STUDY OF FATIGUE TEST

AIM: To Perform fatigue test for plotting S-N curve of mild steel.
APPARATUS: Fatigue testing machine, Standard specimen of mild steel, Vernier calliper,
Dead weight as load, Wrench for tightening the bolt of specimen holder.
THEORY:
Important Parameters and Equations
A fluctuating stress cycle can be considered to be made up of two components, a mean or
steady stress σm, and an alternating or variable stress σa. Consider the range of stress σr, as
can be seen from Figure 1 (a) & (b), the range of stress is the algebraic difference between
the maximum and minimum stress in a cycle.
Thus, the alternating stress is one half of the range of stress. The mean stress is the
algebraic mean of the maximum and minimum stress in the cycle.
Two other parameters are also used for representing fatigue data:
For a fully reversed stress cycle, as shown in Figure 1 (a), the Stress Ratio, R is -1 and if the
stresses are partially reversed, R becomes a negative number less than 1. If the stress is
cycled between a maximum stress and no load, the stress ratio becomes zero. If the stress is
cycled between two tensile stresses, the stress ratio becomes a positive number less than 1.
The results of fatigue crack initiation tests are usually plotted as maximum stress, minimum
stress or the stress amplitude on (y-axis) against the number of cycles to failure, N (on the x-
axis). The number of cycles to failure is generally plotted on the logarithmic scale, while
stress is plotted either on the linear or logarithmic scale.
The regime in which the peak load is above the yield strength of the material is referred to
as the low cycle fatigue. Components usually endure < 104 cycles during low cycle fatigue.
In contrast, when the peak cyclic stress is below the yield strength of the material, the
component undergoes more than 104 cyclic reversals and the regime is referred to as the
high cycle fatigue.
The peak stress in case of cantilever bar testing is obtained by the following formula. For the
four-point cantilever bending the peak stress, σa is given by
Where, Mb =bending moment =PL/2
d =diameter of the sample
P = applied load
L = Length of the sample
FATIGUE TESTING MACHINE:
A fatigue testing machine is a device to assess the fatigue life of materials. It produces cyclic
loads that simulate the conditions of service and measures their effect on a specimen.
APPLICATIONS:
Fatigue tests are critical in manufacturing because they determine a material’s lifespan. One
can conduct fatigue tests in a laboratory setting. Using a machine interface and software,
one can load a known amount of weight down onto the samples to see how much stress
can be placed on them before they break.
ADVANTAGES:
1) Reliability: Fatigue testing machines provide reliable results by simulating real-life
scenarios, allowing manufacturers to test the durability and endurance of their products
under different conditions.
2) Customizable: Fatigue testing machines can be customized to simulate a wide range of
loading conditions and cycles, making it possible to test materials and components under
specific scenarios.
3) Accuracy: Modern fatigue testing machines are highly accurate, with advanced sensors
and measurement tools that can detect even the slightest changes in the material or
component being tested.
4) Safety: Fatigue testing machines are designed to operate safely, with built-in safety
features that prevent accidents and injuries.
5) Faster testing: Fatigue testing machines can test materials and components faster than
traditional testing methods, allowing manufacturers to quickly identify design weaknesses
and improve their products.
PROCEDURE:
1. Polish the sample surface as smooth as possible and observe for any surface defects and
deep scratch/machining marks.
2. Measure dimensions of the given specimen of mild steel.
3. Fit the specimen is in the sample holder such that it passes through the opening provided
in machine.
4. After fitting the sample, keep the desired load on the seat provided for the loads.
5. Switch ON the machine to conduct the fatigue test and record the number of cycles (N)
for the failure, when it occurs.
6. Note the appearance of the fractured surface.
7. Calculate the peak stress (σa) from the formula mentioned above.
8. Report the value of σa and N.
9. Make S-N plots using results of all the batches and obtain the endurance limit.
PRECAUTIONS:
1. The specimen should be prepared in proper dimensions.
2. Tighten the specimen at proper position before starting machine.
RESULT:
The number of cycles (N) for failure of MS specimen =………………………………
Endurance Limit for MS =………………………………………………….
CONCLUSION: