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● For example, Aluminum has less fatigue resistance than a material such as steel.
● Fatigue must be considered in machine components subjected to continuously cyclic loading such
as motor shafts, bolts, springs, gear teeth, valves, turbine blades, airplanes, automobile and gas-
engine parts, suspension bridges, wire ropes and many others.
● Therefore the study of fatigue failure is very important, because 80 to 90% of the total failures of
high-speed machine parts is due to fatigue.
The high temperature increases the mobility of atoms,facilitating slip and hence
the fatigue fracture.
● The final failure event (i.e. catastrophic fracture) can be ductile or brittle,
depending on the material, thickness, temperature and the applied stress.
Fatigue failures typically occur suddenly. The fatigue-induced fracture surfaces of
a broken component are typically smooth and show no evidence of plastic
deformation.
S-N Diagram
S-N diagram can be obtained by plotting the number of cycles of stress
reversals (N) required to cause fracture against the applied stress level (S).
● Fatigue strength and fatigue life are two parameters used to describe fatigue
behavior.
● Tests that show the relationship between stress (S) and number of cycles to
failure (N) can be performed on a component. The data is represented on
what is known as the S-N curve.
● Fatigue limit (or endurance limit) : It is defined as the value of stress below which the material will
not fail even when it is loaded for infinite number of cycles.
● Fatigue life: It is the total number of cycles required to bring about final fracture under a given
condition of use.
4. The material should have fine grain structure and also it should
be free from residual stresses and dislocations.
Creep Fracture
● Creep is defined as time dependent deformation when material is under
constant loading genarally it occur due to variation in grain structure of the
material.
● The creep is defined as the permanent deformation of a material under a
steady load as a function of time, usually at higher temperatures.
● Some materials(soft metals) such as zinc, lead and tin creep, more at room
temperature.
Ex:lead coverings on telephone cables and white metal bearings.
● Some other materials such as iron, nickel, and copper creep more at
elevated temperatures only.
● Ex: furnace parts,turbine blades, pressure vessel parts, rocket and
missiles,supersonic jets, etc.
Creep Curve & it's stages
Three stages:
1) Primary creep, or Stage I
● Creep occurs due to dislocation movement.
● Creep rate decreases with time logarithmically.
● Creep is mostly transiently, not at a steady rate.
● During this stage, the recovery effect is less than
the work-hardening effect.
3. The material should be free from any residual stresses and dislocations.
https://youtu.be/nmZBCOzjT-I
Torsion Test
Torsion is a variation of pure shear, Procedure of test:
wherein a structural a member is twisted 1.Note the dimensions and draw the shape of the specimen.
in the manner. (Note effective length, total length, dia meter etc)
Torsional forces produce a rotational motion 2.Fix specimen into 10 Ton Buckton UTM.
about the longitudinal axis of one end of the 3.Use twist control method (other one is torsional strain control
member relative to the other end. method)
To determine the shear strength,the following 4.To apply the twist to the sample, rotate the handle counter
general torsion equation can be applied clock wise for required degree of twist. Machine’s one
within the elastic range: complete cycle will give 4° of twist.
5.Balance arm of the machine will get disturbed again. Try to
balance it with the help of concerned handle and note down
the value of balancing load.
t, Shearing stress in MPa 6.Repeat the same procedure with increasing value of twist
r, Radius of the shaft in mm. until the member fails.
T, Twisting moment ; θ, Angle of twist. Lever arm = 50.8mm;Torque = lever arm x load 16T
J, Polar moment of inertia.
G, Modulus of rigidity. 7.Examine the failure pattern of the specimen and draw sketch
L, Length of the specimen / Shaft after failure.(same for cast iron )
Torsion Testing Machine
Digital Torsion Testing Machine Vertical Universal Torsion Machine Torsion Test Machine
Hardness Test
Hardness test is performed on a material to Selected hardness Indenter Applied load
know its resistance against indentation and scales
abrasion. i) Rockwell – B scale 1/16” diameter ball 100kg
The main hardness tests and their most ii) Rockwell – C scale 120° diamond cone with
common applications include: 0.2mm radius spherical tip 150kg
1. Mohs, for minerals iii) Rockwell – 15T scale 1/16” diameter ball 15kg
2. The pendulum hammer is raised to known difference in two heights of pendulum on either
3. When the pendulum is released, its potential strength, in foot-pounds or metre-kg, is measured
energy is converted into kinetic energy just from the scale of the impact testing machine.
Initial energy = W· h2
= Potential energy
= Kinetic energy of striking specimen
π
∆
Remaining energy after K. E of the carrying
striking specimen = pendulum to lowest position
= W. h2
Energy delivered Impact value of energy in
to the specimen = fracturing specimen
= Wh1 - Wh2 = W(h1 - h2)
The creep tests are simply tension tests run at (c) There should be means for the accurate
constant load and constant temperature. Then measurement of test-piece extension.
the value of strain of the test piece is noted as a
function of time.
Specimens for creep testing are usually the same
Creep Test
CreepTesting Arrangement Test Procedure:
(i) The specimen to be tested is placed in an electric
furnace. At the electric furnace, the specimen is heated
to the given temperature under the constant load.
(iv) Now the creep curve i.e., the elongation versus time
curves are plotted for each specimen, as shown in
Figure
Creep curve