Group standard PV 3950

Issue 2013-11
Class. No.: 55031

Descriptors: molded headliner, bending resistance, test

Molded Headliner ASSY

Bending Resistance Testing

Previous issues
PV 3950: 2002-08, 2008-12

Changes
The following changes have been made to PV 3950: 2008-12:
– Previous issues added

1 Scope
This Test Specification describes two methods for determining the bending resistance in different
areas of molded headliner ASSYs (e.g., edge zones):
– Test method A (destructive)
– Test method B (non-destructive)

2 Description
Bending resistance according to PV 3950 – A
or
Bending resistance according to PV 3950 – B

Always use the latest version of this standard.

This electronically generated standard is authentic and valid without signature. Page 1 of 13
The English translation is believed to be accurate. In case of discrepancies, the German version is alone authoritative and controlling.
Numerical notation acc. to ISO/IEC Directives, Part 2.

Technical responsibility The Standards department

GQL-P/3 Steffen Belger (test method A) Tel.: +49 5361 9-127965 EKDV/4 Stefanie Reiss EKDV
EKAH/4 Rainer Schmidt (test method B) Tel.: +49 5361 9-39957 Tel.: +49 5361 9-41184 Maik Gummert

All rights reserved. No part of this document may be provided to third parties or reproduced without the prior consent of one of the Volkswagen Group’s Standards departments.
© Volkswagen Aktiengesellschaft VWNORM-2012-05q
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3 Test method A (destructive)

3.1 Test equipment and auxiliary equipment

– Templates for specimens to be cut out, preferably made of plastic
– Band saw or knife
– Materials testing machine, e.g. Zwick type 1447, made by Zwick

3.2 Specimen shape

Length: 150 mm Width: 20 mm
The cross section must be rectangular and free of any rounded edges or corners.

3.3 Aging
The specimens must be aged for 48 h in the ISO 554– 23/50 standard climate.

3.4 Sampling
The specimens are outlined on the back of the molded headliner using templates (see figure 1)
and carefully removed using a band saw or a sharp knife. The sampling locations must be deter‐
mined in agreement with the appropriate department and recorded on the standard production
drawing. An example representation is shown in figure 1.
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Figure 1 – Sampling locations

3.5 Procedure
The specimens are supported on the test machine using two supports and bent at a constant test
rate using a pressure fin.
The specimens must be positioned with the textile face fabric on the supports such that the force
can act on the center of the specimen back (roof side) (see figure 2).
The complete load/deflection curve is recorded during the test using an automatic recording sys‐
tem.
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Legend
1 Textile side
2 Pressure fin
3 Applied force
4 Specimen
5 Supports
6 Support separation
Figure 2 – Test setup

3.5.1 Test parameters

Radius of pressure fin: (6,25 ± 0,1) mm
Radius of support: (6,25 ± 0,2) mm
Support separation: 100 mm
Test rate: 10 mm/min
Preliminary force: 1N

3.6 Computation and representation of results

The bending resistance BR is the ratio of the force difference (F2 - F1) to the associated displace‐
ment difference (s2 - s1). The measurement typically starts at a deflection of 3 mm and ends after
4 mm. Larger bending displacements are permissible, but are subject to agreement. The bending
resistance is indicated in N/mm and calculated according to the equation:

F2 − F1 ΔF (1)
BR = =
s2 − s1 Δs

Where:
F1 = Force at start of measurement, in newtons
F2 = Force at end of measurement, in newtons
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s1 = Displacement at start of measurement, in millimeters (= 3 mm)

s2 = Displacement at end of measurement, in millimeters (= 4 mm)
The points are determined according to the diagram in figure 3.

Figure 3 – Example of a force/deflection curve

The recorded curve is evaluated in the linear area below the maximum force, because experience
has shown that with this method the lowest dispersions occur.
In order to determine whether the headliner under examination was manufactured under optimal
process conditions, each pair of oppositely-situated specimens must be compared in each case
(e.g., specimen 4L with specimen 4R).
The following values are indicated on the results sheet:
– Mean value ξ
– Standard deviation δ
– Number of specimens n
– Lowest individual value as min.
– Highest individual value as max.
– Sampling zone of the specimen (e.g., sun visor and/or rear window area)

4 Test method B (non-destructive)

This test is an ON-LINE test that must be performed at the premises of the molded headliner sup‐
plier. Its use is mandatory for the development and standard production process.
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4.1 Test equipment and auxiliary equipment

Stiffness test stand
– Retainer/mounting of molded headliner
– Loading device/test tool
– Measuring equipment for recording load and displacement
The test device must be approved by the appropriate department and the Quality Department.

4.2 Specimen
Molded headliner ASSY

4.3 Aging
Aging of the molded headliner for 48 h in the ISO 554–23/50 standard climate. Aging starts after
the manufacturing operation. Deviations must be agreed with the appropriate department and re‐
ported. The difference in the stiffness of a molded headliner before and after aging must be deter‐
mined in preliminary tests.

