A

PROJECT REPORT ON
DESIGN AND ANALYSIS OF RECIPROCATING
BENDING FATIGUE TESTING MACHINE

SUBMITTED IN THE PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE

AWARD OF THE DEGREE OF

BACHELOR OF TECHNOLOGY

MAULANA AZAD NATIONAL INSTITUE OF TECHNOLOGY

BHOPAL, 462003

SUBMITTED BY- GUIDED BY-

Vikas Khandelwal (151116021)
Prakhar Agrawal (151116035) DR. R.K. DWIVEDI
Aditya Singh (151116036)
 DECLARATION
We hereby declare that the project work entitled “Design and Analysis of
Reciprocating Bending Fatigue Testing Machine” submitted to MANIT,
BHOPAL is a record of original work done by us under the supervision of
Dr. R.K. DWIVEDI, Associate Professor, Department of Mechanical
Engineering MANIT, BHOPAL, and submitted in the partial fulfilment of the
requirement for the award to the degree of B.TECH in mechanical engineering.

SUBMITTED BY-

VIKAS KHANDELWAL

PRAKHAR AGRAWAL

ADITYA SINGH
 ACKNOWLEGEMENT
It gives us immense pleasure to express our deepest sense of gratitude and sincere thanks to
our highly respected and esteemed guide Dr. R.K. Dwivedi, Associate Professor,
Department of Mechanical Engineering, MANIT, BHOPAL for his valuable guidance,
encouragement and help for completing this work. His useful suggestions for this whole
work and co-operative behaviour are sincerely acknowledge.

We would also like to express our gratitude towards our parents and our college MANIT for
their kind cooperation and encouragement which helped us in completion of this project.

Our thanks and appreciations also go to our colleagues in developing the project and people
who have willingly helped us out with their ability.
 ABSTRACT:

Many engineering machines and mechanical components are subjected to fluctuating stresses,
taking place at relatively high frequencies and under these conditions failure is found to
occur. This is “fatigue failure”. And this led to the invention of a fatigue testing machine. In
view of effective design that will not fail accidentally, this project is conceived. This testing
machine will determine the strength of materials under the action of fatigue load. Specimens
are subjected to repeated varying forces or fluctuating loading of specific magnitude while
the cycles or stress reversals are counted to destruction.
CONTENTS:
1. Introduction 5
2. Literature survey 6
3. Problem Identification 7
4. Project Work 8
5. Analysis 9
6. Observation 13
7. Future Aspects 14
8. References 15
INTRODUCTION

Fatigue is the condition where by a material cracks or fails as a result of repeated (cyclic)
stresses applied below the ultimate strength of the material. Fatigue causes brittle like
failures even in normally ductile materials with little gross plastic deformation occurring
prior to fracture. The process occurs by the initiation and propagation of cracks. Unlike
other failures, fatigue failure gives no visible warning in advance. It is sudden and totally
dangerous. The technical, economic and potential human losses due to fatigue failures
make its consideration during materials design. Fatigue study is important if the challenges
associated with its occurrence are to be eliminated. This project is related with the design of
reciprocating bending fatigue testing machine.

A lot of research interest has been devoted to studying the fatigue behaviour of engineering
materials with a view to arriving at ways to effectively design against the failure mode. Over
the years there have been varied testing equipment and methods developed for fatigue
evaluation.

The servo – hydraulic machines are currently the fastest and most versatile with features
that allow for a wide range of test variations to be performed on it. But these are less
accurate in bending fatigue test in comparison to reciprocating bending fatigue testing
machine and are very costly too. This project work thus aims at addressing this problem by
venturing into the design of a low cost reciprocating bending fatigue testing machine. The
mechanism involved is the conversion of rotating motion of motor into the reciprocation
motion of the slider.
LITERATURE SURVEY
 Fatigue is the condition whereby a material cracks or fails as a result of repeated
(cyclic) stresses applied below the ultimate strength of the material. Fatigue testing
machine is used to determine the fatigue life or fatigue strength of a material. Fatigue
testing machines may be classified from different view-points such as: purpose of the
test, type of stressing, means of producing the load, operation characteristics, type of
load, etc. The most appropriate sequence of these alternatives for building up a
classification system depends upon who is going to use it.

 The simplest way of applying a constant -stress amplitude to a specimen consists of

attaching one end of a coil spring to the specimen and imposing a reciprocating
motion to the other end by means of a direct crank drive. This type of testing machine
was, in fact, used by WOHLER (1871) in his fundamental investigations.

