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053
Drozdov, O.V.
Pisarenko Institute for Strength Problems, the NAS of Ukraine
2, Timiryazevska St., Kyiv, 01014, Ukraine,
Phone: +380 44 286 3424, fax: +380 44 286 1684; drozdov@ipp.kiev.ua
A hardware and software complex has been developed to determine the strength parameters of promising carbon
fiber reinforced polymers and structural elements of rocket and space equipment under different mechanical loads within
the operating temperature range. The developed complex components, in particular, the multi-channel data-measuring
systems and the appropriate software for measurement, acquisition of experimental data, and calculation of strength
parameters of such materials have been described. The complex capacity and effectiveness have been tested.
K e y w o r d s: carbon fiber reinforced polymer, composite materials, strength, deformation, and data-measuring system.
Over the past few decades, the use of various In addition, the processing of primary test data
composite nonmetallic materials has been grow- and the determination of composite material
ing significantly. This is true also for carbon-plas- strength parameters are quite specific processes
tic composite materials that are increasingly used that shall be carried out in accordance with spe-
in rocket-space and aircraft engineering [1, 2] cially developed standards.
due to unique properties of carbon plastics, in It should be noted that the carbon fiber or fi-
particular, their high specific strength and rigid- berglass technology and, accordingly, the struc-
ity, low temperature expansion, and corrosion re- ture of standard samples for strength tests and
sistance. Unlike metals, the composite materials that of product material can vary significantly.
are essentially heterogeneous and anisotropic [3], Therefore, in addition to calculating the strength
which requires more physical parameters (stress, and bearing capacity of specific products made of
strain, displacement, etc.) to be controlled when carbon-fiber composite materials using the data
testing them. In this case, measurement, visual- on elasticity and durability obtained from the
ization, and accumulation of experimental data tests of standard samples, the rocket and space
obtained in real time with the use of modern com- technology corporations conduct field tests of
puter systems are necessary. Unfortunately, the such products, which are expensive, complicated,
existing hardware for testing the structural mate- and time consuming process.
rials designed and manufactured in the past cen- To reduce the scope and to increase the infor-
tury mainly does not meet the present-day needs. mational efficiency of costly field tests, it is pos-
sible due to production of the most relevant ele-
© DROZDOV, O.V., 2017 ments and smaller model structures manufac-
53
Drozdov, O.V.
Ра
Ра T1
Плата РХ 401 МикРа ИЗ
Зусилля
T2
МикРа ИЗ
ε1 Базовий блок
WG002
T3
МикРа ИЗ
Плата РХ 455
T4
Кабелі та погоджувальні пристрої
МикРа ИЗ
Вимірювальна система РМХ
T5
МикРа ИЗ
Плата РХ 455
Перетворювач
Плата РХ 455 USB/RS-485
ε12 AC-4
USB
Ethernet Персональний
комп’ютер
Fig. 3. Flow chart of ІВС PMX-TEST
sel, Batherworth) and its frequency in each mea- displayed both digitally on the respective indica-
surement channel. The disadvantages of Web tor and graphically on time chart in real time.
Server PMX software are slow display of results PMX-TEST-Monitor program ensures per-
and limited graphical visualization and data stor- formance of wide range of user’s functions, in
age capabilities. particular, setting of measuring channels includ-
To ensure the joint operation of PMX and ing units, conversion factor, zeroization of initial
MIKRA-5 measuring systems, as well as to en- signal for each channel, flexible scale setting
hance the functionality of presentation and pro- along the axes of time diagrams, setting of pa-
cessing of experimental data, a single PMX- rameters for display of both digital data and
TEST-Monitor program has been created. The graphical images. The program ensures storing
main requirements for it were convenient and the accumulated experimental data by their re-
intuitive use of its main elements, real time data cord to text file with extension «*.csv». This en-
visualization in both digital and graphical forms, ables their further analysis and processing in MS
accumulation and storage of experimental data Excel, Origin, etc.
on PC. The creation of single PMX-TEST-
Monitor program was possible due to the fact FpTiraTEST PROGRAM
that the IMS operates using a well-known Tel- FpTiraTest program ensures measuring stress-
net network protocol [6], while the MIKRA-5 es, strains, displacements in real time in the course
system uses data exchange via the Modbus RTU of stretching, compression, and bending of sam-
open communication protocol [5]. These proto- ples made of composite carbon plastic materials,
cols are the basis for data exchange between as well as accumulating and storing experimental
PMC-TEST and PC. data for their further processing. In terms of
The graphical interface of PMX-TEST-Moni- physical values measured and stored the program
tor program is shown in Fig. 4. For convenience, is harmonized with standards ASTM D 3039 [7],
all measuring channels are grouped by type of ASTM D695 [8], ASTM D 7264 [9], which regu-
physical value measured: groups of channels for late testing (stretching, compression, and bend-
measuring strain (D1..D12), group of channels ing) of composite materials with plastic matrix.
