Jordan university of science and technology

Faculty of engineering: Industrial engineering department

Engineering Materials Laboratory IE367

Experiments Name: Fatigue test

Instructor name: Amena maen

Technician name: Mohammed al ghananeem

Teaching assistant name: Orayb shraideh

Student name: Tariq almistarehi (126724)

Section (3)

Submission date: 18/11/2020

 Table of contents

i-objectives……………………………………..……3
ii-introduction……………………………………...3
iii-experimental setup………………………....3
iv-experimental procedure………………..…6
v-experimental results...………………………6
vi-discussion……………………………………..…11
vii-conclusion…………………………………..….11
viii-reference…………………………………..….12
Objectives:

To demonstrate the use of the

fatigue testing machine for
testing specimens subjected
to cyclic (fatigue) loadings.
To demonstrate the use of the
fatigue testing machine for
testing specimens subjected
to cyclic (fatigue) loadings.
To demonstrate the use of the fatigue testing machine for testing
specimens subjected to cyclic (fatigue) loadings.

Introduction:

Fatigue of metals is a well-

known situation where
yielding (and then rupture)
can be caused
by a large number of stress
variations (magnitude and
direction) at a point even
though the
max stress is less than the
yield stress and respectively
the ultimate stress.
Fatigue of metals is a well-known situation where yielding (and then
rupture) can be caused by a large number of stress variations (magnitude
and direction) at a point even though the max stress is less than the yield
stress and respectively the ultimate stress.

Experimental setup:
We will use two materials in this experiment which is the Cold Worked
Steel and Cold Worked Aluminum.

Fatigue failure:
Fatigue failure:

A fatigue failure begins

with a small crack
resulting from a tensile
stress at a macro or
microscopic flaw. Once
started, the crack will
develop at a point of
discontinuity in the
material, such as change in
cross section, a keyway or a
hole. Less obvious points at
which
fatigue failure is likely to
begin are internal cracks or
even irregularities caused by
machining
processes. In other words,
when a load below yield
strength of a material is
applied
repeatedly to a metallic
specimen, localized
hardening occurs. Then a
small crack appears,
this crack is a line of stress
concentration which causes it
to grow. As the crack grows,
the
cross sectional area of the
material gets smaller until it
can no longer support the
load. This
loading on which the fracture
takes place is called fatigue
loading and the fracture is
called
fatigue failure
A fatigue failure begins with a small crack resulting from a tensile
stress at a macro or microscopic flaw. Once started, the crack will
develop at a point of discontinuity in the material, such as change in
cross section, a keyway or a hole. Less obvious points at which fatigue
failure is likely to begin are internal cracks or even irregularities caused by
machining processes. In other words, when a load below yield strength
of a material is applied repeatedly to a metallic specimen, localized
hardening occurs. Then a small crack appears, this crack is a line of stress
concentration which causes it to grow. As the crack grows, the cross
sectional area of the material gets smaller until it can no longer support the
load. This loading on which the fracture takes place is called fatigue loading
and the fracture is called fatigue failure see figure (1).
A fatigue failure begins
with a small crack
resulting from a tensile
stress at a macro or
microscopic flaw. Once
started, the crack will
develop at a point of
discontinuity in the
material, such as change in
cross section, a keyway or a
hole. Less obvious points at
which
fatigue failure is likely to
begin are internal cracks or
even irregularities caused by
machining
processes. In other words,
when a load below yield
strength of a material is
applied
repeatedly to a metallic
specimen, localized
hardening occurs. Then a
small crack appears,
this crack is a line of stress
concentration which causes it
to grow. As the crack grows,
the
cross sectional area of the
material gets smaller until it
can no longer support the
load. This
loading on which the fracture
takes place is called fatigue
loading and the fracture is
called
fatigue failure
Figure 1: Fatigue Fracture with Benchmarks

Cracks generally start at the

surface of the material. As
the crack grows, the two
surfaces rub
against each other,
polishing both surfaces to a
dull metallic finish. The
fractured surface
shows the sign of plastic
deformation as well as
crystalline finish.
Cracks generally start at the surface of the material. As the crack grows, the two
surfaces rub against each other, polishing both surfaces to a dull metallic finish. The
fractured surface shows the sign of plastic deformation as well as crystalline finish see
figure (2).
Figure 4 Appearance of typical fatigue
fracture surface
Figure 2: Appearance of typical fati gue fracture surface

Fatigue testing:
Fatigue testing:

To determine the strength

of materials under the
action of fatigue loads,
specimens are
subjected to repeated or
varying forces of specified
magnitudes. For the
rotating test a
constant bending load is
applied and the number of
revolutions of the specimen
required for
failure is recorded.
To determine the strength of materials under the action of fatigue
loads, specimens are subjected to repeated or varying forces of
specified magnitudes. For the rotating test a constant bending load is
applied and the number of revolutions of the specimen required for failure
is recorded. The process is continued and the results are plotted as an S-N
graph, figure(4).

Figure 3: Fatigue Testing Machine

 Figure 4: S-N Graph

Experimental Procedure
1. Take the two standard materials Cold Worked Steel and Cold Worked
Aluminum.

2. we clamped one end of the specimen into the adapter at the shaft end
and the other end into the adapter at the load end.

