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Design and construction of a torsion fatigue machine: Torsion fatigue tests on

two industrial aluminum alloys

Article  in  UPB Scientific Bulletin, Series D: Mechanical Engineering · January 2017

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U.P.B. Sci. Bull., Series D, Vol. 79, Iss. 2, 2017 ISSN 1454-2358

DESIGN AND CONSTRUCTION OF A TORSION FATIGUE

MACHINE: TORSION FATIGUE TESTS ON TWO
INDUSTRIAL ALUMINUM ALLOYS
Jorge L. AVILA AMBRIZ1, Gonzalo M. DOMINGUEZ ALMARAZ2, Julio C.
VERDUZCO JUAREZ3, Erasmo CORREA GOMEZ4, Ishvari F. ZUÑIGA
TELLO5

Most of fatigue machines used for industrial or laboratory applications are

limited to perform a single fatigue test and its components are commonly servo-
hydraulic or pneumatic actuators of high torque capability, leading to high costs. In
the present paper is shown a torsion fatigue machine which works from 0.3 to 10 N-
m of torque and it is used to investigate the fatigue torsion endurance for industrial
materials, such as: steels, aluminum alloys, cast irons and polymers. This machine
employs servomotors mounted with a linear motion mechanism to develop fatigue
tests under torsion. The control and programming of angular motion is carried out by
the freeware "Robotis" software, allowing an easy control for angular rotation. In
this work is presented the general methodology for the setup of torsion tests:
calibration of rotation motion, numerical simulation and the experimental results of
torsion tests. Furthermore, this machine allows working at different load ratios R by
applying an initial static angle before the initiation of torsion testing.

Keywords: Torsion fatigue machine, Torsion energy evaluation, Design –

automatization, Torsion endurance, Fracture surfaces.

1. Introduction

The fatigue behavior of industrial materials is of principal interest to warrant

the safety of the component in service; particularly under oscillating mechanical
loads leading to mechanical fatigue [1-4]. In this matter, it’s important to evaluate
the experimental fatigue endurance of engineering materials due to the fact that
theoretical equations do not always fit the real fatigue behavior [5, 6].

1
Faculty of Mechanical Engineering, University of Michoacan (UMSNH), 58000, Mexico,
Mexico, email: [email protected]
2
Faculty of Mechanical Engineering, University of Michoacan (UMSNH), 58000, Mexico,
Mexico, email: [email protected]
3
Faculty of Mechanical Engineering, University of Michoacan (UMSNH), 58000, Mexico,
Mexico, email: [email protected]
4
Faculty of Mechanical Engineering, University of Michoacan (UMSNH), 58000, Mexico,
Mexico, email: [email protected]
5
Faculty of Mechanical Engineering, University of Michoacan (UMSNH), 58000, Mexico,
Mexico, email: [email protected]
 170 J. L. Avila Ambriz, G. M. Dominguez Almaraz, J. C. Verduzco Juarez, E. Correa Gomez, I. F. Zuñiga Tello

Then, it results necessary to carry out mechanical fatigue tests in different

modalities and on a wide variety of materials to investigate the principal causes of
failure in engineering components subjected to uniaxial and multiaxial loading
[7-9]. Several authors have designed and constructed their own machines for
specific applications [10-12]. In regard the torsion fatigue machines, the first
prototype was developed in the nineteen century [13], in this machine load was
induced by mechanical deflexion and inertia forces. The systematic studies on
torsion fatigue have been carried out in the second half of the twenty century on
aluminum alloys [14]; whereas most recent developments are oriented to the torsion
fatigue machines controlled by a servo-actuator [15], or the use of a resonance
system to induce failure by torsion [16]. This developed machine is oriented to
perform torsion tests under displacement-controlled mode. The description of the
present fatigue machine includes the process to carry out torsion fatigue tests: the
first step is the selection of testing specimen and the definition of its profile by
Autocad software, followed by the machining process of the specimen using a CNC
station. At the same time, it is necessary to carry out numerical simulations to
determine the maximum shear stress at the neck section of testing specimen,
induced by a torsion applied loading.
This paper contains the following sections: section 2 is related to materials
and methods, as well as the general aspects of testing specimen; the numerical
analysis to determine the required load for torsion test is described in section 3, as
well as the evaluation of the theoretical elastic energy accumulated by the torsion
loading; whereas the design and general description of the torsion testing machine
is presented in section 4. Finally, section 5 details the experimental results
accompanied with discussion.