 MOORE and JASPER (1924) introduced a variable-throw crank and a connecting-rod

mechanism, which were also incorporated in a machine by MATTHAES (1935);
TEMPLIN (1933) used two variable eccentrics, and MOORE and KROUSE (1934)
used a cam-operated lever system. This last machine could be operated at a speed of
1000 rev/mm, but in general a reduced speed of 100 to 200 rev/mm was
recommended to prevent vibration and to reduce undesirable inertia forces.

 R.R.MOORE introduced Rotating Beam fatigue testing machine. In this a test piece is
mounted as a cantilever with single point loading and is made to rotate and thus
subjected to a bending moment. This bending moment created alternating bending
stresses causing fatigue. Lot of advancement have been done in Rotating Beam
fatigue testing machine like multi-point loading, multiple specimen holding etc.

 Test conducted on Reciprocating Bending machine used to take long time because
these machines could not be operated at high RPM due to problem of excessive
vibration, friction and inertia forces due to reciprocating parts. Because of these
reasons these machines were not so popular. But in many practical conditions,
machine parts are subjected to continuously variable bending stresses where this
machine can give more accurate results.
PROBLEM IDENTIFICATION
Literature survey leads us to the fact that reciprocating bending fatigue testing machines are
not very popular these days in spite of their good accuracy in the measurement of fatigue life
of the components subjected to bending stresses. The reasons were vibrations, inertia forces,
friction and the long duration of the test.

With the advancement in the material technology, vibration isolation and data acquisition
systems these problems can be handled easily.

So we are designing and performing the analysis of Reciprocating Bending fatigue testing
machines.
PROJECT WORK
ANALYSIS
The model of the fatigue testing machine is created in Solidworks 2016 and is imported to
ANSYS WORKBENCH 15.0 for analysis.

1. MESH : Coarse

2. LOADING CONDITIONS:
Fixed Support: At Plummer base and Guide ways
Force: 40 KN at specimen holder, Torque: 10 Nm at pulley
3. MAXIMUM PRINCIPAL STRESS:
Maximum principal stress of 6.8562e6 Pa occurs at the balls of the bearing.

4. MINIMUM PRINCIPAL STRESS:

Minimum principle stress are shown by red colour and the magnitude is 1.0617e6 Pa
5. TOTAL DEFORMATION:
Maximum deformation occurs at the edges of pulley and deformation is 5.1042e-3 mm
before failure.

6. MAXIMUM ELASTIC STRAIN

Maximum Shear elastic strain of 6.6246e-5 m/m occurs inside bearing.
 Observations with constant stroke
Specimen
Material No. Speed Stroke Failure Time Revolution Fatigue Stress

(RPM) (mm) (min) *10^5 MPa

1 848 30 5 0.42 34.04

MS
2 844 30 10 0.84 33.66

3 846 30 12.5 1.05 32.51

Observations with increasing stroke

Material Specimen No. Speed Stroke Failure Time Revolution

(RPM) (mm) (min) *10^5

1 848 30 12 min 34 sec 1.06

MS
2 844 40 9 min 45 sec 0.82

3 846 50 7 min 26 sec 0.63

Standard S-N Curve

FUTURE ASPECTS
 We will compare our design with the cloud point data obtained with the help of 3-D
scanner.
 This machine can be coupled with the rotating bending fatigue testing machine so
multiple type of testing can be performed simultaneously.
 With the modification in the design of specimen holder, specimen of different cross-
sections can be tested.
REFERENCES:
Journal Paper
1. International Journal of Innovative Research in Science and Engineering, Vol. No.2,
Issue 04, April 2016; (www.ijirse.com)
2. Claude Bathias, Fatigue testing machines and devices, International Journal of
Fatigue, Vol. 28(11), 1438-1445. C.M. Soncino, Fatigue testing under variable
amplitude loading, International Journal of Fatigue, Vol. 29(6), 1080-1089.
3. I Marines, X Bin, & C Bathias, An understanding of very high cycle fatigue of metals,
International Journal of Fatigue, Vol. 25(9), 1101-1107.
4. A Kusaba,S Okazaki, M Endo & K Yanase, Designing of a testing machine for shear-
mode fatigue crack growth, International Journal of Modern Physics, Vol. 6(2012),
318-232.

Books
V.B. Bhandari, Design of machine elements,3rd edition, pg 166-170.