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CHAPTER - 3 DESIGN AND ANALYSIS OF VIBRATION TEST FIXTURES

Vibration testing requires a test fixture to interface the specimen and vibration shaker. Vibration test fixtures simulates mounting interface for both the specimen and vibration shaker on either side. The purpose of a test fixture is to couple mechanical energy from a shaker into a test specimen. During the vibration testing, the effects caused by the fixture are important. Vibration test fixtures [202] exhibit resonant frequencies in the test frequency range due to the mass/stiffness characteristics. The resonant frequencies causes significant problem when conducting vibration tests. However, vibration controller controls the shaker input through a feedback accelerometer and controls the level of vibration input into the test specimen. But, the control

accelerometer controls the level of vibration where the control accelerometer is bonded. This indicates that the resonant behavior of the vibration fixture is dependent on the fixture itself. Thus launch vehicle structures vibration testing poses a challenge to design and realize a good vibration fixture [170].

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3.1 TEST FIXTURES DESIGN

3.1.1 Basic Concepts As a vibration test fixture designer, the following inputs of test article and test equipment are to be considered prior to designing a fixture [203]. Details of the shaker table such as pattern of the attachment holes, bolt size and thread sizes are to be known to which the fixture attaches. Size and configuration of the test article Weight and centre of gravity of test article Details of the test specimen such as the mounting interface PCD, its dynamic characteristics Details of the dynamic test specifications Test axis for which fixture is designed Mass that can be attached to the shaker table without possibly causing damage. Available shaker rating. Necessary pre load between the table and fixture. Awareness of the possibilities of the shaker resonances Anticipated/repeated usage of the fixture

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Test article size and configuration are preliminary information required to size and configure the fixture. Weight of the test item and its C.G at least an estimate of its location are required to calculate the combined C.G of the test specimen and the fixture to fall as close as possible to the centre line of the shaker. The axis of motion such as X, Y or Z should be defined relative to the test item or to the assembly into which the item is attached in normal service. The test intensities must be known for two reasons, The inertia force acting on the test item F=WtA must be with stood by the bolts or other fasteners connecting the test item to the shaker There is a limit to fixture weight that can be allowed without exceeding the force rating of the shaker, since Wa and Wt are fixed.

3.2 DYNAMIC CHARACTERISTICS OF TEST FIXTURES

3.2.1 Mechanical Impedance The concept of mechanical impedance helps explain the interaction between vibration shaker, fixture and specimen [39]. A

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simple definition of mechanical impedance is that it is the force required to produce a desired motion to the specimen. Launch vehicle equipments are exposed to random vibration excitations during launch and is functionally designed to survive random vibration testing. In this testing, the random vibration design

levels are applied at the Vibration shaker-interface. For light weight aerospace structures, the mechanical impedance of the equipment and of the mounting structure are typically comparable, so that the vibration of the combined structure and the load involves modest interface forces and responses. Where as the complex space launch vehicle test fixtures will exhibit resonant and anti-resonant frequencies in the testing frequency band. At anti-resonant frequencies, force exceeding the capability of

vibration equipment is necessitated to maintain the required test level. The extra force requirement leads to infinite mechanical impedance. So, the test fixture has to be designed in such a way that it should not induce mechanical impedance to the specimen during testing.

3.2.2 Transmissibility

The fixture must be as stiff as possible so that it is not deflected by the load and transfers motion with high fidelity. This

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quality is called transmissibility, which is a comparison of the output to the input. At a transmissibility of 1.0, the output faithfully follows input. Ideally, a dynamic test fixture couples the motion from the vibration shaker table to the specimen with zero distortion at all amplitudes and frequencies. This ideal is approached, if the test frequency range is narrow or if the test specimen is small. Practically, the ideal cannot be met and the limitation of the fixture must be known. The basic fixture shortcoming is insufficient stiffness. In theory, with an infinitely stiff fixture, the natural frequency of the fixture-specimen system can be made as high as necessary to prevent resonance in the testing frequency band and to provide a transmissibility of 1.0.

