GMW GMW16652-2012 Standard Test Methods for Quasi-static Physical Testing of Injection Molded Glass Fiber Reinforced Thermoplastics for use in Finite Element Analysis Issue 1 Engli.pdf

1、WORLDWIDEENGINEERINGSTANDARDSTest Procedure GMW16652Standard Test Methods for Quasi-static Physical Testing ofInjection Molded Glass Fiber ReinforcedThermoplastics for use in Finite Element Analysis Copyright 2012 General Motors Company All Rights ReservedOctober 2012 Originating Department: North A

2、merican Engineering Standards Page 1 of 131 ScopeNote: Nothing in this standard supercedes applicable laws and regulations.Note: In the event of conflict between the English and domestic language, the English language shall takeprecedence.These methods provide a way of obtaining physical response pr

3、operties for static tension, long term creep andthermal expansion. The test data permits a design analyst to characterize the physical behavior in a materialmodel in finite element analysis. The scope is restricted to the characterization of injection molded glass-fiberreinforced thermoplastic mater

4、ials used in parts with long flow lengths. Typical applications include intakemanifolds, oil pans and front covers. The methods appear as follows:x Test Method A Tensile Properties. Tensile properties is the method to evaluate the tensile properties oftest specimens cut from an injection molded ther

5、moplastic in the 0 Flow direction, 45 Flow direction, and90 Flow direction at multiple temperatures.x Test Method B Tensile Creep Properties. Tensile creep properties describes the method to evaluatecreep properties of test specimens cut from an injection molded thermoplastic plaques in the 0 Flowdi

6、rection, and 90 Flow direction at multiple temperatures.x Test Method C Thermal Expansion Properties. Thermal expansion properties describes the method toevaluate thermal expansion between -40 C and +150 C, in the 0 Flow direction, 45 Flow direction, 90 Flowdirection, and thickness direction.1.1 Pur

7、pose. The effects of glass fiber orientation and large thermal transitions are captured using these testmethods so that simulations can accurately reflect these behaviors. Finite element analysis using materialmodels defined using the test data from the test methods described herein is used to simul

8、ate and, therefore,predict the mechanical deformation and failure of injection molded glass-fiber reinforced thermoplastic partswith long flow lengths.1.2 Foreword. General Motors Research showed that a structural analysis which uses the orthotropic materialmodel predicts well the deformation and fa

9、ilure characteristics of injection molded glass-fiber reinforcedthermoplastic parts with long flow lengths, such as intake manifolds, oil pans, front covers. This includedrubber modified and non-rubber modified materials. The requirements for this analysis are:a. Predicting the average fiber orienta

10、tion in the part, andb. Fitting the mechanical properties obtained as described in this test method to determine the orthotropicconstants.1.3 Applicability. The data obtained is to be used for finite element analysis of injection molded non-impactand impact modified short glass fiber reinforced ther

11、moplastic parts of long flow length. The non-impactmodified and modified impact glass fiber reinforced thermoplastic must have glass fibers of length smallerthan 3 mm (0.125 in). The methods are intended for rigid, low failure strain materials.2 ReferencesNote: Only the latest approved standards are

12、 applicable unless otherwise specified.2.1 External Standards/Specifications.ASTM D789 ISO 294-1 ISO 527-2 ISO 899-2 ISO 2818ASTM E8 ISO 527-1 ISO 899-1 ISO 960 ISO 11359Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or network

13、ing permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16652 Copyright 2012 General Motors Company All Rights ReservedOctober 2012 Page 2 of 132.2 GM Standards/Specifications.None2.3 Additional References.Master Precision Mold, blueprint number 31197.3 Resources3.1 Faciliti

14、es. A suitable test laboratory with temperature and humidity control where needed.3.2 Equipment.3.2.1 Injection Molding Machine.3.2.1.1 Tools. Injection molding machine mold to make plaques. The mold shall generate plaques that are(3.00 0.02) mm in thickness, (101 2) mm (4 in) or more in width, and

15、(204 2) mm (8 in) or more in length.The plaque must be gated, with an edge gate across the entire width of mold. Reference Figure 1.3.2.1.2 Test Specimen Location vs. Gating, and Locations, Test Bar ISO 527-2/1BA. Tool manufacturedby Master Precision Mold, blueprint number 31197.Figure 1: Schematic

16、Diagram of a Plaque Showing the Location for Specimen Extraction3.2.2 Tensile Testing Machine. See ISO 527-1 for apparatus description.3.2.2.1 Devices for Measuring Width and Thickness of the Test Specimen. See Apparatus in ISO 527-1,Section 5.2.1.3.2.2.2 Test Chamber for Elevated and Low Temperatur

