FATIGUE TEST

OBJECT

To test mild steel specimen in fatigue, plot S-N curve and obtain the
endurance limit.

INTRODUCTION AND THEORY

All engineering components are subjected to loads during service. These loads
need not necessarily be steady. In a majority of cases their magnitudes vary. The
material fails once these fluctuating stresses reach sufficiently high value. The value
of this stress may not be anywhere near the static strength of the material.

In a stressed material certain crystals are strained more than others in the
neighborhood on account of their unfavorable orientations. When the material is
subjected to cyclic loads these overstressed crystals give way starting the minute
crack. This develops the stress concentration which results in propagation of cracks
and ultimate failure. This progressive fracture by the action of repeated load is known
as fatigue of metal.

Depending upon the magnitude of alternating stress, the number of cycles for
failure may vary from a few thousands to a few millions and that maximum stress
which repeated for indefinite number of cycles, the material does not fail is known as
“endurance limit”. At this stage the S-N curve becomes horizontal to X-axis. Some
metals like duralumin do not appear to have a well defined endurance limit, though it
may exist for indefinite cycles of stress.

The endurance limit is usually expressed in relation to the ultimate tensile

strength of metals. Unless otherwise mentioned the fatigue strength of steels can be
taken to be half the tensile strength.

Though fatigue tests are done with cyclic loading in tension, compression,
flexure and shear most common of them is one in flexure with completely reversal of
stress. A rotating beam either a cantilever with end load or a simply supported beam
with constant moment is used for the test. For the machine in the laboratory the
following loading is done.
P/2 P/2

a a
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M = P/2 x a

Knowing M, the stress can be calculated from

𝑀𝑦
𝜎=
𝐼

Where  = Maximum stress

M = Maximum bending moment
I = Moment of inertia
y = d/2, d = diameter of specimen

The factors which affect the fatigue test results are composition, crystal
structure, heat treatment and mechanical workings. Various alloying elements, heat
treatment and cold working processes increase both the fatigue strength and static
strength in general. The surface finish of specimens has a definite effect on the fatigue
strength. The rougher finished specimens have lower endurance limits than polished
or well machined ones. The frequency of alternating stresses within the range of 2000
to 15000 cycles/min does not have appreciable effect on the fatigue strength.

Fatigue test results obtained from the laboratory testing of polished small
fatigue specimens cannot be taken as the sole basis for engineering design. It is opined
that the fatigue test should be made on sample parts preferably than on standard
specimens. Further it is suggested that the testing be performed, if possible, under
the stress cycles similar to those the parts are expected to experience during their life.
The number of stress cycles the part is tested for is arrived at by a prior estimate of
the service life of the engineering components.

The test results should be considered only as a basis for design and not as
statement of precision. Over and above the test data, comes the factor of safety. The
factor of safety is fixed to take over the uncertainties like the corrosive media and the
stresses the engineering members are likely to withstand during their life.

In laboratory tests on actual, structural and machine parts, loads of various

magnitudes can be employed so that the range of stress during a stress cycle will
approximate the stresses experienced by the parts in actual usage. Thus, different
special purpose fatigue testing machines are designed, differing in designs and
capacities depending upon the purpose.

EXPERIMENTAL SET-UP

Use Fatigue testing Machine MYV-6000 and Mild Steel specimen.

The machine tests cylindrical or tapered specimens subjected to complete

reversal of flexural stress. The test-piece is gripped by two spindle heads which are
supported by roller bearings. Through a system of links the spindle heads with the
specimen are pulled, thereby inducing constant bending moment to the specimen as

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shown. The pull is effected by turning a hand wheel, worm geared to the spindle which
in turn disturbs the lever. The lever carries two bearings through which a screw is
rotated by hand wheel and the position of the active lever weight is adjusted. When
the complete balance of the lever is achieved, the pointer fitted on the sleeve of the
screw coincides with the mark on the body of the machine. The end of the lever carries
a piston to work in a dash pot pull upto 20 Kg can be applied.

PROCEDURE

1) Draw a neat sketch of the apparatus and the specimen.

2) Prepare a number of specimens with same dimensions from the material to be

tested for fatigue.

3) Grip the specimen by the spindle heads of the machine which are supported
by roller bearings.

4) Apply a constant load, thereby inducing a constant bending moment to the

specimen.

5) To subject the specimen to alternating stresses, rotate the specimen by

switching on the motor.

6) Note the no. of revolution when the specimen breaks.

7) Repeat the same procedure for other specimens.

(IS-5619 Recommendations for fatigue testing of metals)

OBSERVATION AND COMPUTATION TABLE

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Diameter of the specimen = 0.932 cms.

Distance of loading point from the support = 10 cms.

No. of obs. Load P N  = My/I No. of revolutions X 106

N/mm2
1 340 0.1222
2 330 0.1439
3 320 0.1472
4 310 0.1583
5 300 0.1609
6 290 0.1706
7 280 0.1805
8 270 0.2400
9 260 0.4057
10 250 0.6253
11 240 0.8607
12 230 1.2200

SAMPLE CALCULATIONS

GRAPH

To plot a graph between (s) and No. of Revolutions (N). Find the endurance
limit from the graph.

QUESTIONNAIRE

1) Why are several readings required to know the fatigue strength of a metal?
2) What would be the approximate ratio of the fatigue strength of steel to its
ultimate tensile strength (static)?
3) Why fatigue failure is more hazardous compared to structural failure under static
loading?