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Design and Development of Fatigue Machine: Rotating Bending Fatigue

Testing on different Materials

Research · April 2019

DOI: 10.13140/RG.2.2.32181.32484

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 ISSN 2456-8066
International Journal of Advanced Engineering and Management
Vol. 4, No. 2, pp. 8-15, 2019

Design and Development of Fatigue

Machine: Rotating Bending Fatigue Testing
on different Materials
Shoukat Ali1, Muhammad Hamza Tahir2*, Muhammad Asad Saeed3, Nouman Zaffar4,
Muhammad Kashif Khan5
1
Assistant Professor, Mechanical Engineering Department, Pakistan Institute of Engineering and Technology, Multan,
Pakistan
234
Undergraduate Students. Mechanical Department, Pakistan Institute of Engineering and Technology, Multan, Pakistan
5
Assistant Professor, Coventry University, Coventry, UK
*Corresponding author E-mail: [email protected]

Abstract I. DESIGN OF EXPERIMENTAL SETUP

Fatigue fracture is the most common type of The phenomenon of premature failures
failure as more than 75-90% of documented originating from repeated stress was first noted in the
materials’ failure in engineering components due to railway industry in the 1840s as railroad axles
cyclic loading. So, it is preeminent to test the constantly failed at the shoulders [1]. The rounding
materials before use. This research work has been of sharp corners did not obviate this type of failure
done in order to design and fabricate “Rotating which was termed fatigue and earmarked to failure
Bending Fatigue Testing Machine” which is simple under repeated stresses[2]. The earliest systematic
to understand, perform, portable, safe for use and surveys into this phenomenon were conducted by
more economical than others. A rotating bending August Wohler 1819-1914 who presented the results
fatigue testing machine was developed by keeping in of his fatigue tests at the Paris exhibition of 1867
mind the basic concepts of technical theory of which were also reviewed in the same year in
bending of elastic beams. Different specimens of engineering [3]. In 1870 Wohler concluded that the
6mm to 8mm diameter of different materials were stress range plays a most significant role in fatigue
tested under various loads to analyse the failures. Wohler was the first to introduce the
performance of this machine. The experimental concept of the so-called s-n diagram which relates
readings and theoretical calculations indicate that applied stress “s” to life “n” i.e. to number of cycles
the results were promising to agreement of the to failure. He could thus show that fatigue life
objective had been achieved. It was detected that the decreases with higher stress amplitudes and material
machine has the abilities of generating reliable reaches a fatigue limit. The consideration of fatigue
bending stress – number of cycles data; and the cost failure of materials in industrial use is thus important
of design (31,500 PKR) was lower in evaluation to for the safety of components, particularly under the
that of rotating bending machines from abroad. oscillating loads that leads to fatigue[4]–[7]. The
fatigue life of a component is defined by the total
Keywords
number of stress cycles required to cause failure.
Analysis, Bending, Fracture, Failure, Fatigue, Fatigue is generally understood as the gradual
Fatigue Machine, Stress, weakening of a material which is exposed to cyclic
loads.

Shoukat Ali, Muhammad Hamza Tahir, Muhammad Asad Saeed, NoumanZaffar, Muhammad Kashif Khan, “Design and
Development of Fatigue Machine: Rotating Bending Fatigue Testing on different Materials” International Journal of
Advanced Engineering and Management, Vol. 4, No. 2, pp. 8-15, 2019
 ISSN 2456-8066
International Journal of Advanced Engineering and Management
Vol. 4, No. 2, pp. 8-15, 2019

