TEST METHOD

D42 1235 / - - D

PLASTIC OR RUBBER PARTS

IMPACT BEHAVIOUR

(MASS DROP METHOD)

Renault Automobiles Standardisation

DPMI / Department 67250
RENAULT D42 1235 / - - D

This document is to be considered as a whole, the parts of which must not be separated.

© RENAULT 2010.
No duplication without the consent of the issuing department.
No communication permitted without the consent of RENAULT.

FIRST ISSUE

May 1971

REVISIONS

March 1984 --A

September 1993 - - B Complete revision. Change in numbering:
Addition of the index D42 to the old number.
May 2004 - - C Homogenization of the accuracy on masses.
Editorial modification of § 3.3.
This issue originates from draft NC 2004 0227 / - - -.
December 2010 - - D Method update
Revisions of paragraphs 1., 2., 3.2., 3.3., and 4.
Modifications and additions in Annexes.
This issue originates from draft NC 2010 0848 / - - -

REFERENCED DOCUMENT

Regulation : ECE 21.

© RENAULT 2010 Page 2/17

RENAULT D42 1235 / - - D

1. SCOPE AND FIELD OF APPLICATION

The purpose of this method is to describe the operating conditions used to assess the impact
behaviour by throwing rubber or plastic based material weights.

It applies to rubber or thermoplastic parts, to rubber or plastic coated textiles, to floor covering and
trimming, to soundproofing products, bonded parts etc.

2. PRINCIPLE

On the part fixed in conditions representing the installation on the vehicle and stabilised to the
selected test temperature, drop a steel moving body of fixed shape and mass, and of known height.

Observe the appearance of the part after the test or the resistance of the adhesive and the bonded
parts.

The test conditions (weight and shape of the moving body, dropping height, temperature) are
generally defined in the normative documents. The impact area(s) are also specified in the normative
documents.

NOTE: In certain special cases, the tests are carried out on flanged parts or supported on a
suitable bracket (case of tests described in annexes 7 and 8).

3. APPARATUS

3.1. MOVING BODIES

The different additional loads of various moving bodies indicated below enable the intermediary forces,
which are not applied systematically but only if required for a particular study or if the document
requires it.

3.1.1. Moving body A and additional loads (annex 1)

0
Steel cylinder of 29 mm − 1 mm diameter ending with spherical cap of 20 mm ± 0.5 mm radius. This
moving body is equipped with a threaded shank or any other device used to hold in place one or more
additional loads. The total weight of this moving part is 100 g ± 1 %. The different additional loads
described in annex 1 are used to carry out impacts in load steps of 50 g between 100 g ± 1 % and 850
g ± 1 %.

All the intermediary masses of the moving body are also defined with an accuracy of 1 %.

Annex 1 gives an example of the production of a moving body complying with this definition.

The moving body A is generally used for cold tests on parts having any shape or for tests at ambient
temperature on parts with small dimensions (≤ 30 mm) or parts made of materials that are fragile to
impact (e.g. phenolic plastics).

© RENAULT 2010 Page 3/17

RENAULT D42 1235 / - - D

3.1.2. Moving body B and additional loads (annex 2)

Steel cylinder of 85 mm − 10 mm diameter ending with spherical cap of 80 mm ± 1 mm radius. This

moving body is equipped with a threaded shank or any other device used to hold in place one or more
additional loads. The total weight of this moving part is 500 g ± 1 %. The different additional loads
described in annex 2 are used to carry out impacts in load steps of 100 g between 500 g ± 1 % and
6,800 g ± 1 %.

All the intermediary masses of the moving body are also defined with an accuracy of 1 %.

Annex 2 gives an example of the production of a moving body complying with this definition.

The moving body B is generally used for tests at ambient temperature on parts having any shape, of
dimensions greater than or equal to 30 mm. The moving body B of mass equal to 6800 g is mainly
designed for impact tests on parts required to meet the ECE 21 regulation (e.g. dashboards).

3.1.3. Moving body C and additional loads (annex 3)

Steel knife with rounded cutting edge of 5 mm ± 0.25 mm radius, 42 mm ± 0.5 mm length equipped
with a threaded shank used to attach one or more additional loads. The total weight of this moving part
is 200 g ± 1 %. The different additional loads described in annex 3 are used to carry out impacts in
load steps of 50 g between 200 g ± 1 % and 850 g ± 1 %.

