ME 4600:483 Uncertainty Exercise Material Test System

Problem Description: Estimate the uncertainty in determining the Youngs modulus for a material test system. The test system applies a compressive force F to a test cylinder made of an elastic material and the cylinder deformation L is measured. From this data the linear material response (Youngs modulus E) of the material is calculated. The force F is measured with a load cell and generates a voltage signal V, which is captured by a DAQ board. The block compression L is measured by a displacement sensor with a digital readout. Assumptions: The cylinder deforms uniformly without barreling (the cylinder surfaces are lubricated). The material is incompressible, therefore the cylinder volume is constant. Use this fact to calculate D1 and A1 (cross section area) based on L1. Test Block: Nominal block dimensions: L0=20mm, D0=10mm. After deformation the block dimensions are L1 and D1. A1 is the cylinder cross section area after deformation. Instrumentation: Load Cell to measure the applied load F has a Gain factor G=2004 N/Volt. DAQ card measures the load cell voltage V , has a 12 bit A/D converter and is configured for a voltage range of 0-5V. It also has a hysteresis error of 0.5% at full scale. Displacement sensor for L has a digital display with a resolution of 0.1mm. Other errors for this sensor can be neglected. Ruler to check undeformed block dimensions (L0 and D0) has a 0.5mm resolution. Test Data: The max. applied load F is 100N. At that load the nominal deflection L is about 1.5mm. The experimental data process consists of increasing and decreasing the load and measuring the displacement 14 times at different loads (up to the max of 100N). The raw data of block displ. vs. load cell voltage and the result after conversion to strain and stress are shown below . A linear regression statistics of the strain / stress data is calculated Regression Statistics Strain to Stress: N: 14 a0: 0.0318 [N/mm2] a1: 15.216 [N/mm2] r: 0.992 Syx: 0.0504 [N/mm2] Sy: 0.399 [N/mm2] Sa0: 0.0242 [N/mm2] Sa1: 0.538 [N/mm2]

F
L
L0 D1 D0 L1

Equations:

F ; A1

L L0

; L1 L0 L ; L1 A1 L0 A0 ; A

D 2 ; F G V 4

Solution Approach: 1. Determine the nominal values of the different variables in the test system. Nominal in this case is at the max load expected on the test system. 2. Write an equation, which determines the test result (the modulus) from the test variables. 3. Determine uncertainties for the test variables. 4. Calculate, how uncertainties propagate from the test variables to the test result. 5. Apply the known uncertainties to the propagation equation to calculate the total design stage uncertainty (or bias error); also determine, which variables contribute the most to the design stage uncertainty of the test system. 6. Use the test data regression statistics to determine E 7. From the standard deviation of the slope Sa1, determine its uncertainty (= precision error for E) 8. Combine design state uncertainty and precision error for E to get the total test system uncertainty for this test. 9. State the Youngs modulus E of the elastomer including its uncertainty interval.

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