In fatigue testing a specimen is exposed to interchanged one-half revolution the stress in the
periodically fluctuating constant amplitude stress. fibers initially above the neutral axis of the specimen
The applied stresses may different between equal are inverted from compression to tension for equal
positive and negative value from zero to maximum intensity. Upon finishing the revolution, the stresses
positive or negative value or between equal positive are again inverted, so that during one complete
and negative values or between unequal positive and revolution the test specimen passes through a
negative values [8]. Therefore it is important to complete cycle flexural stresses i.e the specimen is
consider the experimental fatigue failure of materials subjected to the tension and compression cycles. The
as the theoretical equation do not always fit to the cycles are recorded by mean of proximity sensor and
real life fatigue behavior of components [9]. So, it is output is displayed on a revolution counter. The
important to carry out mechanical fatigue tests in machine is equipped with tacho-sensor to show the
different conditions and on a wide variety of revolution per minute(rpm). Specimen is clamped by
materials to investigate the principal causes of failure mean of chucks. The machine features two shafts, a
in engineering components subjected to uniaxial and driving shaft rotated by mean of motor and a driven
multiaxial loading[10]–[12]. shaft for supporting the specimen and application of
Over the years, there have been many testing load.
machines and methods developed for fatigue testing C. Component Selection and Design
by many authors[13]–[15]. In regard of the fatigue Calculations
machines, the first prototype was developed in the
nineteen century[16] , in this machine load was a. Electric Motor
induced by mechanical deflection and inertia forces. The electric motor used is of specifications as
The systematic studies on fatigue have been carried shown in table 1.
out in the second half of the twenty century on Table 1. Motor specifications
aluminum alloys[17].The servo – hydraulic Voltage Phase Frequency Rated RPM
machines are currently the fastest having features Power
that allow for a wide range of test to be performed on 220 V Single 50 Hz 0.75 2880
it [18], [19]. The high price of these machines is a AC KW
downside to its use. This research work addresses the
problem by developing a low-cost rotating bending b. Shaft
fatigue testing machine. The theory governing the A high carbon alloy steel that is EN8/ AISI 1045
design of the fatigue machine is based on elastic was selected as material for shaft. The main function
beam bending theory [20]. Experimental values of of the shaft is to interchange the specimen while it is
fatigue life are confirmed using theoretical under the action of bending moments from the dead
calculations. weights hanged to overhang bearings. The shaft is
subjected to bending moment only so: We know that
A. Design Objectives 𝑀 𝜎
=
The aim is to design and fabricate a rotating 𝐼 𝑦
bending fatigue testing machine that is capable of Where:
testing the fatigue life of various samples of M= bending Moment
𝜋
specimen of different minimum diameters and I= Moment of inertia = × 𝑑4
64
capable of calculating the numbers of cycles required
𝜎 = 𝐵𝑒𝑛𝑑𝑖𝑛𝑔 𝑆𝑡𝑟𝑒𝑠𝑠
to fail specimen. The machine must be cost effective, 𝑑
must have minimized time of experiment and y = Distance from neutral axis =
2
32𝑀
enhanced loading capacity. Final form of equation is 𝜎 =
𝜋𝑑 3
B. General Description For applied load of 300N (30Kg) and a shaft of 1-
The fatigue-testing machine is of the rotating inch diameter and 11.5 inch in length, the maximum
beam kind. The specimen functions as a single bending stress is 69.73 MPa
cantilever beam loaded at one end. When M = W x L = 293.3 x 0.381 = 112.12 Nm

Shoukat Ali, Muhammad Hamza Tahir, Muhammad Asad Saeed, NoumanZaffar, Muhammad Kashif Khan,
“Design and Development of Fatigue Machine: Rotating Bending Fatigue Testing on different Materials”
International Journal of Advanced Engineering and Management, Vol. 4, No. 2, pp. 8-15, 2019
 ISSN 2456-8066
International Journal of Advanced Engineering and Management
Vol. 4, No. 2, pp. 8-15, 2019

