Rotating bending machine for high cycle fatigue testing

D. Brandolisio, J. Symynck, F. De Bal Department of Mechanical Engineering Laboratory of Material Testing KaHo Sint-Lieven University College, Gent Association KULeuven

Aim of the project

- realisation of a rotating bending (RB) machine for high cycle fatigue testing (HCF) cover most of the machines in the market - force range - rotational speed - dimensional flexibility controllable - parameters - data acquisition
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Motives of the project

1 - Additional method for fatigue testing in the laboratory alternative way of investigation - scientific publication: On the difference of fatigue strengths from rotating bending, fourpoint bending, and cantilever bending tests

on Fatimat's website: http://mechanics.kahosl.be/fatimat/ )

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2 - High cycle fatigue testing for SME (Small and Medium Enterprises) HC testing

SH (ServoHydraulic) EM (ElectroMechanical)

OK SLOW

BUT

solution:

EM + rotation

Rotating Bending Fatigue Test

Definition - application of a known constant bending stress to a round sample of the material, combined with the rotation of the sample around the bending stress axis until its failure. bending stress due to bending moment

Main formulae - bending stress

M y = y J

d y max = 2

- area moment of inertia

d4 J= 64

In the paper: comparison different methods for fatigue testing - cantilever bending (two-points)

- four-points bending

- four-points rotating bending

 weakest point (failure initiation) - RB all external section - other B tests only extreme points always may or may not

RB test

other bending tests

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- cyclical fluctuation of stress in RB

Advantages of RB test: more accuracy less scatter in results less specimens for test Disadvantages in RB test: only axialsymmetrical specimens difficulty in non-zero mean stress

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- two types of RB test 4 points bending 2 points bending

constant moment

triangular moment

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- machines in the market

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- basic scheme 4 points RB machine

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Specification of components clamping system - precise - adaptable

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 bearings displacement - axial displacement for pure bending

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Specimen for RB test - ISO 1143 - tolerances - smoothness

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- other geometries - easier (cheaper) realisation

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Loading condition - in real life:

from random to constant amplitude blocks

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- common machines: - static load variation (deadweights) - difficulty in load setting

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 importance of overload and underload conditions - scientific publication:

Effect of compressive underloads and tensile overloads on fatigue damage accumulation in SAE 1045 Steel

- overloads and underloads in cumulative damage alteration of specimen's life

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idea: - application of variable and controlled load - automatic variation - dynamic switching

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Project's choices
Zwick-Roell Z020 electromechanical actuator for loading - adjustable - controlled ( testXpert II)

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 4 points RB test - constant moment inside the specimen - easier specimen's realisation

collet clamping system - precise - resistant - adaptable - not expensive

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Spreadsheets use of main formulae for

- stress on the surface - specimen's curvature - axial displacement - optimum moment's arm - shaft's critical dimensions

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3D Models

frontal view of the machine

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load bearing detail view

section view
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support bearing detail view

support section view

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general view with Zwick/Roell Z020

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Control of the machine

- magnitude of load - rotational speed - cycle counting - moment's arm variation Zwick/Roell testXpert II controller I/O module - displacement sensor - Spider8 - Catman

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Control scheme

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Conclusions - RB valid test for fatigue behaviour - reliable - simple this project - support for SME - study and research possibility

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