EMCH 402 Experimental Stress Analysis Technical Report Determination of Principal Orientations and Stress Magnitudes through Photoelastic Models and Birefringent Coatings Co-Author A (Lead Author): Donaldson, Robert Co-Author B: Stachnik, Michael Co-Author C: Shaw, Erik Lab Group No: Group 3, Team 4 4/2/14, 10:00 am Submission Date: 4/29/14 INTRODUCTION: This lab implements a transmission polariscope and a reflection polariscope to explore polariscope techniques and analyze photoelasticity deformation measurements. These non-distructive, whole field analytical techniques are powerful methods of stress and strain analysis. The observations and measurements can be utilized to determine stress distribution in the material. These optical methods provide visual representation of stress distribution allowing for analysis of discontinuities in a material. These tools can be used to determine critical stress points and concentrations in irregular geometries to gain an understanding of the model before having to implement numerical methods. The transmission polariscope will be implemented in the plane configuration and the circular configuration. The plane configuration consists of a polarizer, analyzer, and a light source. The circular configuration consists of two additional quarter wave plates. Both configurations require photoelastic model materials. The plane polariscope configuration is used to determine the principle orientations of the model from recording isoclinic fringe patterns. The stress-fringe coefficient for the model will be determined from the isochromatic fringe pattern produced from the circular polariscope configuration. The reflection polariscope produces isochromatic fringe patterns from the birefingent coating on the model being stressed. Birefringent materials refract light when under mechanical stress. Deformation can be measured from the stress concentrations which can be related to strain via the stress optic law. This lab will examine three different photoelasic model specimens. A C-shaped specimen and a beam specimen will be observed with the transmission polariscope under loads in each polariscope configuration. An aluminum specimen with a center hole and birefringent coating will be observed with the reflection polariscope. The testing of these specimens will provide hands on interpretations of fringe patterns and allow us to apply photoelasticity to analyze stress concentrations in the models as well as calibrate the material to identify the material. The completion of this lab shows the power of these polariscope techniques and their wide range of applications from identifying materials to determining stress concentrations. On the contrary if these analytic tools are not used properly large errors are produced as was experienced in the conclusion of this lab. 1 THEORY: The governing theories behind polariscope techniques are the wave theory of light, retardation, intensity, and the stress optic law. The stress optic law being of most importance as it related optical phenomena such as retardation and intensity to mechanical aspects. In order to understand the underlying theory we must first start with the wave theory of light. The wave equation can describe optical effects associated with photoelastisity by evaluating the electrical and magnetic components of light. This leads us to the simplified expression, equation 1, for the magnitude of light as a function of position along the axis of propagation. πΈ = acos 2π (π§ + πΏ − ππ‘) π (1) The superposition property of light waves allows for two waves to have the same wavelength and frequency but different amplitudes and phases. This is considered retardation. When considering the phase, δ, and taking the difference between two waves, equation 2, we get retardation. πΏ = πΏ2 − πΏ1 (2) Intensity is a function of retardation between waves of light as described in equation 3 where a is amplitude and proportional to intensity. πΌ ∝ π2 = π(πΏ) (3) Understanding these basic optical concepts we can apply them to the photoelastic material. When the photoelastic material has light passed through it the wave enters the principal stress directions. This causes the waves to travel at different velocities leading to phase retardation between the two components. This gives us the relationship of the stress-optic law in equations 4. β= 2πβ πΆ(π1 − π2 ) π (4) Where β is angular retardation, h is specimen thickness, C is the stress-optic coefficient and π1 and π2 are the principal stresses. We define the fringe order in equation 5 due to interference from the polariscope which reveals additional fringes that are dependent of relative retardation. π= β 2π (5) This allows us to define the stress fringe coefficient or material fringe value as described in equation 6. ππ = π πΆ (6) Rearranging and substituting gives us the in-plane principal stress difference for π1 > π2 in equation 7. 