32𝑥112.12
𝜎= = 69.73 MPa Table 2. Bearing specifications
𝜋0.0254 3
Which is less than the yield strength (310 MPa) of Series Metric
Type Cylindrical Roller
AISI 1045/EN8 Steel.
Code TP-305
So, selected parameters of shaft are:
Alignment Self
Material= AISI 1045/EN8 Deflection 0.50
Diameter= 1 inch Bore 25 mm
Length= 11.5 inch Load bearing capacity 9300 DYN

c. Specimen f. Jaw Coupling

The specimen selected are of 6mm and 8mm Jaw coupling made up of grey cast iron is used to
neck diameter. The maximum bending stress in transfer power from motor shaft to the shaft. Jaw
rotating specimen can be modeled as max bending coupling is used because the spider tolerates the
stress of simply supported beam as: angular misalignment if any and adjust accordingly.
8𝑊𝐿 A coupling of Jaw type, size L/Al090 is selected
𝑆𝑓 =
𝜋𝑑𝑛3 using “Love Joy Coupling Solution Catalog 2010”.
Where They need no lubrication and deliver highly reliable
W= Load applied service for light, medium, and heavy-duty electrical
L= Length of Specimen = 150mm motor.
D= Neck Diameter= 6mm & 8mm Table 3. Coupling Specifications
And the number of cycles is given as: Size Max Bore SOX (NBR) Torque
−3 L/AL090 25 mm 16.3 Nm
𝑆𝑓 × 𝑆𝑒 𝑆
log (0.9 𝑢 𝑆 )
𝑁=[ ] 𝑒
𝑆𝑢 × 0.9 2
g. Rubber Pads and Packing
Where
A rubber pad of 8 x 8 x 0.5 inch is used as a
Sf= max bending stress
packing beneath the motor to damp vibrations that
Se= Endurance limit of material
are coming from the motor and isolate it from the
Su= ultimate strength of material
table hence from the specimen. A metal packing is
placed below the Plummer blocks so as to serve the
d. Drill Chuck vertical alignment.
A three-jaw drill chuck with taper fittings was
selected as the specimen clamp for the fatigue
h. Weight Hanger and U-Clamps
machine. The specimen fasten is expected to firmly
U-clamps and weight support arrangement is
hold the specimens without allowing for extraneous
used to apply load on overhang bearings. U clamps
bending moments during operation of the machine.
are bolted to overhang bearings and weight hanger is
Also, the specimen must not rotate from the grip or
hanged on it. Dead weight is added to the hangers.
be displaced vertically or horizontally.
i. Frame
e. Pedestral Bearing
Frame is the foremost supportive element in the
The bearings carefully chosen for the design
system. The frame has to tolerate all the weight of
were self-aligning roller bearings, which have high
the experimental setup. The force exerted on the
load carrying capacity and it can accommodate
system is distributed to the four legs. The material
misalignment and shaft deflections. Bearings are
used is GI rectangular pipe.
inserted into Plummer blocks. Using NHBB Hi-tech
Ball bearings Design Guide 2010, according to the
II. DESIGN OF EXPERIMENTAL SETUP
diameter of shaft, bearing of following parameters is
i. Schematic Diagram
selected.
The schematic diagram was made on AutoCAD
software.

Shoukat Ali, Muhammad Hamza Tahir, Muhammad Asad Saeed, NoumanZaffar, Muhammad Kashif Khan,
“Design and Development of Fatigue Machine: Rotating Bending Fatigue Testing on different Materials”
International Journal of Advanced Engineering and Management, Vol. 4, No. 2, pp. 8-15, 2019
 ISSN 2456-8066
International Journal of Advanced Engineering and Management
Vol. 4, No. 2, pp. 8-15, 2019

Fig.1 Schematic Diagram of Rotating Bending (a)

Fatigue Testing Machine

The 3D models were generated using two

software:
Microsoft Paint 3D with Mixed Reality
SolidWorks

(b)