2. Materials and Methods

2.1. Specimen's geometry

The specimen used in this machine corresponds to the hourglass shape

profile due its capability to induce a high stress concentration at the neck section
under torsion tests [17]. The minimum diameter has been chosen close to 3 mm,
Fig. 1a; this value was fixed to induce a maximum shear stress for each testing
material and each applied load level. The used stress levels have been: 90, 80, 70,
and 60% regarding the shear stress of the tested 6063.T5 aluminum alloy. It is
important to notice that there is no available international standardization nowadays
for torsion fatigue specimens; the norm ASTM-A938-07(2013) concerns the
uniform section wire under torsion tests [18].
The dimensions of aluminum specimens meant for the present torsion
machine have initially presented an industrial profile as-received, that is: hot-
pressed rod of ¼” of diameter. This dimension is commonly available for a wide
Design and construction of a torsion fatigue machine: torsion fatigue tests on two industrial… 171

variety of metallic alloys and industrial polymers. The Fig. 1a shows the dimensions
(mm), of the hourglass shape torsion specimen.

2.2. Machining process

In order to avoid significant variations on the dimensions of testing

specimens, the machining process was implemented in a CNC turning station under
controlled machining parameters leading to diminish the high variation on the
surface roughness: the roughness parameter Ra (arithmetic average of absolute
values) was close to 10 m for all testing specimens. As previously mentioned,
specimen profiles for torsion fatigue testing are not standardized; some authors have
used different profiles and dimensions [19-22]; nevertheless, it is observed that the
hourglass shape profile is a constant for the torsion fatigue tests. Fig. 1b illustrates
the as-received bar and the machined symmetric hourglass shape specimens used
in this torsion fatigue machine.

3. Numerical analysis of shear stress distribution and elastic energy

determination under torsion loading
3.1 Testing specimen

The general conditions for the torsion testing specimen are as follows:
the bottom end of specimen was clamped and the torsion angle is applied at the top
end, as shown in Fig. 2a. Parallel to the specimen's machining process, numerical
simulations were carried out to determine the relationship between: the torque or
applied rotational angle on the specimen and the induced shear stress at the neck
section, as illustrated in Fig. 2b.

Fig. 1 a) Torsion specimen dimensions (mm). b) Commercial bar and machined torsion fatigue
specimens
 172 J. L. Avila Ambriz, G. M. Dominguez Almaraz, J. C. Verduzco Juarez, E. Correa Gomez, I. F. Zuñiga Tello

With the aid of numerical simulations, it’s possible to predict the shear stress
induced at the neck section when applying a torsion angle. The Fig. 2a shows the
constraints and dimensions of torsion testing specimen; whereas Fig. 2b presents
the shear stress distribution on the X-Y plane under torsion loading of one degree
on the aluminum alloy 6061-T6. The highest shear stress observed under this
torsion load has been 43.8 MPa, located at the neck section of testing specimen.

Fig. 2 a) Dimensions (mm) of testing specimen and testing constrains, b) Shear stress distribution in Pascals
on the X-Y plane, for one degree of the torsion applied angle.

Concerning the loading regime, the load ratio R = 0 was imposed from a
non-stressed initial position 0° to the maximum stress, following the clock wise
direction, as shown in Fig. 3a. The load ratio R=-1 was implemented as show in
Fig. 3b: from the no loaded position (0° on Fig. 3b), the specimen is mounted and
a starting torsion angle is imposed in the clockwise direction; then, it oscillates from
the last position between the maximum and minimum angle in alternating direction
(clockwise direction and counter-clockwise direction, as illustrated in the same
figure).
 Design and construction of a torsion fatigue machine: torsion fatigue tests on two industrial… 173

Fig. 3 Torsion displacements for the two load ratios: a) Load ratio R = 0, b) Full reverse loading
R = -1.

3.2. Elastic energy accumulated by torsion loading.

Elastic energy is accumulated under torsion loading and is the product of

applied torque T and the torsion angle :
1
𝐸 = 2 𝑇𝜃 (1)

In Fig. 4a is shown the free-body diagram for the section of torsion

displacement on testing specimen; this section corresponds to the variable diameter
along the specimen. The radius along this section is a quadratic function of the
coordinate x:
𝑅(𝑥) = 𝑎 + 𝑏 𝑥 2 (2)
For x = 0, the radius is R = 0.0015 m, whereas for x = ± 0.006254 m, the
radius is R = 0.003175 m; then, a = 0.0015 and b = 42.825. The polar moment of
inertia for the section A-B is written as:
𝜋 𝜋
𝐽𝐴𝐵 = 𝑅4 = (0.0015 + 42.825 𝑥 2 )4 (3)
2 2