2 π1 − π2 = ππ β (7) Therefore we can arrive at the analogous strain relationship in equation 8. π1 − π2 = πππ , β 1+π π€βπππ ππ = ( ) ππ πΈ (8) MATERIALS AND METHODS: Three different photoelastic model specimens were used in this lab. One was a C-shaped specimen, another was a beam of an unknown material, and the third was an aluminum specimen with a center hole and birefringent coating. The three different specimen can be viewed below as Figure 1. Figure 1: (Left to Right) C-Shaped Specimen, Aluminum Specimen with hole and coating, Beam Specimen (didn’t get a whole photo of it) These three specimen were subjected to a load in order to view various fringes in both light and dark fields. The fringes would then be used later for experimental strain calculation and compared to the theoretical strain. In this lab, a photoelasticity deformation technique was used with both a transmission and reflection polariscope. Isoclinic fringe pattern data in the plane polariscope dark fringe configuration was collected during this experiment. This data was collected in order to determine principal orientation of the photoelastic specimens. For the circular transmission polariscope, isochromatic fringe pattern data was recorded in both the light and dark fields. For 2-D photoelastic analysis, a photoelastic model material was calibrated in order to determine the stress-fringe coefficient ππ of the beam specimen. Once the ππ is calculated, the beam’s material can be determined based on known values of ππ . In the second part of the lab, a reflection polariscope was used to measure deformation of the opaque aluminum specimen with the birefringent coating. Whole and half-order isochromatic fringe patterns are employed in order to determine the strain-field based on the stress-optic law. A compensator was used to determine fractional fringe orders to completely analyze the effects of stress concentration. 3 In the first part of the lab a C-shaped specimen was loaded in the middle of the transmission polariscope and it was observed in both light and dark fields with the circular polariscope and in dark field with the plane polariscope. The setup of the transmission polariscope can be observed on the next page in Figure 2. Figure 2: Transmission plane polariscope. Wave Plates can be inserted for circular transmission polariscope The C-shaped specimen was loaded in a diametral compressive matter, but due to the shape of the specimen, it underwent both compressive and tensile forces. A small amount of load was applied until isoclinic fringes were observed in dark field. Once loaded to the desired amount, the load was recorded to be 14psi. Symmetry of 0/90 degree isoclinics were observed which determined that the specimen was loaded in the proper manner. The analyzer was rotated in 15 degree increments from 0 to 90 degrees in order to view the locations where isoclinics of all parameters pass through. These points represent the isotropic, or also known as singular points. An image was captured of the C-shaped specimen and can be viewed below in Figure 3. Also displayed in the images are the dark fringe order for both compressive and tensile fringes. Figure 3:C-shaped specimen in dark field. Left, tensile fringe orders. Right, compressive fringe orders. 4 In the next part of the experiment a beam was assembled in the transmission polariscope in a four point bending setup. Two people were needed to setup the beam in this manner because of the four blocks were needed to be setup simultaneously at the perfect locations. Once the setup was completed, the alignment was checked using the isoclinic fringes again like in the C-shaped specimen. Isochromatic fringe data was observed and recorded in the circular polariscope arrangement. The beam was loaded until the 4th fringe was just visible on the edge of the specimen in dark field. An image was captured using a monochromatic filter and also using white diffused light. These images can be observed below in Figure 4 and Figure 5. The fringe orders are also displayed for both the light and dark field on the photographs. Figure 4: Beam loaded in four point bending in light field with monochromatic filter. Figure 5:Beam loaded in four point bending in dark field. In the last part of the experiment, we used a reflective polariscope to load and observe an aluminum specimen with a hole in it with a birefringent coating. The specimen was setup also with a four point bending as well. A digital compensator was also used in this part of the experiment to record the fractional fringe order. The setup can be observed below in Figure 6 on the next page. 5 Figure 6:Setup of the reflection polariscope with the digital compensator After the specimen was setup in the proper location the room light was turned off and the light source was turned on. Specimen alignment was checked using isoclinic fringes as before to make sure it was perfectly aligned. The beam was then loaded in regular force increments until 2.03 fringes appeared in the specimen, which was based on our calculations. The final load was recorded at 214psi once the max number of fringe order was observed. We captured a digital image using a monochromatic filter and an image under diffused white light but they were never uploaded. Finally, we recorded fractional fringe orders using the digital compensator. 