R&D Report Thermal Loading Equipment

8/3/2019 R&D Report Thermal Loading Equipment

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Research and Development Assignment in

Steel Structures

Title: Thermal Loading Equipment for Sandwich Panels, Connected to a Weathering

Testing Chamber

Submitted to: Lassi Martikainen

Group Members

Burak ErkanUlfet Sernur Sekbanoglu

Ebru Huseyinoglu

10.02.2012

Abstract

The report presents the design steps of testing arrangement, which will be produced

to test sandwich panels due to temperature differences occurred at both faces of the

sandwich panel. Testing arrangement is designed to be used with KPK 800 Feutron

chamfer. 600 mm x 1500 mm with 100 and 50 mm thickness sandwich panels are taken

into consideration. In conclusion, two different frames are designed, and certaindrawings and 3d visuals are prepared.


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1. IntroductionThermal expansion of metals phenomenon based on the length, thermal coefficient

and the temperature change of the metal. Since the sandwich panels are designed tobe as an insulator building element, there will be a temperature difference between

two faces. Deflection, occurred by the thermal expansion, is restrained by glue

between metal sheet and core insulation. Then the deflection cannot be linear, so

sandwich panel bends and a curve occurs. The aim of the project is; to design and build

an arrangement which will uniquely fit on KPK 800 Feutron Chamber, and to create

thermal loading, and to measure the deflections.

Design procedure, starts sandwich panel market research and deciding the

dimension range. Since there are several producers and different types of panelsexisting, only Ruukkis products are taken into consideration. After a range

investigation, it is decided that, the arrangement should be designed based on with 100

mm and 50 mm core thickness sandwich panels.

Sandwich panels should be positioned, such a way they can behave freely. According

to that, support conditions had to be handled carefully. There are four swivel supports,

two per face at the up and the down of the panel.

Because, the arrangement must be designed to test sandwich panels with different

thicknesses, supports must be tightened with different spaces. In final design, there are

eight long bolts four per side at the up and the down, can be tighten the sandwich

panel between supports.

Certain amount of insulation has to be placed around the frames to prevent the heat

loss, and provide more secure working environment. Design is done based on real

dimensions, and prototype is ready to manufacture.

2. DimensioningDimensions of the testing machine and sandwich panel is determined to be able to star

designing.


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2.1Dimensions of the machineDimensions of the machine are measured at its place. Feutron Chamfer has a door

and design is done without taking the door away. Hinges of the door provides a 130

degree angle opening. With respect to maximum opening of the door, designed frames

can be attached to the machine. Machine is placed in a little room, where thearrangement cannot be kept inside the room. In addition to that, since the machine will

be used for its own purpose, testing arrangement has to be carried inside the room

whenever it is needed. Because of that, design is based on an easy handle prototype

which can be carried by one person through the door easily.

2.2Dimension Range of Sandwich PanelsSandwich panels are used in construction industry in a wide scope. The aim of the

project is to test sandwich panels due to temperature differences between two faces

of them. Sandwich panels are produced by many different types by differentcompanies, but in this design only Ruukki's products are taken into consideration. In

Ruukki's catalog, there are;

a. 28 products for External Walls

b. 6 products for Internal Walls

c. 5 products for Ceilings

d. 2 products for Cold Storages

e. 4 products for Roofs

In between, products listed above, only Sandwich panels for External Walls, Cold

Storages and Roofs are taken into consideration. It is believed that in other products,

there is not risk for temperature difference between faces.

3. Design3.1Design of FramesSandwich panels have to be placed stable to the machine during the test, and its

position must be available for bending freely. Two separate frames are designed to hold

sandwich panels into testing position. They are called as first and second frames in this

report. First frame is the one which is attached to the machine and the second one is

compressing the sandwich panel through the first panel. During the installation of the

testing arrangement, first frame is carried and fastened to the machine separately.

Frames consist of rectangular hollow sections with 50mm x 30 mm and 2.5 mm

thickness steel cross-sections. Certain technical drawings are available in the Drawing

chapter below.


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3.2Design of SupportsSandwich panel gains bending freedom from supports. Sandwich panel is

compressed between two panels, and it is hold with two pads on each frame. Padsare welded to the bearings, which are providing the rotation. There are many types

of bearings on the market; in our design project YAR 204-2F from SKF is used. System

can be installed with same parameters with any bearing with 20 mm shaft diameter.

During the design procedure, two different solutions are created,

3.2.1 Bearing SupportedA shaft (D 20mm) is placed in C shaped housings. And 10 cm by 60 cm steel

pads are welded to the outer shell of bearings. Shaft will be stable and bearings

provide the rotation. Advantages of this system are, easy to install and cheapersolution since no bearing housings are needed to be used. Disadvantages are during

the preparation of the test it is hard to stable the supports due to gravitational

rotation.

