Specifications for Servo-hydraulic Universal Testing Machine (UTM) 250 kn

Transcription

1 Specifications for Servo-hydraulic Universal Testing Machine (UTM) 250 kn IIT Bombay is intent to procure one Servo-hydraulic universal testing machine of 250 kn load capacity with all necessary accessories. The machine must capable of testing of materials such as Steels, Aluminum, Ceramics, Glass or Carbon fibers, Plastics, Elastomers, Wood, etc. in different modes of tests such as tension test, compression test, flexure test, dynamic test, low cycle fatigue test, high cycle fatigue, fracture toughness, shear test, friction test, peel test, bond test, da/dn vs delta K, da/dn vs G/J, CTOD, J-R curve, Chevron-notch test, DCB test. S No. Particulars Technical Requirement 1 Basic Unit a. Precision aligned two-column load frame with adjustable upper crosshead. b. High Stiffness of load frame at better than 450 kn/mm and at daylight of 1 m. c. Actuator mounted in upper crosshead. d. Three modes of working should be available to the user: Sample running mode, Sample setting mode and Stop Mode. e. Load measurement accuracy must be better than 0.002% of load cell capacity and 0.5% of indicated load. f. A system should be in place such that the hydraulic grips cannot be opened or closed when the test is running. g. Coarse and fine positioning of the actuator should be possible for faster/controlled adjustment in the process of sample loading. 2 Actuator a. Capacity 250 kn with verifiable accuracy up to +/-0.5% in the load range of 250 kn to 1 kn using single load cell and similarly with 25 kn capacity load cell in the load range of 25 kn to 100 N using single load cell. b. Stroke range should be at least +/- 75 mm c. Fatigue rated load cell. d. Servo Valve Control. e. 1 Servo Valve of the maximum power pack capacity and 1 of 3<lpm<5 for high cycle and low cycle fatigue respectively. f. Output pressure to be less than 210/280 Bar. 3 Hydraulic Power Unit a. Digital user interface based protection device for oil temperature, oil pressure, oil level and filter condition. b. Automatic Interlock for high temperatures. c. Line frequency 50 Hz d. A single powerpack should be able to give amplitude of more than.95 mm at a frequency of 10 Hz or higher when the applied load is 200

2 kn with its dimensions not bigger than 2.0mx2.0m: widthxdepth due to space constraints. Noise level must be less than 80 db. (Details of performance curves are to be provided) 4 Load Cell a. Fatigue rated load cell with a capacity of +/- 250 kn. b. Fatigue rated load cell with a capacity of +/- 25 kn. c. Minimum number of cycles for high cycle fatigue tests at the maximum capacity for the load cell: d. The machine should be able to sustain loads at least as much as 150% overload. e. Inertia Compensation, if needed. 5 Electronic Controller The Servo hydraulic test system shall be controlled by a fully digital, closed-loop control system based on at least 32-bit architecture. The system must feature a digital control system capable of controlling the actuator in position, load, and strain modes. Analogue control systems, even if digitally supervised, are not acceptable. 6 Strain Measurement and COD gauges and Alignment Fixture a. The frequency at which the waveform is generated should be able to be varied between Hz to 300 Hz or greater. b. The control system must have auto-tuning. c. The internal waveform generator within the system must be able to generate wave forms of different kinds including sine, triangle, square, random, single ramp, user defined, dual ramp and trapezoid. d. The resolution of the generator should be 32 bit or better. e. The display should show both the number of cycles finished and the ones remaining. f. If there are changes in the compliance of the specimen in a cycle, the control loop should be automatically updated. g. The information about strain, linear position and load should be simultaneously recorded. h. Advanced Digital signal Processing (DSP) signal conditions should be present. a. Strain gauge extensometer suitable for specimen G.L. of 10/12.5 mm, 25 mm, and 50 mm with minimum travel of +/- 10% and max +/- 40%. Operating temperature (-80 to C) b. Crack tip opening displacement gauge that complies with ASTM E399. Gauge length of 6-10 mm and travel of 4-12 mm. 7 Grips and Fixtures a. Fatigue rated hydraulic wedge grips with easy access for specimen insertion and adjustable markers on the flat faces for accurate centering of specimen.

