Confederation of European Environmental Engineering … · Environmental Testing of the Future ......

Environmental Testing of the Future

Reality in reliability, virtual testing & trends in physical testing Date: September 27, 2007

Location: ESA/ESTEC space centre Noordwijk, Holland Organisation: FHI, federation of technology branches / PLOT, Platform Omgevingstechnologie, Dutch

Association for Environmental Engineering

Plenary Sessions

The Costs Of Non Testing By D. Gillissen (500 kb)

Focus On Reliability Testing By Harry Roossien, (620 kb)

BESTPRODUCT - TENEEST By F. Crepain (72 kb)

Confederation of European Environmental Engineering Societies

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The costs of Non Testing

D. GillissenStork FDO


Stork Materials Technology

An operating company within the Stork Technical Services Group


Core activities

• Material testing• Non destructive

testing• Calibration• Consultancy


Materials testing• Mechanical testing ( -80ºC to + 900ºC)

• Bearing strength

• Poisson's ratio

• Tensile, peel and tear

• Bending fatigue

• Special tests


Consultancy

• Applied mechanics

• Strain and stress measurements

• Failure calculations

• Vibration measurements

• Product testing and evaluations

• Sound measurements


Consultancy• Corrosion

• Exposition tests

• SSCC tests

• Corrosion potential measurements

• HIC tests

• Etc.


ConsultancyFailure analyses

• Failure mechanism

• Failure cause

• Repair procedures

• Failure prevention


Experiences of non testing and the consequences

• Testing after or during production• Proven knowledge and changing of the

environment• Designing with stronger materials• Lighter construction and the role of

fatigue• Upgrading of components• Applying new techniques


Testing after production• Industrial components

short delivery times• Test is frequently done

during production• The results are not

according specification• The manufacturer has a

lot of cost and effort to repair the vessel and find back the confidence


Example of a pressure vessel

• HIC test for Hydrogen induced cracking

• Test failed• Vessel subjected to

be rejected by the client


Designing based on proven knowledge

• Swimming pools upgraded to leisure pools

• Trent higher temperatures in in the hall

• Higher level of chemicals for disinfection

• Frequently used materials are subjected to stress corrosion cracking

• Result


In 2001, the suspended ceiling of a municipal swimming pool

collapsed. The reason was the catastrophic failure of stainless

steel grade 304 fasteners, which had suffered stress corrosion

cracking (SCC)


Situation after incident


Microscopic examination


Actions and costs

• Inspection of at least 30 swimming pools with the same construction

• Later on more swimming pools were inspected

• Most of the ceiling have to be replaced• New design criteria had to be made


Designing with stronger materials

• Tension bar in gas handling equipment• Tension shall be increased to ensure

stiffness• Material with higher tensile strength• Result failure during test• Failure analyses shows hydrogen

induced cracking from a corrosion process


Lesson

• High cost for the failure of a very expensive piece of equipment

• Material is not suitable for this application• Searching for new material• If no material is available design shall be

changed• Test program for the new selected material


Lighter constructions

• Aluminum is one of the favorable materials to decrease weight

• Lighter construction lower forces• Fatigue strength is lower• Some processes reduces fatigue


Example

• Support roll• Material changed into aluminum• To improve wear resistance a hard

anodizing coating was applied• Fracture in short time notice


Location of fracture


Examination Scanning Electron Microscope

Initiation point


Failure cause

• Cracks in the hard anodized layer

• Reduction of fatigue strength especially by high strength aluminum after hard anodizing


Effects of anodizing on fatigue strength

Alloy Fatigue strength at E10-6 cyclesNot anodized Anodized

MPa MPA2024 130 1056061 105 407075 150 60


Lessons

• Although extensive calculations failure• Hard anodizing caused a lower fatigue

strength as expected• Testing should have tracked this

abnormality• All produced and built in supports shall be

replaced


Upgrading of components

• Upgrading of machinery requires thicker materials

• Three axial stress conditions can play a role

• These stress conditions are difficult to establish even with Finite elements


Example Fluid Forming Press

Rubber sheetMetal sheet

Oil pressure

clamp

Clamp failure

1500 mm

450 mm


History of the clamp rings

• First statically calculated two halves

• Failure in two weeks• Design adapted

according finite element analyses

• Key hole design • Lifetime 3 months


New design

• Clamp ring built in segments

• Three axial forces are lower

• Lifetime over 10 years

Possibility to contract

Focus on Reliability Testing

Benchmark of Industry Development

Environmental Testing of the Future

Can we predict the future?

