Mechanics of Materials Lab

Introduction:
Fatigue is a progressive and localized structural damage that occurs when a material is subjected to
cyclic loading. The maximum stress values are less than the ultimate tensile stress limit and may be
below the yield stress limit of the material.

Fatigue occurs when a material is subject to alternating stresses, over a long period of time. In this
fatigue testing experiment, the objective is to be able to draw a simplified Wohler diagram (S – N
curve) based on test data.

Fatigue tests are made with the object of determining the relationship between the stress range and
the number of times it can be applied before causing failure. Testing machines are used for applying
cyclically varying stresses and cover tension, compression, torsion and bending or a combination of
these stresses.

The fatigue process consists of three stages, which are:

 Initial crack propagation

 Progressive crack growth across the part
 Final sudden fracture of the remaining cross section.

The specimen was subjected to cyclic loads and the number of cycles it took till failure were noted.
APPARATUS:

 Fatigue Testing Machine (TERCO MT 3012-E)

 Desktop Computer
 Mild Steel Specimen

Figure 1: Fatigue Testing Machine

The fatigue testing machine is equipped with a PC interface and software which serves as a
beneficial tool in understanding and determining the limit at which fracture occur under cyclic
stresses. The primary parts of the machine are the motor, which is operating at a speed of
approximately 3000 rpm, the loading cell and the system.

The specimen is placed in the machine by inserting the conical end of the specimen into the spindle
then adjusting the loading cell so as to align the specimen with the machine and then tightening it.
The machine allows application of 3 loads on specimen simultaneously: Rotary load (from motor),
Tensile load (upwards, from loading cell) and bending. Moreover, the maximum force capacity of the
machine is 255N and by rotating the spindle on top of the loading cell we can set the applied actual
force to any value below 255N. There is also an LCD on the machine that displays the number of load
changes. In addition to the above, there is also a safety lock for the apparatus which is essential for a
safe working environment.

On the system display, the first counter shows the number of

revolutions, the second shows the actual force (which will
keep changing), the third shows the original force(which will
remain constant) and the last counter shows the limiting force
which is the value of force at which the motor will stop
running. The maximum value of the limiting force is 90N and
the value of the actual force can be restored to updated value
using the reset button. Furthermore, the graph displayed has
the actual force on the y axis and no of cycles on the x axis.
Figure 2: System

THEORY
Fatigue is the condition whereby a material cracks or fails as a result of repeated (cyclic) stresses
applied below the ultimate strength of the material.

Fatigue failures generally involve three stages:

I. Crack Initiation,
II. Crack Propagation, and
III. Fast Fracture
Fatigue failures often occur quite suddenly with catastrophic (disastrous) results and although most
insidious for metals, polymers and ceramics (except for glasses) are also susceptible to sudden
fatigue failures.
Fatigue causes brittle like failures even in normally ductile materials with little gross plastic
deformation
Occurring prior to fracture. The process occurs by the initiation and propagation of cracks and,
ordinarily, the fracture surface is close to perpendicular to the direction of maximum tensile stress.

Applied stresses may be axial (tension-compression), flexural (bending) or torsional (twisting) in

nature. In general there are three possible fluctuating stress-time modes possible. The simplest is
completely reversed constant amplitude where the alternating stress varies from a maximum tensile
stress to a minimum compressive stress of equal magnitude. The second type, termed repeated
constant amplitude, occurs when the maxima and minima are asymmetrical relative to the zero
stress level. Lastly, the stress level may vary randomly in amplitude and frequency which is merely
termed random cycling.

The following parameters are utilized to identify fluctuating stress cycles:

tensile stresses are normally considered positive and compressive stresses are considered negative.

The Fatigue Life (Nf) of a component is defined by the total number of stress cycles required to
cause
failure. Fatigue Life can be separated into three stages where

1.) Crack Initiation (Ni) - Cycles required to initiate a crack. Generally results from dislocation pile-
ups
And/or imperfections such as surface scratches, voids, etc.

2.) Crack Growth (Np) - Cycles required to grow the crack in a stable manner to a critical size.
Generally controlled by stress level. Since most common materials contain flaws, the prediction of
crack growth is the most studied aspect of fatigue.
3.) Rapid Fracture - Very rapid critical crack growth occurs when the crack length reaches a critical
value, ac.Since Rapid Fracture occurs quickly, there is no Rapid Fracture term in the Fatigue Life
expression.
A prediction of failure for various stress levels can be made by studying a material’s S-N
F 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 (~10^8) of stress cycles without fracture.

