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Design and Experimental Activity of Testing Machines and Mechanical Test...
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Design and Experimental Activity of Testing Machines and Mechanical Test Rigs

A special issue of Machines (ISSN 2075-1702). This special issue belongs to the section "Machines Testing and Maintenance".

Deadline for manuscript submissions: 20 February 2025 | Viewed by 9306

Special Issue Editors

Prof. Dr. Ciro Santus

E-Mail Website
Guest Editor
Department of Civil and Industrial Engineering—DICI, University of Pisa, Largo Lucio Lazzarino 1, 56122 Pisa, Italy
Interests: machine design; structural dynamics; fatigue and fracture; residual stresses; contact mechanics
Special Issues, Collections and Topics in MDPI journals
Dr. Massimiliano De Agostinis

E-Mail Website
Guest Editor
Department of Industrial Engineering, University of Bologna, Viale del Risorgimento, 2, 40136 Bologna, Italy
Interests: machine design; joining technology; fatigue; additive manufacturing; contact mechanics
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Many mechanical applications require very specific testing of components and materials, such as turbomachinery, which undergoes fretting fatigue or dynamic vibrations, full-scale testing of large components, or gears of any size and other mechanical power transmission components, etc. Each of these applications usually require a dedicated test rig or at least the development of a piece of equipment to be combined with an already-existing testing machine. Most of the time, these testing facilities need to be both conceived and then designed and commissioned. This activity is usually quite demanding, not only in terms of budget, but also quite challenging from a design point of view. Moreover, these testing machines usually require a significant electronic and control part which needs to be interfaced and properly tuned with the mechanical devices.

This Special Issue aims to comprehensively showcase all the steps of the design of any of these testing devices which are usually conceptualized from scratch or just inspired from an already existing piece of equipment which may be however quite different in terms of specifications and performances. Both the mechanical design and/or the control systems are interesting topics of this Special Issue. The experimental results obtained can be either presented or just omitted if it is not of interest; however, the experimental implementation, at least preliminary, is highly recommended to be presented.

We finally hope that, with your papers, we will succeed in encouraging students and researchers to exchange ideas in order to develop other solutions and even more innovative mechanical testing devices.

Prof. Dr. Ciro Santus
Dr. Massimiliano De Agostinis
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Machines is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • mechanical testing
  • fatigue design
  • finite element analysis
  • vibration monitoring
  • optimization
  • electrical actuation
  • safety design
  • commissioning

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Further information on MDPI's Special Issue polices can be found here.

Published Papers (5 papers)

