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08R0018_report.doc of 27/03/2008 pag. 1/28

Length coupling profiles CW50

Requested by : Johan Bollaert Carried out by : Danny Geysels Report number : 08R0018 Date: : 27/03/2008

REYNAERS ALUMINIUM NV/SA Oude Liersebaan 266 • B-2570 Duffel t +32 15 30 85 00 • f +32 15 30 86 00

www.reynaers.com • [email protected]

REPORT


Table of contents 1. Request ______________________________________________________ 4

2. Tests _________________________________________________________ 4

2.1 Test material ___________________________________________________ 4

2.2 Test configuration _______________________________________________ 4

2.3 Test procedure __________________________________________________ 5

2.4 Test results _____________________________________________________ 6 2.4.1 Largest mullion 034.1510 ________________________________________________6 2.4.2 Smallest mullion 034.1501 _______________________________________________6 2.4.3 Overview test results___________________________________________________12

2.5 Comparison test results__________________________________________ 14

3. Simulations __________________________________________________ 17

3.1 Simulation model_______________________________________________ 17

3.2 Simulation results ______________________________________________ 18

4. Comparison test and simulation results ____________________________ 21

5. Conclusions __________________________________________________ 24

6. Appendix ____________________________________________________ 25


List of figures, tables and graphs Figure 1 - Test configuration 034.1510 ________________________________________________4 Figure 2 - Test configuration 034.1501 ________________________________________________5 Figure 3 - Dimensions test configuration _______________________________________________5 Figure 4 - Fixation of the coupling profile ______________________________________________6 Figure 5 - Model for 034.1501 with 300 mm coupling____________________________________17 Figure 6 - Model for 034.1510 with 1000 mm coupling __________________________________17 Figure 7 - Simulation model ________________________________________________________18 Figure 8 - Shell elements___________________________________________________________18 Figure 9 - Deflection mullion profile _________________________________________________19 Figure 10 - 034.1501______________________________________________________________25 Figure 11 - 034.1510______________________________________________________________26 Figure 12 - 034.4593______________________________________________________________27 Figure 13 - 034.4585______________________________________________________________28 Table 1 - Results test 1 without coupling profile _________________________________________7 Table 2 - Results test 1 with 1000 mm fixed coupling _____________________________________7 Table 3 - Results test 1 with 1000 mm loose coupling _____________________________________8 Table 4 - Results test 1 with 750 mm fixed coupling ______________________________________8 Table 5 - Results test 1 with 750 mm loose coupling ______________________________________9 Table 6 - Results test 1 with 600 mm loose coupling ______________________________________9 Table 7 - Results test 1 with 500 mm coupling ___________________________________________9 Table 8 - Results test 1 with 400 mm coupling __________________________________________10 Table 9 - Results test 2 without coupling profile ________________________________________10 Table 10 - Results test 2 with 750 mm coupling _________________________________________10 Table 11 - Results test 2 with 600 mm coupling _________________________________________11 Table 12 - Results test 2 with 500 mm coupling _________________________________________11 Table 13 - Results test 2 with 400 mm coupling _________________________________________11 Table 14 - Simulation results for 034.1501 ____________________________________________19 Table 15 - Simulation results for 034.1510 ____________________________________________20 Graph 1 - Results point M1 test 1 ____________________________________________________12 Graph 2 - Results point M2 test 1 ____________________________________________________12 Graph 3 - Results point M1 test 2 ____________________________________________________13 Graph 4 - Results point M2 test 2 ____________________________________________________13 Graph 5 - Comparison fixed/loose 750 mm coupling_____________________________________14 Graph 6 - Comparison fixed/loose 1000 mm coupling____________________________________14 Graph 7 - Comparison test1/test2 without coupling______________________________________15 Graph 8 - Comparison test1/2 with 750 mm coupling ____________________________________15 Graph 9 - Comparison test1/2 with 600 mm coupling ____________________________________15 Graph 10 - Comparison test1/2 with 500 mm coupling ___________________________________16 Graph 11 - Comparison test 1/2 with 400 mm coupling __________________________________16 Graph 12 - Simulation results 034.1501 in graph_______________________________________20 Graph 13 - Simulation results 034.1510 in graph _______________________________________21 Graph 14 - Theory vs practice ______________________________________________________21 Graph 15 - Comparison without coupling _____________________________________________22 Graph 16 - Comparison with 1000 mm coupling ________________________________________22 Graph 17 - Comparison with 750 mm coupling _________________________________________22 Graph 18 - Comparison with 600 mm coupling _________________________________________23 Graph 19 - Comparison with 500 mm coupling _________________________________________23 Graph 20 - Comparison with 400 mm coupling _________________________________________23


1. Request

The new lengths have to be determined for the coupling profiles of our CW50 system. First we will do some tests on the smallest and the biggest profile, 034.1501 and 034.1510. The coupling profile for these mullions is respectively 034.4593 and 034.4585. Afterwards, we will do finite element simulations and at the end we will compare the simulation results with our test results.