17、es. The chamber internal volume must house thehardware and specimens scheduled for test and permit freedom to mount and remove items in the chamber.3.2.2.3 Axial and Transverse Strain Measuring Devices for Elevated and Low Temperatures. SeeApparatus in ISO 527-1, Section 5.1. Since both the longitud

18、inal and the transverse (width) strains shall bemeasured, use either a biaxial extensometer or the combination of an axial and transverse extensometer. Theextensometer must be designed to work at the specified test temperature. Figure 2 shows an example pictureof a specimen with an axial and a trans

19、verse extensometer mounted.Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16652 Copyright 2012 General Motors Company All Rights Reserve

20、dOctober 2012 Page 3 of 13Figure 2: Tensile Specimen with an Axial and Transverse Extensometer Mounted3.2.2.4 Specimen Cutting System. See ISO 2818. An example cutting system is shown in Figure 3.Figure 3: Example Cutting System3.2.2.5 Vacuum Oven. The purpose of the vacuum oven is to dry test speci

21、mens at 80 C overnight in avacuum condition. An example oven is shown in Figure 4.Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16652 C

22、opyright 2012 General Motors Company All Rights ReservedOctober 2012 Page 4 of 13Figure 4: Example Vacuum Oven3.2.3 Creep Testing Equipment. See apparatus in ISO 899-1 for guidance. Exceptions to ISO 899-1 arenoted in the following paragraphs. An example apparatus schematic is shown in Figure 5.Figu

23、re 5: Example Apparatus for Tensile Creep Testing3.2.3.1 Axial Strain Measuring Devices for Creep Testing. Because the scope of this document covers thecharacterization of injection molded glass-fiber reinforced thermoplastic materials used in parts with long flowlengths, the axial strain measuring

24、requirements are more stringent than indicated in ISO 899-2, Section 4.3.The axial strain measuring device must meet the basic requirements of the ISO 527-1 tensile standard overthe entire 1000 hour test duration. This will typically need to be a clip-on strain gauge style extensometerCopyright Gene

25、ral Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16652 Copyright 2012 General Motors Company All Rights ReservedOctober 2012 Page 5 of 13developed for h

26、igh temperature creep applications or a clip-on capacitive gauge style extensometer designedfor high temperature creep applications.3.2.3.2 Mechanical Loading Devices for Creep Testing. Individual creep loading frames are required.Because the scope of this document covers the characterization of inj

27、ection molded glass-fiber reinforcedthermoplastic materials used in parts with long flow lengths, the specimens may release significant vibrationalenergy into the loading frame. Only one test specimen may be tested in each loading frame to prevent thevibrations from failing specimens from affecting

28、the testing of other test specimens.Figure 6: Example of an Axial Strain Measuring Device (Green Item), Mounted in a Creep System3.2.4 Thermo-mechanical Analyzer (TMA) Instrument. See apparatus in ISO 11359-2, and in Figure 7.Figure 7: Example of a TMA Apparatus3.3 Test Vehicle/Test Piece. See Figur

29、e 1.Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16652 Copyright 2012 General Motors Company All Rights ReservedOctober 2012 Page 6 of

30、 133.4 Test Time. Not applicable.3.5 Test Required Information. Not applicable.3.6 Personnel/Skills. Not applicable.4 Procedure4.1 Preparation.4.1.1 Preparation Method A Tensile Properties.4.1.1.1 Test Specimen Preparation.4.1.1.2 Conditioning of Material, ISO 294-1, Section 5.1.4.1.1.3 The GM plaqu

31、e shall be (3.0 0.02) mm in thickness, (101 2) mm (4 in) in width, and (204 2) mm inlength.4.1.1.4 Procedure for Injection Molding of Plaques. See ISO 294-1, except for Section 5.2.2 regarding theinjection velocity. Instead, the molding conditions shall be such that the injection time, as defined in

32、 ISO 294-1,Section 3.7, is (2.5 0.5) seconds. The plaques shall be injection molded using the mold temperature andmold pressure recommended by the material supplier for test plaques.4.1.1.5 Machining of Test Plaque. The test specimens shall be machined from the plaques in accordancewith ISO 2818. Al

33、l surfaces of the specimen should be free from visible flaws, scratches, or otherimperfections. The test specimens are the ISO 527-2/1BA small specimen described in ISO 527-2, Annex A, ofoverall length equal or greater than 75 mm, and overall width of 100 mm at the ends.4.1.1.6 Location of Test Spec