Fig. 4 a) Free body diagram for the torsion specimen, b) Shear strain corresponding to 0.64 Nm of applied
torque
 174 J. L. Avila Ambriz, G. M. Dominguez Almaraz, J. C. Verduzco Juarez, E. Correa Gomez, I. F. Zuñiga Tello

And the relative differential rotation at section A with respect to the section at B is:

𝐃𝛉 𝐓𝐀𝐁 𝐓𝐀𝐁
( 𝐝𝐱 ) = = 𝛑 𝟒 (4)
𝐀𝐁 𝐆𝐀𝐁 𝐉𝐀𝐁 𝐆𝐀𝐁 (𝟎.𝟎𝟎𝟏𝟓+𝟒𝟐.𝟖𝟐𝟓 𝐱 𝟐 )
𝟐

Where GAB is the shear modulus for the testing material (26 GPa for the
aluminum alloy 6061-T6). Integrating the last equation gives:

𝛉
𝐀 𝟎.𝟎𝟎𝟔𝟐𝟓𝟒 𝐓𝐀𝐁
∫𝚯 𝐝𝛉 = ∫−𝟎.𝟎𝟎𝟔𝟐𝟓𝟒 𝛑 𝟒 𝐝𝐱 (5)
𝐁 𝐆𝐀𝐁 (𝟎.𝟎𝟎𝟏𝟓+𝟒𝟐.𝟖𝟐𝟓 𝐱 𝟐 )
𝟐

With the result for the torsion angle on A:

𝟐𝐓𝐀𝐁 𝟐. 𝟏𝟔𝟐𝟏𝟐 𝟏𝟎𝟔 𝐱 𝟓 + 𝟐𝟎𝟏. 𝟗𝟒𝟗𝐱 𝟑 + 𝟎. 𝟎𝟎𝟓𝟖𝟑𝟓𝟔𝟓𝐱

𝛉𝐀 = +
𝐆𝐀𝐁 𝛑 (𝐱 𝟐 + 𝟎. 𝟎𝟎𝟎𝟎𝟑𝟓𝟎𝟐𝟔𝟑)𝟑
0.006254
+ 3.65327 108 𝑡𝑎𝑛−1 (168.967𝑥) . (6)
−0.006254
And in substituting the limits of integration, it results:
2𝑇𝐴𝐵
𝜃=𝐺 (1.117037 𝑥 109 ) (7)
𝐴𝐵 𝜋

Values for  are in radians, TAB in Nm and GAB in Pascals. An applied torque
TAB = 0.64 Nm on the aluminum alloy 6061-T6 specimen induces a torsion angle
 = 0.0175 rad 1 degree. Under the last conditions of loading and testing material,
the elastic energy accumulated along the variable diameter section of Fig. 4a is
obtained by:
1 1
𝐸 = 2 𝑇𝜃 = 2 0.64 (0.0175) = 0.0056 𝐽 (8)

On Fig. 4b is presented the shear elastic strain along the variable radius
section: the maximum values are located at the surface and at the neck section of
specimen. These values corresponding to the aluminum alloy 6061-T6 with an
applied torque TAB = 0.64 N-m.
A general expression for the differential torsion angle between A and B in
function of geometrical properties of testing specimen (quadratic profile, equation
2) is as follows:
𝐃𝛉 𝐓 𝐓𝐀𝐁
( 𝐝𝐱 ) = 𝐆 𝐀𝐁𝐉 = 𝛑 𝟐 𝟒
(9)
𝐀𝐁 𝐀𝐁 𝐀𝐁 𝐆𝐀𝐁 (𝐚+𝐛 𝐱 )
𝟐

Integrating along the variable radius section, Fig. 4a, the resulting expression is:
Design and construction of a torsion fatigue machine: torsion fatigue tests on two industrial… 175

𝛉𝐀 𝐜 𝐓𝐀𝐁
∫𝚯 𝐝𝛉 = ∫−𝐜 𝛑 𝟒 𝐝𝐱 (10)
𝐁 𝐆𝐀𝐁 (𝐚+𝐛 𝐱 𝟐 )
𝟐

With the result after integration:

√𝑏 𝑥
5𝑡𝑎𝑛−1 ( ) 𝑐
2𝑇𝐴𝐵 √𝑎 5𝑥 5𝑥 𝑥
𝜃𝐴 = [ 7 + 16𝑎3 (𝑎+𝑏𝑥 2 ) + 24𝑎2 (𝑎+𝑏𝑥 2 )2 + + 6𝑎 (𝑎+𝑏𝑥 2 )3 ] . (11)
𝐺𝐴𝐵 𝜋 16𝑎 ⁄2 √𝑏
−𝑐

