REYNAERS ALUMINIUM NV/SA

Oude Liersebaan 266 B-2570 Duffel

t +32 15 30 85 00 f +32 15 30 86 00
www.reynaers.com info@reynaers.com

REPORT

Length coupling profiles CW50

Requested by
Carried out by
Report number
Date:

: Johan Bollaert
: Danny Geysels
: 08R0018
: 27/03/2008

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Table of contents
1.

Request ______________________________________________________ 4

2.

Tests _________________________________________________________ 4
2.1

Test material ___________________________________________________ 4

2.2

Test configuration _______________________________________________ 4

2.3

Test procedure __________________________________________________ 5

2.4

Test results _____________________________________________________ 6

2.4.1
2.4.2
2.4.3

2.5

3.

Largest mullion 034.1510 ________________________________________________6

Smallest mullion 034.1501 _______________________________________________6
Overview test results ___________________________________________________12

Comparison test results__________________________________________ 14

Simulations __________________________________________________ 17
3.1

Simulation model_______________________________________________ 17

3.2

Simulation results ______________________________________________ 18

4.

Comparison test and simulation results ____________________________ 21

5.

Conclusions __________________________________________________ 24

6.

Appendix ____________________________________________________ 25

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List of figures, tables and graphs

Figure 1 - Test configuration 034.1510 ________________________________________________4
Figure 2 - Test configuration 034.1501 ________________________________________________5
Figure 3 - Dimensions test configuration _______________________________________________5
Figure 4 - Fixation of the coupling profile ______________________________________________6
Figure 5 - Model for 034.1501 with 300 mm coupling____________________________________17
Figure 6 - Model for 034.1510 with 1000 mm coupling __________________________________17
Figure 7 - Simulation model ________________________________________________________18
Figure 8 - Shell elements___________________________________________________________18
Figure 9 - Deflection mullion profile _________________________________________________19
Figure 10 - 034.1501 ______________________________________________________________25
Figure 11 - 034.1510 ______________________________________________________________26
Figure 12 - 034.4593 ______________________________________________________________27
Figure 13 - 034.4585 ______________________________________________________________28
Table 1 - Results test 1 without coupling profile _________________________________________7
Table 2 - Results test 1 with 1000 mm fixed coupling _____________________________________7
Table 3 - Results test 1 with 1000 mm loose coupling _____________________________________8
Table 4 - Results test 1 with 750 mm fixed coupling ______________________________________8
Table 5 - Results test 1 with 750 mm loose coupling ______________________________________9
Table 6 - Results test 1 with 600 mm loose coupling ______________________________________9
Table 7 - Results test 1 with 500 mm coupling ___________________________________________9
Table 8 - Results test 1 with 400 mm coupling __________________________________________10
Table 9 - Results test 2 without coupling profile ________________________________________10
Table 10 - Results test 2 with 750 mm coupling _________________________________________10
Table 11 - Results test 2 with 600 mm coupling _________________________________________11
Table 12 - Results test 2 with 500 mm coupling _________________________________________11
Table 13 - Results test 2 with 400 mm coupling _________________________________________11
Table 14 - Simulation results for 034.1501 ____________________________________________19
Table 15 - Simulation results for 034.1510 ____________________________________________20
Graph 1 - Results point M1 test 1 ____________________________________________________12
Graph 2 - Results point M2 test 1 ____________________________________________________12
Graph 3 - Results point M1 test 2 ____________________________________________________13
Graph 4 - Results point M2 test 2 ____________________________________________________13
Graph 5 - Comparison fixed/loose 750 mm coupling_____________________________________14
Graph 6 - Comparison fixed/loose 1000 mm coupling____________________________________14
Graph 7 - Comparison test1/test2 without coupling______________________________________15
Graph 8 - Comparison test1/2 with 750 mm coupling ____________________________________15
Graph 9 - Comparison test1/2 with 600 mm coupling ____________________________________15
Graph 10 - Comparison test1/2 with 500 mm coupling ___________________________________16
Graph 11 - Comparison test 1/2 with 400 mm coupling __________________________________16
Graph 12 - Simulation results 034.1501 in graph _______________________________________20
Graph 13 - Simulation results 034.1510 in graph _______________________________________21
Graph 14 - Theory vs practice ______________________________________________________21
Graph 15 - Comparison without coupling _____________________________________________22
Graph 16 - Comparison with 1000 mm coupling ________________________________________22
Graph 17 - Comparison with 750 mm coupling _________________________________________22
Graph 18 - Comparison with 600 mm coupling _________________________________________23
Graph 19 - Comparison with 500 mm coupling _________________________________________23
Graph 20 - Comparison with 400 mm coupling _________________________________________23

