2 - New Challenges For Mechanical Testing in The Automotive Industry and Zwick Solutions

Intelligent testing
Testing challenges and

solutions for the automotive
industry
Catalin GRIGORESCU
Contents
Challenges for the automotive industry
Zwick and the automotive industry
Testing solutions for the automotive industry
Car parts and components

A modern car is made of 5000 10000 components,
i.e. 30000 50000 individual parts !
Contents Automotive challenges
General challenges
Testing challenges
Challenges for the testing laboratory
General challenges
New technologies change the way cars are being

designed, developed and produced
BMW i3: carbon and electric
Mercedes SClass:
autonomous
drive, LED only
Corporate presentation Automotive
VW XL1:
consumption < 1l/100km (>111
kmpl)
5
2014
General challenges
5 main areas of research and development (Clepa Horizon 2020)
Decarbonisation of road transport:

- ICE technologies and emission treatment systems
- Electrification: Hybrids, Energy managment, Battery technology, alternative fuels, variable compression
Advanced lightweight materials:

- Materials and joints
- New vehicle concepts and structures
Safety:
- Integrated safety systems (combining active & passive safety systems)
- Safety of new superlight vehicles
- Driver behaviour model and monitoring
- Protection of vulnerable road users
Intelligent transport systems:

- Automation: advanced driver assistance, platooning, full automated driving
- Integration: multimodal travel and inter-modality
- Integrated charging and payment systems
Advanced manufacturing and engineering technologies:

- Environmental impact of new materials, sustainability
- Recycling
Blue:
Relevant for
mechanical testing
Contents
General challenges
Testing challenges
Testing challenges
An increasing variety of car models is offered to consumers
which increases the amount of overall testing
Testing challenges
Overall weight reduction objectives are challenging designers
and materials scientists
100 kg weight reduction

compared to previous A3
9
Testing challenges
Metallic structures are becoming a very complex assembly of
advanced materials: Right material at the right place
10
Testing challenges
Hot sheet forming is implemented successfully in the car industry.
45% of the new cars are produced with high-strength materials.
The current issue is optimizing the process.
Improvement of the production process

Warming austenitizing
Forming
Cooling hardening
Warm tests (Tensile/Compression)
Tensile tests at room temperature (small
specimens)
11
Testing challenges
Multimaterial components allow for structural tuning
Optimized for cost
Optimized for weight
12
Testing challenges
Lightweight materials: Composites, new alloys, organosheets need
to be well understood before they replace conventional materials
13
Testing challenges
Hybrid materials (composites/textiles/plastics/metal)
are being developed in various compositions and challenge
mechanical testing equipment
14
Testing challenges
For the quality assurance of heat treatment the specimens are
directly extracted from the finished part which leads to very
small samples
15
Testing challenges
Different powertrain solutions are being developed globally and
introduce new elements to a passenger vehicle
16
Testing challenges
New components require additional testing
Safety
Materials
High Voltage
Cables
Joining technology
Solar Panel
Chassis
Transformer
Climate Control
Electro motor
Engine & Drive Train
Body
Electronics / Mechatronics
Battery Charger
Battery cells
Wheel Hub
Motor
Battery
Management
17
Battery Packs
Battery
climatisation
Interior
Contents
General challenges
Testing challenges
18
Challenges for testing laboratories

The challenges for testing labs are increasing dramatically as the
new developments have to be qualified
New materials and components
Evolving/Changing test requirements
Cost pressure
Lack of time
Limited capacities of test equipment
Limited capacities of staff
Safety for users
Need for correct results
19
2014
Contents
20

Zwick testing systems are widely used to determine mechanical
properties and durability of materials, structures and components
Tension/Peel/Tear
Compression
Flexure
Corporate presentation What is testing
Axial/Torsional
Fatigue/Durability/High Speed
21
Impact
Melt flow
Hardness
2014