1/16th inch marks were made on the specimen along the path between the edge of the hole to the outside of the specimen. RESULTS: Photoelastic materials and birefringent coatings were analyzed using the two techniques outlined in the Materials and Methods section. The first was the transmission polariscope. We used the transmission polariscope to analyze a beam in four point bending, and a C-shape undergoing compressive force. We then used a reflection polariscope to analyze an aluminum specimen. The specimen had a circular hole that acted as a stress concentrator, and also had a birefringent coating. This coating allowed us to observe stresses in the aluminum despite the aluminum not being a photoelastic material. The transmission polariscope allowed for the calculation of fσ, which was needed to analyze the stresses in the material. The beam in four point bending was used for this calculation. The polariscope was set up in a dark field configuration. The beam was photographed using a monochromatic filter to make the fringes more identifiable. The fringes are shown in Error! Reference source not found.. 6 Figure 7:Beam in four point bending, dark field Using the image and specimen dimensions, a plot of y vs. N was made, where y is the distance from the central axis and N is the fringe order as shown in Figure 8. The slope of this plot was used to find the stress-fringe coefficient. This was used to approximate what material the beam was made out of, as well as allowing analysis of stress states. By combining the statics expression for a beam in bending with the stress optic law, Eq. (1) was obtained with related the distance from the center axis (y) with the fringe order (N). π€3 π¦ = ππ (6ππ) π (1) Plotting the distance y from the neutral axis as a function of fringe order is show in Error! Reference source not found.. Using a best fit line, an equation for the line could be determined. This is shown as Eq. (2). π¦ = 0.188π₯ = 0.188π (2) The result of equating Eq. (1) to the equation of the line in Eq. (2) and rearranging is shown as Eq. (3). 6ππ ππ = 0.188 ( π€ 3 ) = 0.188 ( 6∗228ππ π∗0.94ππ ) (1.504ππ)3 (3) 7 Figure 8:Fringe distance from central axis versus fringe order Solving for fσ now yielded 127 lb/(in-fringe). After the stress fringe coefficient was calculated, 2-D photoelasticity of a C-shaped photoelastic model was done. Using the theoretical elasticity equations for polar stress of a thick half circular ring under diametrical compression shown as Eq. (4) and Eq. (6), σθ could be calculated. This was our theoretical stress magnitude. 2π΄ = 2π΄ = π (4) π π 2 −π2 +(π2 +π2 ) ππ( ) π 14ππ π 1.279ππ2 −2.227ππ2 +(1.279ππ2 +2.227ππ2 ) ππ( 2.227ππ ) 1.279ππ = 41.9 (5) π 2 π2 π 2 +π2 ) − π ] π πππ π3 (6) 8.11 6.595 ) − π ] π πππ π3 (7) ππ = 2π΄ [3π − ( ππ = 41.9 [3π − ( To determine the experimental magnitude, we used the stress optic law, but did not account for thickness. Therefore, our equation was as shown in Eq. (8). ππ = πππ (8) Using these equations, plots of magnitude vs. position were generated. The disc was in compression along the inner diameter and tension along the outer diameter. The compression data is shown in Error! Reference source not found. and Figure 9. 8 Figure 9:Magnitude vs. position, compression side The tension data is shown in Error! Reference source not found. and Figure 10. Figure 10:Magnitude vs. position, tension side The max stresses for the tension and compression sides are shown in Error! Reference source not found.. The max fringe order is also shown. For the compression side, the max fringe order was N=5, while for the tension side, the max fringe order was N=3. 9 Next, an aluminum specimen with a birefringent coating was studied with a reflection polariscope. A Babinet-Soliel compensator was used to measure fractional fringe order. Measuring fractional fringe order is necessary to obtain accurate strain readings of locations of interest that do not coincide with a full fringe. Thus, the compensator was used to observe the strain state at incremental distances away from a stress concentrator. In order to determine NQ (fringe order), Eq. (9) was used. The results are tabulated in Appendix A along with the experimental and theoretical strain differences. ππ = 2 − (πππππ‘πππππ ππππππ πππππ ππππ π’ππππππ‘) (9) Using the fractional fringe orders, Figure 11 was made. This plot shows how the fringe order, and therefore strain, decreases rapidly the farther away from the stress concentrator the measurement is made. Figure 11: Fringe order vs position measured by B-S compensator When the compensator gave a negative reading, the fringe orders were bigger than 2; this is only the case for the first measured fringe. To find the correction factor one must use the following Eq. (10). β π πΈ π (1+ππ ) πΉπΆπ = [1 + βπ πΈπ (1+ππ)] ( 10 ) Note c stands for coating and s stands for specimen. 