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Report On
FATIGUE TESTING MACHINE
Submitted By
SWATI MISHRA (08)
AKSHAY AGRAWAL (14)
AYUSH S. JAIN (21)
DIVYANSHU S. TRIPATHI (25)
VEDANG V. BAKHSHI (65)
CERTIFICATE
DECLARATION
We hereby declare that the work being presented in project report entitled
“ FATIGUE TESTING MACHINE” by us in partial fulfillment of
requirement for the mini project submitted in the Department of
MECHANICAL ENGINEERING is record of our own work carried out during
2017-18 guided by Dr. S. Moghe.
PROJECT GROUP
SWATI MISHRA - 08
AYUSH S. JAIN - 21
DIVYANSHU S. TRIPATHI - 25
VEDANG V. BAKSHI - 65
ACKNOWLEDGEMENT
The success and final outcome of this project required a lot of guidance and assistance
from many people and we are extremely fortunate to have such guidance for the
completion of our project work.
We respect and thank our project guide Dr. S. MOGHE for giving us an opportunity to
do this mini project and providing us all the support and guidance which made us
complete the project on time. We are extremely grateful to her for providing such a nice
support and guidance despite of her busy schedule. She is and always will continue to
be our inspiration, in absence of whom we would always have fallen short of our mark.
We are thankful to our respected Dr. K.N. AGRAWAL, H.O.D for his encouragement
and belief in our abilities to succeed in our project.
We extend our thanks to our Principal Dr. R.S.PANDE for being constant source of
motivation this year.
Lastly we are thankful to all the teaching and non-teaching staff of Mechanical
Department and our friends for their contribution and support.
ABSTRACT
Usually the purpose of a fatigue test is to determine the lifespan that may be
expected from a material subjected to cyclic loading, however fatigue strength
and crack resistance are commonly sought values as well. The fatigue life of a
material is the total number of cycles that a material can be subjected to under a
single loading scheme. A fatigue test is also used for the determination of the
maximum load that a sample can withstand for a specified number of cycles. All
of these characteristics are extremely important in any industry where a material
is subject to fluctuating instead of constant forces.
The aim of this thesis work is to discuss the principle of fatigue failure, research
the state of the art fatigue testing methods and finally design a verification
fatigue test set-up to evaluate the performance of the newly developed dynamic
testing machine.
Index
1. Introduction
3. Construction Details
4. Cost Analysis
5. Testing
Purpose of testing
Design and calculations
7. Discussion
8. Conclusion
9. Reference
1. INTRODUCTION
There are millions of materials and their uses are also multitudinous. These large
number of materials came into existence because of various number of industrial needs
for them. The particular property or combination of properties of material should
possess, depends on its specific use and service conditions.
With the development of various machines structure of most of them for simple,
the necessities for materials which possess properties within narrow specific ranges are
arisen. The properties can be classified as;
1. Physical
2. Chemical
3. Mechanical
The fatigue testing machine is based on the material property of mechanical
properties.
These mechanical properties include strength properties like tensile,
compression, shear, torsion, impact, fatigue and creep.
Fatigue testing machine is used for determine the fatigue limit or endurance
limit of any material.
S-N CURVE:-
Fatigue is generally understood as the gradual deterioration of a material which
is subjected to cyclic loads. In fatigue testing, a specimen is subjected to periodically
varying constant amplitude stress. The applied stresses may alternate between equal
positive and negative value from zero to maximum positive or negative value, or
between equal positive and negative values or between unequal positive and negative
values.
A series of fatigue tests are made on a number of specimens of the material at
different stress levels. The stress endured is then plotted against the number of cycle
sustained. By choosing lower and lower stresses, a value may be found which will not
produce failure, regardless of the number of applied cycle. This stress value is called the
fatigue limit of the material or the endurance limit. The plot of the two terms is called
stress cycle diagram or S-N diagram. The fatigue limit may be established for most
steels between 2 and 10 million cycles. Non-ferrous metals such as aluminum usually
show no clearly defined fatigue limit. (Mark´s Standard-Handbook/Strength of
Materials).