The worlds passenger car manufacturers trust Zwick
22

70% of the worlds leading automotive suppliers are Zwick
customers
23
Test standards
Zwick machines are used for hundreds of automotive test
standards of OEMs, suppliers and international standardization
organizations
and more .
24
and more .
2014
Contents
25
Contents
Testing applications in Research & Development and Production
26
2014
Engine
Examples of tested parts on an internal combustion engine
Cover
Exhaust
Injection
system
Fasteners
Valve springs
Con rods
Cams
Camshafts
Solenoids
Pistons
Gears
Chains
Vacuum pumps
Belts
Castings
Bearings
Valves
Fuel line
Charger
27
Seals
2014
Fasteners
Static and fatigue testing of fasteners
Screw (twisted-off)
Whole screw
Standard: ISO 898

28
Vacuum pump
Fatigue testing on vacuum pump elements
Zwick solution:
Testing parameter:
frequency range: 10 - 30 Hz
torque: 10 100 Nm
number of cycles: 10,000,000
Machine: STM (HC10)
Fixture: converts axial actuator
output into torsion loading
Vacuum pump
Amsler HC 10
29
2014
Connecting rods
High cycle fatigue test on a connecting rod
Testing requirements:
high-cycle fatigue determination
strength of drive components
Testing specifications:
high specimen throughput
minimal operating costs
temperature capability (90 - 120 C)
oil environment simulation (engine)
Zwick solution:
Vibrophore
special clevis grips
test frequency up to 250 Hz
oil environment (temp. controlled)
Testing connecting rods
30
2014
Valve springs
Spring characteristics
Testing requirement:
determination of
spring characteristics
Standards:
EN 15800
Zwick solution:
PrecisionLine Manual
PrecisionLine
Automatic
PrecisionLine Vario
PrecisionLine Manual
PrecisionLine Automatic
31
PrecisionLine Vario
2014
Injector needle
Special fixture for determination of fatigue strength of injection
nozzle module
Machine: High Frequency Pulsator HFP 100
Special fixture according to customer design
Difficult test due to hammering procedure
Including oil and temperature
32
Chains
Fatigue strength tests on engine chain drive systems and
chain elements under environmental conditions
Machine: Servohydraulic HB10 for frequencies up
to 100 Hz
Samples subjected to oil fog / spray
Temperature range: -40 / +120C
Explosion safe chamber
33
Crankshafts
Fatigue tests on complete and partial crankshafts
Description:
fatigue strength test on crankshafts
2-point flexure test
F = 1 6 kN
f = 10 30 Hz
smax = 3 mm
N = ca. 3 x 106 (number of cycles to fracture)

force-controlled test
type of loading: sine
testing at ambient temperature
staircase method
Fatigue testing of crank shafts
34
2014
Drivetrain
Drive axle
Transmission gears
Joints
Drive shaft
Gears
Clutch systems
Castings
Fasteners
35
Coupling
2014
Driver controls
Special testing machine for measuring activation forces of
driver controls (pedal systems)
Machine: Z030 and horizontal Zwicki
2 combined machines for tests in 2 axis
-> variation of tests possible
Machines can be independantly
controlled
36
Clutch disk - axial

Clutch testing machine, operation forces
Machine: Z010 Allround
1 machine -> 2 tests
Pneumatic specimen clamping
Accepts many clutch dimensions
37
Clutch disk - torsional

Torsional testing of clutch disks
zero (null) point
pre and main dampening reference curve
friction point
clutch face-plate reference curve
parallelism
clutch disk thickness
drag torque
Standards:
customers standard. No general standards
Zwick solution:
custom-made torsional clutch disk tester
Horizontal testing machine
Clutch disks
38
2014
Clutch disk - axial
Modernized multiaxial testing system for automotive

clutches
Measurement of spring tab
3 drive systems: 1 x pressure, 2 x release
3 new control electronics testControl (linked)
New motors for drive units
testXpert II for individual multiaxial test runs
Customized control cabinet including silent
cooling unit
39
Axle components
Multiaxial measurement of friction moment of automotive

axle components
Testing of automotive axle components
4 drive systems: 2 x pre-load, 2 x friction load
4 new control electronics testControl (linked)
New motors for drive units
testXpert II for individual multiaxial test runs
Safety equipment incl. light grid
40
Cam shafts
Torsion tests on cam shafts with force-fit joints on