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1. Request
The new lengths have to be determined for the coupling profiles of our CW50
system.
First we will do some tests on the smallest and the biggest profile, 034.1501 and
034.1510. The coupling profile for these mullions is respectively 034.4593 and
034.4585.
Afterwards, we will do finite element simulations and at the end we will compare
the simulation results with our test results.

2. Tests
2.1

Test material

We will do tests with the smallest CW50 profile 034.1501 and with the largest
profile 034.1510. The coupling profile for the smallest mullion is 034.4593 and for
the largest 034.4585. The drawings of these profiles can be found in the appendix
at the end of this report.
Two Mitutuyo digital measuring apparatus are used to measure the deflection.
One pneumatic cylinder (Festo DNC-125-200-PPV) will be used to push on the
mullion.

2.2

Test configuration

The following pictures show us the test configuration to determine the length of the
coupling profile.

Figure 1 - Test configuration 034.1510

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Figure 2 - Test configuration 034.1501

The mullions were supported on the two sides with steel bars.
Following figure gives a representation of the dimensions of our test configuration.

Figure 3 - Dimensions test configuration

A force is put on 250 mm from the centre of the mullion. We will use a pneumatic
cylinder for this force.
The deflection of the mullion is measured at two points M1 and M2.

2.3

Test procedure

First, we will do measurements of the deflection for the whole mullion. Slightly we
will increase the force to have some measuring points.
Afterwards we will cut the mullion in half and couple the two parts. First with a
coupling profile of 1000 mm; then we will reduce the length of the coupling profile
in different steps. Again we will measure the deflection using different lengths of
coupling profile. At the end we will compare the different results we obtained.

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2.4
2.4.1

Test results
Largest mullion 034.1510

The maximum force that can be obtained with our setup is about 7500 N. With this
force we measured a deflection of 2,92 mm. This is too small to evaluate the
interference between the coupling profile and the mullion.
We will continue with the smallest mullion.
2.4.2

Smallest mullion 034.1501

We have done two tests with the smallest profile to have some results we could
compare. Results of the deflections are in mm.
The results for test 1 with a coupling profile of 1000 mm and 750 mm were also
done with a fixed coupling profile. The following figure shows how this is done.

Figure 4 - Fixation of the coupling profile

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2.4.2.1 Test 1
o

No coupling profile

034.1501
No coupling profile
F (kg)
M1
M2
8,4
26,4
9,8
26,4
51,2
76
101,2
10,2
50,4
102
126,4
151,4
10,4
101,8
152
175,2
200,6
10,2

0
1,59
0,5
1,59
3,22
4,85
6,5
0,7
3,28
6,56
8,12
9,7
0,91
6,66
9,78
11,25
12,47
1,06

0
1,66
0,55
1,67
3,34
5,01
6,69
0,74
3,41
6,76
8,36
9,96
0,81
6,86
10,04
11,54
12,5
0,95

