College of Engineering

Petroleum Engineering Department

2nd Stage
Strength Of Materials
LAB
(Fatigue)
Prepared by: Supervisor:
Omed Haji Shaaban Dr. AbdulNasser
Ibrahim Hassan
2022-2023
Contents:

Abstract….3

Objectives…3

Introduction….3

Fatigue Testing Machine…4

Lathe Machine……4

Theory……5

Fatigue Failure….6

Fatigue testing…..6

Types of fatigue testing….7

experimental testing…..8

conclusion……9

References…..9
Objective:

To demonstrate the use of the fatigue testing machine for testing

specimens subjected to cyclic (fatigue) loadings.
To analytically approximate the fatigue damage accumulated in a part
which is subjected to a known fatigue spectrum.

What is The Importance Of Studying Fatugue?

Fatigue properties are among the most important aspects of
mechanical response of materials, and sufficient fatigue resistance is
crucial for practical application of structural materials

Introduction:
Fatigue life is defined as the number of loading (stress) cycles of
a specified character that a specimen sustains before failure of
a specified nature occurs. The number of cycles is related to
engine speed. It can be converted to equivalent durability
hours.experiment aims to provide a practical demonstration of
fatigue testing of materials. The specimen used for the
experiment is mild steel. This report summarizes the objectives
of the experiment, the apparatus used throughout the
experiment, followed by an introduction and theory regarding
the experiment. Furthermore the experimental procedure is
mentioned along with the results and graphical visualization.
Apparatus

Fatigue Testing Machine:

Using this bench top unit, the basic principles of
fatigue testing can be conveyed. A rotating
metal test bar, clamped at one end, is loaded
using a spring balance with a point force. This
results in a cyclic bending load on the cylindrical
specimen. The amplitude of the cyclic loading
can be continuously adjusted using a threaded
spindle with hand wheel. After a certain
number of load cycles, the specimen breaks as a
result of material fatigue. In this case the
machine is shut down automatically by the stop
switch. The number of load cycles is counted by
an electrical counter and displayed digitally.
Figure(1)
Lathe Machine:
A lathe is a tool that rotates the work piece
about an axis of rotation to perform various
operations such as cutting, sanding, knurling,
drilling, deformation, facing, turning, with tools
that are applied to the work piece to create an
object with symmetry about that axis.

Figure(2)
Theory
Fatigue Failure

Figure 3: Fatigue Fracture with Benchmarks

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 4 Appearance of typical fatigue fracture surface

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
finish.

Figure 5: SN Graph
A prediction of failure for various stress levels can be made by studying
a material’s S-N curve. The most important part of the curve is often
the portion to the right of the bend (or knee) in the curve that identifies
what is termed the Endurance Limit or the Fatigue Limit. The Endurance
Limit defines the stress level below which the material will theoretically
withstand an infinite number (~108) of stress cycles without
fracture.Material Stress and Strain

Figure 5: Fatigue Testing Machine

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 first test is made at a stress which is somewhat
under the ultimate strength of the material. The second test is
performed at a stress less than that used in the first. The process is
continued and the results are plotted as an S-N graph.
Types of fatigue testing:
1. The Rotating Bending Testing Machine is similar to the original
railroad axle-type Wohler used where the bending moment is constant
along the beam length. Each point on the Surface of the Rotating Bend
Specimen is subjected to fully-reversed cycling (σm = 0) and the tests
are generally Constant Amplitude.

2. Reciprocating Bending Testing Machines utilize a rotating crank to

achieve a non-zero mean stress through positioning of the specimen
with respect to the motor.

3. Similar to the Reciprocating Bending set-up, the Direct Force Fatigue

Testing Machines apply axial loads.

4. None-the-less, computer controlled "Servo hydraulic Systems" are

the most common in operation today. Computerized Servo hydraulics is
capable of both monitoring and controlling a desired cyclic pattern in
any of the following:

• Load-Time

• Strain-Time

• Displacement-Time

5. Component Testing or Full-Scale Prototype Tests are still carried out

on Fatigue-Critical structures. Most fatigue testing is conducted at the
basic material level; differences between laboratory and service
conditions must be considered by mechanical designers.
Experimental procedure
1. First of all we performed turning on the specimen to reduce it to the
size (7.8 mm in diameter) we needed for this experiment.

2. Then we used sand paper to make its surface smooth so it can

perform more efficiently during the experiment.

3. Then 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.

4. After that we applied approximately 240 N loads to have a precise

bending loading condition. Any load above 250 N was highly prohibited
as it would have damaged the specimen.

5. 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.

6. The test terminated itself through the fracture of the specimen,

opening the micro switch and hence stopping the motor.

7. We noted the time it took for the fracture to occur from the
computer connected with the apparatus.

8. From the time taken for fatigue failure, we calculated the number of
cycles to failure [N = RPM × time for failure (min)].

9. Then we noted the appearance of the fractured surface. Two

different colors appeared at the fractured area, one darker area and
one brighter one. The darker area for striations, slow crack growth and
brighter ones for sudden fracture.

Using results which the computer displayed along with the Force (N)-
Revolutions graph for this experiment we obtained the endurance limit.
Readings and Graphical Visualization
The image below shows the force exerted on the specimen and the
number of revolutions it took for fracture to occur. It also contains a
graph of the force acting on the specimen at a certain number of
revolutions.

Figure 7
The next two images give us a table of the force acting on the specimen
taken at various numbers of revolutions
Figure 9
At the end of the experiment, the image below shows the appearance
of the specimen.

Figure 10: Specimen after experiment

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. A Wohler machine was used to producing various
rotating bending stresses on known specimens

The results verify the theory. Fatigue strength is the highest stress that a
material can withstand for a given # of cycles without rupture. There are
two types of fatigue.

1. Normal Fatigue 2. Thermal Fatigue.

Fatigue failure is catastrophic means something happens suddenly. Endurance can be
defined as # of cycles which the specimen rotates before it fails. Endurance and # of
cycles are same. Crack Initiation is the starting of crack develops in the weaker part of
the specimen. Crack propagates linearly from the centre of initial crack and travels in
the same direction until final rupture. The factors that may effect on the fatigue life of
specimen are magnitude of stress, quality of surface, material, surface roughness,
surface treatments, imperfection in assemblies of components etc. We can upgrade
the fatigue life and surface hardness of steel alloys by heat treatment
(carburizing).Thermal fatigue is a specific type of fatigue failure mechanism that is
induced by cyclic stresses from repetitive fluctuations in the temperature of
equipment. Our experiment does not belong to thermal fatigue since mechanical
load was applied. When the specimen has good surface finish, it has higher fatigue
life.

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

https://en.wikipedia.org/wiki/Lathe

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