Usually, the natural frequency of the fixture lies within the test specification range. In this case, the motion delivered to the test item is higher than the input in the region around resonance and lower than the input above resonance. Suppose the natural frequency of a fixture is 400 Hz, and the specification calls for a 5g vibration from 20 to 2,000 Hz. From fig.4.2 the input to the specimen is 50g at 400 Hz (F1/Fn = 1.0 and T = 10) and only 0.2g at 2,000 Hz (F1/Fn = 5.0 and T = 0.04). Most modern test facilities incorporate automatic amplitude control, so that if the vibration amplitude is measured at the input to the test specimen, a uniform

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5g would be applied to the specimen. Thus we might conclude that stiffness of the fixture is of little consequence in the region of resonance. But such is not the case; fixture stiffness is still important. At 2,000 Hz, the shaker has to vibrate at 125g to provide 5g at the specimen (5/0.04 = 125). Presently, there is no equipment that can provide this high level of vibration. Therefore, the test specification cannot be met at high frequencies.

Fig. 3.1 Transmissibility curve for single degree of freedom system

Thus, the most important factor in fixture design is a high natural frequency above the frequency of interest. However, weight and cost factors require some design tradeoffs. Weight is a drawback as it infringes the capability of the vibrator to deliver enough acceleration to the specimen. Cost considerations influence whether several single-purpose fixtures or one general purpose

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fixture will be built. Weight and cost considerations almost always compromise fixture performance. 3.2.3 Cross axis Response The armature assembly is designed to move in one direction and is held centrally by a suspension system. This system is designed to have high stiffness at right angles to the vibration axis. If high overturning moments are applied to the armature then the suspension guide will be compromised. This cross axis force applied during vibration needs to be understood and kept low so as not to damage the bearings and armature. Designing all fixtures to be light and stiff will assist in preventing unwanted cross axial motion. The centre of gravity should be precisely calculated and each fixture should be rigidly coupled to the armature or slip table. If the C. G of the payload is kept low and aligns with the armature centre then cross axial stress will be minimized. However if the payload C. G is high or offset, then a turning moment is introduced during vibration. Each vibrator has some allowance for cross axis forces and limits the payloads C. G positional distance to the mounting face. 3.2.4 Fixture-Specimen Resonance A simple way to model the fixture-specimen dynamic system is to assume that the test specimen is an ideal, resonant-free mass

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that loads the fixture. An idea of the fixture design problem in terms of how stiff the fixture can be obtained from the formula D = (3.13/Fn) 2, D = the fixture static deflection caused by the specimen that produces the desired Fn in inches Fn = the desired resonant frequency of the specimen-fixture system.

Preferably, Fn is higher than the test spectrum, but usually this ideal is impractical or impossible. For instance, many specifications call for testing up to 2,000 Hz. If, to keep transmissibility close to 1.0, Fn is targeted for 3,000 Hz, the above equation shows that the fixture must not deflect more than 1 milli inch under the weight of the specimen. In most cases, such a stiff fixture is not feasible. Thus, often it is more convenient to develop a fixture, compute stiffness, and then solve for Fn using the above equation. Of course, this approach is crude. But it does provide order-of-magnitude information. The important factor left out of the equation is the mass of the fixture itself which acts to reduce Fn. The amount of reduction varies according to the test configuration and the ratio of the fixture mass to the specimen mass.

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3.3 MATERIAL CHARACTERISTICS

The material should be as low in mass as possible without detriment to the stiffness. As F=m x a, the material mass will have an influence on the shakers thrust ability. Often a fixture will be sculptured and material removed to reduce the mass. The dynamics of the fixture remain unchanged but the stiffness and strength may be compromised and should be considered. If the first resonant frequency can be kept above the test frequency range the quality of test will be improved. The fixture must be stiff enough not to influence the test or change during a test. The fixture will see high stress levels from the applied vibration or the specimen response and must be strong enough to transmit the forces and survive the tests. For fixtures with high Q resonances, the control method will require some investigation. If possible it is preferable to use damping at the fixtures points of influence to reduce the Q. For example a hollow tube will be damped by filling it with foam and often clamping or additional supports will prevent a high Q response. A fixture needs to be significantly stronger than the specimen so that it does not fatigue during use. Avoid any thin brackets, small bolts, sharp corners, overhanging areas and weak areas that will fatigue quickly improve the quality of the fixture.