Procedure:
1. Clean the Twist and Bend Machine MT210 before use.
2. Open the beam supports using Allen key.
3. Take one of the three rods and fix it in the beam supports on both sides such that the Length
of the specimen is 600mm.
4. Tighten the screws by setting the weight hanging shaft in such a way that it touches the
upper bar, this may give it a space for lowering when the specimen experiences twist and
the shaft turns at an angle.
5. Set the dial on the shaft at the place where it is carved horizontally.
6. Remove any zero error on the dail before start of experiment by just turning the outer part
of the dial
7. Start by placing an initial weight of 2.5 Newtons on the shaft in the hanger and measure the
deflection produced in the shaft due to it, from the dial.
8. Add more weight of 5 Newtons so a total of 7.5 Newtons is hanging and measure the
deflection.
9. Similarly take the deflection reading for 12.5 Newtons force.

Procedure 2.
1. Clean the Twist and Bend Machine MT210 before use.
2. Open the beam supports using Allen key.
3. Take one of the three rods and fix it in the beam supports on both sides such that the Length
of the specimen is 600mm.
 4. Tighten the screws by setting the weight hanging shaft in such a way that it touches the
upper bar, this may give it a space for lowering when the specimen experiences twist and
the shaft turns at an angle.
5. Set the dial on the shaft at the place where it is carved horizontally.
6. Remove any zero error on the dail before start of experiment by just turning the outer part
of the dial
7. Start by placing a weight of 12.5 Newtons on the shaft in the hanger and measure the
deflection produced in the shaft due to it, from the dial.
8. Change the clamped length of the specimen by using Allen key to 500 mm.
9. Take reading for deflection for same weight in this condition.
10. Similarly take deflection reading for 400mm and 300 mm clamped length.

Pictures of Specimen:

Figure 3.1 Material before subjected to load

 Figure 3.2 Material after subjected to load

Figure 3.3 Material after load subjection

Figure 3.3 Material after subjected to load

Observations:
The outer smooth cut is because of the torsional force acting on the specimen and the rough cut in
the center is due to the shear force acting as shown in fig. 3.3
Graphs:

Figure 4.1

Figure 4.2
Figure 4.3 Load vs Revolutions

Figure 4.4 Load vs Revolutions

 Figure 4.5

Discussion:
In this experiment fatigue limit or endurance limit of Mild Steel specimen which is subjected to
bending with specific load is determined by measuring the number of cycles for that load at which
the specimen breaks. The factors that affect fatigue life is mean stress σm reduction in mean stress
will increased the fatigue life. Similarly, corrosion , quality of the surface of material, loading
frequency, temperature also determines fatigue life. The specimen used in this experiment is of
Mild steel that contains approximately 0.05–0.25% carbon making it malleable and ductile. The
ductile material will have high fatigue limit compared to brittle material .This is because ductile
material will elongated first before it breaks and it will increase the fatigue limit. However, fatigue
failure is brittle like even in normal ductile materials .Characteristic pattern of concentric rings over
smooth region of fracture surface known as beachmark or striations forms because of crack growth
or can also be exhibited by oxidation of free surface by exposure to atmosphere. For carbon and
low-alloy steels,(Mild steel), the magnitude of the environmental effects on fatigue life increases .

Results:
The fatigue testing is one of fracture analysis technique that is manipulated to know the cause of
failure and fatigue limit of material. So this proves helpful in selection of material and safe design of
product.
Conclusion:
Within the limits, certain material can withstand the load applied to it. Though the load varies but
effectively, it remains near 235N and when the torsional load increases with time, it ultimate breaks.

References:
[1] R. Hibbeler, "Mechanics of Materials," New Jersey, Pearson Education, 2004, p. 32.

[2] https://www.element.com/materials-testing-services/fatigue-testing

[3] J. M. Hodgkinson, in Mechanical Testing of Advanced Fibre Composites, Cambridge:

Woodhead publishing, 2000, pp. 132-133.

[4] A. Boresi, Adnvanced Mechanics of Materials, New York: John Wiley and Sons, 1993.