2.1. Literature -
Design of a Cantilever - Type Rotating Bending Fatigue Testing Machine
K. K. Alaneme, Vol. 10, No.11, pp.1027-1039, 2011
Jmmce.org Printed in the USA.
Journal of Minerals & Materials Characterization & Engineering
Department of Metallurgical and Materials Engineering
Federal University of Technology, Akure, PMB 704, Nigeria
Fatigue failures are reported to account for more than 75% of documented
materials failures of which a great percent occur catastrophically. Study of fatigue life is
essential in many industrial and specialized fields such as aerospace, defense, power
generation etc. Fatigue life of a component can be found by various fatigue testing
machines based on the loading condition. In the present study a low–cost four point
loading rotating bending fatigue testing machine is designed, fabricated and tested. The
design principle is based on the adaptation of the technical theory of bending of elastic
beams. The machine performance was evaluated using test specimens which were
machined in conformity with standard procedures. It was observed that the machine has
the potentials of generating combined bending and torsional stress. Specimens of
diameter varying between 6 to 8 mm where subjected to loads between 30Kgs to 90Kgs
and the number of cycles to failure was found by both experimental method and
theoretical calculations. It was observed that the results are under close agreement.
3. CONSTRUCTION DETAILS
3.3 Components:-
3.3.1 Motor:-
The electrically driven motor is use to rotate the shaft and mechanical counter
is used to count the number of revolution of shaft which is driven by the belt
arrangement.
Motor specification :-
1. Power - 0.5 HP
2. Main supply - 220 VOLTS ( Single Phase)
3. RPM - 2800
4. Frequency - 50 HZ a-c
5. Motor shaft diameter - 19 mm
3.3.2. Pulleys:-
Fig: 3.3.2 Pulleys
In all we used 2 cast iron pulleys. The 3 inch cast iron pulley is mounted on
motor shaft and 6 inch pulley is mounted on main shaft also the 3 inch plastic pulley is
mounted on shaft which drives the counter as shown in fig.3.2.
A pulley is a wheel on an axle or shaft that is designed to support movement and
change of direction of a taut cable, supporting shell is referred to as a “block.”A pulley
may also be called a sheave or drum and may have a groove or grooves between two
flanges around its circumference. The drive element of a pulley system can be a rope ,
cable ,belt , or chain that runs over the pulley inside the groove or grooves.
Pulleys are also assembled as part of belt and chain drives in order to transmit power
from one rotating shaft.
3.3.5. Shaft:-
Fig. 3.3.5 Shaft
The shaft is made up of mild steel with minimum diameter of 16mm at the point
where chuck is mounted. The maximum diameter of shaft is 28mm and the diameter at
the parts where bearing are press fitted is 25mm, length of shaft is 330mm.The shaft
Rotates at speed of 3000rpm or more. The shaft is supported by two bearing housing.
The details of the shaft are as shown in fig.3 .5
They are mainly classified into two types:-
Transmission shafts are used to transmit power between the source and the machine
absorbing power; e.g. counter shafts and line shafts. Machine shafts are the integral part
of the machine itself; e.g. crankshaft .
Materials:-
The material used for ordinary shafts is mild steel . When high strength is required,
an alloy steel such as nickel, nickel-chromium or chromium-vanadium steel is used.
Shafts are generally formed by hot rolling and finished to size by cold drawing or
turning.
Bearing housing are used to locate the bearing which is turn support the shaft
for proper working. It is split type housing, the upper part is fitted to the base part by
means of nuts and bolts. It is made of cast iron.
Firstly the bearings are mounting on the shaft by press fitting. Then we placed
the shaft in housing in such a way that the bearing of shaft gets located into the slots
provided in the housing. Finally we put the cap of the housing and tighten it with nuts
and bolts.
Bearing housings are usually made of grey cast iron. However, various grades
of metals can be used to manufacture the same, including ductile iron, steel, stainless
steel, and various types of thermoplastics and polyethylene-based plastics. The bearing
element may be manufactured from 52100 chromium steel alloy (the most common),
stainless steel, plastic, or bushing materials such as SAE660 cast bronze, or SAE851 oil
impregnated sintered bronze, or synthetic materials.