2. Tests

2.1 Test material

We will do tests with the smallest CW50 profile 034.1501 and with the largest profile 034.1510. The coupling profile for the smallest mullion is 034.4593 and for the largest 034.4585. The drawings of these profiles can be found in the appendix at the end of this report. Two Mitutuyo digital measuring apparatus are used to measure the deflection. One pneumatic cylinder (Festo DNC-125-200-PPV) will be used to push on the mullion.

2.2 Test configuration

The following pictures show us the test configuration to determine the length of the coupling profile.

Figure 1 - Test configuration 034.1510


Figure 2 - Test configuration 034.1501

The mullions were supported on the two sides with steel bars. Following figure gives a representation of the dimensions of our test configuration.

Figure 3 - Dimensions test configuration

A force is put on 250 mm from the centre of the mullion. We will use a pneumatic cylinder for this force. The deflection of the mullion is measured at two points M1 and M2.

2.3 Test procedure

First, we will do measurements of the deflection for the whole mullion. Slightly we will increase the force to have some measuring points. Afterwards we will cut the mullion in half and couple the two parts. First with a coupling profile of 1000 mm; then we will reduce the length of the coupling profile in different steps. Again we will measure the deflection using different lengths of coupling profile. At the end we will compare the different results we obtained.


2.4 Test results

2.4.1 Largest mullion 034.1510

The maximum force that can be obtained with our setup is about 7500 N. With this force we measured a deflection of 2,92 mm. This is too small to evaluate the interference between the coupling profile and the mullion. We will continue with the smallest mullion.

2.4.2 Smallest mullion 034.1501

We have done two tests with the smallest profile to have some results we could compare. Results of the deflections are in mm. The results for test 1 with a coupling profile of 1000 mm and 750 mm were also done with a fixed coupling profile. The following figure shows how this is done.