for measuring loads (pressure, stress — P1..P4), FpTiraTest graphical interface is shown in
and group of channels for measuring temperature Fig. 5. In the left part, there is the indication and
(T1..T5). The graphical interface is divided into measurement control panel that contains sepa-
two parts along vertical extent. In its upper left rate digital indicators for each measuring chan-
part, there is the control panel that runs IMS nel. Nearby, there are buttons for setting the zero
PMX-TEST, starts and ends data accumulation, value and the polarity of value measured. Below,
indicates current time and number of experimen- there is an indicator of current test time and the
tal data counts. Nearby, on the interface, there is number of counts (measurements) performed
the load P1..P4 view bar (stress, pressure, etc., to- with the buttons for starting and stopping the ac-
tally 4 channels) and to the right, in the upper cumulation of experimental data. Underneath,
part, there is the temperature Т1..Т5 view bar (5 there are windows for inputting the maximum
channels). In the lower part of PMX-TEST- values for viewing the measured values as curves
Monitor graphical interface, there is the strain in the corresponding diagrams.
D1..D12 view bar (12 channels). For convenient Most of the graphical interface is occupied by
visualization, the view bar of strains measured customized rollover pages. The «Test Descrip-
contains a graphic window displaying measure- tion» page is intended for entering and saving the
ment results from all channels as bar chart, in its settings of measuring channels (name of physical
left part (Fig. 4). Each of 21 measured values is value, units of measurement, conversion factor,
ISSN 2409-9066. Sci. innov. 2017, 13 (5) 57
Drozdov, O.V.
number of digits after the decimal point in mea- values (stress, strain, displacement) measured.
surement result displayed for visualization), the For viewing several different physical values with
experiment description (date of test, name of test different maximums on the same axis, this axis is
facility, type and rate of load, etc.), and the sam- presented as range from 0 to 100% of maximum
ple description (material, number, dimensions). values set for each measuring channel. For a quick
All information contained on this page, after the view of the arrays of data received, there is
test, is stored in experiment data file together Datasheet page. It presents all arrays of measured
with the arrays of values measured. For display- physical values (time, stress, displacement, and
ing the measured values in the graphic form, there strain) in tabular form.
are Load Chart and Time Chart pages. The Load FpTiraTest program was developed in such a
Chart page shows the current stress on the Y axis way as to take special measures for reducing the
and readings of other channels (strain, traverse random components of measurement errors
shift) on the X axis. On the Time Chart page, the caused by effect of electrical or electromagnetic
X-axis indicates the current value of test time, interference from the industrial AC network op-
and the Y axis represents the readings for all four erating at a frequency of 50 Hz. To this end, the
58 ISSN 2409-9066. Sci. innov. 2017, 13 (5)
Hardware and Software Complex to Determine the Strength Parameters of Composite Materials
frequency of measurement on all channels is set mental data obtained from mechanical tests of
as high as possible, with the measurement result samples made of composite materials using the
for each channel defined as the average over the FpTiraTest program or similar one. It also pro-
time interval divisible by the alternating cur- vides statistical data processing using the two-
rent period. parameter Weibull distribution. It should be not-
ed that stretching, compression and bending tests
CFRP STRENGTH PROGRAM are the most common and informative tests for
To computerize the calculations of strength and carbon-fiber composite materials and enable not
elasticity properties of carbon-plastic composite only measuring the strength but also the produc-
materials under stretching, compression, and tion of strain diagrams for the material with de-
bending, a special program CFRP STRENGTH termination of appropriate parameters.
has been developed. The CFRP abbreviation The program starts with opening and reading
means Carbon Fiber Reinforced Polymer. The the file with original experimental data. The pro-
program is designed to process primary experi- gram provides reading of plain text files with ex-
ISSN 2409-9066. Sci. innov. 2017, 13 (5) 59
Drozdov, O.V.
tensions «*.csv» or «*.txt». It is also possible to processing of the test results, namely, the estima-
transfer the initial data from open books in MS tion of average mean for each value, its standard
Excel, Origin, etc. to the program by «Copy- deviation and variation in accordance with stan-
Paste» method. dards [7-9]. The calculation results can be saved
The program provides preliminary processing as a text file with extension «*.csv» or exported
of original experimental data, namely, the perfor- in tabular form via the clipboard into a MS Word
mance of the most frequently used processing or MS Excel document.
procedures, in particular, linear transformation An important feature of the CFRP Strength
of the input data array via a separate channel in- program is the ability to calculate the parameters
to the output array of a particular physical quan- of two-parameter Weibull distribution. This dis-
tity. Usually, the recorded original data have a tribution is often used for statistical estimation of
significant random error associated with the ef- material strength. This distribution is considered
fect of arbitrary interference or if a measurable to describe well the strength distribution of indi-
value is significantly lower than the nominal vidual carbon fibers and carbon bundles, and the
measurement range. The error random compo- results of fatigue tests for composite materials
nent can be reduced by finding the average va- with a plastic matrix [10]. In addition, the Weibull
lue of individual measurement results. CFRP two-parameter distribution is also used for the
STRENGTH program performs the simple mov- statistical estimation of the strength of samples
ing average function, which enables averaging from composite carbon-plastic materials for dif-
the array of original data. ferent types of mechanical load.
