Vibrophores for the Determination of Finite Life Fatigue Strength and Long Life Fatigue Strength

Due to their design, Vibrophores—also known as resonance testing machines— have in the past been used exclusively as dynamic materials testing machines for determining the fatigue life of materials and components with regard to finite life fatigue and long life fatigue. This includes, for example high cycle fatigue testing to DIN 50100 (S-N curve), in the tensile, compression, pulsating load and alternating load ranges.

The latest generation of Vibrophores (high-frequency pulsators) from ZwickRoell can be used as both dynamic and static materials testing machines—a first for this type of machine—with test loads up to 1000 kN. Typical applications for resonance testing machines are material fatigue tests and durability tests on standardized specimens and components (for example, piston rods, crankshafts, and screws), and production and quality control of components exposed to dynamic loads during their service life, such as concrete and reinforcing steel, as well as quasi-static tensile and compression tests and fracture mechanics tests on CT and SEB specimens.

Vibrophores für Prüfkräfte von 5 kN bis 1000 kN

Key Advantages and Features

Advantages & Features

  • Optimal conditions with regard to exact alignment of test axes thanks to the stiff four-column load frame - Prevention of mechanical influences on the specimen - Precise measurement results
  • Reliable testing of both short and long specimens, made possible by the large crosshead travel
  • Ergonomic operation thanks to low mounting table
  • Repeatable and precise specimen change for defined grip-to-grip separation due to the integrated crosshead travel measuring system
  • Minimal maintenance costs due to the absence of wear parts
  • Easy installation without the need for additional infrastructure (e.g. hydraulics, coolant, compressed air)

Two in One

Two in One—The Vibrophore Is a Full-Fledged Dynamic and Static Testing Machine in One 

Dynamic testing with the Vibrophore

The operating principle of the ZwickRoell Vibrophore is based on the concept of a mechanical resonator with electromagnetic drive. The mean force is applied by moving the upper crosshead with the lead screw drive. The dynamic load is generated by an oscillation system that works when the system operates at full resonance. In this way test frequencies of up to 285Hz are possible, provided the specimens are sufficiently stiff. The dynamic and static drives are controlled separately, so that stress ratios (R-ratios) of any kind are possible. Tests can be force-, displacement- or strain-controlled.

Static testing with the Vibrophore

Mechanical clamping of the oscillating crosshead and the deployment of testXpert III software transform the Vibrophore into a true static materials testing machine.

Generous connecting surfaces and robust components ensure high machine stiffness. In combination with precision crosshead guidance, the Vibrophore minimizes unacceptable mechanical influences on the specimen. By using suitable accessories, both static and dynamic tests can be performed under various environmental conditions (temperature, aggressive media). The Vibrophore can also be configured for torsion and flexure tests. The absence of a central lead screw enables test area variability to be maximized on the new Vibrophore, which makes it possible to test very short specimens as well as large components.

Advantages of the two-in-one principle

  • Short test times and a high specimen throughput level for dynamic tests due to high frequencies
  • Minimum energy is required thanks to the resonance principle (approx. 2% of the energy required by a servohydraulic testing machine)

Video

0:53

Vibrophore 1000 – connecting rod and screw tests with Vibrophores

Vibrophores with high forces are used for connecting rod and screw tests.

Technical Overview

Overview

The Vibrophores are available in seven versions:

  • Vibrophore 25
  • Vibrophore 50
  • Vibrophore 100
  • Vibrophore 250
  • Vibrophore 500
  • Vibrophore 600
  • Vibrophore 1000

25 kN

Fmax

25

kN

Mean load max.

±25

kN

Force amplitude max.

±12.5

kN

Specimen elastic strain (oscillation displacement) max.

6 (±3)

mm

Test frequency range[1]

35 to 300

Hz

No. of frequency steps[2]

8

No. of guide columns

4

No. of lead-screw drives

2

Frame stiffness at 1000mm crosshead separation[3]

Approx. 170

kN/mm

Drive

Static tests and for mean force control

AC drive

min. crosshead speed

0.0001

mm/min

max. crosshead speed

600

mm/min

Maximum crosshead return speed

1000

mm/min

Repeat positioning accuracy on crosshead

±2

µm

Motor holding break

Yes

Dynamic tests

Wear-free electro-magnetic drive

Load-frame dimensions

H4 - height

2375

mm

H3 - clamping-table height

693

mm

H2 - height of test area

1200

mm

H5 - height test area including force measurement chain

1100

mm

B2 - width

890

mm

T3 - depth

645

mm

T2 - depth, base

482

mm

Weight (approx.)[4]

1900

kg

Test area dimensions

Test-area height without load cell

1200

mm

Test area depth

482

mm

Free access width between columns

610[5]

mm

Max. travel, machine frame

1099

mm

Item No.

Vibrophore 25 including testControl II

1050926

Optional: two in one for static tests

1028357

Optional: oscillation displacement measurement

1033236

  1. The testing frequency is determined by the stiffness and mass of the test arrangement.
  1. via activation / deactivation of weights
  1. Load frame stiffness: this value is obtained via direct deformation measurement between the crossheads (moving and base crossheads) and does not take into account deformation of the drive and load cell.
  1. Weight without specimen grips or fixtures
  1. without bellows

50 kN

Fmax

50

kN

Mean load max.

±50

kN

Force amplitude max.

±25

kN

Specimen elastic strain (vibration displacement) max.

6 (±3)

mm

Test frequency range[1]

35 to 300

Hz

No. of frequency steps[2]

8

No. of guide columns

4

No. of lead-screw drives

2

Frame stiffness at 1000mm crosshead separation[3]

approx. 170

kN/mm

Drive

Static tests and for mean force control

AC drive

min. crosshead speed

0.0001

mm/min

max. crosshead speed

600

mm/min

max. crosshead return speed

1000

mm/min

repeat positioning accuracy on crosshead

±2

µm

Motor holding brake

Yes

Dynamic tests

wear-free electro-magnetic drive

Load-frame dimensions

H4 - height

2375

mm

H3 - clamping-table height

693

mm

H2 - test-area height

1200

mm

H5 - test-area height including load cell

1100

mm

B2 - width

890

mm

T3 - depth

645

mm

T2 - depth of base

482

mm

Approx. weight[4]

1900

kg

Test area dimensions

Test-area height without load cell

1200

mm

Test area depth

482

mm

Free access width between columns

610[5]

mm

Max. travel, machine frame

1099

mm

Item No.

Vibrophore 50 including testControl II

1023099

Optional: Two in One for static tests

1028360

Optional: vibration displacement measurement

1033326

  1. The testing frequency is determined by the stiffness and mass of the test arrangement.
  1. via activation / deactivation of weights
  1. Load frame stiffness: this value is obtained via direct deformation measurement between the crossheads (moving and base crossheads) and does not take into account deformation of the drive and load cell.
  1. Weight without specimen grips or fixtures
  1. without bellows cover

100 kN

Description

Value

Fmax

100

kN

Mean load max.

±100

kN

Force amplitude max.

±50

kN

Specimen elastic strain (oscillation displacement) max.

6 (±3)

mm

Test frequency range[1]

30 ... 285

Hz

No. of frequency steps[2]

8

No. of guide columns

4

No. of lead-screw drives

2

Frame stiffness at 1000mm crosshead separation [3]

approx. 380

kN/mm

Drive

Static tests and for mean force control

AC drive

min. crosshead speed

0.0001

mm/min

max. crosshead speed

600

mm/min

max. crosshead return speed

1000

mm/min

repeat positioning accuracy on crosshead

±2

µm

motor holding brake

yes

Dynamic tests

wear-free electro-magnetic drive

Load-frame dimensions

H4 - height

2565

mm

H3 - clamping-table height

794

mm

H2 - test area height

1200

mm

H5 - test area height including load cell

1007

mm

B2 - width

1094

mm

T3 - depth

770

mm

T2 - base depth

553

mm

Approx. weight[4]

3200

kg

Test area dimensions

Test-area height without load cell

1200

mm

Test area depth

550

mm

Free access width between columns

626[5]

mm

Max. travel, machine frame

977.5

mm

Item No.