3.2.2 Shaft SupportedA shaft (D20 mm) is placed in two bearings at the end of the shaft. And

bearings are placed by bearing housings or welded to the frame. Basically in this

system, shaft is providing to the rotation. Advantages of this system are easy to

handle with the gravitational rotation of the supports during the installation of test

equipment. Disadvantages of the solution are, expensive and the rotational

curvature is bigger than the first solution.

Final design is done with the first solution, a stable shaft and rotational pads

are supporting the sandwich panel, two on each side at the top and the bottom.

3.3Design of ConnectionsThere are two main connections in the system, connection to the machine and

the connection of the frames to each other.

3.3.1 Connection of First Frame to the MachineFirst frame is carrying the sandwich panel and the second frame. Connection has to

be strong enough to keep system stable during the testing. However the machine itself is

an unknown in case of to find a proper place to fix the first frame, it can be fixed with six M

16 bolts around the whole frame. There is a steel welded frame at the bottom of the

machine, and it can be used for fastening of the frame.


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3.3.2 Connection of The Second Frame to The First FrameSecond frame is compressing the sandwich panel. Compression is provided by 8 bolts

in total, four at the top and four at the bottom. An idea of welding bolts to a

rectangular steel piece would be easier for connecting and reduces the localdamages during fastening. At first project is done for 50 mm and 100 mm thick

sandwich panels, but system can be used for other thicknesses too, a range from 0

mm to 100 mm thick sandwich panels can be tested with this system.

3.3.3 Connection of Shaft to The FramesMain supporting elements are shafts in the system; they are holding the pads which

are compressing the sandwich panel from both sides. To be able to test sandwich

panels with different lengths, shafts have to be replaced. Shafts are placed to theframes with C shaped welded housings, which provide different span lengths.

4. Drawings and Figures4.1Main Parts

4.1.1 Frames

Figure 4.1.1 (a) Section cut of frame member


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Figure 4.1.1 (b) First Frame


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4.1.2 Supports

Figure 4.1.2 Shaft, Bearings and Pad

4.1.3 Shaft Housing

Figure 4.1.3 (a) C Shaped Housings for Shaft


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Figure 4.1.3 (b) Housings are placed against the compression axis

Figure 4.1.3 (c) Housings Can Provide Shorter Span Length


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4.1.4 Bolt Group

Figure 4.1.4 (a) Bolt Group

Figure 4.1.4 (b) Fastened Bolt Group and Steel Piece as a Washer

4.1.5 Connections

Figure 4.1.5(a) Bottom of the First Frame and Bolted Connections


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4.2 Photos from Innosteel

Photo 4.2 KPK 800 Feutron Chamfer


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4.3Previous Prototypes

Figure 4.3 (a) Bearing Housings

Figure 4.3 (c) Bigger Rotational Curvature

Figure 4.3(b) First designed whole system


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4.4AnimationsAnimations can be found on Youtube.

4.4.1 Bending of the Sandwich Panelhttp://youtu.be/AdxSOHU6L94

4.4.2 Installation of Frameshttp://youtu.be/pSvFPoNIdmY

4.4.3 Installation of Systemhttp://youtu.be/rwaRcqwDzrY

4.5Production DrawingsFor detailed view please see attached dwg file

Figure 4.5 Production Details
http://youtu.be/AdxSOHU6L94http://youtu.be/AdxSOHU6L94http://youtu.be/pSvFPoNIdmYhttp://youtu.be/pSvFPoNIdmYhttp://youtu.be/rwaRcqwDzrYhttp://youtu.be/rwaRcqwDzrYhttp://youtu.be/rwaRcqwDzrYhttp://youtu.be/pSvFPoNIdmYhttp://youtu.be/AdxSOHU6L94


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5 ConclusionThermal expansion of metals phenomenon is the main idea of the project. Thermal

linear expansion on steel sheets is restrained by glue between the sheet and the coreinsulator material in case of sandwich panels. When both faces are exposed to the

different temperatures, bending of the sandwich panel is expected. Aim of the project

is to design a testing arrangement which will uniquely fit on the KPK 800 Feutron

chamfer, and test sandwich panels against temperature loadings.

Design procedure started with dimensioning and visualization and followed by

prototype creation. There are many different and possible answers for that design

work, but in very first step of the project, some criteria are decided to follow. Such as,

economical, ergonomic, multiuse and adjustable design solutions.

Designed system consists of two main frames and sandwich panel is compressed

between them by bolt groups. Rotational pads, supports are providing sandwich panel

to bend freely.

As it is mentioned above, design could be done in different ways but our solution is

simple and effective. Exact tools can be used for sandwich panels with different length

and thickness. Our Design provides effective freedom to sandwich panel to bend with

cheapest solution. Parts are moveable easily and machine can be used for its own

purpose whenever needed. With provided drawings and animations system is ready to

build and use.

Documents

R&D Report Thermal Loading Equipment