Future = What… if … then … else …

What would happen if:

• SonyEricsson would enter car manufacturing…– you could select different horn melodies…

• When Microsoft starts making telephones…

What would happen if:

• You could predict the future…– at least:

it would be less interesting…

Different approaches with same conclusions?

• Reliability Roadmap.– current developments in reliability testing.

• Benchmark with Industry Developments.– developments in Industry related to approaches in reliability.

• Conclusion– Reliability Maturity Model.

new

old

new

time

1. Reliability Roadmap

SingleSimulation

SimulationPrograms

CombinedTesting

SingleRobustness

Robustness Programs

HALT

HASS

production testing

Simulation Robustness Acceleration

?

Virtual??

ROSE

ESS

Q$

tR

p

PoF?

Base: PLOT members / CEEES / supplier base

HVS, HASS, HASTTestfilosophy

Mmtfocus

?• Failure Hotel

Test only on the known failure mechanisms.

• Life Cycle AnalysisBase the test(criteria) on the real world conditions the product will face. Eventually with a safety margin.

• Fix allNo base quality levels, but intention to fix all failures.Trade off and impact analysis per observed failure.

• Virtual testing / Zero verification Based on simulation and modelling confidence on end quality

• Quality Supply ChainBase the end result on the sum of all part verifications.Determine the quality erosion

Today

Tomorrow

Yesterday is historyTomorrow is mysteryToday is a giftThat’s why we call it PRESENT

Yesterday

Tendency

2. Benchmark of Industry Developments

A paperless office has about as much chance as a paperless bathroom(anonymous)

Developments in organisation structures• Formalisation, rational approaches

– Weber (bureacratics)– Fayol (management activities)– Taylor (scientific management)

• Human relations approach– individuals in organisation

• System approaches– Lawrence and Lorch (contingency approach)– Galbraith (information model)– influence environment (Porter 5S)

• Organisation culture approach– organisation structure and culture

• Lean and mean– flexibility, core business– Van Weele (rafting organisations)

Benchmark industry development

Weber:Bureacratism

Fayol:Mmt activities

Taylor:Scientific Mmt

Socio/technicalHuman Relations

Porter: Environment/Contingency

System Approach

CLASSIC

MODERN

Informal Orga-nisation Culture

Flexibility–CoreLean and Mean

Utmost dynamicRafting organisation

Development of organisation structures

Development of testing

VirtualTesting

TailoredTesting

Life CycleAnalysis

HALT/HASS

ROSE

commitmenttailoring

analysis

prediction

Development of regular education

TUE

FMECA

standarisation

SimulationTests

SimulationPrograms

integration

Q

PLOT

© www.reliability-test.nl

http://www.reliability-test.nl

Utmost dynamic environmentsRAFTING ORGANISATIONS

• flat structure – minimum mmt layers• structure organised around core processes*

(not line or function)• 3 to 5 core processess*• outsourcing of non-core processes*• multifunctional and multi employable teams• simple directive structure with clear

tasks, responsibilities and targets• orderly, manoeuvrable (flexible), sober unit,

but extremely good organised for task

• * = or core activities, core competencies.