0.119∗0.36(1+0.29) πΉπΆπ = [1 + 0.0625∗10(1+0.28) ] = 1.06908 ( 11 ) 10 Then by using the corrected reinforcement factor, we can find the experimental principal strain difference from the following Eq. (12). π π ππ₯π₯ − ππ¦π¦ = πΉπΆπ (ππ ∗ πΉ) ( 12 ) Where F was given to be 633µε. For each fringe order, the experimental strain differences were calculated and all the values were assembled to form Figure 12. Figure 12:Experimentally determined strain differences along the position between AB on the specimen Next, theoretical values for the strain difference were calculated by first deriving the principal stresses along AB using the equations for stresses. The resultant equations are Eq. (13) and Eq. (14). πππ = π0 [(1 − 2 π2 3π2 ) (1 + { 2 π π2 πππ = π0 [(1 + 2 π2 3π 4 ) ({1 + 4 } πππ 2π)] 2 π π − 1} πππ 2π)] ( 13 ) ( 14 ) Where a stands for the radius of the hole, and r stands for the location of the fringe. These values can translate easily into x and y coordinates since theta is always zero since we want to know the values along the x axis. So πππ translates into ππ¦π¦ and πππ translates into ππ₯π₯ . ππ₯π₯ πππ ππ¦π¦ can be determined from the generalized Hooke’s law again given in Shukla and Dally as eq. 2.15. 1 π 1 π ππ₯π₯ = πΈ ππ₯π₯ − πΈ (ππ¦π¦ + ππ§π§ ) ππ¦π¦ = πΈ ππ¦π¦ − πΈ (ππ₯π₯ + ππ§π§ ) ( 15 ) ( 16 ) The stresses are from the above calculated values, and the material properties from the specimen are used in this case to calculate the strains. The specimens Young’s Modulus is 10Msi and the Poisson’s ratio of the specimen is 0.29. With these values the theoretical strain difference can be calculated from the following equation: 11 πβπππππ‘ππππ ππ‘ππππ ππππ = |ππ₯π₯ − ππ¦π¦ | ( 17 ) From the calculated values for theoretical strain, the plot in Error! Reference source not found. was formed below showing the theoretically determined principal strain difference vs. position along path AB. Figure 13: Theoretically calculated strain difference along the x axes from the edge of the hole to the edge of the specimen DISCUSSION: Comparing the stress fringe coefficient obtained from the experimental data to literature values, was unsuccessful. This could likely be due to inaccuracies with the measurement of y, which was done using pixels from the photo. The stress fringe coefficient obtained was 127 lb/in-fringe. This would put the material in range of a celluloid material. However, the material was definitely not cellulose based. It was more likely polycarbonate. Polycarbonate has stress fringe coefficient of 40 lb/in-fringe respectively. There is a large error associated with this, so the material is not conclusively polycarbonate. For the data analysis, a stress fringe coefficient of 40 lb/in-fringe was used by the class to analyze the data. The calculations for stress in the C-shaped specimen had high errors, ranging from 68 to 110 percent. Once again, measurement of the position r was done by counting pixels, which has inherent error. While quantitatively our results had high error, qualitatively they indicated that the compression stress increased towards the inner diameter, and the tension stress increased towards the outer diameter. This is reasonable and can be supported by the fringes seen on the specimen. Using the birefringent model, we were able to obtain the correct characteristic shape for the plot of microstrain vs. position. However, there was once again high error in the experimental data. This was most likely due to inexperience with the Babinet-Soliel compensation device. 12 CONCLUSIONS: The results obtained from the experimental data largely did not agree with the theoretical calculations. Qualitatively, plots were obtained that showed representative indicators of what stresses were experienced by the specimens studied. Large sources of error were attributed to inexperience with the technique as well as inaccuracies with measurement of experimental data. The results showed that photoelasticity is powerful analytic tool that has a wide range of applications. Fringe order can be used to determine a materials stress fringe coefficient. That in turn could be used to identify an unknown material, and calculated stresses in the material using the stressoptic law. The Babinet-Soliel compensator could be used to measure fractional fringes. This is especially useful when dealing with small numbers of fringes and obtaining more accurate information about stress states at specific points. Adding a birefringent coating to a material that has no photoelastic properties, like aluminum, is a useful way to study specimens like bridge trusses or support beams. Photoelasticity has many useful applications, and both transmission and reflection polariscopes are powerful analytic