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Static load testing

Published with permission from the Federation Internationale de l' Automobile.

ARTICLE 18 : STATIC LOAD TESTING
18.1 Conditions applicable to all static load tests :
18.1.1
The tests described in Articles 18.2, 18.3, 18.4 and 18.5 must be carried out on every survival cell intended for use. During these tests (on deflections greater than 3.0mm), the deflection across the inner surfaces must not exceed 120% of the deflection obtained on the chassis used for the tests described in Articles 17.2 and 17.3.
18.1.2 Deflections and deformations will be measured at the centre of area of circular load pads and at the top of rectangular pads.
18.1.3 All peak loads must be applied in less than three minutes, through a ball jointed junction at the centre of area of the pad, and maintained for 30 seconds.
18.1.4 Following the tests described in 18.2, 18.3, 18.4 and 18.5, permanent deformation must be less than 1.0mm (0.5mm in 18.3 and 18.4) after the load has been released for 1 minute.
18.1.5 All tests must be carried out by using measuring equipment which has been calibrated to the satisfaction of the FIA technical delegate.
18.1.6 A radius of 3mm is permissible on the edges of all load pads and rubber 3mm thick may be placed between them and the test structure.
18.1.7 For the tests described in 18.2, 18.3, 18.4 and 18.5, the survival cells must always be produced in an identical condition in order that their weights may be compared. If the weight differs by more than 5% from the one subjected to the impact tests described in Articles 16.2 and 16.3 further frontal and side impact tests and roll structure tests must be carried out.
18.1.8 Any significant modification introduced into any of the structures tested shall require that part to pass a further test.
18.2 Survival cell side tests :
18.2.1
For test 1), referred to in Article 15.5.4, pads 100mm long and 300mm high, which conform to the shape of the survival cell, must be placed against the outermost sides of the survival cell with the lower edge of the pad at the lowest part of the survival cell at that section.
A constant transverse horizontal load of 25.0kN will be applied and, under the load, there must be no structural failure of the inner or outer surfaces of the survival cell.
18.2.2 For test 2), referred to in Article 15.5.4, pads 200mm in diameter which conform to the shape of the survival cell, must be placed against the outermost sides of the survival cell.
The centre of the pads must pass through the plane mentioned above and the mid point of the height of the structure at that section.
A constant transverse horizontal load of 30.0kN will be applied to the pads and, under the load, there must be no structural failure of the inner or outer surfaces of the survival cell and the total deflection must not exceed 15mm.
18.3 Fuel tank floor test :
A pad of 200mm diameter must be placed in the centre of area of the fuel tank floor and a vertical upwards load of 12.5kN applied.
Under the load, there must be no structural failure of the inner or outer surfaces of the survival cell.
18.4 Cockpit floor test :
A pad of 200mm diameter must be placed beneath the survival cell, on the car centre line and with its centre 600mm forward of the rear edge of the cockpit entry template, and a vertical upwards load of 15kN applied.
Under the load, there must be no structural failure of the inner or outer surfaces of the survival cell.
18.5 Cockpit rim tests :
Two pads, each of which is 50mm in diameter, must be placed on both sides of the cockpit rim with their upper edges at the same height as the top of the cockpit side with their centres at a point 250mm forward of the rear edge of the cockpit opening template longitudinally.
A constant transverse horizontal load of 15.0kN will then be applied at 90° to the car centre line and, under the load, there must be no structural failure of the inner or outer surfaces of the survival cell and the total deflection must not exceed 5mm.
This test must be repeated at positions 50mm and 150mm forward of the rear edge of the cockpit opening template longitudinally.
18.6 Nose push off test :
During the test the survival cell must be resting on a flat plate and secured to it solidly but not in a way that could increase the strength of the attachments being tested.
A constant transversal horizontal load of 40.0kN must then be applied to one side of the impact absorbing structure, using a pad identical to the ones used in the lateral tests in Article 18.2.1, at a point 550mm from the front wheel axis.
The centre of area of the pad must pass through the plane mentioned above and the mid point of the height of the structure at the relevant section. After 30 seconds of application, there must be no failure of the structure or of any attachment between the structure and the survival cell.
18.7 Side intrusion test :
18.7.1
The test must be carried out in accordance with FIA Test Procedure 02/05, in the presence of an FIA technical delegate and by using measuring equipment which has been calibrated to the satisfaction of the FIA technical delegate. A copy of the test procedure may be found in the Appendix to the Technical Regulations.
18.7.2 The test panel must be 500mm x 500mm and will be tested by forcing a rigid truncated cone through the centre of the panel at a rate of 2mm (+/-1mm) per second until the displacement exceeds 150mm.