All the intermediary masses of the moving body are also defined with an accuracy of 1 %.

Annex 3 gives an example of the production of a moving body complying with this definition.

The moving body C is generally used for tests on parts like tubes, sections, covers, etc.

3.1.4. Moving body E (annex 4)

0
Hollowed cylinder, in steel, of diameter equal to 85 mm − 1 mm, equipped with a threaded shank.

The total weight of this moving part is 200 g ± 1 %.

The additional loads used are those described in Annex 2, in order to be able to carry out impacts in
steps of 100 g ± 1% up to 2000 g ± 1%.

All the intermediary masses of the moving body are also defined with an accuracy of 1 %.

The moving body E is generally used for tests on the edges of the parts when it is difficult to adjust the
point of impact with a moving body B.

© RENAULT 2010 Page 4/17

RENAULT D42 1235 / - - D

3.2. MOVING BODY GUIDE WAY

These devices held in the vertical position using a suitable set up, must enable a free fall, without any
force, of moving bodies from a known height.

Examples of guide devices are found in Annex 5.

3.2.1. Moving body A guide way

+ 1
Pipes having an internal diameter equal to 30 mm 0 mm used for drop heights of 50 cm and 100
cm.

3.2.2. Moving body B and E guide ways

+ 1
Pipes having an internal diameter equal to 90 mm 0 mm used for drop heights of 50 cm and 100
cm.

3.2.3. Moving body C guide way

Device with "guillotine" type guide rails used for moving body drop heights of 50 cm.

NOTE: If guide tubes of length greater than 100 cm are to be used for special tests, they must be
perforated at intervals to enable the entrapped air to come out.

3.3. GUIDE TUBE RETAINING DEVICE FOR MOVING BODIES A, B AND E (annex 6)

To ensure the verticality of the drop of the moving body on the part, as well as the constraints of the
impact area, a stand with adjustable attachment arms helps hold the moving body guide tubes. E.g.
this stand can be made as described in Annex 6. It is coupled with a metal plate of 2000 mm × 1000
mm and 140 mm thickness. This plate constitutes a baseplate on which the part to be tested must be
placed or the assembly on which the latter must be attached. This assembly is placed in the
conditioned chamber (3.4.).

In the case of impact tests carried out at temperatures different from the ambient temperature
(generally cold tests with the moving body A) a special stand coupled with a metal baseplate of 200
mm × 300 mm and 20 mm thickness is used. In this last case the drop height is limited to 50 cm.

NOTE: - For the cold impact tests relating to fuel feed pipes and power brake system vacuum
systems, refer to Annex 7.

- For ambient temperature or cold impact tests on interior trimming plastic parts, which
are not attached in conditions representing the assembly on the vehicle, refer to Annex
8.

- In the case where the shape or the size of the part does not allow for the use of a stand,
the guide tube alone may be used. But make sure the tube is properly vertical in order
to avoid any friction of the moving body against the walls of the tube.

3.4. CONDITIONED CHAMBER SET TO 23°C ± 2°C and 50 % ± 5 % relative humidity .

3.5. REFRIGERATED CHAMBER

This chamber must be set to the temperature mentioned in the normative documents, with an
accuracy of 1°C, (in general - 30°C); it must enabl e the prior conditioning of the parts to be tested and
materials described earlier, required for the test.

© RENAULT 2010 Page 5/17

RENAULT D42 1235 / - - D

3.6. THERMOMETER FOR CONTROLLING THE TEMPERATURE OF THE REFRIGERATED

CHAMBER (3.5.) or any other equivalent device.

NOTE: For impact tests at ambient temperature, the moisture conditioning can be neglected when
the characteristics of the materials constituting the parts do not change with the degree of
moisture.

Conversely, for parts made up of hygroscopic materials (polyamides, polyamide-based alloys, etc.),
the conditioning must be described, e.g.: after drying for 5 hours at 80°C or after 1 week at 23 °C + 2
°C and 65 % ± 5 % relative humidity.

