E2-MAB2023

EXPERIMENT 2

FATIGUE TESTING
Objective: To examine the effects of fillet radius and surface roughness on the fatigue resistance of shaft specimens (material SIS 1940), when subjected to rotary bending. To be able to draw a simplified Wohler diagram (S-N curve) based on test data from relevant specimen and analyzing it (Part 2). Introduction: Fatigue is a form of failure that occurs in structures subjected to dynamic and fluctuating stresses (e.g., bridges, aircraft, and machine components). Under these circumstances it is possible for failure to occur at a stress level considerably lower than the tensile or yield strength for a static load. Most machinery and structures do not operate under a constant load and stress. In fact, these loads and stresses are constantly changing such as the rotating shaft or axle on a motorcar. The bending stresses change from tension to compression as the axle rotates. This constant change in stress can cause fatigue failure in which the structures suddenly break even though the stress is everywhere less than the yield stress. The process that leads to fatigue failure is the initiation and growth of cracks in the materials. Fracture occurs when the crack grows so large that the remaining uncracked cross-sectional area can no longer support the applied load. This can be characterized by a typical fracture surface as shown in Figure E2-1. It reveals a relatively smooth, light-colour annular ring where fatigue cracks initiate from the circumference and slowly propagates inwards until static rupture occurs and leaves a rough, dark-color surface at the center.

Figure E2-1. Fracture surface of a rotating surface due to fatigue failure. In fatigue testing, a specimen is subjected to periodically varying constant-amplitude stresses by means of mechanical or magnetic devices. The applied stresses may alternate between equal positive and negative values, from zero to maximum positive or negative values, or between unequal positive and negative values. The most common loading is alternate tension and compression of equal numerical values obtained by rotating a smooth cylindrical specimen while

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under a bending load. 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 cycles sustained. By choosing lower and lower stresses, a value may be found which will not produce failure, regardless of the number of applied cycles. This stress value is called the fatigue limit. The diagram is called the stress-cycle diagram or S-N diagram. Typical S-N curve is shown in Figure E2-2.

Figure E2-2. Typical S-N diagram (wohler diagram), stress amplitude (S) versus logarithm of the number of cycles to fatigue failure (N) for (a) a material that displays a fatigue limit, and (b) a material that does not display a fatigue limit. Procedure: Experiment Part 1: i. Effect of fillet radius When components have one or more dimensions, which vary greatly from the main dimensions, such differences in dimensions create concentration of stress ii. Effect of surface finish As the fracture starts with a crack on the surface, the surface condition must have an effect on fatigue resistance. Cracks form much quicker on a surface with rougher surfaces, while a well polished component will have a higher fatigue resistance.

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Four specimens with different fillet radius and fillet surface roughness are provided. Sketch and mark their dimensions accordingly. Use an appropriate sketching method that can visualize the specimens used. To measure the fatigue resistance of materials, a cyclic load is applied to a specimen until it breaks. The number of cycles to failure, N is the indication of its fatigue life. The fatigue testing is conducted by using a rotating beam fatigue tester MT 3012 as shown in Figure E2-3. The equipment can record the number of cycles to failure with the counter. The number of cycles to failure indicates the lifespan of the specimen.

Figure E2-3: Rotating Beam Fatigue Tester MT 3012

NOTE: This experiment involves rotating machine, strictly FOLLOW the procedures and handle with extreme CARE to avoid injury! Consult the instructor if in doubt.

1. To secure the specimen onto the machine, lower the loading device to the same height as the drive shaft. 2. Slide the lock nut over the specimen. In the right end, insert the narrow shaft of the specimen into the bearing of the loading device. 3. In the left end, attach the conical part to the motor shaft and CW tighten (CW) the lock nut thoroughly using wrenches. Make sure it is properly tightened. 4. To avoid any loosening during the rotation. 5. RESET the counter to zero and adjust the loading control to 20 kg on the scale. 6. Always RESET the microswitch before turning on the electrical supply. 7. Switch on the power and press the switch button to start the test. 8. Once fracture occurs, record the number of load cycles (x 10) on the counter. 9. Loosen the lock nut and spring load. Remove the specimen from the tester and examine the fracture surfaces. 10. Repeat the procedures for next specimens.

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Experiment Part 2: If a number of fatigue tests are carried out at different loads and the amplitude tension is referred as a function of the total load changes, a Wohler diagram (S-N diagram shown in Figure E2-4) can be constructed.

Figure E2-4: Typical Wohler diagram (S-N curve) for ferrous metals. Note the fatigue limit starts at 7 x 106 cycles.

When using a steel test piece, the curve in Figure E2-4 levels out and approaches the limit value u. No break will occur if a < u. The limit value is known as the fatigue limit when testing with rotary bending. Different fatigue limits can be reached depending on which type of loading the test piece has been subjected to. Fatigue limits are reached after approximately 10 million (10 7) load changes. 1. Use 2 points to draw a simplified Wohler diagram for specimen no. 2 and 4 2. For point 1, determine the bending stress, using the following equation:

32FL d3

Where: B = Bending stress F = Bending load, N. L = Distance to fracture surface, mm. D = Diameter, mm. 3. For point 2, refer to the attachment and determine all the factors: , , in order to calculate the reduced fatigue limit, u.red by using design parameters of specimen no.2 and no.4. This value corresponds to a change of 2 x 106 cycles to failure. Show all your calculation. 4. Based on two points calculated from step (1) and (2), draw a simplified Wohler diagram with B versus log (N). Draw a straight line connecting both points and determine the asymptote. The Wohler curve follows the fatigue limit without actually reaching that value.

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Data Gathering & Recording:
Table E2-1 below shows an example on how your data/results can be tabulated. You may redesign the table (by using the same test design parameters) to suit the tests objectives and requirements. Table E2-1: Design Parameters for 4 specimens Fillet radius, Height of Fillet Fillet surface RA (mm) radius, LA (mm) roughness, A,, 0.5 0.5 4 1 1 4 2 2 4 2 2 25

Specimen No.

Number of load cycles to failure

1
2 3 4

Discussion:
You may design appropriate flow of discussion based on your groups decision. However the discussion for Part 1 should cover at least the following BUT not limited to: Fatigue failure mechanism Fatigue specimens fractured surfaces Appropriate way of comparing fatigue failure on specimens 1, 2 and 3. The fillet radius effect on its lifespan. Appropriate way of comparing fatigue failure on specimens 3 and 4. The fillet surface roughness effect on fatigue for this experiment. Meanwhile the discussion for Part 2 should cover the following BUT not limited to: Fatigue limit (or endurance limit) and its significant in designing of part. Sketch and describe a simple Wohler curve for nonferrous metals. Re-design specimen no.2 and its loading conditions so that it is safe to operate for unlimited lifespan. Justify you design. Comparing to this simplified Wohler diagram, what should be the proper way of constructing an accurate Wohler diagram? Discuss various factors that can affect the fatigue limit. If the specimen is exposed to corrosive environment, discuss what will happen to its fatigue resistance Name the material that does not have a fatigue limit.

References 1. William D. Callister, Materials Science and Engineering, An Introduction, Sixth Edition, 2007, John Wiley & Sons. 2. J. F. Shackelford, Introduction to Materials Science for Engineers, Sixth Edition, 2005, Practice Hall. Symonds, 3. John, Mechanical Properties of Materials, Marks Standard Handbook for Mechanical Engineering, McGraw-Hill Companies Inc., 1999.

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