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3.4 INPUTS DESIGN

REQUIRED

FOR

TEST

FIXTURES

Advanced launch vehicle consists large sub systems such as Heat shield, CBS, Equipment bay, inter stages ITS, SONC. These subsystems are to be qualified for the Vibration Environment. By

considering the weights of all sub systems, it is seen that the maximum weight of the specimen to be tested is 55 kN. The technical details of the large subsystem are given in table 1&2. Table 3.1 Large subsystem details Weight of test specimen Max dia of specimen at fixture attachment points Mounting details of the specimen PCDs on vibration table for fixture attachment Height of C.G of specimen from fixture interface Max vibration test acceleration level Instantaneous peak acceleration level Direction of excitation All three mutually perpendicular axes. 28.8g 9.6 grms 13 dia holes, 120 Nos equispaced on PCD 4030mm 1200mm,1000 mm,800 mm,22 ,16 & 8 1750 mm 5500 kg 4060 mm

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Table 3.2 Dynamic Characteristics Minimum natural frequency >100 Hz

(fundamental mode) Transmissibility at any resonance <8 frequency Maximum target weight of fixture General Configuration <1.5 t Conical shell with

stiffeners / Cylindrical shell with stiffeners Flatness at fixture attachment 0.05 mm

Interface plane

3.5 DESIGN OF TEST FIXTURE FOR VERTICAL AXIS

The vertical test setup is made by coupling two

Electrodynamic shakers in vertical axis and a common bare table is attached to the shakers. The common bare table is called as load bearing platform (LBP). The LBP acts as a test table in dual shaker system. The LBP is having a maximum PCD of 1200mm for fixing the test article/test fixture. From the technical details of the advanced launch vehicle sub systems, the sub systems are having interface PCD of

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4060mm. Where as the LBP is having a max PCD of 1200mm in vertical mode. Hence, it is not possible to assemble the test specimen directly on the shaker table. Vibration testing of a sub system in vertical axis is necessitates an intermediate structure to connect the test specimen to vibration table. This intermediate structure is called as vibration test fixture. The test fixture is to be designed to interface both the PCDs of the test specimen and shaker table. It is seen that the maximum weight of the specimen to be tested is 55 kN. The predicted maximum random vibration test specification of large subsystems of advanced launch vehicle is 9.6 grms and instantaneous peak acceleration is 28.8 grms (three times of maximum value). The available force rating of the Dual shaker system is 300 kN max and 900 kN instantaneous peak. Fixture Weight Large sub system weight Instantaneous peak acceleration Force rating required = 15kN (assumption) =55kN = 28.8 grms = ((55+15) x28.8) =2016 kN >900kN (Shaker Capacity) In view of this, the test accelerations are to be fixed judiciously.

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By limiting the shaker force to 900 kN, The peak acceleration the specimen can be subjected = 900/(55+15) = 12.8grms Maximum possible g=300/70=4.3g Static loads on fixture: Max. test acceleration Instantaneous peak acceleration Ratio=28.8/9.6=3 max instantaneous force on the fixture due to specimen =55x4.3x3 =709 kN=710 kN Load due to self-weight of fixture =15x4.3x3 =193.5 kN =9.6 grms =28.8 grms

Fig. 3.2 Design calculations in vertical axis

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After studying number of design configurations with different parameters of shape, radius, thickness of plates, the test fixture is configured as an expanding conical structure expands from 1200mm to 4100mm and stiffened with internal and external radial ribs. In view of large dimensions and weight, the fabrication method chosen is welding. The fixture has overall dimensions of 1460 mm base diameter and height of 800 mm and at top the flange diameter is 4100 mm. The base plate is 40 mm thick and a tapered conical shell (tapering from 40 mm to 20 mm thick) of 560 mm height is an integral part of it (bottom shell). Another tapered conical shell 16 mm thick and height of 247 mm is welded to the bottom shell. Internally 24 nos of ribs of 16 mm thick are connecting to the bottom shell and conical shell and externally 30 Nos of 16 mm thick stiffeners are connecting the bottom shell, tapered conical shells and top flange. Holes of 13 mm dia (total 81 nos) are provided on base plate on 22, 800,1000,1200,1400 mm PCDs to suit the vibration table. Interfacing of the fixture to the specimen is through 90 Nos of 13 dia holes provided on 3240 mm PCD and 120 Nos of 13 dia holes provided on 4030 mm PCD on top flange.