The chuck is used to hold the specimen it is a three jaw drill which is self-
centered. It has three jaws which are housed in slot cut 120 apart in the chuck body,
which houses these jaws having thread cut at the back that mashes with a ring nut. The
ring nut is attached to the sleeve. Bevel teeth are cut along around the sleeve body.
This sleeve may be rotated by rotating a key having bevel teeth on the sleeve.
The rotation of the sleeve causes the ring nut to rotate in affixed position and the entire
three jaws center, holding or releasing the job. The chuck is having 16TPI threads at
the back and hence it is screwed to the shaft.
Some high precision chucks used ball thrust bearings to reduce friction in the
closing mechanism and maximize drilling torque. One brand name for this type of
chuck, which is often generalized in colloquial used although not in catalogues, is
super-chucks.
3.8. Specimen:-
The loading assembly consists of one round type of thread to which a load is
attached to it. The number of load is made is up of hollow raw material rod. As there
are total 20 Kg of weights which is used to attach to the specimen with the help of
rounded rope.
3.3.10. Frame:-
A frame is made of a steel and welded together so to form the stable platform
the supporting various components mounted on it. The description of the different part
required for the fabrication and high strength.
Designation - ISA 5050
Size - 6 x 13 (mm)
Thickness (T) - 6.0 (mm)
3.3.11. Bearing:-
Bearing used are ball bearing. [SKF mark] made up of high quality steel. In all
we have used two bearing which are used to support the shaft i.e. [SKF6205].
Ball bearings tend to have lower load capacity for their size than other kinds of
Fig: 4.3.11. Bearing
rolling element bearings due to the smaller contact area between the balls and races.
However, they can tolerate some miss alignment of the inner and outer races.
.
3.3.12.Setting Up The Machine
The base should first of all be set leveled so that the weight will hang
perpendicularly to the axis of the specimen. Wires in conduct from the power supply
are run to the connecting block in the base of the machine and soldered to the lugs
provided. The machine is equipped to operate from an AC power source at 10volts,
60 cycles, and single phase. Motor and relay equipment to operate from a power
source of different rating can be provided on special order. With mild steel legs, the
machine is set on five rubber tyres. The weight hanger is of such length that it will
clear the desk since it is mounted on the legs. A shock absorber in the hanger
prevents the slight vibration of the housing from being impacted to the weight. The
base is provided with holes so it can be bolted down if desired.
Assemble the housing with a sample of specimen provided in accordance with the
direction given below, and start the machine to see if there is any misalignment. This
will be indicated by noise and vibration. Examine the housing wind for oil. It should
stand about midway of the windows when the machine is idle.
4. COST ANALYSIS
Sr.No. Components Rates ( INR)
1 AC motor 5000
3 Specimen 100
5 Frame 600
6 Weights -
7 Coupling 500
Purpose of testing:-
“One of the important considerations in design of a machine is ‘strength’, a
characteristic that enables the device to serve its function safely and well”.
Mechanical testing is concerned with determination of load and change in
length. These are than translated into terms of stress and strain through considerations
of the dimensions of the test piece.
Mechanical properties include the strength properties like tension, bending,
compression, shear, torsion, impact, creep, fatigue and hardness.
Fatigue test is a long time test in which the specimen is subjected to repeated
load of small magnitude whereas the creep test can be practically considered as a high
temperature tensile test.
Taking into account all the properties, these tests can be classified into two major
categories as follows:-
1. Reactive test.
2. Service condition test.
Reactive test:-
In reactive test, the tensile, bending, shear, compression, torsion test are
accommodated, while the fatigue, creep and impact test are the actually service
condition tests. In any testing process, the actual use of material is kept in view and the
necessity for the test is first decided.
The two groups of tests, destructive type and non-destructive type can be classified
further:-
Destructive Type:-
a) Tension Test.
b) Compression Test.
c) Shear Test.
d) Bending Test.
e) Impact Test.
f) Creep Test.
g) Fatigue Test.
h) Hardness Test.
Non-destructive type:-
a) Visual Examination.
b) Leakage Testing.
c) Penitent Method.
d) Magnetic Method.
e) Acoustic Method.
f) Radiography.
g) Thermal Tests.
h) Electrical Methods.