Table 1 - Results test 1 without coupling profile

Coupling profile = 1000 mm FIXED

034.1501
Lengte 034.4593 = 1000 mm VAST
F (kg)
M1
M2
8,2
0
0
25,2
1,28
1,32
9,2
0,13
0,14
26,2
1,36
1,41
50,4
3,19
3,27
76
5,11
5,23
101,4
7
7,14
10
0,39
0,39
50,4
3,4
3,47
101
7
7,14
126,8
8,77
8,93
150,2
10,37
10,57
10
0,5
0,5
101,4
7,26
7,38
150,6
10,45
10,65
176
12,07
11,84
200,4
13,4
10
0,69
0,95
Table 2 - Results test 1 with 1000 mm fixed coupling

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Coupling profile = 1000 mm LOOSE

034.1501
Lengte 034.4593 = 1000 mm LOS
F (kg)
M1
M2
4,6
0,37
0,36
4,6
0
0
26
1,73
1,87
10
0,5
0,63
26
1,74
1,9
50,8
3,63
3,83
76
5,5
5,73
101,2
7,32
7,57
10
0,63
0,78
51
3,84
4,03
102,2
7,43
7,67
126
9,04
9,3
151,4
10,76
11,05
10,2
0,72
0,86
101,4
7,56
7,8
151,8
10,88
11,17
175,2
12,36
12,6
202
13,49
12,94
10
0,86
0,55
Table 3 - Results test 1 with 1000 mm loose coupling

Coupling profile = 750 mm FIXED

034.1501
Lengte 034.4593 = 750 mm VAST
F (kg)
M1
M2
8,4
0,74
0,75
8,4
0
0
26,4
1,4
1,43
9,4
0,15
0,16
25,8
1,4
1,42
51,4
3,36
3,4
75,6
5,2
5,27
101,4
7,13
7,22
10
0,33
0,33
50,6
3,49
3,53
101,2
7,21
7,3
125,6
8,92
9,04
150,6
10,69
10,82
176,4
12,32
12,57
10
0,44
0,36
Table 4 - Results test 1 with 750 mm fixed coupling

Coupling profile = 750 mm LOOSE

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034.1501
Lengte 034.4593 = 750 mm LOS
F (kg)
M1
M2
8,8
0,86
0,94
8,6
0
0
25,6
1,38
1,43
9,2
0,14
0,16
25,4
1,39
1,43
51
3,38
3,47
75,4
5,2
5,34
100,6
7,02
7,2
9,8
0,39
0,42
51
3,62
3,71
100,8
7,09
7,26
125,8
8,83
9,04
151,2
10,55
10,8
10,2
0,49
0,62
100
7,27
7,53
105,8
10,68
11,01
176,8
12,42
12,78
196
13,72
9,8
0,63
0,77
Table 5 - Results test 1 with 750 mm loose coupling

Coupling profile = 600 mm

034.1501
Lengte 034.4593 = 600 mm
F (kg)
M1
M2
7,4
0,77
0,79
7,4
0
0
25,4
1,63
1,68
51
3,7
3,81
76,2
5,67
5,82
100,8
7,53
7,73
125,6
9,35
9,59
150,4
10,84
10,95
10
0,72
0,74
Table 6 - Results test 1 with 600 mm loose coupling

Coupling profile = 500 mm

034.1501
Lengte 034.4593 = 500 mm
F (kg)
M1
M2
8,4
0,92
0,95
8,2
0
0
25,4
1,71
1,75
50
3,86
3,96
76
6
6,14
100,6
7,92
8,11
126,4
9,9
10,13
134,4
10,79
11,04
9,4
0,75
0,78
Table 7 - Results test 1 with 500 mm coupling

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Coupling profile = 400 mm

034.1501
Lengte 034.4593 = 400 mm
F (kg)
M1
M2
6
0,74
0,77
5,8
0
0
25
2,02
2,07
50,2
4,42
4,53
75,4
6,63
6,77
100,6
8,73
8,92
125,8
10,78
10,99
9,8
0,91
0,92