Torsionline
Determination of torque level at which joint formed

Virtual gage-marks are used on each of the two
individual shaft elements
Laser-speckle flow method allows the relative
torsion angle of the two measuring points to each
other to be determined when torsion is applied to
the shaft.
This measurement is only possible with laserXtens
41
Drive shaft
Torsion test on automotive drive shafts and cardanic joints
Machine: TorsionLine 1000 for torque
testing up to 1000 Nm
Measurement of Tmax and calculation of
torque ratio at different positions
Exhaust systems
Structural fatigue
Weld seams
Insulation mats
Sheet metal formability
43
2014
Exhaust systems
Exhaust test rigs
Reproduce service data
Includes entire exhaust
system with engine
2 Actuator rig
4 Actuator rig
44
Catalytic converter material

Testing support mats for catalytic converters during expansion
under high temperature influences
Machine: Z030
- RCTF: Real Condition Test Fixture
- TMA: Thermo-Mechanical Analysis
- Friction coefficient under
temperature and compression
Indepenently heated 10 kN
compression platens (up to 1050C)
45
laserXtens extensometer for noncontact measurement of separation
Chassis
Steering linkage
Shock absorbers
Suspension springs
Brake discs
Brake pads/
linings
Tie rods
Steering system
Wheels
Tires
46
Steering column
2014
Steering wheel mechanism

Measurement of steering wheel adjustment mechanism
3 testing axis for 3 different test profiles
47
Steering linkage
Multi-axial testing
1
2
Automatically adjustable axes:

1 tension / compress. 20 kN maximum
2 torsion 100 Nm max.
tension / compression 1 kN max.
3
Manually adjustable axes
(various components):
adjustment of lateral load
4 vertical position
5 horizontal position
6
Universal
multi-hole baseplate for mounting
fixtures and supports
3 test axes
48
2014
Axial Torsion Strut

MacPherson strut
determination of axial friction forces on struts
under lateral load influences
determination of torque on struts under lateral
load influences
determination of spring piercing points and the
resulting force, force progression and the side
load on the compression coil springs
Zwick solution:
20 kN testing system
torsion drive unit (located below the crosshead)
3-channel measurement platform above and a 6channel set-up below
optional side load up to 3 kN force
MacPherson Strut
49
2014
Disk brake pads

Compression test on disk brake pads
deformation/stiffness under compression load
Zwick solution:
3 measuring transducers connected in parallel,
deformation 1 3 m, accuracy 0.1 m
interchangeable compression die (brake piston)
solutions for various brake pads (position stop
system)
Brake pad testing
Allround-Line
50
2014
Steering linkage
Modernized test system for truck steering linkages
100% inline production control
Special design grips for sequential testing
laserXtens extensometer for torsional
play measurement
51
Suspension spring
3D online imaging of the resulting force guarantees fast, safe
component evaluation during spring testing
Static testing machine
Test results
Results calculated and displayed online:

point of application and point of effect of the
resultant force
spring height
spring diameter with additional enveloping

circumference measuring device
all torques
52
up to 9 force channels
2014
Helical and leaf springs

Testing machine for leaf and helical springs
Removable fixture for helical springs
Large bending fixture for leaf springs
53
Air suspension springs