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Fig. 3.3 Vertical axis test fixture modal

3.6

DESIGN OF TEST FIXTURE FOR HORIZONTAL AXIS

The horizontal test setup is made by coupling two

Electrodynamic shakers in horizontal axis and connected to a large slip table. The large slip table acts as a test table in horizontal testing. The large slip table is having a maximum PCD of 2800mm for fixing the test article/test fixture. From the technical details of the advanced launch vehicle sub systems, the sub systems are having interface PCD of 4060mm, where as the slip table is having a max PCD of 2800mm. Hence, it is not possible to assemble the test specimen directly on the large slip table. Vibration testing of a

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sub system in horizontal axis is necessitates an intermediate structure to connect the test specimen to slip table. The test fixture is to be designed to interface both the PCDs of the test specimen and slip table. The available Max force rating of the shaker = 300kN Instantaneous Force rating (Dual Shaker mode) = 900kN Overturning moment of the large slip table = 1600kNm. Since the test specifications called for testing the specimens beyond the available full force rating & over turning moment considerations Required max force rating: 1872kN Required overturning moment= 3283kNm (with a CG height of 2.0m from the base), It was necessary to revisit the test specifications. Accordingly the specifications are revised. Design overturning moment capacity of Large Slip Table = 1600 kNm Max mass of specimen = 55 kN (cg at 2 m from Large slip table) Mass of fixture = 0.963 t (cg at 0.14 m from slip table) Moment due to specimen and fixture @ 1g lateral acceleration

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(5.5*2 + 0.963*0.14) *10 = 111.34 kNm Max acceleration for design = 1600/111.34 = 14.37 g Lateral force applied = 5.5*14.37*10 = 790.35 kN Moment on the top flange of fixture = 790.35*1.75 = 1383.11 kNm These loads are applied on the fixture interface for finite element analysis Support condition due to tightening torque Tightening torque considered (T) = 66 Nm (on all 60+60 Nos of M12 bolts) Pretension in bolt due to the initial torque P P = T/ 0.2d = 27.5 kN per bolt Total load applied at the interface of fixture and slip table = 27.5*120 = 3300 kN Area of base plate = 1.672e6 mm2 (OD- 2912 / ID- 2520 mm) Compressive stress at interface = 2 MPa Moment = 1600 kNm I and Z of base plate = 1.55e12 mm4 and 1.064e9 mm3 Bending stress due to moment = 1.5 MPa Since the compressive stress at the interface is more than the Bending stress due to overturning moment the surfaces are always in contact and the entire surface can be considered as participating.

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With a target weight < 1.0t, number of design configurations with different parameters, shapes, radius and thickness of plates are studied. Finally, the fixture is configured as a cylindrical structure stiffened with radial ribs.

Fig. 3.4 Horizontal axis test fixture modal

3.7 MATERIAL SELECTION FOR FABRICATION

Materials generally considered for vibration fixtures like Stainless Steel, Aluminum, Magnesium have similar E/ ratio (ratio of Youngs modulus to density) not affecting the natural frequency of the fixture. However, when the shakers are operating at their full performance level, like in the present case, weight of

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the fixture dominates the selection of the material. Composite materials [176] though are ideal for fixture to test large and heavy specimen, fabrication of the same is highly difficult. Though Magnesium is a lighter metal, fabricability issues and availability of indigenous fabrication techniques have compelled to choose Aluminum alloy AA6061-T6 as the candidate material. The fixture is fabricated (an all welded structure) from Aluminum alloy AA6061-T6 plates (Physical Density properties: Fatigue youngs strength:

Modulus=0.689MPa,

=2700kg/m3,

96.5MPa, yield strength: 276MPa, poisons ratio: 0.33) based on the lightness and fatigue strength requirements of the fixture. The fixture is cylindrical in shape with top flange having internal and external ribs. Alloy 6061 is one of the most widely used alloys in the 6000 Series. This standard structural alloy, one of the most versatile of the heat-treatable alloys, is popular for medium to high strength requirements and has good toughness characteristics. This alloy is having good damping property. Applications range from transportation components to machinery and equipment

applications to recreation products and consumer durables. Alloy 6061 has excellent corrosion resistance to atmospheric conditions and good corrosion resistance to sea water. This alloy also offers good finishing characteristics and responds well to anodizing;

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Alloy 6061 is easily welded and joined by various commercial methods. Since 6061 is a heat-treatable alloy, strength in its -T6 condition can be reduced in the weld region. Selection of an appropriate filler alloy results in the desired weld characteristics.