Table 8 - Results test 1 with 400 mm coupling

2.4.2.2 Test 2
o

No coupling profile

034.1501
GEEN KOPPELPROFIEL
F (kg)
M1
M2
8,6
0,73
8,6
0
0
26,6
1,23
1,28
51
2,87
2,96
75,2
4,4
4,54
101,4
6,09
6,27
125,6
7,58
7,8
150,8
9,19
9,46
174,6
10,7
10,99
198,4
12,2
12,52
10
0,31
0,34
Table 9 - Results test 2 without coupling profile

Coupling profile = 750 mm

034.1501
Lengte 034.4593 = 750 mm
F (kg)
M1
M2
8,4
1,08
1,15
8,4
0
0
25,6
1,47
1,53
49,8
3,48
3,62
76,4
5,53
5,74
100,2
7,29
7,55
125,6
9,11
9,42
150,4
10,88
11,22
175,4
12,49
9,8
0,8
Table 10 - Results test 2 with 750 mm coupling

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Coupling profile = 600 mm

034.1501
Lengte 034.4593 = 600 mm
F (kg)
M1
M2
8,4
0,92
0,97
8,4
0
0
24,8
1,48
1,54
49,8
3,56
3,69
76,2
5,54
5,74
99,8
7,3
7,56
125,4
9,18
9,5
150,6
11,03
11,41
9,6
0,61
0,62
Table 11 - Results test 2 with 600 mm coupling

Coupling profile = 500 mm

034.1501
Lengte 034.4593 = 500 mm
F (kg)
M1
M2
8,4
0,96
1,01
8,4
0
0
26
1,58
1,65
50,2
3,61
3,74
75,8
5,44
5,5
102,2
7,66
7,68
125,8
9,55
9,63
130
10,26
10,39
9,6
0,56
Table 12 - Results test 2 with 500 mm coupling

Coupling profile = 400 mm

034.1501
Lengte 034.4593 = 400 mm
F (kg)
M1
M2
8,2
1,26
1,27
8
0
0
25,4
1,73
1,81
49,8
4,05
4,21
76,2
6,38
6,61
101
8,55
8,84
126
10,71
11,07
134,6
11,45
11,82
9,4
0,94
0,82
Table 13 - Results test 2 with 400 mm coupling

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2.4.3

Overview test results

The following graphs show the deflection with different lengths of coupling profile.
0341501

250

200

150

400 mm

Force (kg)

500 mm
600 mm
750 mm
1000 mm
No coupling
100

50

0
0

10

12

14

16

Deflection point 1 (mm)

Graph 1 - Results point M1 test 1

0341501

250

200

150

400 mm

Force (kg)

500 mm
600 mm
750 mm
1000 mm
No coupling

100

50

0
0

10

12

14

Deflection point 2 (mm)

Graph 2 - Results point M2 test 1

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0341501

250

200

150
Force (kg)

400 mm
500 mm
600 mm
750 mm
No coupling
100

50

0
0

10

12

14

Deflection point 1 (mm)

Graph 3 - Results point M1 test 2

0341501

250

200

150
Force (kg)

400 mm
500 mm
600 mm
750 mm
No coupling
100

50

0
0

10

12

14

Deflection point 2 (mm)

Graph 4 - Results point M2 test 2

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2.5

Comparison test results

The following graphs show the difference in results for the fixed and loose coupling
profile.
Coupling 750 mm fixed/loose
200
180
160

Force (kg)

140
Fixed point 1

120

Fixed point 2

100

Loose point 1

80

Loose point 2

60
40
20
0
0

10

15

Deflection (mm)

Graph 5 - Comparison fixed/loose 750 mm coupling

Coupling 1000 mm fixed/loose

200
180
160

Force (kg)

140
Fixed point 1

120

Fixed point 2

100

Loose point 1

80

Loose point 2

60
40
20
0
0

10

15

Deflection (mm)

Graph 6 - Comparison fixed/loose 1000 mm coupling

The difference in deflection between a fixed or loose coupling profile is hardly

noticeable. Fixing the coupling profile gives a small decrease in the measured
deflections. This can be best seen in graph 6.