Static test to EN 13597
Testing air suspension spring
leakage test (compression against time)
compression in relation to axial force
axial and radial stiffness, axial isobar characteristics
Control parameters:
axial force and travel, horizontal force and travel
air pressure or fluid charge
Zwick solution:
250 kN test machine (wide) with specimen-positioning table and
horizontal testing axis
load measurement platform with 5 load cells
load measurement platform above the crosshead with three vertical
and two horizontal load cells
horizontal drive unit (lower left)
54
2014
Tires
Tire bulge test
testing lateral stability of vehicle wheels
measurement of deformation on tire and rim
Control parameters:
axial force and crosshead travel
horizontal force and travel
tire air-pressure
Zwick solution:
Zwick 50 kN test machine (wide frame) with 20 kN horizontal drive
system ( 50 mm)
five-component load measurement platform (axial and horizontal
directions)
testXpert software to control both the drive systems and the air
pressure
Tire bulge test
55
2014
Wheels
Wheel-testing system
compression test on wheel-rim flange
Zwick solution:
100 kN materials testing machine
T-slotted crosshead
compression mandrel
Wheel testing system
56
2014
Chassis
4 Post road simulator modernized with Control Cube
4 Actuators
2 Dual-channel Cubes
QanTiM
Dura
57
Chassis
FlexMAST system modernized with Control Cube
8 Actuators
8 x Single channel Cubes with 1SV8TX
64 transducers
QanTiM
Dura
8 x 1SV8TX
58
Wheels
Dynamic road surface loading rig
5 Actuators
Vertical x 2, Lateral, Longitudinal, Brake
Cyclic, block program loading
59
Body
Adhesives
Structures
Rivets
Joints
Crash structures
Spot welds
Sheet metal
Paint
Fasteners
60
Insulation
2014
Joints
Rivets: Specific Tests - Fatigue
Riveted Overlap-specimen
For fatigue design of (riveted) die
riveted aluminum structures you need
an precise knowledge of stress
conditions (generated due to exterior
loadings) as well as the
corresponding
strengths and expected durability.
Test Task:
S-N Curve
Control of production quality
(possible influences of failures)
61
Sheet metal
Draw-bead test
Description:
determine the supplier quality and formability characteristics of galvanized
steel for car bodies
Zwick solution:
hydraulic gripping system with interchangeable inserts to satisfy different
test specifications:
draw-bead test
friction coefficient for Renault
friction coefficient for VW Salzgitter
(abrasion)
Draw-bead test
Hydraulic grips
62
2014
Sheet metal
High-speed tensile/ compression and penetration tests on
sheet metal
Servohydraulic High Speed Testing Machine
- Fmax = 500 kN
- vmax = 10 m/s
- Piston stroke = 250 mm + 50 mm end cushioning
3 large proportional valves (1500 l/min) for high
speeds and additional servo valves for low speeds
Rigid 4-column test frame, dynamic test force 2 MN
Piezoelectric force measurement
testControl II with testXpert Research
63
Crash structures
1200 kN testing machine for deformation tests on bodywork
components at low speeds.
Machine: Z1200E materials testing machine
- Fmax = 1200 kN
- vmax = 400 mm/min
- high lateral rigidity
Load cell with multiple strain-gage applications
and transverse force monitoring
T-slot platform: width 2350 mm,
depth 4000 mm
Interface for 3-dimensional optical
deformation analysis
64
Reinforcement structures
Flexure test machine for tests on steel reinforcement
structures
3-pt. flexure test on door structures
Easily adjustable supports
65
Sheet metal
Special test fixture for short span flexure tests on metal and
aluminum sheets according to Daimler standard PAPP PWT
4101 and VDA 238-100
Reinforced support rollers and cage for
short support spans