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Research

19 pages, 4774 KiB  
Article
Resonant Fatigue Tests on Polished Drill Pipe Specimens
by Ciro Santus, Lorenzo Romanelli, Leonardo Bertini, Alessandro Burchianti and Tomoya Inoue
Machines 2024, 12(5), 314; https://doi.org/10.3390/machines12050314 - 3 May 2024
Cited by 1 | Viewed by 995
Abstract
In this study, the fatigue strength of polished drill pipe specimens was investigated and compared with previous test results of corroded and not-corroded pipes. The resonant fatigue test rig, which was designed and implemented by the University of Pisa, is initially presented by [...] Read more.
In this study, the fatigue strength of polished drill pipe specimens was investigated and compared with previous test results of corroded and not-corroded pipes. The resonant fatigue test rig, which was designed and implemented by the University of Pisa, is initially presented by providing a detailed description of the set-up of the machine, the calibration of the strain gauges, the control system, and the correct identification of the vibrational node locations. A polishing rig was also designed and put into operation to remove the corrosion pits from the outer surface of almost the entire length of the drill pipe specimens. After the fatigue tests with the resonant rig, and the observation of the fatigue fracture of the specimens, a few samples were extracted from different zones (corroded and not corroded) of the failed drill pipe specimens. This allowed for investigations to be carried out using a scanning electronic microscope. The obtained results were analyzed using the Murakami model, and a discussion is presented about the effect of the corrosion pits on the fatigue strength. Full article
(This article belongs to the Special Issue Design and Experimental Activity of Testing Machines and Mechanical Test Rigs)
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17 pages, 15855 KiB  
Article
Design and Development of a Brake Test Bench for Formula SAE Race Cars
by Luca Vecchiato, Matteo Negri, Giulio Picci, Luca Viale, Giulio Zaltron, Stefano Giacometti and Giovanni Meneghetti
Machines 2024, 12(2), 135; https://doi.org/10.3390/machines12020135 - 14 Feb 2024
Cited by 3 | Viewed by 3057
Abstract
The optimization of the brake systems is crucial for vehicle performance and safety of Formula SAE (FSAE) race cars. This study introduces a specialized brake test bench designed to enhance the understanding and testing of these systems. The bench integrates a rotating mechanical [...] Read more.
The optimization of the brake systems is crucial for vehicle performance and safety of Formula SAE (FSAE) race cars. This study introduces a specialized brake test bench designed to enhance the understanding and testing of these systems. The bench integrates a rotating mechanical system mounting a brake disc-caliper group, which is driven by an electric motor, a pneumatic brake pedal assembly to simulate real braking conditions, and a comprehensive array of sensors that facilitate the measurement of critical parameters, such as rotation speed, braking torque, oil pressure, and disc temperature. Its structure, sensor integration, and control electronics are fully described, demonstrating the capability to replicate on-track scenarios in a controlled environment. The results underscore the utility of the bench in providing precise and consistent testing conditions essential for analyzing the efficiency, durability, and safety of the braking systems of FSAE race cars. Full article
(This article belongs to the Special Issue Design and Experimental Activity of Testing Machines and Mechanical Test Rigs)
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14 pages, 4863 KiB  
Article
Design of Special Equipment for the Mechanical Testing of Runway Light Fixtures
by Dario Croccolo, Massimiliano De Agostinis, Stefano Fini, Mattia Mele, Giorgio Olmi and Chiara Scapecchi
Machines 2024, 12(1), 41; https://doi.org/10.3390/machines12010041 - 8 Jan 2024
Cited by 1 | Viewed by 1272
Abstract
Runway lights are essential components of the airstrip. However, there is currently no international standard that outlines methods for the testing of runway light fixtures. In this study, a novel testing method is developed to simulate the forces exerted on the lights during [...] Read more.
Runway lights are essential components of the airstrip. However, there is currently no international standard that outlines methods for the testing of runway light fixtures. In this study, a novel testing method is developed to simulate the forces exerted on the lights during landing. The testing equipment is specifically designed to be easily mounted on a standard hydraulic press commonly used for tensile tests. This system allows for the regulation of the normal force between the aircraft tire and the fixture of the runway lighting system. To minimize load fluctuations during part sliding, Belleville washers are employed. The overall compliance of the system is validated through finite element analysis. Tests carried out by means of the proposed testing equipment allow the effective description of the variations in load at different positions during sliding. The system presented in this paper can be used to investigate the effects of landing on various combinations of cap design and tire material. Full article
(This article belongs to the Special Issue Design and Experimental Activity of Testing Machines and Mechanical Test Rigs)
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29 pages, 24569 KiB  
Article
New Method for Precise Measurement of Clamping Plate Deformations on Forming Presses
by Georg Ivanov, Thomas Burkhardt, Lars Penter and Steffen Ihlenfeldt
Machines 2024, 12(1), 40; https://doi.org/10.3390/machines12010040 - 5 Jan 2024
Viewed by 1393
Abstract
The deformation of press bolster plates under load can significantly impact the quality of manufactured workpieces. Consequently, press manufacturers are usually obliged to provide the metric proof of the permissible deformation values during the press commissioning process. Unfortunately, the existing measurement methods for [...] Read more.
The deformation of press bolster plates under load can significantly impact the quality of manufactured workpieces. Consequently, press manufacturers are usually obliged to provide the metric proof of the permissible deformation values during the press commissioning process. Unfortunately, the existing measurement methods for determining bolster plate deformations present flaws in the measurement accuracy, the application flexibility, the metrological effort, and other aspects. These issues have been addressed through the development of a new measurement method using multiple inclination profiles on the surface of the measured object. Based on the difference in the inclination between the unloaded and loaded states, the method approximates the inclination surface and calculates the deformation of the measured object through integration. The measurement method was first used for commissioning tests of forming presses. A comparison with the results obtained with a measurement frame equipped with high-resolution measurement probes demonstrates an accuracy of the new method of less than 20 µm. Full article
(This article belongs to the Special Issue Design and Experimental Activity of Testing Machines and Mechanical Test Rigs)
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19 pages, 10071 KiB  
Article
Influence of Piston Mass and Working Pressure on the Impact Performance of a Hydraulic Rock Drill Using the Stress Wave Method
by Zhenyi Yang, Jun Li and Guoyan Yu
Machines 2023, 11(11), 987; https://doi.org/10.3390/machines11110987 - 25 Oct 2023
Cited by 2 | Viewed by 1830
Abstract
To optimize and improve the impact performance of a hydraulic rock drill, it is helpful to test the stress waves of the drill and analyze the impact energy, impact frequency, and energy utilization rate. For this study, a stress wave test bench was [...] Read more.
To optimize and improve the impact performance of a hydraulic rock drill, it is helpful to test the stress waves of the drill and analyze the impact energy, impact frequency, and energy utilization rate. For this study, a stress wave test bench was designed and built, according to international standards, in order to study the impact process of a hydraulic rock drill under the working pressures of 18 MPa and 23 MPa. The impact energy, impact frequency, and energy utilization rate of two different hydraulic rock drill pistons in low, middle, and high gear were analyzed using a control variable method. The results demonstrate that the impact stress waves of the rock drill periodically occur in the drill rod, and then decay exponentially until they become close to zero. Moreover, the amplitude of the incident stress wave determines the rock-breaking ability of the drill. The impact energy of the short piston is greater than that of the long piston, with a maximum average value of 346.1 J; the impact frequency of the long piston is higher than that of the short piston, with a maximum average value of 62 Hz; and the energy utilization rate of the short piston is higher than that of the long piston, with a maximum average value of 56.92%, which is close to the theoretical ideal efficiency. Therefore, it can be concluded that the impact performance of a hydraulic rock drill can be effectively tested using the proposed horizontal bench, and that piston characteristics and the working pressure are the main factors affecting impact performance. Accordingly, when developing a hydraulic rock drill, it is advisable to select a shorter piston and a higher working pressure, thus allowing the drill to provide good impact performance. Full article
(This article belongs to the Special Issue Design and Experimental Activity of Testing Machines and Mechanical Test Rigs)
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