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The differences in results between test 1 and test 2 can be found in the following
graphs.
No coupling
250

Force (kg)

200
150

Test1_M1_No_coupling
Test2_M1_No_coupling

100
50
0
0

10

15

Deflection (m m )

Graph 7 - Comparison test1/test2 without coupling

Coupling 750 m m
200

Force (kg)

150
Test1_M1_750mm

100

Test2_M2_750mm

50
0
0

10

15

Deflection (m m )

Graph 8 - Comparison test1/2 with 750 mm coupling

Coupling 600 m m
160
140
Force (kg)

120
100

Test1_M1_600mm

80

Test2_M1_600mm

60
40
20
0
0

10

15

Deflection (m m )

Graph 9 - Comparison test1/2 with 600 mm coupling

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Coupling 500 m m
160
140
120
100
Test 1_M1_500mm

80

Test 2_M1_500mm
60
40
20
0
0

10

12

14

D e f l e c t i on ( m m )

Graph 10 - Comparison test1/2 with 500 mm coupling

Coupling 400 m m
160
140

Force (kg)

120
100
Test1_M1_400mm

80

Test2_M2_400mm

60
40
20
0
0

10

15

Deflection (m m )

Graph 11 - Comparison test 1/2 with 400 mm coupling

We notice a small difference in the results between test 1 and test 2. There are no
big differences measured so we can say that the results are realistic.
In the next paragraph we will do finite element simulations and afterwards we will
compare the simulation results with the test results.
From graphs 1 4 , we can see that the measured difference in deflection gets
larger when the length of the coupling profile decreases.
Starting from a coupling length of 500 mm, the measured differences increase
more rapidly.

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3. Simulations
3.1

Simulation model

We built up a 3D model in solidworks. The mullion and the coupling profile are
replaced with rectangular tubes that have the same stiffness.
Following figures show the models for the smallest and the biggest mullion.

Figure 5 - Model for 034.1501 with 300 mm coupling

Figure 6 - Model for 034.1510 with 1000 mm coupling

After the model was build, we put forces and restraints on it.
This can be seen in the following figure.

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Figure 7 - Simulation model

The simulation model is built up in the same way that the tests were executed.
Translation was restricted at the sides and the force was put on the right distance
from the edge.
We will use shell elements for the simulation as can be seen in the following
figure.

Figure 8 - Shell elements

3.2

Simulation results

We did the simulations for different coupling profile lengths and with different
forces. We wanted to know the deflection of the mullion.

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Figure 9 - Deflection mullion profile

The results of these simulations are shown in the following tables and graphs.
Length coupling profile (mm)
Applied force (kg) Deflection (mm)
300
50
6,48
100
12,95
150
19,43
400
50
4,83
100
9,65
150
14,48
500
50
4,1
100
8,2
150
12,3
600
50
3,73
100
7,46
150
11,19
750
50
3,42
100
6,85
150
10,27
1000
50
3,25
100
6,49
150
9,74
without coupling
51
3,01
75
4,44
101
5,98
125
7,41
151
8,89
Table 14 - Simulation results for 034.1501

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Length coupling profile (mm)

Applied force (kg) Deflection (mm)
300
250
14,91
500
29,82
1000
59,64
400
250
7,31
500
14,62
1000
29,24
500
250
4,08
500
8,16
1000
16,32
600
250
2,69
500
5,38
1000
10,76
750
250
1,69
500
3,38
1000
6,75
250
1,01
1000
500
2,02
1000
4,04
without coupling
250
0,58
500
1,16
1000
2,32
Table 15 - Simulation results for 034.1510

Deflection 034.1501 with coupling profile

25
300 mm
400 mm

Deflection (mm)

20

500 mm
600 mm
750 mm

15

1000 mm
Zonder koppeling
10

Linear (Zonder koppeling)

Linear (300 mm)
Linear (400 mm)

Linear (500 mm)

