial Force Measurement .............................................................................................. 48

Combined forces and Moments: .................................................................................... 49

Stress and Deformation plot ........................................................................................... 50

Conclusions and Recommendations .................................................................................. 51

10.1 Conclusions .................................................................................................................... 51

12.1 Appendix A .................................................................................................................... 54

TABLE 7-2 CALIBRATION DATA (2) ......... 40

TABLE 7-3 CALIBRATION DATA (3)

TABLE 7-4CALIBRATION DATA (4) ......... 41

TABLE 7-5CALIBRATION DATA (5)

TABLE 7-6 CALIBRATION DATA (6) .............. 42

TABLE 9-1NF MEASUREMENT ........................................................................................................ 46

Design, Optimization and Calibration of 6-Component External Wind Tunnel Balance

1.1 Wind Tunnels

1.2 Working method of Wind Tunnel

Department of Mechanical Engineering, B M S College of Engineering, Bangalore.

Design, Optimization and Calibration of 6-Component External Wind Tunnel Balance