Sources: Van der Hart and Gelderman, Business Marketing, 2003Gelderman, Management competencies

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VIRTUAL

FMECA

MTBF

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3. Reliability Maturity Model


…

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VIRTUAL

FMECA

MTBF

LCA

physics

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Reliability Maturity Model


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DEVELOPERSCONSERVATIVES

INNOVATORS PIONEERS

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• Insight current position– SWOT – focus areas, analysis or testing

• Benchmark your position– with suppliers/test houses– with competitors

• Strategy development– current and wanted position– vision (how to develop, which direction)



Summary and focus points

• 2 different visions (old and new)– fit in one model: Reliability Maturity Model

• You cannot be good in all segments of the model – specialisations, organisation type

• Understanding is key for future testing– ROSE, PoF, analysis

• Focussed and Fast Testing – Tailored testing, virtual testing– Not only products testing (components, analysis, virtual simulation)

• Power of suppliers and customers– opportunity and thread (unrealistic demands)

Testing remains popular

Thais Rush To Condom TestAugust 23, 2007

Some 1,000 amorous Thais volunteered to test condoms for customer satisfaction Wednesday. At least 500 positions were available as part of a campaign to promote safe sex in the region. According to Durex, a Thai marketing firm for condoms, "We are surprised to see huge interest in our campaign with almost 1,000 applicants wanting to take part. "

read article | comments (0)

Thank you!Let’s enjoy the future together

Can we predict future?

• Where are you?

• Where are your suppliers?

• Where are your competitors?

• Where do you want to be in the future?

More information via:

www.plot.nl

www.reliability-test.nl

http://www.plot.nl



BestProductBestProduct -- TeneestTeneestE! 3517E! 3517

September 2007September 2007

www.eneest.euwww.eneest.eu

http://www.eneest.eu



Presentation overview

1. CEEES2. EUREKA Project E! 3517

BESTPRODUCT3. Other Project Proposals4. Advantages and Conclusions


Confederation of European Environmental Engineering

Societies - CEEES

established 1984


Member Societies• ASTE France• BSMEE Belgium• AITPA Italy• GUS Germany• KOTEL Finland• Nacei Czech Republic• ÖGUS Austria• PLOT The Netherlands• SEE United Kingdom• SEES Sweden• SOPSAR Portugal• SSEE Switzerland


CEEESAims and Objectives• Exchange of Information and Experience• Advancement of EE science & Technology• Achieving Recognition as an Expert Pool• Arranging International Symposia and Workshops• Participation in Standardization and Best Practices

Elaboration• Encouraging Members to Support each other


BestProductBestProduct -- TeneestTeneestE! 3517E! 3517

September 2007September 2007

www.eneest.euwww.eneest.eu




ORGANISATIONORGANISATION•• Conference of Ministers: coordinating bodyConference of Ministers: coordinating body

•• High Representatives of participating countries: to High Representatives of participating countries: to prepare and to assist the Conference of Ministersprepare and to assist the Conference of Ministers

•• SecretariatSecretariat

•• National Project Coordinators National Project Coordinators of participating countries: of participating countries: to help establishing EUREKA projects (finding partners, to help establishing EUREKA projects (finding partners, defining the project, access funding,..)defining the project, access funding,..)


EUREKA Project (criteria)

• Proposed ,defined & managed by itspartners (bottom-up approach)

• International partners from at least 2 EUREKA members

• Led by industry• Developing hi-tech

products/processes/services for the market.


BESTPRODUCTBESTPRODUCT

•• GoodGood productproduct

•• BetterBetter productproduct

•• BESTBESTPRODUCT: PRODUCT: is a product in a optimized is a product in a optimized harmony with its environment, it serves market needs as harmony with its environment, it serves market needs as well as ecological requirements.well as ecological requirements.


How BESTPRODUCT?How BESTPRODUCT?

•• Urgent need to merge in a network the Urgent need to merge in a network the knowledge of highly qualified EE specialists and knowledge of highly qualified EE specialists and to make an inventory of the existing EE technical to make an inventory of the existing EE technical capabilities all over Europecapabilities all over Europe

•• To use that experience for designing and To use that experience for designing and producing a best product.producing a best product.

•• BestproductBestproduct--Through a European Network of Through a European Network of Environmental Engineering Sciences and Environmental Engineering Sciences and Technology.Technology.