Specimen size 60 x 60 x t mm
Flexure fin with r=0,2 mm and 0,4 mm
Design improved together with
Daimler for standardization
Standard fixtures do not work!
66
Electronics/mechatronics
Overview of applications
Rotary switch
Cable testing
Wire indentation test
Electrical connectors
Circuit board
Mechatronics
67
2014
Interior
68
2014
Seating
Head restraints
Fabrics
Foam
Airbags
Sensors
Leather
Drive mechanisms
Structure systems
69
Adjusters
2014
Seats
Dynamic compression test on seats
Description:
dynamic seat testing to determine the
characteristics and durability of seats as supplied
Zwick solution:
flexible bi-axial component testing system (servohydraulic)
special wide load frame with hydraulic jacks and
locking system and adjustable horizontal actuator
rated at 10 kN
special T-slot mounting base, bi-directional slip
table (Teflon bearings) and three-dimensional
seat platen with gimbaled mount
70
2014
Foam
Test arrangement with two axes for seat testing
71
2014
Foam
Testing foam
Description:
durability test on soft foam
determination of compression stress value before /
after durability test
Testing foam
72
2014
Seat structure
Test on car seat structures in various positions
with 2000 mm/min
Special support fixtures to
allow tensile tests under
various angles
73
Seats
Static seat-testing
Description:
supplier quality assurance testing; support for
new product development
(integrated seat sensors for safety and airbag
control)
Zwick solution:
Special laod frame with a mounted moveable
electromechanical actuator and special platen for
mounting seat component
74
2014
Headrest
Testing headrests
Description:
electro-mechanical testing actuator for static or
dynamic tests
example: 1kN testing actuator for compression
tests on headrest supports
determine the quality, strength and durability of
passenger headrest supports
Zwick solution:
actuator: 1 kN to 30 kN
stroke:
200 - 400 mm
speed:
up to 30 m/min
positioning accuracy: 2.5m
control: force, travel or external signal
Testing of headrests
75
2014
Interior trim
76
2014
Window seal
Window-seal testing
Description:
determine supplier quality and characteristics of window seals
with integrated tactile sensors (safety feature for accidental
closure on fingers, heads etc.)
Zwick solution:
zwicki table-top testing system, 1.0 kN force
specially-designed seal-holder
barcode reader (window seal identification)
integral electrical resistance measurement system
(e.g. 30 N force = 600 ohm signal in the window-seal sensor)
Window seal testing
77
2014
Controls
Haptics and acoustics measurement station for car control
elements
Machine: Zwicki with torsion drive
Measurement of acoustics
- Frequencies: 20 Hz .. 20 kHz
Measurement of haptics and misuse
- Tmax = 0,025 .. 2 Nm
- Fmax = 20 .. 500 N
- Data capture at 10 kHz
Evaluation of the haptics measurement results
either in testXpert (500 Hz data capture) or in
external application (20 kHz data capture)
78
Elastomer joints
Test fixture for the determination of mounting and dismounting
forces of elastomer joints according VW PV 3365
Base unit with spring supported base plate
Load cell mounted on fixture crosshead
Specimen support and compression platens
For various sheet metal thicknesses (0,8 4,5mm)
79
Doors
Testing of car doors and interior components
Complete test rig to be operated inside a
temperature chamber
New control electronics testControl
New motor for drive unit
testXpert II Graphical Sequence Editor
for customized test runs
Several modifications for optimized
handling, new wear parts
80
Safety
81
2014
Seat belts
Tensile test on seat belts according to ECE standard
Description:
tensile test on seat belts
Zwick Z050 Allround-Line for