3 b. Set of Flat serrated jaw faces of at least 50 mm wide for gripping flat specimen 1-25 mm thick. c. Set of Vee jaw faces for gripping round specimen 6 25 mm diameter. d. Fatigue rated 3 point bending test fixture (100 kn) capable of handling specimens up to 50 mm wide and up to 250 mm span (distance between supports). Anti-rotation arrangement for top. The minimum width that can be tested should be 30 mm. Roller diameter: 5 mm and 10mm. e. Conversion kit to change 3-point bend test fixture to 4 point bend test fixture. f. Fracture mechanics grips for compact tension specimens of for sample thickness 12.5 mm and 25 mm with anti-buckling fixture. g. High temperature grips suitable with furnace for threaded and specimens that can take temperatures from C. Diameter of the grips: 6.25 mm and 12.5 mm. h. Compression Test fixtures for (a) room temperature and (b) high temperature usage (DE9-09). All grips and fixtures must withstand the maximum load capacity of the system (250 kn) at room temperature, unless otherwise specified and required. 8 Hardware a. PC desktop (from reputed vendor) capable of supporting the UTM system software and also interfacing with the UTM controller hardware and having at least Intel i5 or equivalent processor and at least 8 GB RAM, minimum1 TB hard drive, with CD/DVD readwrite drive, SD card drive, USB ports, HDMI port, Ethernet port and wifi capable and 24 inch HD monitor with HDMI cable. b. Controller should be comprising of dedicated and intelligent interfacing board with high speed, ably supported by A to D and D to A card of high resolution, immunity from and power fluctuation, expandable, universal conditioner, High resolution signal processing, capable of working at room temperature till 40 degree centigrade and 60 to 85% relative humidity, etc. c. Should also have features like transducer excitation, equal or better than 32 bits/64 bits waveform generation, data acquisition rates better than 5 khz, user selectable signal filter, data resolution of 19 bits or better. 9 Standards to be followed and the software a. Basic features like set-up and configuration of display screen and control panel, set-up limits and gain controls, report generation template, live runtime test plots with automatic scaling and zoom in/out, saving and retrieval of test methods and data, example test methods.

4 10 High Temperature Furnace 11 Installation and Commissioning b. Complete test suite comprising of Tension test, Compression test, Flexure test, K1c, J1c, R curve, CTOD, da/dn vs G and K, crack propagation, S-N curve, Low cycle fatigue, high cycle fatigue, shear test, shear lap test, peel, tear, bond friction test, chevron notch test, double cantilever beam test, DIC software. Standards: DE9-09,E399, D5528, D3518, D3163, D5868 and E c. Easy GUI based steps to create multi step, variable ramp rate loading sequences, Single and nested looping of steps. d. Ability to create different types of loading wave forms like Sine, Cosine, Triangular, Square, Holds, ramps, trapezoidal, user-defined wave forms and sample data visualization. e. Test methods to be easily and quickly constructed using series of configuration steps within the software. f. Data logging and data reduction tools. g. Ability to visualize real time up to 4 channels of data. Real time graphic display: X-Y, Y-t, Multichannel, Chart recorder etc. h. Detailed manuals of software in English along with electronic copies. i. Extensive data logging: per cycle data (max/min/amplitude/mean level), full hysteresis data, or both combine: at linear, log, change in value or user defined intervals. j. Control of digital and analogue outputs. k. Ability to pause and resume a test; Control of digital and Analogue outputs. l. Data storage to computer disc in ASCII format or any other standard format which is accepted by major data analysis programs. m. Saving and recovery of past test methods. n. Security with passwords. o. Login/Password can be created for different users. a. The sample should be able to attain a temperature from C to C. b. Temperature controller. c. Thermocouple Cable for the sample. d. It should be able to test specimens of minimum length 25 mm and should have 3 zones for good temperature control. e. Temperature overshoot should not be greater than +/- 2 0 C and the system should remain stable within +/-2 0 C of the desired temperature in the range of C. f. The necessary grips/pull rods/cooling for doing the tests at high temperatures should be supplied. The vendor should take full responsibility for supply, installation and commissioning of the structural testing system in the MEMS Department