BESTPRODUCTBESTPRODUCT--TENEESTTENEEST

•• BESTPRODUCT BESTPRODUCT -- TThrough a hrough a EEuropean uropean NNetwork on etwork on EEnvironmental nvironmental EEngineering ngineering SSciences and ciences and TTechnologiesechnologies

•• EUREKA Project (Factory) Nr. EUREKA Project (Factory) Nr. ΣΣ ! 3517 (June 2005)! 3517 (June 2005)

•• An individual project under the Factory umbrellaAn individual project under the Factory umbrella


ΣΣ ! 3517 ! 3517 OBJECTIVESOBJECTIVES

•• To create a To create a networknetwork in order to merge the EE expertise in order to merge the EE expertise of highly qualified specialists and the EE technical of highly qualified specialists and the EE technical capabilities all over Europe.capabilities all over Europe.

•• This network is :This network is :–– aiming on a durable integration of experts’ knowledgeaiming on a durable integration of experts’ knowledge–– a platform of excellence for solving on a concrete manner a platform of excellence for solving on a concrete manner

relevant problems in EE relevant problems in EE –– a tool for generating new EUREKA projects emphasizing a tool for generating new EUREKA projects emphasizing

cooperation between industries and R&D centres (bottomcooperation between industries and R&D centres (bottom--up).up).


Project TasksProject Tasks•• Assessment of all existing EE activities, survey of Assessment of all existing EE activities, survey of

research and test centres,...research and test centres,...•• Establishment of an international network as Establishment of an international network as

preparation for the creation of a preparation for the creation of a virtual EEvirtual EEcompetence centrecompetence centre..

•• Determination of the gaps where facilities and Determination of the gaps where facilities and activities are missing.activities are missing.

•• Creation of possibilities for international coCreation of possibilities for international co--operationoperation

•• Detection of possible research topics and Detection of possible research topics and stimulation of EUREKAstimulation of EUREKA--projectsprojects


European Skills directory for European Skills directory for product testingproduct testing

•• First initiative: the set up of an electronic First initiative: the set up of an electronic European skills directory for product testing.European skills directory for product testing.

•• A short questionnaire (registration process) is A short questionnaire (registration process) is given on the EE website: given on the EE website: www.eneest.euwww.eneest.eu

•• Companies interested in EE, either as users Companies interested in EE, either as users or as service providers, are asked to express or as service providers, are asked to express their interest in this initiative.their interest in this initiative.

•• The areas of interest of the company or what The areas of interest of the company or what skills are offered can be indicated.skills are offered can be indicated.




SUPPORTING COUNTRIESSUPPORTING COUNTRIES

•• Countries supporting the project:Countries supporting the project:–– BelgiumBelgium–– FinlandFinland–– GermanyGermany–– SpainSpain–– SwedenSweden–– SwitzerlandSwitzerland–– The Czech RepublicThe Czech Republic–– TurkeyTurkey–– CEEES as international body is the main participantCEEES as international body is the main participant

•• Project is open: countries may always joinProject is open: countries may always join


What has been realised?What has been realised?

•• KickKick--off meeting (Brussels 15 Feb 2006)off meeting (Brussels 15 Feb 2006)•• Consortium agreement signed in Sept 2006Consortium agreement signed in Sept 2006•• The technical Steering Committee met 4 timesThe technical Steering Committee met 4 times•• 4 international workshops took place4 international workshops took place•• Registration Process (January 2007)Registration Process (January 2007)•• Web site Web site www.eneest.euwww.eneest.eu operational (April 2007)operational (April 2007)•• Networking startedNetworking started•• Projects proposalsProjects proposals




3. Eureka Project Proposals

• Creation of an artificial climate• Ageing and life prediction• VPET• Simulation of ageing and corrosion


Creation of an artificial climateCreation of an artificial climatein closed environmentsin closed environments

•• Creating an artificial climate in a fixed or mobile closed Creating an artificial climate in a fixed or mobile closed environment. environment. ModelisationModelisation of a laminar airflow in a high of a laminar airflow in a high care facility for burn patients.care facility for burn patients.

•• Study of all relevant parameters in creating an artificial Study of all relevant parameters in creating an artificial climate in a building, active facade, shelter, cockpit, climate in a building, active facade, shelter, cockpit, cabin, etc.cabin, etc.

•• Relevant parameters are moisture, radiation, Relevant parameters are moisture, radiation, temperature (wet and dry bulb), air movement and air temperature (wet and dry bulb), air movement and air ventilation.ventilation.