4. OPERATING PROCEDURE

4.1. CASE OF TESTS AT 23°C (apart from interior tri mming parts or wheel arch shield tested
according to annex 8)

- Fix the part to be tested on its assembly. Place the assembly on the baseplate described in paragraph
3.3., keep it in the chamber (3.4.) for at least 3 hours before carrying out the tests. In the case of
parts made of hygroscopic materials (for example polyamides), it is recommended to condition
them beforehand in order to bring them to a known humidity content (by drying or by
humidification).

- Select the moving body and the guide way of suitable shape and length as required in the
documents. If necessary, attach the additional load(s) to obtain the required mass on the moving
body with an accuracy of 1%.

- Place the moving body in the guide way in such a way that the distance between the lower part of
the moving body and the point of impact on the part is equal to the value mentioned (generally 50
cm).

- Adjust the guiding position in relation to the part in such a way that the point of impact of the
moving body is compliant with the indications of the normative documents concerning the part. In
the absence of indications, carry out the impacts preferably in the most fragile areas of the parts
(re-weld lines, injection point, sharp angles, etc.)

- Let the moving body drop vertically on the part.

Observe the appearance of the part particularly in the impact area and near the attachments;
note down the possible distortions or ruptures, with or without shards.

If many impacts are carried out on the same part, space out the points of impact by a distance of
at least 150 mm for the moving body A, 250 mm for the moving bodies B and E, 50 mm for the
moving body C.

- Repeat the test on two more parts.

4.2. CASE OF COLD TESTS (apart from fuel feed pipe and power brake system tested
according to annex 7 as well as the interior trimming parts or wheel arch shield tested
according to annex 8)

The stand, guide tube, selected moving body (with additional load if necessary) as well as the part
raised or clamped are conditioned at the required temperature for at least 4 hours before carrying out
the impact. The latter must be carried out according to the test recommendations at ambient
temperature and by ensuring that the different experiments do not lead to modifications in the
temperature specified.

© RENAULT 2010 Page 6/17

RENAULT D42 1235 / - - D

5. STATEMENT OF RESULTS

The experimental conditions are identified by:

- the reference of the moving body,

- product weight in g,

- the drop height in centimetres,

- the temperature in degree Celsius.

E.g.: A : 400/50/- 20 °C,

B : 3 000/100/23°C,

C : 200/50/- 30°C.

Mention the damage undergone by the part, such as the dimensions of cracks or shards, for example the
whitening of the impact area.

NOTE: Some documents prior to the 1984 edition may not have the indication of the mass of the
moving bodies A and C. In this case, this mass must be considered equal to 200 grams.

6. TEST REPORT

In addition to the results obtained, the test report must include:

- the reference of this test method,

- The complete part numbers of the part and the material tested as well as the name of the Supplier

- the number of parts tested,

- operating details not specified in the method as well as any possible incidents which might have
affected the results.

© RENAULT 2010 Page 7/17

RENAULT D42 1235 / - - D

ANNEX 1
MOVING BODY A (3.1.1.) AND ADDITIONAL LOADS
Material: XC 48 F – Density: 7.8

= H6 nut

= flat
washer

= 1 additional load of 50 g

= 1 additional load of 100 g

= Radius of the sphere 20 +/- 0,5 = 3 additional loads of 200 g

Weight of moving bodies without additional loads: 100 g.

© RENAULT 2010 Page 8/17

 RENAULT D42 1235 / - - D

ANNEX 2
MOVING BODY B (3.1.1.) AND ADDITIONAL LOADS
Material: XC 48 F - Density: 7.8

H8 nut =

= flat washer

= 4 additional loads of 100 g

= 12 additional loads of 500 g

= Radius of the sphere 80 +/- 1

Weight of moving bodies without additional loads: 500 g.

© RENAULT 2010 Page 9/17

RENAULT D42 1235 / - - D

ANNEX 3
MOVING BODY C (3.1.3.) AND ADDITIONAL LOADS
Material: XC 48 F - Density: 7.8

= 1 additional load of 100 g

= 3 additional loads of 200 g

= Threaded shank

= knife = 1 additional load of 50 g

= flat washer
= H6 nut

Weight of moving body (threaded shank + knife) without additional loads: 200 g.

© RENAULT 2010 Page 10/17

RENAULT D42 1235 / - - D

ANNEX 4
MOVING BODY E (3.1.4.)
Material: XC 48 F - Density: 7.8

Weight of the moving body without additional loads: 200g.