Fig. 2 3D Model

III. FINITE ELEMENT ANALYSIS (c)

A simple setup of shaft and specimen is
modelled in Solid Works and then it is imported into
ANSYS WORKBENCH. Fig 3a Various loading
situations like bending, torsional moments and cyclic
speed are applied. Fig 3b
1. Cyclic Speed: 300 rad/s
2. Bending Force: 500N on both ends
3. Fixed Support at both end
And solved for solution of following parameters,
a) Total deformation-it shows that maximum
deformation occurs at midpoint of specimen
as shown in Fig 3cand deformation is
0.2854 mm before specimen undergoes
failure. (d)
Fig. 3 Ansys simulation result (a) Assembly,
b) Safety factor (in fatigue tool)-this shows (b) boundary Conditions
that failure will occur at minimum cross- (c) deformation (d) safety Factor
sectional area of specimen as it has zero
safety factor as shown in Fig 3d.

Shoukat Ali, Muhammad Hamza Tahir, Muhammad Asad Saeed, NoumanZaffar, Muhammad Kashif Khan,
“Design and Development of Fatigue Machine: Rotating Bending Fatigue Testing on different Materials”
International Journal of Advanced Engineering and Management, Vol. 4, No. 2, pp. 8-15, 2019
 ISSN 2456-8066
International Journal of Advanced Engineering and Management
Vol. 4, No. 2, pp. 8-15, 2019

IV. FABRICATION PROCESS A. Fatigue Life

After finalizing design of rotating bending testing
set up materials were obtained from local market and a. Cast Carbon Iron
assembly was carried out.
Angular bars were cut according to dimension and Table 4. 4.5% Cast Carbon Iron
welded to make table frame. Metallic sheet was cut Sr Load Max Bending Number of Number of
No (N) Stress Cycles (N) Cycles (N)
and was welded into the frame which was used as
(Sf)(MPa) Theo. exp.
base for mounting. The layout of whole setup was
1 100 84.5 627099 ꝏ
sketched on table according to dimensions of
2 120 101.5 131667 ꝏ
components. Motor was mounted on platform and
3 140 118.4 35439 23,970
rubber pads were used as packing below the motor. 4 160 135 11590 9,439
Coupling was tapped so that motor shaft fixes into 5 180 152.3 4150 3,801
one of the flanges and other flange holds shaft. 6 200 169 1710 1,201
Shafts were cut and tapered at one end and supported 7 220 186.1 753 559
by block bearings. The tapered end was fixed and 8 240 203 359 239
tightened into drill chuck. Slot was made using 9 260 220 181 103
jigsaw machine in table for overhanging of U 10 280 234 107 60
clamps. After that weight hanger was hanged to U 11 300 253 55 -------
clamps and loaded with dead weights. Electrical
connections were made for the motor and main panel
board. The sensors were positioned near the
coupling. Fig. 4 shows the experimental setup. Stress

260

240

220

200
Stress (MPa)

180

160

140

120

100

80

-100000 0 100000 200000 300000 400000 500000 600000 700000

Number of Cycles (N)

Fig. 4 Fabricated Machine

Stress

V. RESULTS AND DISCUSSION 240

Fatigue tests were performed and analyzed on four 220

different materials: 4.5% cast carbon iron, aluminum 200

6061-T6, mild steel 1080 and stainless steel 1020.

Stress (MPa)

180

The tests were obtained at room temperature (22°C) 160

and with environmental humidity comprised between

140

45% and 60%. The four materials were subjected to

120
fatigue tests at different levels of applied load. All
100
tests were performed at 50 Hz of frequency. 0 5000 10000 15000 20000 25000
Number of Cycles (N)

Fig. 5S-N Curve of Cast Carbon Iron

Shoukat Ali, Muhammad Hamza Tahir, Muhammad Asad Saeed, NoumanZaffar, Muhammad Kashif Khan,
“Design and Development of Fatigue Machine: Rotating Bending Fatigue Testing on different Materials”
International Journal of Advanced Engineering and Management, Vol. 4, No. 2, pp. 8-15, 2019
 ISSN 2456-8066
International Journal of Advanced Engineering and Management
Vol. 4, No. 2, pp. 8-15, 2019