testing seat belts
Tensile test on seat belts with videoXtens
82
2014
Seat belt tensioner

Testing seat-belt components
Torsion testing arrangement for dynamic tests on seat- belt components
83
Seat-belt components
2014
Airbag
Tensile test on airbag textiles
Description:
determination of material
properties (airbag
texture) for quality
assurance
Tensile test
testXpert screenshot
84
2014
New components in E-Cars

New components require additional testing
Safety
Materials
High Voltage
Cables
Joining technology
Solar Panel
Chassis
Transformer
Climate Control
Electro motor
Engine & Drive Train
Body
Electronics / Mechatronics
Battery Charger
Battery cells
Wheel Hub
Motor
Battery Packs
Battery
Management
85
Battery
climatisation
Interior
Li-Ion batteries
Testing surface layer adhesion of anodes and cathodes of
lithium-ion batteries
Machine: Z010 Allround-Line with
testControl II electronics
Fast (2000 Hz) synchronous measuredvalue acquisition
Special Z-direction tensile fixture to
measure adhesion forces
High repeatability due to up to 5 tests in
sequence
86
Electric motor
Shear test to measure magnet adhesion in stator of electric
motor
Special rotation fixture for precise
positioning
Manual magnet positioning
87
Composites and hydrogen

Tensile, flexure and fracture toughness tests on composite
specimen submerged into liquid nitrogen (77 Kelvin)
3-point flexure test
hydraulic actuators
Dewar vessel
lead-through for load

transmission
interlaminar fracture toughness
88
Fuel cells - Hydrogen

Fuel cell components such as gas diffusion layers, anodes and
cathodes but also stack structures are being tested
89
2014
Services: Consulting and Testing

Let our Applications Test Laboratories use their expertise to
find an individual solution to your testing problems
Demonstrations
Pre-testing
Comparsion testing
Contract testing
Definition of problem
Our worldwide Applications Test Laboratories are equipped with state-of-theart testing systems plus a comprehensive range of accessories.
Our applications engineers offer wide-ranging, practical expertise.
We provide the best possible support in the selection of the right testing
system plus accessories.
Optimum configurations for your testing situation or materials.
Varied solutions for your testing requirements.
Corporate presentation Customer Support
90
2013
Consultation
Demonstration/ pre-testing
Your Solution
Global software solutions

testXpert II Corporate License supports companies with
multiple locations in achieving reliable test results
Internet
Zwick server:
versions +
licenses
Customer
Customers server:
testing procedures
+ jobs + results
Advantages for globally active companies

central control and administration of testing
situations
information about worldwide machinery
availability enables efficient use of testing
equipment
use of uniform test specifications / test
sequences
specification and verification of testing equipment
/ sensors used
local software automatically has uniform status
comprehensive test traceability and
documentation
Reliable, reproducible and comparable test
results with testXpert II Corporate License
Zwick client
Central client
Corporate presentation testXpert
Lab manager
91
Tester client
2012
Thank you!
92
2014

2 - New Challenges For Mechanical Testing in The Automotive Industry and Zwick Solutions

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2 - New Challenges For Mechanical Testing in The Automotive Industry and Zwick Solutions

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Intelligent testing

Testing challenges and

Testing solutions for the automotive industry

Car parts and components

Contents Automotive challenges

New technologies change the way cars are being

Corporate presentation Automotive

Decarbonisation of road transport:

Advanced lightweight materials:

Intelligent transport systems:

Advanced manufacturing and engineering technologies:

100 kg weight reduction

Improvement of the production process

Optimized for cost

Optimized for weight

Engine & Drive Train

Challenges for testing laboratories

Corporate presentation Automotive

Testing solutions for the automotive industry

Zwick and the automotive industry

Corporate presentation What is testing

Zwick and the automotive industry

Zwick and the automotive industry

Testing solutions for the automotive industry

Corporate presentation Automotive

Standard: ISO 898

Corporate presentation Automotive

Testing connecting rods

Corporate presentation Automotive

Corporate presentation Automotive

N = ca. 3 x 106 (number of cycles to fracture)

Fatigue testing of crank shafts

Corporate presentation Automotive

Clutch disk - axial

Clutch disk - torsional

Horizontal testing machine

Corporate presentation Automotive

Clutch disk - axial

Modernized multiaxial testing system for automotive

Multiaxial measurement of friction moment of automotive

Torsion tests on cam shafts with force-fit joints on

Determination of torque level at which joint formed

Sheet metal formability

Corporate presentation Automotive

Catalytic converter material

laserXtens extensometer for noncontact measurement of separation

Corporate presentation Automotive

Steering wheel mechanism

Automatically adjustable axes:

Corporate presentation Automotive

Axial Torsion Strut

Corporate presentation Automotive

Disk brake pads

Brake pad testing

Corporate presentation Automotive

Static testing machine

Results calculated and displayed online:

spring diameter with additional enveloping

Corporate presentation Automotive

Helical and leaf springs

Air suspension springs

Testing air suspension spring

250 kN testing system