NOTE: H8 nut, flat washer and additional loads are described in annex 2.

© RENAULT 2010 Page 11/17

RENAULT D42 1235 / - - D

ANNEX 5

EXAMPLES OF GUIDE WAYS

Systems for retaining the weights (handles

that we pull to release the weights).
50 cm

Comply with the 50 cm of drop height between the

weight retaining system and the base of the tube.

© RENAULT 2010 Page 12/17

 RENAULT D42 1235 / - - D

ANNEX 6

EXAMPLE OF A RETAINING DEVICE FOR GUIDE TUBES

= plastic tube

= linking nut

= bracket
rotating arm =

= steel tube

= linking nut

= movable
stopping ring

= nut break

= marble = plastic tube

Adjustable pad =

© RENAULT 2010 Page 13/17

RENAULT D42 1235 / - - D

ANNEX 6 (continued)

EXAMPLE OF A RETAINING DEVICE FOR GUIDE TUBES

© RENAULT 2010 Page 14/17

RENAULT D42 1235 / - - D

ANNEX 7
FUEL FEED PIPE AND POWER BRAKE SYSTEM

1. EQUIPMENT

1.1. TEST PIECE RETAINING DEVICE. This device made of aluminium including the two
symmetrical parts [refer to annex 6 (2/2)].

1.2. SHIMS of 15 mm thickness.

2. OPERATING PROCEDURE

- Condition the test pieces and the testing device at the temperature indicated in the documents for
at least 4 hours,

- To carry out the impact, position each end of the test piece in the part slot of the device (1.1.) and
position the retaining plates of the test piece on each slot, the free part of the test piece to be
tested must have a length equal to 100 mm,

- In the case of a fuel feed pipe located under the vehicle chassis, position the shim (1.2.) under the
test piece,

- Hold in this way for 15 minutes before carrying out the impact,

- After the test remove the test piece from the chamber and condition it for 30 minutes at 23°C ± 2°C,

- Observe the internal and external part of the test piece.

3. STATEMENT OF RESULTS

Note down the possible appearance of cracks, ruptures, separations between layers.

© RENAULT 2010 Page 15/17

RENAULT D42 1235 / - - D

ANNEX 7 (continued)
TEST PIECE RETENTION DEVICE (1.1.)

= M5 screw

= Shim

= retaining device

© RENAULT 2010 Page 16/17

RENAULT D42 1235 / - - D

ANNEX 8

INTERIOR TRIMMING PARTS OR WHEEL ARCH SHIELD NOT FIXED ON THE UNIT

1. EQUIPMENT

1.1. XC 48 F steel RINGS.

- Tests with the moving body A

Ring internal Ø 60 mm ± 1 mm

internal Ø 80 mm ± 1 mm,

height 80 mm ± 1 mm

shelving of edges 2 mm ± 0.1 mm

- Tests with the moving body B

Ring internal Ø 120 mm ± 1 mm

internal Ø 150 mm ± 1 mm,

height 50 mm ± 1 mm

shelving of edges 2 mm ± 0.1 mm

1.2. WOODEN SHIMS of different heights to ensure the horizontal position of the area subjected
to impact.

2. OPERATING PROCEDURE

2.1. IMPACT ON THE FLAT AREA OF THE PART

Place the ring (1.1.) adapted to the impact moving body on the baseplate described in paragraph 3.3.
of the general method.

Ensure that the axis of the ring is the same as that of the guide way (e.g. by clamping the ring to the
baseplate).

Place the part on the ring, immobilise it if necessary using shims (1.2.) to maintain its horizontal
position and carry out the impact on the area intended with the selected moving body.

2.2. IMPACT ON ROUND EDGES OR EDGES OF THE PART TO BE TESTED

Place the part on the baseplate (3.3. of the general method). Use suitable shims (1.2.) to ensure the
stability of the part and the horizontal position of the area to be tested.

Drop the moving body using the guide way (described in paragraph 3.2. of the general method).

After the impact, observe the visible and non visible faces of the part in the vehicle configuration.

3. STATEMENT OF RESULTS

Refer to paragraph 5 of the general method.

© RENAULT 2010 Page 17/17