From the values obtained TABLE 4 during the c. Mild Steel 1080
testing of the specimen of 4.5% cast carbon iron, S- Table 6.Mild Steel 1080
N graph is plotted with stress (MPa) on y-axis and Sr No Load Max Number Number
number of cycles to failure on x-axis. From the (N) Bending of Cycles of Cycles
Stress (N) Theo (N) exp
above graph it can be noted that with reduction in
(Sf)(MPa)
load the number of cycles to failure rises. Below a
1 100 176.84 7509 7019
certain load limit the number of cycles to failure
2 120 212.3 5336 4900
rises and approaches infinity, this limit is known as 3 140 247.6 4812 4498
endurance limit. 4 160 283 3799 3371
5 180 318.47 2888 2109
b. T6 6061 Aluminum 6 200 353.8 1733 1311
Table 5. T6 6061 Aluminum 7 220 389 1184 927
Sr Load Max Bending Number of Number of 8 240 424.6 424 302
No (N) Stress Cycles (N) Cycles (N) 9 260 460 166 91
(Sf)(MPa) Theo. Exp. 10 280 495 70 54
1 100 84.5 129351 ----------- 11 300 530.7 31 18
2 120 101.5 71232 65,913
3 140 118.4 57017 49,827
4 160 135 44941 37,796
Stress
5 180 152.3 33901 26,731
6 200 169 21338 17,631 550

7 220 186.1 13829 9,671 Theoratical Values

500
8 240 203 7503 5,630
450
9 260 220 4286 3,336
400
10 280 234 2534 1,673
Stress (MPa)

11 300 253 1303 879 350

300

250

200

Stress
150

260 -1000 0 1000 2000 3000 4000 5000 6000 7000 8000
Actual Values
240 Number of Cycles (N)

220

200 Stress
Stress (MPa)

180
550
160
500 Actual Values
140
450
120

400
100
Stress (MPa)

80 350
0 10000 20000 30000 40000 50000 60000 70000
Number of Cycles (N) 300

250

200
Fig. 6 S-N Curve of T6 6061 Aluminum
150
From the values obtained TABLE: 5 during the
-1000 0 1000 2000 3000 4000 5000 6000 7000 8000
testing of the specimen of T6 6061 Aluminum, S-N
Number of Cycles (N)
graph is plotted with stress (MPa) on y-axis and
number of cycles to failure on x-axis. From the
above graph Fig 6., the endurance limit of material is Fig. 7S-N Curve of Mild Steel 1080
the obtained.

Shoukat Ali, Muhammad Hamza Tahir, Muhammad Asad Saeed, NoumanZaffar, Muhammad Kashif Khan,
“Design and Development of Fatigue Machine: Rotating Bending Fatigue Testing on different Materials”
International Journal of Advanced Engineering and Management, Vol. 4, No. 2, pp. 8-15, 2019
 ISSN 2456-8066
International Journal of Advanced Engineering and Management
Vol. 4, No. 2, pp. 8-15, 2019