Figure 4 - Fixation of the coupling profile


2.4.2.1 Test 1

o No coupling profile

F (kg) M1 M2

8,4 0 0

26,4 1,59 1,66

9,8 0,5 0,55

26,4 1,59 1,67

51,2 3,22 3,34

76 4,85 5,01

101,2 6,5 6,69

10,2 0,7 0,74

50,4 3,28 3,41

102 6,56 6,76

126,4 8,12 8,36

151,4 9,7 9,96

10,4 0,91 0,81

101,8 6,66 6,86

152 9,78 10,04

175,2 11,25 11,54

200,6 12,47 12,5

10,2 1,06 0,95

034.1501No coupling profile

Table 1 - Results test 1 without coupling profile

o Coupling profile = 1000 mm FIXED

F (kg) M1 M2

8,2 0 0

25,2 1,28 1,32

9,2 0,13 0,14

26,2 1,36 1,41

50,4 3,19 3,27

76 5,11 5,23

101,4 7 7,14

10 0,39 0,39

50,4 3,4 3,47

101 7 7,14

126,8 8,77 8,93

150,2 10,37 10,57

10 0,5 0,5

101,4 7,26 7,38

150,6 10,45 10,65

176 12,07 11,84

200,4 13,4

10 0,69 0,95

034.1501Lengte 034.4593 = 1000 mm VAST

Table 2 - Results test 1 with 1000 mm fixed coupling


o Coupling profile = 1000 mm LOOSE

F (kg) M1 M2

4,6 0,37 0,36

4,6 0 0

26 1,73 1,87

10 0,5 0,63

26 1,74 1,9

50,8 3,63 3,83

76 5,5 5,73

101,2 7,32 7,57

10 0,63 0,78

51 3,84 4,03

102,2 7,43 7,67

126 9,04 9,3

151,4 10,76 11,05

10,2 0,72 0,86

101,4 7,56 7,8

151,8 10,88 11,17

175,2 12,36 12,6

202 13,49 12,94

10 0,86 0,55

034.1501Lengte 034.4593 = 1000 mm LOS

Table 3 - Results test 1 with 1000 mm loose coupling

o Coupling profile = 750 mm FIXED

F (kg) M1 M2

8,4 0,74 0,75

8,4 0 0

26,4 1,4 1,43

9,4 0,15 0,16

25,8 1,4 1,42

51,4 3,36 3,4

75,6 5,2 5,27

101,4 7,13 7,22

10 0,33 0,33

50,6 3,49 3,53

101,2 7,21 7,3

125,6 8,92 9,04

150,6 10,69 10,82

176,4 12,32 12,57

10 0,44 0,36

034.1501Lengte 034.4593 = 750 mm VAST

Table 4 - Results test 1 with 750 mm fixed coupling

o Coupling profile = 750 mm LOOSE


F (kg) M1 M2

8,8 0,86 0,94

8,6 0 0

25,6 1,38 1,43

9,2 0,14 0,16

25,4 1,39 1,43

51 3,38 3,47

75,4 5,2 5,34

100,6 7,02 7,2

9,8 0,39 0,42

51 3,62 3,71

100,8 7,09 7,26

125,8 8,83 9,04

151,2 10,55 10,8

10,2 0,49 0,62

100 7,27 7,53

105,8 10,68 11,01

176,8 12,42 12,78

196 13,72

9,8 0,63 0,77

034.1501Lengte 034.4593 = 750 mm LOS


o Coupling profile = 600 mm

F (kg) M1 M2

7,4 0,77 0,79

7,4 0 0

25,4 1,63 1,68

51 3,7 3,81

76,2 5,67 5,82

100,8 7,53 7,73

125,6 9,35 9,59

150,4 10,84 10,95

10 0,72 0,74

034.1501Lengte 034.4593 = 600 mm



F (kg) M1 M2

8,4 0,92 0,95

8,2 0 0

25,4 1,71 1,75

50 3,86 3,96

76 6 6,14

100,6 7,92 8,11

126,4 9,9 10,13

134,4 10,79 11,04

9,4 0,75 0,78

034.1501Lengte 034.4593 = 500 mm

Table 7 - Results test 1 with 500 mm coupling



F (kg) M1 M2

6 0,74 0,77

5,8 0 0

25 2,02 2,07

50,2 4,42 4,53

75,4 6,63 6,77

100,6 8,73 8,92

125,8 10,78 10,99

9,8 0,91 0,92

034.1501Lengte 034.4593 = 400 mm


2.4.2.2 Test 2

o No coupling profile

F (kg) M1 M2

8,6 0,73

8,6 0 0

26,6 1,23 1,28

51 2,87 2,96

75,2 4,4 4,54

101,4 6,09 6,27

125,6 7,58 7,8

150,8 9,19 9,46

174,6 10,7 10,99

198,4 12,2 12,52

10 0,31 0,34

034.1501GEEN KOPPELPROFIEL

Table 9 - Results test 2 without coupling profile


F (kg) M1 M2

8,4 1,08 1,15

8,4 0 0

25,6 1,47 1,53

49,8 3,48 3,62

76,4 5,53 5,74

100,2 7,29 7,55

125,6 9,11 9,42

150,4 10,88 11,22

175,4 12,49

9,8 0,8

034.1501Lengte 034.4593 = 750 mm




F (kg) M1 M2

8,4 0,92 0,97

8,4 0 0

24,8 1,48 1,54

49,8 3,56 3,69

76,2 5,54 5,74

99,8 7,3 7,56

125,4 9,18 9,5

150,6 11,03 11,41

9,6 0,61 0,62

034.1501Lengte 034.4593 = 600 mm



F (kg) M1 M2

8,4 0,96 1,01

8,4 0 0

26 1,58 1,65

50,2 3,61 3,74

75,8 5,44 5,5

102,2 7,66 7,68

125,8 9,55 9,63

130 10,26 10,39

9,6 0,56

034.1501Lengte 034.4593 = 500 mm



F (kg) M1 M2

8,2 1,26 1,27

8 0 0

25,4 1,73 1,81

49,8 4,05 4,21

76,2 6,38 6,61

101 8,55 8,84

126 10,71 11,07

134,6 11,45 11,82

9,4 0,94 0,82

034.1501Lengte 034.4593 = 400 mm



2.4.3 Overview test results

The following graphs show the deflection with different lengths of coupling profile.