Linear (750 mm)
0

Linear (1000 mm)

0

50

100

150

200

Linear (600 mm)

Force (kg)

Graph 12 - Simulation results 034.1501 in graph

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Deflection 034.1501 with coupling profile

70

300 mm
400 mm

60

500 mm
Deflection (mm)

50

600 mm
750 mm

40

1000 mm
Zonder koppeling

30

Linear (Zonder koppeling)

Linear (300 mm)

20

Linear (400 mm)

10

Linear (500 mm)

Linear (750 mm)

0
0

200

400

600

800

1000

Linear (1000 mm)

1200

Linear (600 mm)

Force (kg)

Graph 13 - Simulation results 034.1510 in graph

From the results we can see that the difference in deflection starts to increase
more rapidly at the coupling profile of 500 mm.

4. Comparison test and simulation results

First we will do a comparison, theory vs practice, of the measured deflection for
the 034.1501 profile without coupling profile. This can be viewed in the next graph.
Theory vs practice M2
14,00
Deflection (mm)

12,00
10,00

Theorie

8,00

Simulation

6,00

Test 1

4,00

Test 2

2,00
0,00
0

500

1000

1500

2000

2500

Force (N)

Graph 14 - Theory vs practice

We see that the results from a beam calculation and a finite element simulation
are exactly the same. The measured deflections in reality were a bit higher than
the theoretical results.
The next graphs show the simulation results versus the test results.

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Comparison simulation test - No coupling

14,00

Deflection (mm)

12,00
10,00

Simulation

8,00

Test

6,00

Linear (Test)

4,00

Linear (Simulation)

2,00
0,00
0

50

100

150

200

250

Force (kg)

Graph 15 - Comparison without coupling

Comparison simulation test - Coupling 1000 mm
16

Deflection (mm)

14
12

Simulation

10

Test

Linear (Test)

Linear (Simulation)

4
2
0
0

50

100

150

200

250

Force (kg)

Graph 16 - Comparison with 1000 mm coupling

Comparison simulation test - Coupling 750 mm
14

Deflection (mm)

12
10

Simulation

Test

Linear (Test)

Linear (Simulation)

2
0
0

50

100

150

200

Force (kg)

Graph 17 - Comparison with 750 mm coupling

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Comparison simulation test - Coupling 600 mm

12

Deflection (mm)

10
Simulation

Test

Linear (Test)

Linear (Simulation)

2
0
0

50

100

150

200

Force (kg)

Graph 18 - Comparison with 600 mm coupling

Comparison simulation test - Coupling 500 mm
14

Deflection (mm)

12
10

Simulation

Test

Linear (Test)

Linear (Simulation)

2
0
0

50

100

150

200

Force (kg)

Graph 19 - Comparison with 500 mm coupling

Comparison simulation test - Coupling 400 mm
16

Deflection (mm)

14
12

Simulation

10

Test

Linear (Test)

Linear (Simulation)

4
2
0
0

50

100

150

200

Force (kg)

Graph 20 - Comparison with 400 mm coupling

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We notice that in some cases (no coupling, 1000 mm coupling) the measured
deflections in the tests were higher than for the simulations.
For a coupling of 750 mm, 600 mm and 500 mm the test and simulation results
were the same.
From the above graphs, we can surely say that the simulations give a good
comparison with the reality.

5. Conclusions
The following conclusions can be made from these tests and simulations:

The smaller the coupling profile, the higher the deflections get.
Fixing the coupling profile to the mullion has a negligible effect on the
deflection of the mullion. A small decrease in deflection was measured.
Finite element simulations give a good comparison with the test results and
can be used to draw conclusions.
Test and simulation results indicate a big increase in deflection starting
from a coupling profile of 500 mm. Therefore the coupling length has to be
500 mm 600 mm.

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6. Appendix

Figure 10 - 034.1501

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Figure 11 - 034.1510

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Figure 12 - 034.4593

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Figure 13 - 034.4585

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