4.4 Alignment of the test tool

The test tool must be aligned in the z-direction. As a deviation from this requirement, a contour-
dependent alignment of the test tool may be agreed with the appropriate department. The distance
of the measuring points from the side edge must be selected such that the contact surface of the
test tool is always in contact with the molded headliner surface during the test.
e.g., Passat B6 displacement a = 25 mm

4.5 Test parameters

Test tool: Round, d = 15 mm; material: aluminum (see figure 4)
Surface: Ra 32
Test force: Preliminary tests (see section 4.6.1) are used to determine the test force for
the specific component, which is specified in agreement with the appropri‐
ate department.
e.g., Passat B6 F = 30 N
Test rate: ≤30 mm/s
Test direction: Loading of back of headliner (side facing the roof) in the z-direction. Con‐
tour-dependent alignment in special cases.
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Figure 4 – Test tool diagram

4.6 Procedure
The molded headliner is fastened to the mounting points of the roof grab handles, sun visors, and,
if applicable, pillar trims – corresponding to the installed condition in the vehicle. The fasteners of
the test bed must clamp and hold the headliner in the areas of the roof grab handle base, sun visor
mounting, and, if applicable, net partition, in the same way that the headliner is fastened in the in‐
stalled condition with original parts. Deviations must be specified in agreement with the appropriate
department.
The headliner must be tested at the measuring points shown by way of example in figure 5. The
position of the testing and mounting points must be determined in agreement with the appropriate
departments, Vehicle Safety Department, Testing Department, Design Engineering Department,
and Quality Assurance Department and recorded on the standard production drawing.
A total of 12 to 22 measuring points per headliner are intended.
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Figure 5 – Measuring points

Adjacent measuring points must not be loaded simultaneously. If several points are tested in paral‐
lel, any influence between the points must be ruled out.
During the test, the component must be loaded at all measuring points with a specified force that
was determined in preliminary tests, and the deformation displacement s (mm) must be recorded
for each individual point.

4.6.1 Determination of the test force (preliminary tests)

During preliminary tests, a load/displacement curve must be recorded with a test force F = 100 N,
see figure 6. Preliminary tests must be performed at all measuring points, and the measuring point
with the lowest stiffness must be considered when selecting the test force.
A test force in the linear area of the curve must be selected for the non-destructive testing in agree‐
ment with the appropriate departments, Vehicle Safety Department, Testing Department, Design
Engineering Department, and Quality Assurance Department.
e.g., Passat B6 F = 30 N

4.6.2 Determination of the desired values

The specified test force (see section 4.6.1) is used to determine and document the deformation
displacements for the various components in the load/displacement curve (see section A.2). The
upper and lower limits of the desired value are determined based on the various measurements
with the help of the appropriate department (see section A.1).

4.7 Evaluation
The measured load and displacement values must be recorded and must be represented and eval‐
uated in load/displacement curves. The characteristics of the recorded curves are compared with
one another.
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In the linear area of the curves, the slope defines the spring rate of the material as a constant
F
k = , see also figure 6. The value of this constant is produced from the test force F (N) and the
s
displacements s (mm) traveled during the measurement.
Until technical engineering approval is granted, the test results must be submitted automatically to
the Design Engineering Department and the Quality Assurance Department of the vehicle manu‐
facturing plants. After technical engineering approval is granted, the test results are submitted to
the quality assurance departments of the vehicle manufacturing plants.

4.8 Procedure if results are not OK

The quality assurance departments of all plants within the Volkswagen Group installing this compo‐
nent as well as the appropriate departments must be informed immediately.
Once the defect has been eliminated and depending on the type of damage, the quality assurance
departments of all plants within the Volkswagen Group installing this component may specify an
increased test frequency.
Expenses resulting from the higher test rate are borne by the party responsible for the degradation.

Figure 6 – Load/displacement curve

The results for k (N/mm) must be documented in the form of test diagrams and a value table (see
section A.2).
Desired values and tolerances are specified as part of the technical engineering approval by the
Volkswagen engineering department and must be recorded on the standard production drawing.

4.9 Test frequency

A 100% testing is intended up until technical engineering approval is granted.
The test frequency is specified in writing in agreement with the appropriate departments, Vehicle
Safety Department, Testing Department, Design Engineering Department, and Quality Assurance
Department.
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After technical engineering approval is granted, the test frequency is based on the specifications
from table 1 in agreement with the appropriate department, taking into consideration the molded
headliner variants manufactured, such as standard roof, sun roof, with and without net partition, as
well as all possible color variants. The approved test frequency must be documented as specified
in section A.3.
Following changes in the manufacturing process or changes in the molded headliner design, the
test frequency must be specified again in agreement with the appropriate department.

Table 1 – Testing during standard production – Example

Phase Time relative to start of stand‐ Test quantity
ard production
1 1st month 9 parts per shift
2 2nd to 7th month 6 parts per shift
3 7th month before EOP 3 parts per shift

The parts must be taken from manufacturing at different times during the shift, i.e., start, middle,
and end.
The test frequency is reviewed again by the Quality Assurance department of the vehicle manufac‐
turing plant as soon as variables pertaining to quality (e.g. design features, process parameters)
change. Switching back to an earlier phase in the test frequency scheme may be necessary.

5 Applicable documents
The following documents cited in this standard are necessary to its application.
Some of the cited documents are translations from the German original. The translations of Ger‐
man terms in such documents may differ from those used in this standard, resulting in terminologi‐
cal inconsistency.
Standards whose titles are given in German may be available only in German. Editions in other
languages may be available from the institution issuing the standard.

ISO 554 Standard atmospheres for conditioning and/or testing; Specifications

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Appendix A (normative)

A.1 Result sheet – Determination of constant k, determination of lower and upper limit

Legend
LL Lower limit
LU Upper limit
Figure A.1 – Result diagram
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A.2 Result sheet – Test results

Figure A.2 – Test results

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A.3 Result sheet – Test frequency

Figure A.3 – Test frequency