The integration limits [-c, c] correspond to a third geometrical property of

testing specimen: the length of the variable radius section. Concerning the constant
b in equation 2, its value is obtained by:

𝑏 = (𝑅(𝑐) − 𝑎)/𝑐 2 (12)

On Fig. 5 are plotted the evolution of the torsion angle , against the three
geometrical dimensions of testing specimen: a, b and c, for constant values of TAB
and GAB. The radius at the neck section of specimen a, seems to be a critical
parameter for the increase of the rotation angle: the reduction of a induces an
exponential growth to the fourth power on . The reduction on parameter b induces
a moderate increase on the torsion angle ; whereas the torsion angle increases with
the geometrical dimension c, from 0 to an asymptotical value.

Fig. 5 Qualitative evolution of torsion angle  with the specimen’s geometrical dimensions: a, b, c
 176 J. L. Avila Ambriz, G. M. Dominguez Almaraz, J. C. Verduzco Juarez, E. Correa Gomez, I. F. Zuñiga Tello

4. Design and description of the torsion fatigue machine.

In Fig. 6 is shown the fatigue machine designed for torsion fatigue tests. A
DYNAMIXEL MX-106R servomotor is used to communicate rotating motion to
the vertical or principal axis through a chain and gears; whereas a linear actuator
induces deflection to achieve the bending modality. Both actuators work at 12 VDC
and are controlled by the interface of a program developed with the “Robotis”
platform, allowing communicating rotating motion with 0.1 degrees of precision.
In this way, the vertical axis connects with testing specimen through a free torsion
chuck and the specimen's bottom end is clamped by a second fixed chuck.
The Fig. 7a shows the final assembled machine and components; the
manufacture process is described in other published work [23]. Two aluminum
plates support the linear and rotary actuator, whereas the four columns of "celoron"
material isolate the upper and lower aluminum plates of the machine. The Fig. 7b
shows in detail the chucks and torsion specimen; it is noticeable that the fixed or
inferior chuck is clamped to a steel plate which is separated by 4 mm from the lower
aluminum plate: when the specimen is broken, its two broken parts are separated
and the fixed chuck drops (4 mm) together with the steel plate. This particularity
allows separating the two broken parts of specimen when fracture occurs, avoiding
to damage the fracture surfaces due to friction.

Fig. 6 Principal elements of the torsion fatigue machine.

Two important characteristics of this machine are: its capacity to record the
number of cycles of fatigue life in real time and to stop the counter of cycles
automatically when fracture occurs. The last capacity was implemented through
Design and construction of a torsion fatigue machine: torsion fatigue tests on two industrial… 177

current continuity along the testing specimen: when fracture occurs, current
continuity is interrupted and both devices turn off (the torsion machine and the
electronic counter). In the case of non-conducting material such as polymers,
current continuity is provided by a thin conductor wire which is broken
simultaneously with the specimen failure.

Fig. 7 a) Frontal view of the torsion fatigue machine, b) Amplification for chucks and testing
specimen.

5. Results and discussion.

5.1. Torsion fatigue results.

Torsion fatigue tests were performed and analyzed by optical microscope and
SEM on two aluminum alloys: 6061-T6 and 6063-T5. The tests were obtained at room
temperature (22°C) and with environmental humidity comprised between 35% and
45%. The two aluminum alloys were subjected to torsion fatigue tests at four levels of
applied load, induced by a fixed torsion angle of: 2.43°, 2.16°, 1.89°, 1.62°, which
corresponds to 50.9%, 45.2%, 39.6%, 34% the shear strength of 6061-T6 alloy and
90%, 80%, 70%, 60% of 6063-T5 aluminum alloy, Fig. 8. All tests were performed at
10 Hz of frequency and with the loading ratio R=0. The lines in Fig. 8 have been
obtained by logarithmic interpolation of the experimental data.
The torsion fatigue behavior plotted in Fig. 8 suggests that for the high applied
load (high torsion angle), the aluminum alloy 6061-T6 presents higher torsion fatigue
endurance compared to the 6063-T5; this difference seems to decrease with decreasing
the applied load.
The Figs. 9a and 9b show laterals views of torsion fracture where
predominant ductile behavior was observed on the aluminum alloy 6063-T5: this
fracture is characterized by a crack path almost perpendicular with respect to the
longitudinal axis of the testing specimen. On the other hand, a predominantly brittle
 178 J. L. Avila Ambriz, G. M. Dominguez Almaraz, J. C. Verduzco Juarez, E. Correa Gomez, I. F. Zuñiga Tello