0341501

0

50

100

150

200

250

0 2 4 6 8 10 12 14 16

Deflection point 1 (mm)

Fo

rce (

kg

)

400 mm

500 mm

600 mm

750 mm

1000 mm

No coupling

Graph 1 - Results point M1 test 1

0341501

0

50

100

150

200

250

0 2 4 6 8 10 12 14


Fo

rce

(k

g)

400 mm

500 mm

600 mm

750 mm

1000 mm

No coupling



0341501

0

50

100

150

200

250

0 2 4 6 8 10 12 14


Fo

rce

(k

g)

400 mm

500 mm

600 mm

750 mm

No coupling


0341501

0

50

100

150

200

250

0 2 4 6 8 10 12 14


Fo

rce (

kg

)

400 mm

500 mm

600 mm

750 mm

No coupling



2.5 Comparison test results

The following graphs show the difference in results for the fixed and loose coupling profile.

Coupling 750 mm fixed/loose

0

20

40

60

80

100

120

140

160

180

200

0 5 10 15

Deflection (mm)

Fo

rce (

kg

) Fixed point 1

Fixed point 2

Loose point 1

Loose point 2

Graph 5 - Comparison fixed/loose 750 mm coupling

Coupling 1000 mm fixed/loose

0

20

40

60

80

100

120

140

160

180

200

0 5 10 15

Deflection (mm)

Fo

rce (

kg

) Fixed point 1

Fixed point 2

Loose point 1

Loose point 2

Graph 6 - Comparison fixed/loose 1000 mm coupling

The difference in deflection between a fixed or loose coupling profile is hardly noticeable. Fixing the coupling profile gives a small decrease in the measured deflections. This can be best seen in graph 6.


The differences in results between test 1 and test 2 can be found in the following graphs.

No coupling

0

50

100

150

200

250

0 5 10 15

Deflection (mm)

Fo

rce (

kg

)

Test1_M1_No_coupling

Test2_M1_No_coupling

Graph 7 - Comparison test1/test2 without coupling

Coupling 750 mm

0

50

100

150

200

0 5 10 15

Deflection (mm)

Fo

rce

(kg

)

Test1_M1_750mm

Test2_M2_750mm

Graph 8 - Comparison test1/2 with 750 mm coupling

Coupling 600 mm

0

20

40

60

80

100

120

140

160

0 5 10 15

Deflection (mm)

Fo

rce (

kg

)

Test1_M1_600mm

Test2_M1_600mm


.


Coupling 500 mm

0

20

40

60

80

100

120

140

160

0 2 4 6 8 10 12 14

D e f le c t i on ( mm)

Test1_M1_500mm

Test2_M1_500mm


Coupling 400 mm

0

20

40

60

80

100

120

140

160

0 5 10 15

Deflection (mm)

Fo

rce

(kg

)

Test1_M1_400mm

Test2_M2_400mm

Graph 11 - Comparison test 1/2 with 400 mm coupling

We notice a small difference in the results between test 1 and test 2. There are no big differences measured so we can say that the results are realistic. In the next paragraph we will do finite element simulations and afterwards we will compare the simulation results with the test results. From graphs 1 – 4 , we can see that the measured difference in deflection gets larger when the length of the coupling profile decreases. Starting from a coupling length of 500 mm, the measured differences increase more rapidly.


3. Simulations

3.1 Simulation model

We built up a 3D model in solidworks. The mullion and the coupling profile are replaced with rectangular tubes that have the same stiffness. Following figures show the models for the smallest and the biggest mullion.

Figure 5 - Model for 034.1501 with 300 mm coupling

Figure 6 - Model for 034.1510 with 1000 mm coupling

After the model was build, we put forces and restraints on it. This can be seen in the following figure.


Figure 7 - Simulation model

The simulation model is built up in the same way that the tests were executed. Translation was restricted at the sides and the force was put on the right distance from the edge. We will use shell elements for the simulation as can be seen in the following figure.

Figure 8 - Shell elements

3.2 Simulation results

We did the simulations for different coupling profile lengths and with different forces. We wanted to know the deflection of the mullion.


Figure 9 - Deflection mullion profile

The results of these simulations are shown in the following tables and graphs.