From the values obtained from TABLE: 6 during the mild steel of grade 1080, t6 6061 aluminum and
testing of the specimen of Mild Steel, S-N graph is 4.5% cast carbon iron.
plotted with stress (MPa) on y-axis and number of
cycles to failure on x-axis. From the above graph B. Cost Analysis
Fig.7, the endurance limit of mild steel is obtained. The materials and equipment used in the design are
locally obtained, and the overall cost of designing the
d. Stainless Steel 1020 machine is approximately 31,500 PKR ($228.28). The
Table 7. Stainless Steel 1020 machine is economical in comparison to similar designs
from abroad.
Table 8. Cost Analysis
Sr Load Max Number of Number of
No (N) Bending Cycles (N) Cycles (N) Our Nigerian
Stress Theo. Exp. Design Design
Sr. Description
(Sf)(MPa) Quantity Cost Cost [21]
No. (Materials)
Price
1 100 176.84 368,797,728 --------- Price (₦)
(PKR)
2 120 212.3 43,110,770 --------- 1 Electric Motor 1 2,850 30,000
3 140 247.6 7,088,677 --------- 2 Proximity 2 2,200 17,200
4 160 283 1,471,278 ---------- 3 Speed Counter 1 2,300 24,500
5 180 318.47 367,716 ---------- 4 Chucks 2 1,000 4,000
6 200 353.8 106,737 ---------- 5 Bolts and Nuts --- 500 2,450
7 220 389.04 34,959 29331 6 Ball Bearings 4 1,600 2,400
8 240 424.6 12,516 9,271 Flat Metal
9 260 460 4,878 3,201 7 1 3,800 6,000
Plate
10 280 495 2,062 1,931 8 Shaft 2 500 5,000
11 300 530.7 911 607 9 Cycle Counter 1 1,800 17,200
10 Switch 3 550 1,400
Emergency
Stress 11 1 175 800
Switch
540 Wood press
12 -- 1,600 7,500
Actual Values sheet
520
13 Frame -- 4,600 15,000
500 Electrical
14 -- 2,000 5,000
480
Connections
Stress (MPa)

15 Coupling 1 700 6,000

460
16 Paint -- 2,000 6,500
440 18 Fabrication -- 3,500 30,000
PKR 180,950
420
31,500 Naira
19 Total
400 USD USD
380
228.28$ 504.04$

0 5000 10000 15000 20000 25000 30000

Number of Cycles (N)
VI. CONCLUSION
The testing machine was fabricated and tested.
Fig 8.S-N Curve of Stainless Steel 1020 The experimental results were compared with
From the values obtained TABLE: 7 during the theoretical calculations and it was found that there
testing of the specimen of Stainless Steel 1020, S-N was little variation in results. It was also observed
graph is plotted with stress (MPa) on y-axis and that the machine has the potentials of generating
number of cycles to failure on x-axis. From the reliable bending „stress-number of cycles‟ data. The
above graph Fig 8, the endurance limit of stainless study and test directed so far shows that fatigue
steel is obtained. failure cannot be predicted correctly since material
From the test conducted on these four different failure under fatigue are exaggerated not by just
materials it can be concluded that the stainless steel reversal loading alone but also by factors such as
of grade 1020 has better fatigue strength than the fluctuating stress, temperature, atmospheric

Shoukat Ali, Muhammad Hamza Tahir, Muhammad Asad Saeed, NoumanZaffar, Muhammad Kashif Khan,
“Design and Development of Fatigue Machine: Rotating Bending Fatigue Testing on different Materials”
International Journal of Advanced Engineering and Management, Vol. 4, No. 2, pp. 8-15, 2019
 ISSN 2456-8066
International Journal of Advanced Engineering and Management
Vol. 4, No. 2, pp. 8-15, 2019

condition, both internal and external defect on Assessment in Load Carrying Components,
material subjected under fatigue stress. Such flaws 25–73.
include notch, inclusion, stress concentration and [10] Susmel, L. (2004). A unifying approach to
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non-homogeneity. The advantage of the present
notched components subjected to both uniaxial
design is the easiness of its modeling and ease of and multiaxial cyclic loadings. Fatigue and
understanding. By using simple mechanism, the cost Fracture of Engineering Materials and
of this machine has been decreased to Rs. 31,500 Structures, 27(5), 391–411.
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On the other hand, market price of this machine used fatigue limit under multiaxial loading.
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165.
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[12] Liu, Y., & Mahadevan, S. (2007). A unified
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[13] Marcelo, F., & Bustos, P. (2012). Design and
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Shoukat Ali, Muhammad Hamza Tahir, Muhammad Asad Saeed, NoumanZaffar, Muhammad Kashif Khan,
“Design and Development of Fatigue Machine: Rotating Bending Fatigue Testing on different Materials”
International Journal of Advanced Engineering and Management, Vol. 4, No. 2, pp. 8-15, 2019

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