fracture is observed in the neck section of aluminum alloy 6061-T6, as illustrated

on Fig. 9c: in this figure appears the lateral fracture path near to 45° in regard the
longitudinal axis of specimen. Furthermore, a frontal fracture surface of another
6061-T6 specimen is shown on Fig. 9d, presenting important plastic deformation at
the external zone of fracture surface (dark zones), where the cracks initiate. In the
last fracture surface is localized also a granular zone at the center (bright zone),
related to a rapid crack propagation with no high apparent plastic deformation.

Fig. 8 Torsion fatigue endurance for the aluminum alloys: 6061-T6 and 6063-T5, under load ratio
R=0.

Fig. 9. Torsion fracture paths: a) and b) lateral ductile fracture for aluminum alloy 6063-T5;
c) lateral brittle fracture and d) frontal fracture surface for aluminum alloy 6061-T6.
Design and construction of a torsion fatigue machine: torsion fatigue tests on two industrial… 179

Images by SEM (scanning electron microscope), show that microcracks initiate at

the specimen surface and propagate on a radial path towards its center for the
aluminum alloys 6061-T6, as shown on Fig. 10a. Such microcracks are the result
of the coalescence of microvoids at microscopic scale which are associated to
plastic deformation at this scale, as illustrated in Fig. 14b.

Fig. 10. Fracture surfaces of 6061-T6 aluminum alloy observed by scanning electron microscope:
a) 200 m of amplification, b) 50 m of amplification.

Fig. 11. Fracture surfaces of 6063-T5 aluminum alloy observed by scanning electron microscope:
a) micrograph at one corner of fracture surface, b) micrograph at the center of fracture surface

Concerning scanning electron microscope images for fracture surfaces

under torsion testing on aluminum alloy 6063-T5, in Fig. 11a and 11b are presented
the principal features: plastic deformation and microcracks are observed in radial
direction as in the previous case with the hardening effect at the microscopic scale
[24, 25]; nevertheless, this time the density of microcracks in radial direction seems
to decrease, Fig. 11a: a higher ductility of aluminum alloy 6063-T5 compared to
 180 J. L. Avila Ambriz, G. M. Dominguez Almaraz, J. C. Verduzco Juarez, E. Correa Gomez, I. F. Zuñiga Tello

6061-T6, tends to reduce the crack initiation sites. On the other hand, at the center
of fracture surface of this aluminum alloy are observed radial microcracks
generated by large microvoids, Fig. 11b. The increase of ductility on aluminum
alloys induces an increase of the sizes of microvoids, leading to facilitate the
coalescence of them and reducing the crack propagation paths, when subjected to
fatigue load [26].

6. Conclusions

The following conclusions can be draw from this work:

1. The description of a new torsion fatigue machine is presented with experimental

results on the AISI aluminum alloys: 6061-T6 and 6063-T6.
2. The precision of the torsion applied angle with this torsion machine is close to 0.1
degrees.
3. Numerical simulations indicate high shear elastic strain along the variable radius
section: the higher value is located at the surface and in the necking section of the
specimen.
4. It was obtained the elastic energy accumulated in the torsion testing specimen in
function of the applied torque and the torsion angle: the case for aluminum alloy
6061-T6 and the general expression.
5. The induced torsion angle  increases dramatically with the reduction of the neck
section radius of specimen (parameter a); whereas the reduction on parameter b
induces a moderate increase on the torsion angle. The torsion angle  increases with
the geometrical dimension c, from 0 to an asymptotical value.
6. From the torsion fatigue results, the aluminum alloy 6061-T6 presents higher
torsion fatigue endurance compared to the 6063-T5 for the high applied load (high
torsion angle); this difference seems to decrease with decreasing the applied load.
7. The fracture surfaces show radial propagation of microcracks for the two aluminum
alloys. The higher ductility of aluminum alloy 6063-T5 compared to 6061-T6
induces higher sizes of microvoids on the first alloy, leading to reduce the crack
initiation sites and increasing microcrack size.

Acknowledgments
The authors gratefully acknowledge the University of Michoacan
(UMSNH) in Mexico for the facilities provided in developing this work. A special
mention of gratitude to CONACYT (The National Council for Science and
Technology, Mexico) for the financial support to this work by the grant: CB-
241117-2014.
Design and construction of a torsion fatigue machine: torsion fatigue tests on two industrial… 181

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