•• The study of those climates is important for human The study of those climates is important for human safety and comfort, but also to investigate the ageing of safety and comfort, but also to investigate the ageing of the materials used in the materials used in ““indoor facilitiesindoor facilities””. .


Ageing and life time predictionAgeing and life time predictionin automotive engineeringin automotive engineering

•• Ageing and life time prediction of light materials used in Ageing and life time prediction of light materials used in automotive automotive engineering.(enginsengineering.(engins) and the caused ) and the caused environmental degradationenvironmental degradation

•• Chalmers University, Sweden.Chalmers University, Sweden.•• Prof. Lars Prof. Lars NyborgNyborg and Ass. Prof Janand Ass. Prof Jan--Erik Erik SvenssonSvensson..•• KanthalKanthal AS, AS, SandvikSandvik Materials Technology AB, AB Materials Technology AB, AB

Volvo (Volvo Volvo (Volvo PowertrainPowertrain), Volvo Car Corporation, Audi, ), Volvo Car Corporation, Audi, Sweden. Sweden.

•• Institute de Institute de IaIa Corrosion, University Pierre and Marie Corrosion, University Pierre and Marie Curie, France.Curie, France.


VPETVPET•• Virtual and Physical Environmental Testing.Virtual and Physical Environmental Testing.•• The goal of virtual testing is to avoid development testing The goal of virtual testing is to avoid development testing

of test setof test set--ups, test fixtures, etc. and to use physical ups, test fixtures, etc. and to use physical testing for validation and verification only.testing for validation and verification only.

•• More limited proposal:More limited proposal: synthesis of test profiles used in synthesis of test profiles used in environmental vibration tests.environmental vibration tests.

•• SemconSemcon, Sweden. , Sweden. •• LMS International, Belgium.LMS International, Belgium.•• RMA BelgiumRMA Belgium•• DevotechDevotech, Norway (interested)., Norway (interested).•• Nokia Siemens Networks , GermanyNokia Siemens Networks , Germany•• VTT Technical VTT Technical Centre,FinlandCentre,Finland


Methods for acceleration of Methods for acceleration of ageing and corrosion testsageing and corrosion tests

•• Methods for simulation of ageing and corrosion caused Methods for simulation of ageing and corrosion caused by internal chemical environment in e.g. contaminated by internal chemical environment in e.g. contaminated products especially in electronics.products especially in electronics.

•• Methods for acceleration of ageing and corrosion caused Methods for acceleration of ageing and corrosion caused by internal chemical by internal chemical environment(e.genvironment(e.g. in electronics).. in electronics).

•• BodycoteBodycote Materials Testing AB, Materials Testing AB, DeLavalDeLaval International International AB, Volvo AB, Volvo LastvagnarLastvagnar, Sweden., Sweden.

•• Delta Electronics Testing, Denmark.Delta Electronics Testing, Denmark.•• Siemens AG, Germany (interested).Siemens AG, Germany (interested).


4. Advantages & Conclusions

• Advantages to participate• Conclusions• Advantages to participate• Conclusions


Advantages in participating Advantages in participating in in BestproductBestproduct--TENEESTTENEEST

•• Faster access to better information creates Faster access to better information creates efficiency and productivityefficiency and productivity

•• With specific problem to right expertWith specific problem to right expert•• Access to industry experts and the on line Access to industry experts and the on line

directory on the web sitedirectory on the web site•• Possibility to exchange technical Possibility to exchange technical

informationinformation•• Participate at new EUREKA projects in EEParticipate at new EUREKA projects in EE


ConclusionsConclusions

•• A unique opportunity to become a member A unique opportunity to become a member of a great family of EE experts.of a great family of EE experts.

•• No or low costsNo or low costs•• A few minutes for the preliminary A few minutes for the preliminary

questionnaire.questionnaire.•• INTERNET INTERNET www.eneest.euwww.eneest.eu




QUESTIONS ?

• THANK YOU FOR YOUR ATTENTION

• DON’T FORGET TO REGISTER

Confederation of European Environmental Engineering … · Environmental Testing of the Future ......

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