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Raging Stain Gauges: Chris Drewelow

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Raging Stain Gauges

Chris Drewelow

Cody Grudenkauf

Bart Graybill
What is a strain gauge? It’s a device used to measure strain, naturally. Why do

we use strain gauges?  Strain gauges are frequently used in mechanical engineering

research and development to measure the stresses generated by machinery. What is

strain and why do I need to measure it? Strain, by definition, is

“Change per unit length in a linear dimension of a part or specimen, usually

expressed in % strain … based on original length of specimen.”

(http://www.instron.us/wa/glossary/Strain.aspx)

                 Using particle mechanics and assuming elastic deformation only, Hooke’s

Law relates the strain with the forces applied by the normal stresses with the Modulus of

Elasticity, E. This is a direct relationship.

Strain gauges are designed to convert mechanical displacement to an electrical

signal. The strain gauges are connected to a specimen of known mechanical properties

as mentioned above, such as the Modulus of Elasticity, cross-sectional area being

measure, etc. The change in resistance in the sensor is directly related to the applied

stress on the specimen. Comparing the measurements to that of the known specimen

can be helpful in design and applications of the specimen type. Strain gauges can also

be applied to measure thermal stresses, such that of those in railroad rails.


Why are strain gauges important? Millions of strain gauges are used for research

every day. The importance of precision matters greatly. Knowing the types of materials

being tested may change the application of the strain-gauge or maybe even a different

type of gauge is needed. A new problem arising is the use of fiber-composite materials,

such those used in aerospace engineering. The differences of directionality of the fibers

is much different than that of metals, so these differences must be taken into account to

provide correct precision (Eberlain). We can measure strain deformation in five different

ways: mechanical, optical, acoustical, pneumatic and electrical (Omega). Through

various research and design uses, electrical strain gauges are the most effective and

cost efficient.

Strain gauges are not only used to measure strain. They are very critical in uses

in load-cell tranducers, which measure tensile and compressive forces. The gauge is

set up on the body of a known area which can convert the strain measurements to

direct loading output. They can also measure pressure outputs by using the same set-

up as the load-cell, but the sensor measures the applied load over a discrete area.

Another use for the strain gauge is by measuring torsion forces in a rotational shaft. To

make this measurement, the strain gauge must be wired through a slip ring or data must

be transferred wirelessly to a receiver. By using a combination of gauges, they are also

able to measure shear strain and stresses. The gauges should be installed with 90-

degree angles between them and the two measurements can be used to find shear

strain, which can lead you to calculate shear stresses.


Common Issues With Strain Gauges…

Issues arising from the use of strain gauges are limiting the ‘outside resistances’. These

include, noise, humidity, bonding connections to the speciman and other electrical

mishaps. Shielding is used on the lead wires to block out noise and other electrical

interference. Twisting the lead wires should cancel out the magnetic induction voltages

caused by the connection of dissimilar metals. To take the change in temperature into

effect, each strain gauge is attached to a thermal coefficient during production (Omega).

Also, a known gauge factor should be taken into consideration. Gauge factor is the

amount of stresses that can be measured with each gauge. The adhesive which

connects the gauge to the speciman, must be an electrical insulator and helps work to

transmit the measurements. Humidity is another factor to consider. Coatings can be

applied to wires. Otherwise bare wires must be used in a dry, clean laboratory. Humidity

causes a drastic change to resistance when present. Other gage characteristics and

properties that should be considered for each measurement include: Gauge length,

number of gauges in gauge pattern, arrangement of gauges in pattern, grid resistance,

strain sensitive alloys, carrier material, gauge width and configuration of solder tabs

(omega).

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