During the first 100mm of displacement the load must exceed 250kN and the energy absorption must exceed 6000J. There must be no systematic damage to the border or damage to the fixture before these requirements have been met.
18.8 Rear impact structure push off test :
During the test the gearbox and the structure must be solidly fixed to the ground but not in a way that could increase the strength of the attachments being tested.
A constant transversal horizontal load of 40kN must then be applied to one side of the impact absorbing structure, using a pad identical to the ones used in the lateral tests in Article 18.2.1, at a point 400mm behind the rear wheel axis.
The centre of area of the pad must pass through the plane mentioned above and the mid point of the height of the structure at the relevant section. After 30 seconds of application, there must be no failure of the structure or of any attachment between the structure and the gearbox.
18.9 Side impact structure push off tests :
18.9.1
Each team must supply detailed calculations which clearly show that the mountings of the upper and lower side impact structures are capable of withstanding :
a) Horizontal loads of 40kN and 60kN applied simultaneously to the upper and lower structures respectively in a rearward direction through ball-jointed pads, which may conform to the shape of the structures, measuring 100mm high x 100mm wide and whose centre of area lies 100mm inboard of the centre of the outermost longitudinal vertical cross-section of the impact structure.
b) Horizontal loads of 40kN and 60kN applied simultaneously to the upper and lower structures respectively in a forward direction through ball-jointed pads, which may conform to the shape of the structures, measuring 100mm high x 100mm wide and whose centre of area lies 100mm inboard of the centre of the outermost longitudinal vertical cross-section of the impact structure.
c) A vertical load of 35kN applied in an upward direction to the lower impact structure through a ball-jointed pad, which may conform to the shape of the structure, measuring 200mm long x 100mm wide whose centre of area lies 100mm inboard of the centre of the outermost longitudinal vertical cross section of the impact structure.
d) A vertical load of 27kN applied in a downward direction to the upper impact structure through a ball-jointed pad, which may conform to the shape of the structure, measuring 200mm long x 100mm wide whose centre of area lies 100mm inboard of the centre of the outermost longitudinal vertical cross section of the impact structure.
In all cases the calculations should show that there will be no structural failure of the parts. It should be assumed that ball-jointed pads are used, the joint lying at the centre of area of the pad.
18.9.2 These tests may be carried out on any survival cell provided it has been successfully subjected to the tests described in Articles 17.2, 17.3 and 18.2-5. The tests may be performed on either side of the survival cell.
During the push off tests the survival cell must be resting on a flat plate and secured to it solidly but not in a way that could increase the strength of the attachments being tested.
Temporary spacers representing part sections of the panels described in Article 15.4.7 may be incorporated within the assembly of the impact structures to the survival cell. These spacers may not in any way increase the strength of the survival cell being tested.
Dummy test parts may be used in place of the impact structure provided the test part incorporates identical mounting details to those described in Article 15.5.2(c) and does not in any way increase the strength of the attachments being tested.
During the first test rearward horizontal loads of 40kN and 60kN applied simultaneously to the upper and lower structures respectively through ball joints or ball-jointed pads whose centre of area lies 100mm inboard of the centre of the outermost cross-section of the dummy impact structures.
During the second test an upward vertical load of 35kN must then be applied to the lower impact absorbing structure using a ball joint or a ball-jointed pad whose centre of area lies 100mm inboard of the centre of the outermost cross section of the dummy lower impact structure.
After five seconds of application there must be no failure of any structures or of any attachment between the structure and the survival cell.
18.10 Side impact structure squeeze tests :
This test may be carried out on any survival cell which has been subjected to the tests described in Articles 17.2, 17.3 and 18.2-5. The test may be performed on either side of the survival cell.
During the test, the survival cell may be supported in any way provided this does not increase the strength of the attachments being tested.
Temporary spacers representing part sections of the panels described in Article 15.4.7 may be incorporated within the assembly of the impact structures to the survival cell. These spacers can not in any way increase the strength of the survival cell being tested.
Dummy test parts may be used in place of the impact structure provided the test parts incorporate identical mounting details to those described in Article 15.5.2(c) and do not in any way increase the strength of the attachments being tested.
Loads of 100kN and 150kN must be applied simultaneously to the dummy upper and lower structures respectively in a lateral direction using a hemispherical pad or ball joint, loading through the centre cross section, 292mm from the outermost longitudinal vertical cross-section of both impact structures.
After five seconds of application there must be no failure of the survival cell or the attachments between the structures and the survival cell.
Each team must supply detailed calculations which clearly show that the mountings of the upper and lower side impact structures satisfy the requirement of 15.5.2(c)(i).