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ISSN 2409-9066. Sci. innov. 2017, 13(5): 53—62 https://doi.org/10.15407/scine13.05.

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

HARDWARE AND SOFTWARE COMPLEX


TO DETERMINE THE STRENGTH PARAMETERS
OF COMPOSITE MATERIALS AND STRUCTURAL ELEMENTS
OF ROCKET AND SPACE EQUIPMENT

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.

tured using similar technology with their sub-


sequent mechanical tests under similar stress
schemes. This would enable comparing the
strength and elasticity of samples and models
and developing a method for more reliable calcu-
lation of strength and bearing capacity of struc-
tures made of composite materials. The absence
of multichannel information and measuring sys-
tems (IMSs) as part of standard or specially de-
signed test facilities or stands makes it impossible
to conduct tests of models and structural ele-
ments made of composite materials and to obtain
the necessary experimental data. This compli-
cates calculations of the design parameters of
critical elements of rocket and space engineering Fig. 1. Data accumulation module USB 1901(ADLINK
Technology Inc.)
structures.
To address the above-mentioned problems, a measurement and record of experimental data:
specialized hardware and software complex has the first one is for measuring stress, the second
been developed and created, which enables the one is for measuring test installation traverse
mechanical tests of both standard samples and displacement, the third and fourth ones for mea-
elements of structures made of composite mate- suring strain (for instance, tensile strain or com-
rials and the determination of appropriate dura- pression). The input physical values, including
bility characteristics. The created complex in- stress, displacement, and strain are converted us-
cludes multi-channel information measuring ing measuring devices that are part of FP 100/1
systems FpTiraTest-1901 and PMX-Test for test- and TIRAtest 2300, standard stress converters,
ing the samples and structural elements of com- traverse displacement sensors, and some resis-
posite materials, respectively, as well as special tive strain sensors for measuring strains using
software for measurement and accumulation of strain-gauge station 4ANCH-22. The mentioned
experimental data, and for calculation of strength IMS can be used at other test facilities and ma-
parameters of these materials. chines. For its operation appropriate FpTiraTest
software with characteristics listed below has
INFORMATION AND MEASURING SYSTEM been developed.
FpTiraTest-1901
In order to automate the measurement and re- PMX-TEST INFORMATION
cording of experimental data during testing of AND MEASURING SYSTEM (IMS)
composite materials on standard test facilities, in While for testing the samples of composite ma-
particular, FP 100/1 and TIRAtest-2300, data terials it is sufficient to have IMS with at least,
acquisition modules USB 1901 (ADLINK Tech- four channels, testing the elements and models of
nology Inc., Taiwan) (Fig. 1) have been used; structures made of these materials requires mul-
1901 USB module has 16 analog inputs, provides tichannel IMS. Taking into account an advanta-
discrete analog-to-digital conversion: 16 bits at a geous price-technical quality ratio of the system,
frequency of up to 250,000 samples per second; it PMX modular measuring amplifier system [4] by
is connected to the outputs of regular test mea- HBM (Germany), a well-known manufacturer of
suring systems FP100/1and TIRAtest-2300. To- various measuring devices and systems, which
tally, IBC FpTiraTest-1901 has 4 channels for has a rich experience in their application in vari-
54 ISSN 2409-9066. Sci. innov. 2017, 13 (5)
Hardware and Software Complex to Determine the Strength Parameters of Composite Materials

ous industries, has been selected as base unit for


the designed multifunctional IMS. The advan-
tages of PMX system include high precision, reli-
ability, applicability to industrial scale, the use of
special high-quality measuring technology from
HBM, the ability to increase the total number of
measurement channels by connecting multiple
PMX systems to one computer.
The PMX system includes a basic device (WG002)
containing a case, communication connectors with
indicators, and 4 slots (on each, a four-channel Fig. 2. External view of ІВС PMX-TEST
measuring card can be installed). Thus, the maxi-
mum number of channels for one PMX system is
16. When choosing the cards, the conditions for The strains are measured using three PX-455
the implementation of multichannel strain mea- four-channel cards to which ε1..ε12 strain gauge
surements and availability of several channels for transducers are connected via cables and inter-
measuring stress parameters (stress, pressure) faces. The mentioned above loads are measured
were met. To this end, the PMX is equipped with using four-channel measuring card PX-401.
PX-455 (3 pcs), measuring cards (modules), and РМХ IMS is connected to PC via Ethernet,
PX-401 card (1 pc.). The measurement card PX- while МIКRА-5 temperature measuring system
455 is used to connect full/half-bridge strain is connected via serial USB using USB/RS-485
gauge and inductive transducers, as well as pi- АС-4 converter.
ezoresistive and potentiometric sensors. The mea- The strains of tested object surface are mea-
suring card PX-401 is for input and further trans- sured in each of 12 measuring channels using a
formation of direct current and voltage analog strain gauge with a nominal resistance of 200 or
signals. It can be connected to the stress and/or 400 Ohm. To realize the half-bridge circuit, spe-
pressure sensors that have an output signal in the cial interfaces/adapters comprising additional
form of a constant voltage or direct current or di- precision resistors are used. To measure load
rectly to test machine or bench output signals (stress, pressure) when testing elements and
proportional to the stress parameters. models of structures made of composite materi-
Insofar as the PMX system does not allow for als, any measuring converters that ensure out-
the connection of any temperature converters, to put current signal ranging within 4—20 mА or
measure temperature a separate five-channel 0—20 mА can be used. The described IMS con-
MIKRA-5 system has been developed and manu- tains pressure converters of two types: РС-28
factured based on MIKRA I3 programmable in- (APLISENS, Poland) and SEN-8601 (KOBO-
dicator of process parameters (Ukraine). LD, Germany) of the same structural design.
The appearance of a small PMX-TEST IMS The output current varies from 4 to 20 mА, with
designed to test the strength/durability of struc- maximum range of measurements being from 0
tural elements and models made of composite to 50 MPA. The limit reduced error for РС-28
materials is presented in Fig. 2. The PMX-TEST and SEN-8601 pressure converters is ±0.2%, and
block diagram is shown in Fig. 3. It comprises a ±1%, respectively.
system (12 channels) for measuring strains and The temperature measuring system was de-
loads, in particular, pressure and stresses (4 chan- signed with the following factors taken into con-
nels) and a temperature measurement system sideration: low output signal quantity of existing
MIKRA-5 (5 channels). thermoelectric transducers, which usually does
ISSN 2409-9066. Sci. innov. 2017, 13 (5) 55
Drozdov, O.V.