Test Procedure:-
A number of standards test specimens are made from the metal under test. The
first specimen is tested at a high value of load. The number of revolutions the specimen
experienced before fracturing is noted on the counter. Another specimen is fixed in the
machine and this time, the load is slightly decreased the number of revolutions that are
indicated in the counter this time, will be more than that in the previous case. The other
specimens are also time reducing the load, and noting the number of revolutions .The
procedure is continued until a value of stress is reached when the specimen dose not
fail, say even after 10 million revolutions.
From the data thus obtained, the stress number of reversals of referred to as an
S-N diagram, is plotted .The stress value is plotted on the Y-axis &the number of stress
value at which the curve become nearly horizontal, is taken to be endurance limit of the
metal.
Fatigue Failure In Service:-
Fatigue failure is most common in shafts, main shafts of automobile and naval
vessels etc. The keyways, changes in sections, screw threads & oil-holes, are the
general originators fatigue failure. Very interesting fatigue failure occurred in the mid-
fifties due to which the B.O.A.C comet air craft were cost.
The plane leakages recovered from the sea beds were investigated into and it
was determined that the fatigue failure of the fuselage. It was assumed that the cracks
originated at the corners of the aerial windows.
Torsion Fatigue Testing:-
The advent of torsion bar suspension of automobiles and the requirements of
the service condition testing of springs brought out the necessity of torsion fatigue
testing. The Scheck Torstar is one that operates on the principle of mechanical response.
torsion fatigue can also be determined by the combined stress fatigue testing machine
this machine, practically can test the fatigue strength under any type of loading by a
suitable variation of the specimen mounting
2 πNT
Power =
60
Where, P = Power (W)
N = Speed (RPM)
T = Torque (N-MM)
2 π × 1496 ×T
0.5 x 735 =
60
T1 β
= e µθ cosec
T2
R 1−¿ R 2
Sinβ = x
¿
Where, x = Distance between two center of pulleys.
β = 2.20 °
2β = 4.40 °
θ = 80 + 2 × 4.40
θ = 188.82 °
T1 µθcosecβ
= e
T2
T1
= e 0.3×188.82× cosec 2,92
T2
T1
= 17.85
T2
( T 1 −T 2 ) ×r p =T
Where, r p = radius of pulley (6 inch) = 75 mm
T1
= 17.85
T2
T 1 =17.85T 2 ¿
R A + R B=3.9+18.88+ 1.02+147
R A + R B=170.8 N
R A =−12 .37
Negative RA indicates that reaction at A is in downward direction.
T
Torque on shaft =
2.4
Te = √ M2 +T 2
For M:-
Find SFD & BMD
107.5 77.5
138.5 61
Rᴀ = 12.37 Rʙ = 183.17 N
For SFD:-
SFA = -12.37 N
For BMD:-
BMA = 0 N
BMC = -12.37 × 107.5 = -1329.778 N
BMD = -12.37 × (138.5) – 3.9× 31
BMD = -1837.14 N
BME = -12.37 × 199.5 – 3.9 × 92 – 19.9 × 61
BME = -4040.51 N
BMB = 0 N
SFD & BMD:-
.˙. M = 4040 .51 N
.˙. Te = √ M2 +T 2
.˙. Te = √ 4040 . S ₁2+520.83 2
.˙. D = 16.8 mm
π
Te = × τ × D³
16
π
4073.93 = × τ × 16.8³
16
Taking value,
Fъ = 6ъ = 17.83 N/mm²
Since the stress value that we have obtained i.e. 17.43 N/mm² is much
less than the max permissible stress value i.e. 88 N/mm² and our design is safe.
6055.44
C= = 617.27 Kgf
9.81
And Max permissible speed 6720 rpm.
The bearing we have chosen as
Design No. [SKF] = 6205
having dynamic capacity = 1100 kgf.
And max permissible speed 13000rpm.
C/P = 14.50
C = 14.50 x 163.17
= 2365.965 N
Select deep groove ball bearing for
C = 241.178 Kgf.
And Max. Permissible speed = 6720 rpm.
We have chosen
Design no. (SKF) = 6202 having dynamic capacity
= 610 kgf.
And max rpm = 16000.
