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Fatigue Test

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8 views

Fatigue Test

Uploaded by

b00095424
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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MCE 332L

Material and Manufacturing Process


Laboratory

Lab.5
Fatigue Test
Objectives
 Introduction
 Fatigue Stages
 Uniaxial and Multiaxial Loading
 Fundamental Concepts on Fatigue Fracture
 Stress-Life Curve
 Fatigue Limit
 Mean Stress Effect
 Endurance Limit Modification Factors
 Summary
 Fatigue Test Apparatus
 Fatigue Test Samples
 Loading Specimen
 Test Procedure
 Report Requirements

2
Introduction

 Fatigue is responsible for the majority of failures in engineering


components in:
 Aircraft industry
 Automotive
 Nuclear
 Offshore and Rail

 The process of gradual cracking due to application of repeated load cycles


to an engineering components is called Fatigue Phenomenon.

 Fatigue cracking results from cyclic stresses that are below the ultimate
tensile stress, or even the yield stress of the material. (in the elastic
regime)

3
Fatigue Stages

 The facts that the original bulk design strengths


are not exceeded and the only warning sign of an
impending fracture is an often hard to see crack,
makes fatigue damage especially dangerous.

 It can be said that fatigue failure occurs in three


stages: crack initiation; slow stable crack growth;
and rapid fracture (due to reduction in area ).

4
Fatigue Stages

5
Fatigue Stages

6
Fatigue Stages
Start

7
Uniaxial and Multiaxial Loading

8
Fundamental Concepts on Fatigue Fracture

9
Stress-Life Curve

 The fatigue life of a component


can be expressed as the
number of loading cycles
required to initiate a fatigue
crack and to propagate the
crack to critical size.

 The basic method of presenting


engineering fatigue data is by
means of the Stress-Life curve.

10
Fatigue Limit

 Fatigue Limit (Endurance limit):


For a few engineering materials such
as steel and titanium, the stress-life
curve becomes horizontal at a certain
limiting stress. Below this limiting
stress, which is called fatigue limit,
the material can endure an infinite
number of cycles without failure.

Most non-ferrous metals like


aluminum, magnesium, and copper,
stress-life curve slope gradually
downwards with increasing number
of cycles and curve never become
horizontal (no fatigue limit).

11
Fatigue Limit

 Care must be taken when using


the endurance limit since it can
disappear due to:
1. Periodic overloads ( which
unpin dislocations)
2. Notch and geometry Notch
discontinuity
3. Corrosive environments (fatigue
corrosion)
4. High temperature (which
mobilize dislocations)

12
Mean Stress Effect

13
Mean Stress Effect

14
Endurance Limit Modification Factors

15
Endurance Limit Modification Factors

16
Endurance Limit Modification Factors

17
Endurance Limit Modification Factors

18
Endurance Limit Modification Factors

19
Endurance Limit Modification Factors

20
Endurance Limit Modification Factors

21
Endurance Limit Modification Factors

22
Endurance Limit Modification Factors

23
Endurance Limit Modification Factors

24
Endurance Limit Modification Factors

25
Summary

 In order for fatigue cracks to initiate, three basic factors are


necessary:
 First, the loading pattern must contain minimum and maximum
peak values with large enough variation or fluctuation. The peak
values may be in tension or compression and may change over
time but the reverse loading cycle must be sufficiently great for
fatigue crack initiation.
 Secondly, the peak stress levels must be of sufficiently high
value. If the peak stresses are too low, no crack initiation will
occur.
 Thirdly, the material must experience a sufficiently large number
of cycles of the applied stress. The number of cycles required to
initiate and grow a crack is largely dependent on the first two
factors.

26
Summary

 In addition , there are a host of other variables, such as : stress


concentration, corrosion, temperature, overload, metallurgical structure,
and residual stresses which can affect the propensity for fatigue.
 Since fatigue cracks generally initiate at a surface, the surface condition of
the component being loaded will have an effect on its fatigue life. Surface
roughness is directly related to the level and number of stress
concentrations on the surface.
 The higher the stress concentration the more likely a crack is to nucleate.
Smooth surfaces increase the time to nucleation.
 Notches, scratches, and other stress risers decrease fatigue life. Surface
residual stress will also have a significant effect on fatigue life.
Compressive residual stresses from machining, cold working, heat treating
will oppose a tensile load and thus lower the amplitude of cyclic loading

27
Fatigue Test Apparatus

 With WP 140 Fatigue Testing machine, is it possible to demonstrate the


basic principle of fatigue strength testing including the production of
stress-number diagram.

 The sample is subjected to a pure reversed bending stress in the machine

28
Fatigue Test Apparatus

 Via different sample shapes, it is possible to show the influence of the


notch effect and influence of surface quality on fatigue strength.
 The amplitude of the reversed stress is infinitely adjustable.
 The machine switches off automatically if the sample raptures.
 The number of cycles displayed via a digital counter.

29
Fatigue Test Apparatus

 In the revolving fatigue testing machine, a rotating sample which is


clamped on one side is loaded with concentrated force. As a result, an
alternating bending stress is created in the cylindrical sample. Following a
certain number of load cycles, the sample will rupture as a result of
material fatigue.

30
Fatigue Test Apparatus

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Fatigue Test Apparatus

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Fatigue Test Apparatus

33
Fatigue Test Apparatus

34
Fatigue Test Samples

35
Loading Specimen

36
Test Procedure

37
Test Procedure

38
Test Procedure

39
Test Procedure

40
Report Requirements

41

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