Design and verification of a strain gauge based load sensor for medium-speed dynamic tests with a hydraulic test machine

• System ringing is investigated with a second order mass-spring-damper system.
• Methodology and procedure of the load sensor design are concluded.
• Application of the customized load sensor shows its effectiveness in reducing ringing.
• FE simulation shows velocity and stress–strain input greatly influence ringing.
• Recommendations about load sensor design are made according to FE simulation.

System ringing in load measurement during dynamic tests is investigated with a second order system consisting of a mass, a spring and a damper. According to the analysis of the time-domain and harmonic performances, a procedure for designing load sensor to relieve the influence of system ringing is proposed. Subsequently, a practical design of load sensor and its application procedure are presented. The dynamic test results of two metal materials under strain-rates of 10, 100 and 200 s−1 show that the sensor is effective for reducing system ringing. Based on this design, system ringing as well as the influence of several design variables is investigated with the help of Finite Element simulations. Simulation results indicate that the loading velocity and the stress–strain relation of the tested material are the two important influential factors. In the end of the paper, recommendations are made for the design of load sensor and the position for placing strain gauges.