3. Then we set the revolution counter to zero and started the motor. The
revolution counter noted the number of cycles after which the failure
occurred.

4. The test terminated itself through the fracture of the specimen, opening
the micro switch and hence stopping the motor.

5.take the number of cycles from the counter and do the calculations.

Experimental Results
Equations we will use:
 MC
σ=
I

π D4
I=
64

D
C=
2

WHERE

σ =¿ applied stress

M==bending moment

C==the distance from the neutral surface (half the thickness for a sample of symmetrical cross
section)

D==diameter

I=second moment of area of the section

Cold Worked Steel

Fracture Shape: flat & burnished with crystalline appearance
Do (mm) Moment (Ib. In) # of Cycles Max Stress (psi)
1 9.57 240 40000000 45729.53 
2 9.57 250 18875100 47634.93 
3 9.57 260 827000 49540.32 
4 9.57 270 477000 51445.72 
5 9.57 280 427000   53351.12
6 9.57 290 425600   55256.52
7 9.57 295 340000 56209.21 
8 9.57 300 254000   57161.91
9 9.57 320 107000   60972.71
1 9.57 330 95900
  62878.10
0
1 9.57 340 95300
  64783.50
1
1 9.57 350 93500
  66688.90
2
1 9.57 360 87100
  68594.30
3
1 9.57 370 77100
70499.70 
4
1 9.57 380 74000
72405.10 
5
1 9.57 390 72700
  74310.49
6
1 9.57 390 66500
  74310.49
7
1 9.57 390 51000
  74310.49
8
 Table (1): Cold Worked Steel

First point

D0=9.57 mm=0.3767717 inch

0.3767717
C= =0.18838585 inch
2

M=240 Ib. inch

π ¿ 0.3767717 4
I= =9.88696 * 10−4
64

240∗0.18838585
σ= =45729.53 psi
9.88696∗10−4

Doing the same calculations for the other points.

80000 S-N DIAGRAM

70000

60000

50000
stress

40000

30000

20000

10000

0
0 5000000 10000000 15000000 20000000 25000000 30000000 35000000 40000000 45000000
number of cycles

Graph (1): cold worked steel

Fatigue limit =49540.32

 Cold Worked aluminum
Fracture Shape: flat & burnished with crystalline appearance
Do (mm) Moment (Ib. In) # of Cycles Max Stress (psi)
1 9.57 130 1284000 24770.16 
2 9.57 135 955400 25722.86
3 9.57 140 785000 26675.56
4 9.57 150 436000 28580.96
5 9.57 150 333000 28580.96
6 9.57 165 157000 31439.05 
7 9.57 170 131000 32391.75
8 9.57 175 130000 33344.45 
9 9.57 180 101000 34297.15 
1 9.57 185 94000 35249.85 
0
1 9.57 185 93000 35249.85 
1
1 9.57 190 92000 36202.54 
2
1 9.57 190 90000 36202.54
3
1 9.57 195 83000 37155.24
4
1 9.57 200 58000  38107.94
5
1 9.57 205 37000  39060.64
Table (2): 6 Cold
Worked 1 9.57 205 37000 Aluminum
 39060.64
7
1 9.57 205 37000  39060.64
8

First point
D 0=9.57 mm=0.3767717 inch

0.3767717
C= =0.18838585 inch
2

M=130 Ib. inch

π ¿ 0.3767717 4
I= =9.88696 * 10−4
64

130∗0.18838585
σ= =24770.16 psi
9.88696∗10−4

Doing the same calculations for the other points.

45000 S-N DIaGRAM

40000

35000

30000

25000
stress

20000

15000

10000

5000

0
0 2 0 0 0 00 4 0 00 0 0 6 0 0 0 00 8 0 00 0 0 1 0 0 0 00 0 1 2 00 0 0 0 1 4 0 0 00 0
number of cycles

Graph (2): cold worked aluminum

Fatigue limit=25722.86.
At the end of the experiment,
the image below shows the
appearance of the specimen.
At the end of the experiment, the image below shows the appearance of one of the specimen.
Figure (5).

Figure 5: Specimen after experiment

Discussion
*From the graph (1) and (2) we can notice that when the applied stress is
decreasing we need more number of cycles to break the specimen which
mean we need more time.

*We can notice that each point of the specimen is subjected to alternative
stress between tension and compression once during each revolution.

*We draw S-N diagram to collect the fatigue limit (endurance limit): is the
stress level below which an infinite number of loading cycles can be applied
to a material without causing fatigue failure.

*Specimen of steel need more number of cycles than aluminum to break so

its need more time.
Conclusion
*From this experiment it is concluded that fatigue is a material property
which varies from material to material. Initially the material starts
breaking slowly and then breaks faster with increasing cycling load

*The disadvantages of fatigue test:

1) that is need a long time because every specimen need a time for number
of cycles to break the specimen.

2)its expensive test because we need to break large number of specimens

to be able to draw the S-N diagram

References
http://www.mutiaranata.com/product/detail/wp-140-fatigue-testing-
machine

http://www.materials.unsw.edu.au/tutorials/online-tutorials/1-fatigue-
testing

https://www.engineeringtoolbox.com/steel-endurance-limit-d_1781.html