tools. APPLICATIONS: The separation by integration of equilibrium equations consists of an integration of the equilibrium equations for elastic conditions. The equilibrium equations are the partial equations with the absence of volume forces and applies to the case of plane stress. After integration of the equilibrium equations and the use of the finite difference approximation, the equation can be written in this way: π ππ₯π = ππ₯0 − ∑π=1 Δππ₯π¦π Δπ¦ Δπ₯ 18 This equation is needed to establish the values of principal stresses and strains. This equation allows ππ₯π to be found at the point of interest. Increases in shear stress Δππ₯π¦π can be obtained from the values ππ₯π¦π of the points above and below the lines in Figure A1 of the Appendices. In this figure, the x and y axes are arbitrarily chosen and the separation is shown as being parallel to the x-axis. To solve the equation, data on the fringe order and the angle of the principal directions (1, 2 in Figure A1) are needed for the line of separation and the lines above and below it as well. The stress optic law is also needed to solve for ππ₯0 once all of the fringe orders, mechanical properties, specimen specs, and angles of principal directions are recorded. The stress optic law can be found in the appendices as equation B1. Once ππ₯π is calculated at the point of interest, ππ¦π and ππ₯π¦π can be calculated through the stress optic law and the representation of Mohr’s circle. The isoclinic angle must be used in the evaluation of the shear stress gradient. This measurement is less precise than the measurement of isochromatic fringe order. To reduce errors, it was determined that equation 18 could be also expressed as a function of the difference of principal stresses or principal strains instead of a function of shear stress. This equation can be viewed in the appendices as equation B2. 13 The advantage of this technique was that it did not require any special instruments for stress separation. Although, this technique did present a few disadvantages, one being propagation and accumulation of a number of numerical errors. This rendered the assessment of ππ₯0 because of the presence of residual stress as well as the evaluation of the gradient of shear stress. In addition to numerical errors, another downfall was because it was a lengthy technique besides in the simplest of cases. The technique was later modified when graphical techniques were used to reduce the time spent on integration. The technique was also improved after computers were invented and a few algorithms were developed for the calculations of the stress differences. The most recent improvement was when a wholefield separation technique was implemented, which eliminated the need for pixel on a free boundary for every integration line. REFERENCES: [1] Fernández, M. Solaguren-Beascoa, J. M Alegre Calderón, P. M Bravo Díez, and I. I Cuesta Segura. "Stress-separation Techniques in Photoelasticity: A Review." The Journal of Strain Analysis for Engineering Design 45.1 (2010): 1-17. Print. 14 APPENDIX: Section A: Figures Figure A1: A series of points used to analyze and apply the shear difference technique. Section B: Equations Stress Optic Law: πΈ π π 0 ππ₯0 = ± 1+π ( βπ ) cos2 πΌ0 π Difference of Principal Stresses: ππ₯π = ππ₯0 − ∑π=1 Δ(π1π −π2π )π ππ2πΌπ Δπ₯ 2Δπ¦ B1 π − ∑π=1 (π1π −π2π )πππ 2πΌπ Δπ¦ Δαi Δπ₯ B2 15 Section C: Sample Calculations Calculating stress using stress optic law Experimental: ππ,26.6 = πππ ππ,26.6 = −2 ∗ 40 = −80ππ π Theoretical: ππ,26.6 = 41.9 [3 ∗ 1.52 − ( 8.11 6.595 ) − ] sin(.464) 1.523 1.52 ππ,26.6 = −47.0ππ π Percent error: (80 − 101.6) π. πΈ. = πππ [ ] × 100 = 21.2% 101.6 Calculating NQ using B-S compensator ππ = 2 − 9 − 0.430 = 2.43 Tabulated data from B-S compensation technique: Fringe Position 0.5 0.5625 0.625 0.6875 0.75 0.8125 0.875 0.9375 1 Average Recorded Fractional Fringe Order Measurement -0.43 NQ 2.43 Experimental Strain Difference (µε) 1644.447396 0.05 0.385 0.72 0.815 0.85 0.875 0.91 0.97 1.95 1.615 1.28 1.185 1.15 1.125 1.09 1.03 1319.618281 1092.914627 866.2109741 801.9218783 778.236422 761.3182389 737.6327826 697.0291432 Theoretical Strain Difference (µε) 8.505668528 5.882078302 4.467520446 3.668963955 3.202849023 2.924549501 2.756320911 2.654518701 2.593739356 16 Calculating principle strain difference π π ππ₯π₯ − ππ¦π¦ = 1.06908(1.95 ∗ 633µε) = 1319.62µε Calculating stress for fringe order 1.95 πππ = 214ππ π 0.5042 0.5042 [(1 − + ∗ − 1} cos(2 ∗ 0))] = 50.82ππ π ) (1 {3 2 0.56252 0.56252 πππ = 214ππ π 0.5042 0.5044 ((1 + ∗ [(1 + ) {3 }) cos(2 ∗ 0))] = 506.79ππ π 2 0.56252 0.56254 Example strain calculations are shown for fringe order 1.95 ππ₯π₯ = 1 0.29 ππ (0.50679ππ π + 0) = −9.62πΈ − 6 ∗ 0.05082ππ π − 10000ππ π 10000ππ π ππ ππ¦π¦ = 1 0.29 ππ (0.05082ππ π + 0) = 4.92πΈ − 5 ∗ 0.50679ππ π − 10000ππ π 10000ππ π ππ Calculation of theoretical strain difference for fringe order 1.95 πβπππππ‘ππππ ππ‘ππππ ππππ = |−9.62πΈ − 6 − 4.92πΈ − 5| = 5.88ππ 17