The mechanical characteristics of composite
carbon fiber materials in this program are com- TRIALS OF THE COMPLEX
puted taking into account the requirements of Using the developed hardware and software
standards [7—9]. The tensile, compression, and complex for measuring the strength parameters
bending strength is determined based on the of composite materials and elements of rocket
sample size according to the known formulas and space engineering structures, a batch of sam-
presented on the CFRP STRENGTH graphical ples of new promising carbon-plastic material ma-
interface (Fig. 6). The most difficult and labor- nufactured at Pivdenne Design Office has been
intensive calculation of carbon-plastic compos- tested. The sample strength and elasticity while
ite materials mechanical characteristics is the bending at a room temperature and at 200 °С
calculation of elastic modulus. Therefore, the have been determined. It has been established
CFRP STRENGTH program contains special that the obtained characteristics have a little
procedures to simplify the calculations. To this spread and remain high as temperature increases
end, the program interface panel has two sliders to 200 °C.
to set the initial and final relative strains (Fig. 6, Model shells from a new carbon-plastic com-
b), among which the elasticity module will be posite material made at Pivdenne Design Office
found. ASTM D 3039 standard [7] recommends have been tested on the original trial equipment
the initial and final relative strains to be equal to using the created complex, at the Pisarenko In-
0.001 and 0.003 m/m, respectively. The elastic stitute of Problems of Strength of the NAS of
modulus is calculated by the program using the Ukraine. Stretching, compression, internal pres-
least squares method. sure and combined load tests have been carried
Having obtained the material mechanical char- out in the range from ambient temperature to
acteristics for a single sample, CFRP STRENGTH 300 °C.
provides the data accumulation in a separate da- The tests have shown that the software com-
tasheet and the subsequent standard statistical plex created with the use of modern measuring
60 ISSN 2409-9066. Sci. innov. 2017, 13 (5)
Hardware and Software Complex to Determine the Strength Parameters of Composite Materials
a b c d
Fig. 6. Parts of CFRP STRENGTH interface for measuring strength and elasticity modulus under stretching (а, b); bend-
ing strength (c, d)
equipment provides multichannel measurement TEST for testing strength of models and ele-
of strains, displacements, and load parameters ments of structures made of composite materials
while testing the materials and elements of struc- have been designed.
tures from composites. Its software performs all FpTiraTest and PMX-TEST-Monitor softwa-
necessary functions, in particular, high-precision re for recording, visualizing and storing the ori-
measurements, visualization, accumulation, stor- ginal experiment data related to the tests of sam-
age and processing of experimental data and has a ples and elements (models) of composite material
convenient and intuitive interface. structures as well as CFRP STRENGTH prog-
The use of complex has enabled obtaining im- ram for measuring strength and elasticity of the
portant physical and mechanical properties of mentioned materials have been developed.
shell material and comparing them with sample All components of created complex have been
ones. The obtained important mechanical prop- tested. The test results have shown their effec-
erties of tested carbon plastics will be used for tiveness and ability to perform the tasks as-
making and adjusting the design calculations of signed.
important elements of rocket and space engineer- Important physical and mechanical properties
ing structures. of carbon plastic composite materials of the sam-
ples and model shells have been obtained, which
CONCLUSIONS can raise effectiveness and reliability of design
Based on the terms of reference, a pilot hard- calculations for the critical elements of rocket
ware and software complex for measuring the and space engineering structures and reduce the
strength parameters of promising composite ma- scope of their field tests.
terials and elements of rocket and space engi- In the view of availability of unique test facili-
neering structures under various mechanical ties at Pisarenko Institute for Problems of
loads within working temperature range has Strength of the NAS of Ukraine, which enables to
been designed in cooperation with Pivdenne De- test both the samples and the structural elements
sign Office. under various thermal and mechanical loads
As a results, hardware complexes ІВС FpTi- within working temperature range it is expedient
raTest-1901 for testing samples under stretch- to continue the joint use of the complex both at
ing, compression, and bending and ІВС PMX- the Institute and at Pivdenne Design Office.
ISSN 2409-9066. Sci. innov. 2017, 13 (5) 61
Drozdov, O.V.