not exceed 50 mV, necessity of output signal lin- РМХ-TEST-MONITOR PROGRAM


earization, temperature of cold thermal junction, To operate the PMX system [4], HBM has de-
possibility of stand-alone operation and transfer veloped MBX Web Server software that is spe-
of measurement results to PC. Proceeding from cially designed for the initial configuration of
the above considerations, MIKRA I3 (Ukraine) system's channels, primary signal processing,
programmable indicator of process parameters and for simple visualization of data received.
has been selected. It ensures the measurement This software enables to set the initial parame-
and indication for a wide range of thermoelectric ters for each channel of the system individually,
transducers and data transfer via RS-485 inter- namely, to select the type of input instrument
face using open protocol Modbus RTU [5]. The converter (full bridge, half-bridge etc.), to set
designed MIKRA-5 system for temperature mea- the linear signal conversion function, to reset the
surement includes 5 independent channels, each initial signal, as well as to set the filter type (Bes-
having MIKRA I3 programmable indicator.

Система вимірювання деформацій, Система вимірювання


зусилля та тиску температур МИКРА-5

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

56 ISSN 2409-9066. Sci. innov. 2017, 13 (5)


Hardware and Software Complex to Determine the Strength Parameters of Composite Materials

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.

Fig. 4. Graphical interface of PMX-TEST-Monitor

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

Fig. 5. Graphical interface of FpTiraTest

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

Tensile Strength Tensile Modulus of Elasticity Flexural Strength Flexural Strength


F
Δσ 3LF 3LF
σ=
F
E= = 86,3 GPa σ= σ=
bh Δε 2bh2 F 4bh2 F/2 F/2
b, mm b, mm b, mm
Poisson's Ratio
h, mm ε1 h, mm h, mm
Δε2
ε b ν= = 0,11 L, mm δ L, mm δ
Δε1 L L
ε2 6h
ε= δ F/2 F/2 4,36h F/2 F/2
ε= δ
L2 L2
σ = 956,6 MPa
tu

εtu = 0,012121 σbu = 890,7 MPa σbu = 876,9 MPa


F εbu = 0,036270 εbu = 0,13309

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.

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(Last accesed: 12.06.2017). Киев, 01014, Украина, тел.+380 44 286 3424,
7. ASTM D 3039/D 3039M — 00 Standard Test Method факс.+380 44 286 1684, drozdov@ipp.kiev.ua
for Tensile Properties of Polymer Matrix Composite
Materials. 13 p. АППАРАТНО-ПРОГРАММНЫЙ КОМПЛЕКС
8. ASTM D 695 — 02a Standard Test Method for Com- ДЛЯ ОПРЕДЕЛЕНИЯ ПАРАМЕТРОВ
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for Flexural Properties of Polymer Matrix Composite КОНСТРУКЦИЙ РАКЕТНО-КОСМИЧЕСКОЙ
Materials. 10 p. ТЕХНИКИ
10. ASTM D 3479/D 3479M — 96 Standard Test Method Разработано аппаратно-программный комплекс для
for Tension-Tension Fatigue of Polymer Matrix Com- определения параметров прочности перспективных
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Received 12.05.17
ментов конструкций ракетно-космической техники
при разных видах механической нагрузки в рабочем
О.В. Дроздов
диапазоне температур. Приведено характеристику сос-
Інститут проблем міцності ім. Г.С. Писаренка тавных частей созданного комплекса, а именно много-
НАН України, канальных информационно-измерительных систем и
|вул. Тимірязєвська, 2, Київ, 01014, Україна, соответствующего программного обеспечения для
тел.+380 44 286 3424, факс.+380 44 286 1684, измерения, накопления экспериментальных данных и
drozdov@ipp.kiev.ua выполнения расчетов параметров прочности таких ма-
АПАРАТНО-ПРОГРАМНИЙ КОМПЛЕКС териалов. Выполнено тестовые испытания комплекса,
ДЛЯ ВИЗНАЧЕННЯ ПАРАМЕТРІВ МІЦНОСТІ которые показали его работоспособность и эффектив-
КОМПОЗИЦІЙНИХ МАТЕРІАЛІВ І ЕЛЕМЕНТІВ ность.
КОНСТРУКЦІЙ РАКЕТНО-КОСМІЧНОЇ ТЕХНІКИ
Клю че вы е слова: углепластик, композиционные ма-
Розроблено апаратно-програмний комплекс для ви- териалы, прочность, деформация, информационно-изме-
значення параметрів міцності перспективних вугле- рительная система.

62 ISSN 2409-9066. Sci. innov. 2017, 13 (5)

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