3.8

FINITE ELEMENT ANALYSIS

Ansys Workbench is a computer based analytic tool for solving problems related to structures [159]. Both the fixtures are modeled in work bench as per the finalized configuration. As per the requirements, drilled holes in the specified PCDs are incorporated in the top and bottom flanges. The structural design starts with modeling of the structure by dividing it into an equivalent system of simple elements (solid elements) such as quards or triangles, with easily obtained stress and deflection characteristics [191]. Initially free mesh is used by considering solid (quard) element. Afterwards element size was modified and solved to get improvements in the results. Upon specifying the material, material properties, boundary conditions, and loads, the analysis is completed by computer programs, utilizing arrays of matrix equations.

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FEA allows the determination of free vibration natural frequencies and the associated mode shapes of a structure [172, 189]. It provides valuable information for use in the design stages of a program, allowing optimization of the design by varying key parameters [173]. The major issue with the use of FEAs is the relatively high cost associated with modeling, impute properties and loads, debugging, running of the computer analysis,

interpreting of results etc.

3.8.1 Vertical Axis Test Fixture Analysis

The following FE Analyses are carried out for the vertical axis test fixture. Modal analysis of the fixture: In this analysis boundary conditions is: Bottom plate is fixed in all degrees of freedom. Static analysis of the fixture: In this analysis boundary conditions are: 1) Bottom plate is fixed in all degrees of freedom. 2) Load of 710 kN applied on the top flange of the fixture and load due to 12.8g acceleration on the fixture is applied.

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3.8.1.1 Vertical Axis Test Fixture Analysis Results

Table 3.3 Modal & Static Analysis Results of vertical fixture 1st Natural frequency mode Max Von mises stress (local) 123.5 Hz 199.6 to 224.6 N/mm2 (Middle of the ribs) Max Von mises stress (general) Normal stress (SY) 25 to 100 N/mm2 57.3N/mm2 locations) 3 to 40N/mm2 (general) Deflection (Y-axis) Max bolt load 4.7mm 36.4kN (At some discrete

3.8.2 Horizontal Axis Test Fixture Analysis The following FE Analyses are carried out for the horizontal axis test fixture. Modal analysis of the fixture: In this analysis boundary conditions is: Bottom plate is fixed in all degrees of freedom.

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Static analysis of the fixture: In this analysis boundary conditions are: 1) Bottom plate is fixed in all degrees of freedom. 2) Vibration analysis along lateral axis is carried out for a load of 14.34g applied to the specimen and fixture. Lateral load of 790.37kN and moment of 1383.11kNm applied at the fixture flange in addition to the self weight of the fixture

3.8.2.1 Horizontal Axis Test Fixture Analysis Results Table 3.4 Modal & Static Analysis Results horizontal fixture First Natural Frequency Max von mises stress in bolt location Von mises stress in other locations Max bolt load 323Hz 203 MPa < 60 MPa 100 kN

3.9 FABRICATION OF

TEST FIXTURES

The vertical axis fixture is having a conical section and a top flange with external and internal ribs. The base conical portion wall thickness is varying. The sections are welded along the hoop and in radial direction. Welding of Aluminum alloy AA6061 is very critical and requires very clean finish to attain high welding

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efficiency. Due to the lengthy weld joints, the weld distortions were high. Especially, the two conical sections joining were very critical (to attain the required geometric tolerance). Initially during the fabrication phase, even after taking adequate precautions, there was noticeable deformation of top flange and top cone portion. To overcome the noticeable deformation on top flange, the supplier filled the top flange with metal deposit thus introducing weld deformation gone at flange to conical weld region. Full welding of the external ribs induced few distortions, which was corrected using jacks. The horizontal axis test fixture is fabricated by taking necessary precautions to avoid the difficulties faced during vertical axis fixture fabrication.

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Fig. 3.5 Fabricated vertical axis test fixture

Fig. 3.6 fabricated horizontal test fixture