Length coupling profile (mm) Applied force (kg) Deflection (mm)

300 50 6,48

100 12,95

150 19,43

400 50 4,83

100 9,65

150 14,48

500 50 4,1

100 8,2

150 12,3

600 50 3,73

100 7,46

150 11,19

750 50 3,42

100 6,85

150 10,27

1000 50 3,25

100 6,49

150 9,74

without coupling 51 3,01

75 4,44

101 5,98

125 7,41

151 8,89 Table 14 - Simulation results for 034.1501


Length coupling profile (mm) Applied force (kg) Deflection (mm)

300 250 14,91

500 29,82

1000 59,64

400 250 7,31

500 14,62

1000 29,24

500 250 4,08

500 8,16

1000 16,32

600 250 2,69

500 5,38

1000 10,76

750 250 1,69

500 3,38

1000 6,75

1000 250 1,01

500 2,02

1000 4,04

without coupling 250 0,58

500 1,16

1000 2,32 Table 15 - Simulation results for 034.1510

Deflection 034.1501 with coupling profile

0

5

10

15

20

25

0 50 100 150 200

Force (kg)

Defl

ecti

on

(m

m)

300 mm

400 mm

500 mm

600 mm

750 mm

1000 mm

Zonder koppeling

Linear (Zonder koppeling)

Linear (300 mm)

Linear (400 mm)

Linear (500 mm)

Linear (750 mm)

Linear (1000 mm)

Linear (600 mm)

Graph 12 - Simulation results 034.1501 in graph


Deflection 034.1501 with coupling profile

0

10

20

30

40

50

60

70

0 200 400 600 800 1000 1200

Force (kg)

Defl

ec

tio

n (

mm

)

300 mm

400 mm

500 mm

600 mm

750 mm

1000 mm

Zonder koppeling

Linear (Zonder koppeling)

Linear (300 mm)

Linear (400 mm)

Linear (500 mm)

Linear (750 mm)

Linear (1000 mm)

Linear (600 mm)

Graph 13 - Simulation results 034.1510 in graph

From the results we can see that the difference in deflection starts to increase more rapidly at the coupling profile of 500 mm.

4. Comparison test and simulation results

First we will do a comparison, theory vs practice, of the measured deflection for the 034.1501 profile without coupling profile. This can be viewed in the next graph.

Theory vs practice M2

0,00

2,00

4,00

6,00

8,00

10,00

12,00

14,00

0 500 1000 1500 2000 2500

Force (N)

Defl

ecti

on

(m

m)

Theorie

Simulation

Test 1

Test 2

Graph 14 - Theory vs practice

We see that the results from a beam calculation and a finite element simulation are exactly the same. The measured deflections in reality were a bit higher than the theoretical results. The next graphs show the simulation results versus the test results.


Comparison simulation test - No coupling

0,00

2,00

4,00

6,00

8,00

10,00

12,00

14,00

0 50 100 150 200 250

Force (kg)

Defl

ecti

on

(m

m)

Simulation

Test

Linear (Test)

Linear (Simulation)

Graph 15 - Comparison without coupling

Comparison simulation test - Coupling 1000 mm

0

2

4

6

8

10

12

14

16

0 50 100 150 200 250

Force (kg)

Defl

ecti

on

(m

m)

Simulation

Test

Linear (Test)

Linear (Simulation)

Graph 16 - Comparison with 1000 mm coupling


0

2

4

6

8

10

12

14

0 50 100 150 200

Force (kg)

Defl

ecti

on

(m

m)

Simulation

Test

Linear (Test)

Linear (Simulation)




0

2

4

6

8

10

12

0 50 100 150 200

Force (kg)

Defl

ecti

on

(m

m)

Simulation

Test

Linear (Test)

Linear (Simulation)



0

2

4

6

8

10

12

14

0 50 100 150 200

Force (kg)

Defl

ecti

on

(m

m)

Simulation

Test

Linear (Test)

Linear (Simulation)



0

2

4

6

8

10

12

14

16

0 50 100 150 200

Force (kg)

Defl

ecti

on

(m

m)

Simulation

Test

Linear (Test)

Linear (Simulation)



We notice that in some cases (no coupling, 1000 mm coupling) the measured deflections in the tests were higher than for the simulations. For a coupling of 750 mm, 600 mm and 500 mm the test and simulation results were the same. From the above graphs, we can surely say that the simulations give a good comparison with the reality.

5. Conclusions

The following conclusions can be made from these tests and simulations:

• The smaller the coupling profile, the higher the deflections get.

• Fixing the coupling profile to the mullion has a negligible effect on the deflection of the mullion. A small decrease in deflection was measured.

• Finite element simulations give a good comparison with the test results and can be used to draw conclusions.

• Test and simulation results indicate a big increase in deflection starting from a coupling profile of 500 mm. Therefore the coupling length has to be 500 mm à 600 mm.


6. Appendix

Figure 10 - 034.1501


Figure 11 - 034.1510


Figure 12 - 034.4593


Figure 13 - 034.4585

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