34、imens in the Plaque. The test specimen shall be machined at 0 degrees,45 degrees, and 90 degrees to the flow direction, as shown in Figure 1, for the GM plaque. Only one specimenshall be obtained per plaque.4.1.1.7 Storage of Plaques after Removal from the Mold, and of Test Specimens. Immediately up

35、onremoval from the mold, the plaques shall be sealed in containers that are impermeable to water vapor. Cuttingof the specimen shall be done after the plaques are maintained for a minimum of 24 hours in the sealedcontainers at (23 2) C. Immediately after being cut, the specimens shall be sealed so t

36、hat they remain in thedry condition. Individual specimens shall not be removed from the sealed containers until immediately beforetesting.4.1.1.8 Conditioning. Dry. Specimens are to be heated to 80 C in a vacuum oven overnight ( 10 hours and10 hours and10 hours and 15 hours) to achieve a dryconditio

37、n and immediately sealed in containers that are impermeable to water vapor. Test specimens must betested with 48 hours of the completion of overnight drying.4.2 Conditions.4.2.1 Environmental Conditions.4.2.1.1 Environmental Conditions Method A Tensile Properties. For powertrain applications, Tensil

38、e,Stress/Strain testing will be conducted at the following temperatures in the flow direction, cross flow directionand 30 degree to flow direction.Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without l

39、icense from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16652 Copyright 2012 General Motors Company All Rights ReservedOctober 2012 Page 8 of 13The temperatures are:x -40 Cx +23 Cx +80 Cx +130 Cx +150 Cx +200 C4.2.1.2 Environmental Conditions Method B Tensile Creep Properties. For power train appl

40、ications,Creep testing will be conducted at the following temperatures in the 0 Flow and 90 Flow directions.The temperatures are:x +23 Cx +80 Cx +130 Cx +150 Cx +200 C4.2.1.3 Environmental Conditions Method C Thermal Expansion Properties. CLTE will be measuredfrom test specimens cut from fresh plaqu

41、es. The CLTE will be determined across a temperature range of-40 C through +150 C.4.2.2 Test Conditions. Deviations from the requirements of this standard shall have been agreed upon. Suchrequirements shall be specified on component drawings, test certificates, reports, etc.4.3 Instructions.4.3.1 In

42、structions Method A Tensile Properties. Tensile properties is the method to evaluate the tensileproperties of test specimens cut from an injection molded thermoplastic in the flow direction, cross flowdirection, and 45 degrees to the flow at multiple temperatures.4.3.1.1 Number of Test Specimens. Da

43、ta shall be acquired for three specimens cut in the flow direction,three specimens cut in the cross flow direction, and 5 specimens cut in the 45 degrees to the flow direction.This number of test specimens will be used for Tensile Data, Creep Data, and CLTE. The total number ofsamples needed for all

44、 testing is 180, though the supplier should be prepared to produce 200 plaques toaccommodate this need.4.3.1.2 Setting the Extensometer. See ISO 527-1, Section 9.5. Both the longitudinal and transverse (width)elongations shall be measured, using extensometers and not optical measurements. If two ext

45、ensometers areused rather than a biaxial extensometer, the two extensometers shall be mounted at the same time and insuch a way that they are measuring elongations in the same region of the sample. The extensometers need tobe allowed to stabilize at test temperatures for about 15 minutes and re-zero

46、ed immediately prior to loading thespecimen. Alternately, a new extensometer gage length may be determined based one the shift and used forthe calculation of strain.4.3.1.3 Tensile Speed. Regarding testing speed in ISO 527-1, Section 9.7, the speed of the moving crossheadshall be set to 3 mm per min

47、ute.4.3.1.4 Recording of Data. In addition to the requirements of ISO 527-1, Section 9.7, record at least20 points/second.4.3.1.5 Test Results Acceptance. Specimens that break within the shoulders or the yielding of which spreadsto the width of the shoulders shall be discarded and further specimens

48、shall be tested. Data from parallel-sidedspecimens where jaw slippage occurs, or where failure occurs within 10 mm of either jaw, or where an obviousfault has resulted in premature failure, shall not be included. Repeat tests shall be carried out on new testspecimens. Data, however variable, shall n

49、ot be excluded for any other reason, as the variability in such datais a function of the variable nature of the material being tested.4.3.2 Instructions Method B Tensile Creep Properties. Tensile Creep Properties describes the method toevaluate the creep properties of test specimens in the 0 Flow, 90 Flow, and 30 Flow directions.4.3.2.1 Creep Stre