OPERATING PRINCIPLE:-
L = Length =95.5 mm
d3
∴ Z = section modulus =
32
M ×32
fB =
π ×d ³
Where:- W in kg
RB In kg/mm2
M in kg-mm
d in mm
Note: - The load ‘w’ includes the weight of loading assembly and hanger.
Testing example:-
In the first case, large number of specimen out of the same stock of subject
material is prepared. Different loads are applied producing different bending stresses on
this specimen and the number of revolutions at which specimen fail are revolution on x-
axis and y-axis. The S-N dia. which is a graph of stress on y-axis and number of
revolutions on x-axis on semi logarithmic graph is then drawn. This diagram tells us
about the behavior of material under application of repeated load.
In the second case, generally the bending stress to be applied is decided upon
the design requirements suppose the design requirement is such that it should with
stand a bending stress of 4000 Kg/mm². Then the load is to be applied is calculated as
follows:-
95.5× W ×32
Rb =
π×d ³
π × d ³ × Rb
W=
32× 9.55
Where, d=0.70cm
∴ W=15.33Kg
This load is applied and the number of revolution at which the specimen
fails are recorded and checked against the expected.
Observation Table:-
Stress Load in N Stress No of revolution.
After taking the reading we plot curve between stress on Y axis and number of
stress cycles on X axis on semi logarithmic graph.
The number of the curve is as shown in Fig.
Fig: - S-N Curve
Result Analysis
We test the specimen of the material on the machine for different stress value
i.e. for different loads. The number of stress cycles after which the specimens fails is
noted from the mechanical counter reading.
The first specimen is tested at larger stress value so that the failure will occur
after small number of application of stress. Succeeding specimen are then tested at
lower stress values so that the number of revolution required will be increase as the
stress decrease. At least three reading should be taken for each load and the observation
table is made. We multiply the reading of mechanical counter by 5.4 so as to get the
actual number of stress cycles.
After taking the readings we plot curve between stress on Y-axis and number of
stress cycles on X -axis on semi logarithmic graph.
As results S-N curve shows the fatigue limit of tested specimen and life of
specimen is determined.
7. DISCUSSION:-
7.1. Advantges Of Fatigue Testing Machine:-
1. This Fatigue testing machine is suitable for determining any shapes &
sizes specimen fatigue limit.
2. Any type of materials specimen can easily tested by our fatigue testing
machine.
3. Machine satisfy the all particular property of component in which the
component proved to be deficient by testing.
4. Proper life of specimen can easily determine by this machine.
5. No requirement of any skilled worker.
6. Total cost of this machine is less as compare to any other machine
which present in market.
7. Size of machine less as compare to other machine which present in
market.
8. CONCLUSION
From the S-N curve graph we get the value of endurance limit or fatigue limit of
the tested material. The stress value at which the curve turns parallel to X- axis
indicating that if we apply stress below this value for infinite number of stress / cycles
the specimen will not break this stress value is called endurance limit or fatigue limit of
the material. In our fatigue testing machine case, we have carried out the testing of mild
steel and the endurance limit was found out to be 4 kg/ mm2 .
When fatigue stress is induced on a material due to the action of force reversing and
fluctuating, a failure known as fatigue failure takes place. The study and test conducted
so far shows that fatigue failure cannot be predicted accurately since material failure
under fatigue are affected not by just reversal loading alone but also the number of
revolution (cycle per minute) and fluctuating stress and other factors such as
temperature, atmospheric condition, both internal and external defect on material
subjected under fatigue stress. Such defect includes notch, inclusion, stress
concentration and non-homogeneity
Suggesions:-
This fatigue testing machine is used for determining the endurance limit or
fatigue limit of any material .for determining the endurance limit or fatigue limit of any
material this type of machine is very important.
Many fatigue testing machine are present in market but all these machine are
very costly and big in size and shape .our machine cost is less as compare to any other
machine which are present in market and our machine size and shape is also less as
compare to any other machines which are present in market.
But one limitation of our fatigue testing machine is that our machine is totally
manually operated and one operator is necessary for our fatigue testing machine.
But future scope for our machine is, we add some sensor on our fatigue machine
and make fully automatic fatigue testing machine in less price and in less size.
9. REFERENCES