Vibrophore 100 including testControl II

084142

Optional: two in one for static tests

1009579

Optional: oscillation displacement measurement

1001259

  1. The testing frequency is determined by the stiffness and mass of the test arrangement.
  1. via activation / deactivation of weights
  1. Load frame stiffness: this value is obtained via direct deformation measurement between the crossheads (moving and base crossheads) and does not take into account deformation of the drive and load cell.
  1. Weight without specimen grips or fixtures
  1. without bellows boot

250 kN

Description

Value

Fmax

250

kN

Mean load max.

±250

kN

Force amplitude max.

±125

kN

Specimen elastic strain (oscillation displacement) max.

6 (±3)

mm

Test frequency range[1]

30 ... 285

Hz

No. of frequency steps[2]

8

No. of guide columns

4

No. of lead-screw drives

2

Frame stiffness at 1000mm crosshead separation [3]

approx. 380

kN/mm

Drive

Static tests and for mean force control

AC drive

min. crosshead speed

0.0001

mm/min

max. crosshead speed

600

mm/min

max. crosshead return speed

1000

mm/min

repeat positioning accuracy on crosshead

±2

µm

motor holding brake

yes

Dynamic tests

wear-free electro-magnetic drive

Load-frame dimensions

H4 - height

2565

mm

H3 - clamping-table height

794

mm

H2 - test area height

1200

mm

H5 - test area height including load cell

915

mm

B2 - width

1094

mm

T3 - depth

770

mm

T2 - base depth

553

mm

Approx. weight[4]

3200

kg

Test area dimensions

Test-area height without load cell

1200

mm

Test area depth

550

mm

Free access width between columns

626[5]

mm

Max. travel, machine frame

925

mm

Item No.

Vibrophore 250 including testControl II

1001253

Optional: two in one for static tests

1009581

Optional: oscillation displacement measurement

1001259

  1. The testing frequency is determined by the stiffness and mass of the test arrangement.
  1. via activation / deactivation of weights
  1. Load frame stiffness: this value is obtained via direct deformation measurement between the crossheads (moving and base crossheads) and does not take into account deformation of the drive and load cell.
  1. Weight without specimen grips or fixtures
  1. without bellows boot

500 kN

Fmax

500

kN

Mean load max.

± 500

kN

Force amplitude max.

± 250

kN

Specimen elastic strain (oscillation displacement) max.

4 (± 2)

mm

Test frequency range[1]

35 to 285

Hz

No. of frequency steps[2]

8

No. of guide columns

4

No. of lead-screw drives

2

Frame stiffness at 1000mm crosshead separation[3]

approx. 960

kN/mm

Drive

Static tests and for mean force control

AC drive

min. crosshead speed

0.0001

mm/min

max. crosshead speed

250

mm/min

Maximum crosshead return speed

1000

mm/min

Repeat positioning accuracy on crosshead

± 2

µm

Motor holding brake

Yes

Dynamic tests

Wear-free electro-magnetic drive

Load-frame dimensions

H4 - height

3465

mm

H3 - clamping-table height

930

mm

H2 - height of test area

1680

mm

H5 - height of test area including load cell

1347

mm

B2 - width

1220

mm

T1 - depth

1369

mm

Weight (approx.)[4]

9000

kg

Test area dimensions

Test-area height without load cell

1700

mm

Test area depth

640

mm

Free access width between columns

780[5]

mm

Max. travel, machine frame

1700

mm

Item No.

Vibrophore 500 including testControl II

1011633

Optional: two in one for static tests

1012275

Optional: oscillation displacement measurement

1012273

  1. The testing frequency is determined by the stiffness and mass of the test arrangement.
  1. via activation / deactivation of weights
  1. Load frame stiffness: this value is obtained via direct deformation measurement between the crossheads (moving and base crossheads) and does not take into account deformation of the drive and load cell.
  1. Weight without specimen grips or fixtures
  1. without bellows boot

600 kN

Fmax

± 600

kN

Mean load max.

± 600

kN

Force amplitude max.

± 300

kN

Specimen elastic strain (oscillation displacement) max.

