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    Design & Fabrication of Low Cost Small-Scale Fatigue Testing Machine

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    kshitij
    This document presents the design and fabrication of a low-cost small-scale fatigue testing machine. It discusses fatigue failure in engineering components under fluctuating stresses and the need for a fatigue testing machine. The objectives are to design and fabricate an inexpensive machine capable of performing fatigue tests. The methodology involves literature review, machine design analysis using CAD and ANSYS, and fabrication. Key components include an electric motor, specimen shaft, flexible coupling, bearings, drill chucks, and weights. The working principle involves applying cyclic bending stresses to the specimen as it rotates. Experimental results match theoretical calculations, demonstrating the machine can reliably test fatigue life.

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    Design & Fabrication of Low Cost Small-Scale Fatigue Testing Machine

    Uploaded by

    kshitij
    38 views12 pages
    This document presents the design and fabrication of a low-cost small-scale fatigue testing machine. It discusses fatigue failure in engineering components under fluctuating stresses and the need for a fatigue testing machine. The objectives are to design and fabricate an inexpensive machine capable of performing fatigue tests. The methodology involves literature review, machine design analysis using CAD and ANSYS, and fabrication. Key components include an electric motor, specimen shaft, flexible coupling, bearings, drill chucks, and weights. The working principle involves applying cyclic bending stresses to the specimen as it rotates. Experimental results match theoretical calculations, demonstrating the machine can reliably test fatigue life.

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    rjrahul-190920062628

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    This document presents the design and fabrication of a low-cost small-scale fatigue testing machine. It discusses fatigue failure in engineering components under fluctuating stresses and the need for a fatigue testing machine. The objectives are to design and fabricate an inexpensive machine capable of performing fatigue tests. The methodology involves literature review, machine design analysis using CAD and ANSYS, and fabrication. Key components include an electric motor, specimen shaft, flexible coupling, bearings, drill chucks, and weights. The working principle involves applying cyclic bending stresses to the specimen as it rotates. Experimental results match theoretical calculations, demonstrating the machine can reliably test fatigue life.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    38 views12 pages

    Design & Fabrication of Low Cost Small-Scale Fatigue Testing Machine

    Uploaded by

    kshitij
    This document presents the design and fabrication of a low-cost small-scale fatigue testing machine. It discusses fatigue failure in engineering components under fluctuating stresses and the need for a fatigue testing machine. The objectives are to design and fabricate an inexpensive machine capable of performing fatigue tests. The methodology involves literature review, machine design analysis using CAD and ANSYS, and fabrication. Key components include an electric motor, specimen shaft, flexible coupling, bearings, drill chucks, and weights. The working principle involves applying cyclic bending stresses to the specimen as it rotates. Experimental results match theoretical calculations, demonstrating the machine can reliably test fatigue life.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    of 12

    Presentation on

    Design & Fabrication of Low Cost


    Small-Scale Fatigue Testing Machine

    Presented by:
    Avinash Barve
    CONTENTS
    Sr. No. Contents
    1. Introduction

    2. Why we choose FTM?

    3. Objectives

    4. Methodology

    5. Design Analysis

    6. Design

    7. Description of Components

    8. Working Principle

    9. Conclusion
    INTRODUCTION

     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”.
     A fatigue is a failure of material or machine due to the action of repeated or fluctuating stress on a
    machine member for some number of times/cycles . This failure begins with a small crack. The
    initial crack is so minute that it cannot be detected by the naked eye and is even quite difficult to
    locate .And this led to the invention of a fatigue testing machine.
     In view of effective design that will not fail accidentally, this research 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. The first test will include the fatigue test of the material .
    The second test which we are going to combine testing of bending or torsion . Thus the results of
    these processes will be plotted through software integration.
    Why we choose a FTM?

     We know about fatigue and feel it many times in our body after long workout.
    Similarly engineering components also fails due to fatigue. Fatigue in any
    engineering component occurs when these components are subjected to cyclic
    loading or we can say that the fluctuating stresses are induced in the components.
     Fatigue is the time dependent permanent deformation which is seen in almost every
    engineering component when they work under cyclic loading conditions.
     Most of the time the engineering components fails only because of fatigue. Due to
    this, this machine help us to know about the life of the material under test because of
    which many hazardous accidents due to fatigue can be prevented.
     Thus, FTM is capable of testing the fatigue life of various specimen and help us to
    determine the life of various materials.
    OBJECTIVE

     Objective of fatigue testing is generally to determine the fatigue


    life and the location of danger point i.e Location of failure of a
    specimen subjected to sequential stress amplitude.
     To design and fabricate a machine in low cost which is capable
    of performing fatigue test.
     Purpose of a fatigue test is to determine the lifespan of the
    material subjected to cyclic loading.
    METHODOLOGY

    Literature Review Machine Design Fabrication


    & Data Collection & Analysis

    • CAD Design • Fabrication as


    • Research • Analysis of per design.
    Papers model using
    • Industries ANSYS
    • Calculations
    • Graphs
    • Sensors
    Design Analysis
    AISI 1018 (MS)

    Load (Kg) Total Stress Strain Factor of safety


    Deformation generated generated (minimum)
    (mm) (Mpa) (mm)
    10 12.203 6.599e8 0.0032 0.56065
    Aluminium

    Load Total Stress Strain Factor of safety


    (Kg) Deformation generated generated (minimum)
    (mm) (Mpa) (mm)
    10 13.715 6.256e8 0.00916 0.3996
    CAD MODEL
    DESCRIPTION OF COMPONENTS
    Part Description

    Electric motor single phase AC 0.745KW, 1 horse power


    motor
    Shaft and specimen A high carbon alloy steel that is AISI 1018
    (MS)
    Flexible coupling transmit power or torque form one shaft to
    another
    Pedestal bearing Bearings of 20 mm bore diameter

    Drill chucks A three jaw drill chuck with taper fittings

    Weight hanger and U to apply load on overhang bearing


    clamps
    Analog counter The output of the counter can be used to
    count the number of pulses.
    WORKING PRINCIPLE
     The fatigue-testing machine is of the simply supported beam type. The
    specimen functions as a single beam which is loaded at both the side point
    load. When rotated, the stresses on the fibers originate above the neutral
    axis of the specimen and are reversed from compression to tension for equal
    intensity.
     Upon completing the revolution, the stresses are again reversed, so that
    during one complete revolution the test specimen passes through a complete
    cycle of flexural stress.
     Rotating beam type machine for a simply supported beam, the specimen of
    circular cross- section is held at its ends in holders(chucks) and loaded
    through two bearings with equal distance from the center of the span.
     Thus, equal loads on these bearings are applied by means of weights
    that create a uniform bending moment in the specimen between the
    loaded bearings.
    CONCLUSION

    Material testing equipment is generally very expensive, this has given us a


    challenge to make a low cost testing machine , but we had made a machine that
    is easy to fabricate and procure accurate and precise results and compete with the
    equipment already available in the market. According to the planned
    methodology the machine is fabricated and tested. The experimental results are
    compared with theoretical calculations and it was found that there is little
    variations in results. On completion and testing, it was observed that the machine
    has the potentials of generating a reliable bending stress number of cycle data.
    The machine has the advantages of ease of operation and maintenance, and is
    safe for use.

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