5 12 Maintenance and service support of system during and after the warranty period and performance of the system demonstrated to the satisfaction of the users. Necessary fittings and fixtures required for the installation of UTM in the reaction frame will be in the scope of the vendor. a) The vendor should have competent and reliable service network in India for quick and necessary repair and maintenance of the equipment. b) The vendor should provide the list of users of similar equipment (viz. IITs, NITs, etc.) along with their contact details. c) Details of the nature of service support the vendor can provide should be given along with the proposal. d) Warranty should be for at least three years (3 years) after installation. e) The vendor should commit to provide maintenance service and supply necessary spares for the equipment for at least 10 years after successful installation and commissioning. 13 Other terms and condition a. Two sets of operation and maintenance manuals along with all necessary drawings should be supplied along with the testing system. b. The vendor should enclose all the relevant technical documents and catalogues for all the components included in the proposal. c. Necessary consumables like connecting cables, power pack oil, hoses, etc. will be in the vendor s scope. d. Additional equipment like UPS, Suitable PC with compatible operating system, etc. will be in the vendor s scope. 14 Prequalification Criteria a. To provide details of minimum 3-5 users of similar system in India specifically in IIT, IISc, reputed national labs like DMRL, NAL etc. for getting first hand feedback from them about the product. b. There should be OEM or exclusive agency in India for at least the last 5 years to ensure strong ties inside India for future maintenance/warranty/software upgrade convenience for the UTM. c. Support of hardware and spare for 10 years. 15 Other conditions a. Maximum education discount, if any, should be offered. b. Training to laboratory personnel by the experts from the headquarter branch after installation and commissioning at IIT Bombay. (10 man days of training) c. Prices should include the installation and training cost. d. Quotation should carry proper certifications like agency certificate, proprietary certificate, etc. e. Up-gradation of software free for 10 years that will be compatible to any higher version of windows operating system f. The warranty has to be valid for minimum 3 years. 16 Optional Indicate the quotation for the following optional items separately. For 2, quote the prices of a-g separately. 1. Chiller/Cooling Must quote separately for quality chiller and cooling tower, if

6 tower required. 2. Additional Strain Measurement and COD gauges, Alignment Fixture and grips & fixtures 3. Non-contacting Video Extensometer and DIC 4. Environmental Chamber 5. AMC a. Operating Temperature from C to C for the extensometer to be used in the furnace. The extensometer should be suitable for specimen gauge length of 25 mm and 50 mm. b. Alignment fixture setup for both round and flat specimens for precision of 1 degree and better with the necessary calibration sample and software. c. Set of Collet grips with diameter of 5 mm, 10 mm, 15 mm and 20 mm. d. Double cantilever fixture and shear test fixture. See D5528. For DCB : sample width 25 mm and 50 mm and thickness to be 10 mm and 20 mm. e. See ASTM 3518, ASTM D3163, D5868 for shear test and shear lap test. Dimensions: Sample thickness 5 mm-30 mm. f. Fixture for chevron-notched test. Sample size. Thickness 10 mm, 15 mm and 20 mm and height and width to be 50 mm. See E g. Fracture mechanics grips for compact tension specimens of for sample thickness 10 mm, 15 mm and 20 mm with anti-buckling fixture. a. It should be able to measure strains for both static and dynamic tests with a minimum speed of 60 mm/sec for static tests and 500 mm/sec for dynamic tests. b. It should have the capability to be used in different UTM machines and should be movable. c. The images should be recorded such that can be analyzed later in DIC. d. It should work for metals, plastics, composites, films and biomaterials. e. ASTM D638 should be obeyed. f. Modulus and strain can be measured. g. Continuous camera image collection should be supplied. h. Resolution of the extensometer should be better than 1um. i. DIC system has to be supplied as well with the necessary software. Provide the price of an environmental chamber (-100 to C) with

7 necessary grips that can test samples under liquid nitrogen environment. At least 2 years of annual maintenance contract (AMC) after 3 years warranty should be there and its cost can be included as optional.