Fatigue testing machine

Fatigue Group :-Abed Al Salam HammouzAhmad AbazaAla’ MustafaMohammad Bahish

Supervised by :-Dr. Ahmad Al Ramahi

Outline

•Part one Review.

•Design stage.

•Manufacturing and Assembly

•Testing and documentation

•Cost analysis and further work

Part One Review

•Literature review about fatigue

•Preliminary design

Preliminary Design - Specimens

• Four point clamping test specimen .

• Three point clamping test specimen .

Preliminary Design – Life Estimation

Stress based approach :

1 10 100 1000 10000 100000 1000000 10000000 100000000150

1500

350

588.14

350

700588.14

The Expected S-N diagram for AISI 1050 - Theoretically

low Cycle Fatigue Power (low Cycle Fatigue ) High Cycle Fatigue Power (High Cycle Fatigue ) Infinte life

Number of load cycles

Fati

gue s

trength

Project Stages

Fatigue Testing Machin

e

Design

Fabrication

Testing

Design stage

1. Machine Functions and Layout.

2. Design Calculation.

Machine Functions and Layout

Rotating bending

Cantilever

Rotating bending test•Put the specimen under pure bending

moment

Rotating bending test

Forcing method using dead weights.

F/2F/2

Rotating Bending

Rotating Bending

Cantilever

Cantilever

Manufacturing and Assembly Used Manufacturing processes

Welding

Turning

Milling

video

Manufacturing Challenge

Machine Features •Ease of use.

Machine Features •It has a good flexibility.

Electrical Circuit

•Ease of operate machine.

•Control the time of experiment .

•Give accurate results for number of

cycles to failure .

•Support safety for both user and

machine .

Electrical Circuit

Electrical Circuit

Safety mode

•The motor does not work until:

•The main switch is ON.

•Emergency switch and (ON/OFF switch)

are ON.

•Cover of the motor is completely closed.

Electrical Circuit

Accuracy in reading results

•To get the accuracy in results.

• The normally open limit switches are ON.

• The normally closed limit switches are

ON.

• Then sensor feeds signals.

Electrical Circuit

•Open limit switches are ON means the

cover of the motor is closed, the house is

not aligned, does not happen any failure

in the specimen.

•Closed limit switches are ON means, the

contactor start connecting, and there is a

load affecting on the specimen.

Electrical Circuit

•When start getting signals from the

sensor,

•counter counting until the specimen

fails, then:-

•The motor stop rotating,

• Sensor stop feeding with signals,

•And the counter holds the values on.

Cost analysis and similar machines

Comparison criteria

Our Fatigue Testing Machine(FTM)

Other manufacturer (OM)

Marks

Cost 2500 $ 12,000 $ FTM

Machine functions

Three types of tests.

One type. FTM

Productivityexperience

Lake of experience, first trial.

Professional work.

FTM

Specimen Forming

Specimen Forming

•video

Polishing

Testing and Documentation •Testing operation

Testing and Documentation

1 10 100 1000 10000 100000 1000000 10000000 100000000150

1500

Experimental Results Plotted on Theoretically obtained S-N Curve

low Cycle Fatigue Power (low Cycle Fatigue ) High Cycle Fatigue Infinte life Test No. 1 Test No. 2 Test No.3

Number of load cycles

Fati

gue s

trength

Thanks