4 (±2)

mm

Test frequency range[1]

30 ... 265

Hz

No. of frequency steps[2]

8

No. of guide columns

4

No. of lead-screw drives

2

Frame stiffness at 1000mm crosshead separation[3]

approx. 880

kN/mm

Drive

Static tests and for mean force control

AC drive

min. crosshead speed

0.0001

mm/min

max. crosshead speed

250

mm/min

max. return speed

1000

mm/min

Repeat positioning accuracy on crosshead

± 2

µm

Motor holding brake

Yes

Dynamic tests

wear-free electro-magnetic drive

Load-frame dimensions

H4 - height

3465

mm

H3 - clamping-table height

930

mm

H2 - test area height

1680

mm

H5 - test area height including load cell

1347

mm

B2 - width

1220

mm

T2 - depth

1369

mm

Weight approx.[4]

9000

kg

Test area dimensions

Test-area height without load cell

1700

mm

Test area depth

640

mm

Free access width between columns

780[5]

mm

Max. travel, machine frame

1700

mm

Item No.

Vibrophore 600 including testControl II

1030616

Optional: two in one for static tests

1012275

Optional: oscillation displacement measurement

1012273

  1. The testing frequency is determined by the stiffness and mass of the test arrangement.
  1. via activation / deactivation of weights
  1. Load frame stiffness: This value is obtained via direct deformation measurement between the crossheads (moving and base crossheads) and does not take into account deformation of the drive and load cell.
  1. Weight without specimen grips or fixtures
  1. without bellows boot

1000 kN

Fmax

±1000

kN

Mean load max.

±1000

kN

Force amplitude max.

±500

kN

Specimen elastic strain (oscillation displacement) max.

4 (±2)

mm

Test frequency range[1]

30 ... 285

Hz

No. of frequency steps[2]

8

No. of guide columns

4

No. of lead-screw drives

2

Frame stiffness at 1000 mm crosshead separation[3]

approx. 880

kN/mm

Drive

Static tests and for mean force control

AC drive

min. crosshead speed

0.0001

mm/min

max. crosshead speed

250

mm/min

max. crosshead return speed

1000

mm/min

Repeat positioning accuracy on crosshead

± 2

µm

Motor holding brake

Yes

Dynamic tests

Wear-free electro-magnetic drive

Load-frame dimensions

H4 - height

4538

mm

H3 - clamping-table height

1058

mm

H2 - test area height

2320

mm

H5 - test area height including load cell

2005

mm

B2 - width

1620

mm

T2 depth

1445

mm

Weight approx.[4]

17500

kg

Test area dimensions

Test-area height without load cell

2310

mm

Test area depth

1995

mm

Free access width between columns

982[5]

mm

Max. travel, machine frame

mm

Item No.

Optional: Two in one for static tests

1017257

Optional: Oscillation displacement measurement

1012273

  1. The testing frequency is determined by the stiffness and mass of the test arrangement.
  1. via activation / deactivation of weights
  1. Load frame stiffness: This value is obtained via direct deformation measurement between the crossheads (moving and base crossheads) and does not take into account deformation of the drive and load cell.
  1. Weight without specimen grips or fixtures
  1. without bellows boot

testControl II electronics

testControl II measurement and control electronics

Control frequency

10 kHz

Measured-value acquisition

10 kHz, 24 bits, arithmetical

Slots

5 x module bus (2 occupied as default)

PC interface

GigaBit Ethernet

Integrated safety concept

2-channel specification for maximum safety

interface for interlocked safety doors

interface for Emergency STOP loop

Display-equipped remote control unit

set-up or testing mode

Emergency STOP button

key-switch for switching between setup and testing modes

Dimensions, testControl II measurement and control electronics

H1-height without table plate

1000

mm

B1-width

600

mm

T1-depth

600

mm

Approx. weight

135

kg

Length of cable Vibrophore - testControl II

5

m

Accessories

Universal measurement amplifier (029443)

Choice of AC/DC supply

Half and full-bridge strain-gages

4 and 6-conductor technology

I/O card (029448)

1 analog ± 10V input (controllable)

2 analog ± 10V outputs

4 digital inputs, 24V

3 digital outputs, 24V

1 relay output, potential-free

Russian research center relies on testing technology from ZwickRoell

The Central Institute of Aviation Motors (CIAM) is the leading Russian research institute in the field of aeronautical engine development. In order to further advance the development of energy-efficient drive technologies, the institute chose a fatigue testing machine from ZwickRoell.
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