FATIGUE TESTING OF MATERIAL

Submitted to: Ms Rida Jabbar

Submitted by:
Name Syeda Rumesa Ali Tehman Saleem Muhammad
Hannan
Reg No. 220101053 220101043 220101021

DEPARTMENT OF AERONAUTICS AND ASTRONAUTICS

INSTITUTE OF SPACE TECHNOLOGY
ISLAMABAD
OBJECTIVES
To determine the behavior of a material subjected to Fatigue loading.

APPARATUS
Fatigue tester MT 3012 provides a simple way of learning the effect of radius of fillet, surface
smoothness, etc. on a material subjected to fluctuating flexural stresses. It is driven by an induction
squirrel cage motor at 3000rpm. Power supply provided is 220V single phase. The motor is
connected on one side to a counter mechanism, which can record up to 8 digit numbers. A fixture
is attached to the shaft at the other end. The machine is delivered with interface to PC and Software.

Fig. 1 Fatigue Testing Machine

MT 3012-E is driven by a 1-phase asynchronous motor. The number of load changes is read
directly on the LCD display as well as the applied force. The loading device consists of a spherical
ball bearing and a micro switch, which automatically switches off the motor when the fracture
occurs. By turning the loading wheel clockwise the loading on the test piece can be increased. A
spring balance measures the loading value.

Specifications of the Apparatus

Max. Load (which can be applied through this machine) = 255 N
Supply voltage = 230V 50-60Hz (MT 3012-E)
Frequency of voltage = 110V 60Hz (MT 3012-E-116)
Speed (approx) of the motor used in the machine = 3000 rpm
Weight of the machine = 24 kg

INTRODUCTION
The fatigue test is a dynamic type of test which determines the relative behavior of materials when
subjected to repeated or fluctuating loads. It attempts to stimulate stress conditions developed in
parts by vibration of cyclic loads. The stress placed on the specimen during test continually
alternates between two values, the maximum of which is usually lower than the yield strength of
the material. The cycles of stress are applied until failure of the specimen or until a limiting number
of cycles has been reached.
Fatigue damage of components subjected to normally elastic stress fluctuations occurs at regions
of stress (strain) raisers where the localized stress exceeds the yield stress of the material. After a
certain number of load fluctuations, the accumulated damage causes the initiation and subsequent
propagation of a crack, or cracks, in the plastically damaged regions. This process can and in many
cases does cause the fracture of components. The more severe the stress concentration, the shorter
the time to initiate a fatigue crack.
In this experiment a fatigue test of a material (mild steel) is carried out to check that in how many
cycles of continuous flexural loads this sample fails. We plot an S-N diagram from the data
tabulated in the table. Furthermore, we examine the failed/broken specimen under an optical
microscope and analyze how the material gets affected with continuous cyclic loading.

PROCEDURE
1. Lower the loading device to the same height as the drive shaft.
2. Slide the locking nut over the test piece.
3. Insert the narrow end of the test piece in the bearing on the loading device.
4. Slide the conical part of the test piece back to the shaft and tighten the locking nut thoroughly
using the special key.
5. Set the revolution counter to zero.
6. Pull start button up and switch mains power on.
7. Switch computer on. Run the software supplied with the machine.
8. Set load limit through the machine control-panel. (Generally 20% of the applied load)
9. Apply desired load through tightening spring-loaded mechanism on the top right. The load
scale is given on its side for reference.
10. Close and lock safety cover over specimen.
11. Start the stop-watch and press the start button simultaneously.
12. At fracture, stop the stop-watch note time and number of cycles shown. Multiply time in
minutes with R.P.M to verify number of cycles. Use this method if the machines display is
not working.
13. Normally the test terminates itself through the fracture of the specimen opening the micro
switch and hence stopping the motor. As the onset of fracture approaches the specimen will
bend more and this may open the micro switch before complete fracture occurs. In this case
move the micro switch down slightly and restart the motor.
14. Loosen and remove the locknut. Remove the conical piece remaining by inserting the mandrel
into the hole in the fixing shaft and driving firmly inwards.
15. Print graph.

Fig. 2 Mounted Specimen Position

CALCULATIONS
Number of cycles = 3000  Time

Table: Experimental Readings

Test of Initial load Final load Number of Time
specimen (N) (N) cycles (min-sec)
1 210 210 9815 15 mins

Graph
Scale
On x-axis: number of cycles, 1 big block = 102
On y-axis: initial load, 2 big blocks = 200 Newton.

Fig. 3 Computerized Generated Graph

 400

300

200

100

Load (N) 1 5 10
No of cycles

Fig. 4 S- N Diagram
OBSERVATIONS
After the completion of test the broken specimen is analyzed under optical microscope, and one
can distinguish through his/her naked eyes the two different (smooth and rough) surfaces as shown
in the Figure-3. The test has revealed us that as the cycles of the fluctuating load increases the
plastic deformation in the material also increases till a time comes when the applied load becomes
more than enough for the available area and there the failure of the material (specimen) emerges.

Relatively rough surface caused as

a result of over loading as
compared to the remaining area for
the applied stress.

Relatively smooth surface caused

as a result of Fatigue.

Fig. 3 The broken specimen after fatigue testing

SOURCE OF ERRORS
a. The fatigue tester machine should be placed upon a rigid, straight and horizontal table so that
the table provides enough required support to the machine.
b. Reset the counter on the LCD and monitor to exact zero.
c. The stop watch must be started and stopped in accordance with the machine.
d. Keep a safe distance from the machine during its operation.
e. The specimen used, must have a smooth tapped surface before undergoing fluctuating flexural
loading to get the failure of the material right at the radius of fillet.
f. When the specimen is being mounted on the spindle make sure it levels the ball bearing hole
i.e. unload the spring completely.
g. Do tight the nuts holding the specimen to avoid any casualties.
h. Don't put any excessive force on the loading arm! It will damage the specimen.

CONCLUSIONS
Many parameters affect the fatigue performance of structural components. They include
parameters related to stress (load), geometry and properties of the component, and the external
environment. The stress parameters include state of stress, stress range, stress ratio, constant or
variable loading, frequency, and maximum stress. The geometry and properties of the component
include stress (strain) raisers, size, stress gradient, and metallurgical and mechanical properties of
the base metal and elements. The primary factor that affects the fatigue behavior of structural
components is the fluctuation in the localized stress or strain. Consequently, the most effective
methods for increasing the fatigue life significantly are usually accomplished by decreasing the
severity of the stress concentration and the magnitude of the applied nominal stress (Low cyclic
loading). In many cases, a decrease in the severity of the stress concentration can be easily
accomplished by using transition radii in fillet regions, keyways, geometrical changes, and by
minimizing the size of weld discontinuities.

REFERENCES
1. Handouts and Manuals of Machine/Apparatus
2. www.terco.se
3. Foundation of Material Science and Engineering – 4th edition, William F. Smith
4. Workshop Technology (Manufacturing Process) – 6th edition, R.S Khurmi, J.K. Gupta
5. www.astm.org.Pdf
6. www.enwikipedia.org/wiki/Fatigue
7. www.ocw.kfupm.edu.sa