Rotating bending machine for high cycle fatigue testing

D. Brandolisio*, G. Poelman, G. De Corte, J. Symynck, M. Juwet, F. De Bal

Department of mechanical engineering, KaHo Technological University Sint-Lieven Ghent,

Gebroeders Desmetstraat 1, B-9000 Gent

March 26, 2009

KaHo Sint Lieven - Departement Gent

Technologiecampus Gent
Gebroeders Desmetstraat 1,
B-9000 GENT
*Corresponding author: daniele.brandolisio@gmail.com

Abstract

The aim of the project is to develop and build an innovative rotating bending (RB) fatigue
testing machine. This new apparatus has to cover most of the commercial available machines
in testing possibilities, due to its wide range in force, rotation speed and dimensional
flexibility. Furthermore it needs to have an open and versatile acquisition for measurements,
with the synchronisation ability for a controllable bending moment.

Keywords: rotating bending fatigue, Zwick/Roell Z020, Zwick/Roell testXpert II

1 Introduction Zwick/Roell electromechanical actuator (already existing in

Material testing is fundamental for the production and
construction sector. As the well-known relation time=money
is a common rule, sometimes it's requested to speed up the
fatigue's tests. To do this, servo-hydraulic machines are the
fastest solution. Because of the extremely high price of these,
SME (Small and Medium Enterprises) are obligated to adopt
electromechanical systems, more affordable but with the
disadvantage of a slower response; often this class of
companies has to ask for external support.
The aim of this project, beside providing the laboratory with
an additional method for fatigue's testing, which gives an
alternative way of investigation of material's behaviour under
fatigue, is to satisfy the time-saving demand: the solution is
proposed in the combination of the rotational motion with the
the laboratory).
After an accurate study of the fatigue theory, the next step is
the realisation of a general setup. This concerns the study of
all the components involved, starting with the specimen's
geometry and behavior under test. In detail, the clamping
system for the specimen, how the load should be applied, the
rotation's transmission, the main frame, plus conventional
parts such as bearings and supports, need particular attention:
the study of them is fundamental to verify the final feasibility,
plus the identification and solution of weak points.
The result of the study brings to the real design: with a 3D
modeling software all the parts are drawn, taking into account
the method of their construction. The subsequent physical
realization is carried out. An additional attention is given to
the control system: with the TestXpert software, coupled to

1
the Zwick/Roell Z020 actuator, and a control device for the – the 2 points RB test, with the cantilever
motor drive, it is possible to regulate the rotation speed and configuration but static load and rotation.
the intensity of the load; the result of this controlled action is
a precise, accurate and valid test.

2 Bending fatigue's theory

2.1 Definition
The rotating bending (RB) fatigue test consists in the
application of a known constant bending stress (due to a
bending moment) to a round sample of the material, (a) (b)
combined with the rotation of the sample around the bending
stress axis until its failure.

2.2 Main formulae

The calculation of the bending stress is given by the equation:
M
  y= y
I constant moment triangular moment
where M is the bending moment, J is the surface moment of
inertia (since we're talking about round specimens, this is (c) (d)
referred to a circular area), y is the distance between the
center and a generic point. The maximum distance is situated
Figure 2.2: (a) cantilever bending, (b) 4 points bending, (c) 4
on the surface, and correspond to the dimension of the radius, points RB and (d) 2 points RB with the respective moments'
as seen in the figure 2.1. diagrams.

Since the failure of the specimen starts from the weakest

d4
I=
64
Figure 2.1: I formula and cross-section.
2.3 Validation of this method
Different methods concerning fatigue's bending testing are
compared1 (see figure 2.2):
– the cantilever bending test, which consist in the
application of a variable load on an extreme
edge of the specimen, while the other edge is
embedded;
– the 4 points bending test, where the specimen is
bended by two fluctuating loads of the same
magnitude applied at the same distance from the
two supports;
– the 4 points RB test which has the same
configuration of the 4 points bending, but the
load applied is static and at the same time the
specimen is in rotation;
1
On the difference of fatigue strengths from rotating bending, four-point
bending, and cantilever bending tests – T. Hassa, Z. Liu
point, situated in proximity of the surface, we obtain:
– in the RB, because of the rotation, under
bending all the portion of material close to the
surface of the specimen is tested under the
maximum stress;
– in the other tests, only the top and the bottom
points of the surface are stressed during the
alternate bending.
The conclusion is that in RB test the weakest point is always
individuated, while in the other tests it may or may not be
contained in the portion of material involved (figure 2.3).
As a result, we can underline several advantages in RB:
– more accuracy in the results: the weakest point
is always determinate, so more fidelity in
investigating the material's behaviour
– less scattering in the results, derived from a
coherent examination (weak point on surface)
– less number of specimens for the test to reach
reliable results
– in particular, in the 4 points RB the bending
moment is constant inside all the length of the
specimen; hence a less complex shape of it to
assure an homogeneous investigation.

2

Figure 2.3: RB and other bending tests weakest point zone.
3 Design of the RB machine
3.1 Four points RB machine's concept
Figure 2.4 shows the basic scheme of a four points RB
machine. The main elements are:
– motor drive, which gives the rotation;
– two main bearings, which create the two
supports;
– two load bearings, where the load is applied.
Figure 2.4: RB machine main scheme.
3.2 Main components
Particular attention is spent for several elements' choice.
Clamping system
It permits the installation of the specimen in the machine. It
must be precise (because of the rotation) and adaptable to
different dimensions of the specimen, both in the diameter
and in the length. As a result, the choice is for collets in
figure 3.1. These are used in the milling machines for the
tool's clamping. A high precision and resistance are
guaranteed, plus they can adapt different diameters. In the
end, they're also not expensive therefore replaceable after
each test for a better precision and stability.
3
Figure 3.1: collet clamping system.
Application of the load
In the reality, an element that works under fatigue's
conditions is subjected to an alternate and non-constant load.
For laboratory testing, we need to transform this random
condition in a more readable and repeatable situation.
The idea is the application of a variable and controlled load,
this to obtain an automatic variation of the load amplitude
between the blocks of cycles, and to give the ability to
generate overload and underload's conditions.
The choice is the use of the Zwick/Roell Z020
electromechanical actuator (figure 3.2). This is able to
guarantee a load which is dynamically adjustable and
controlled (by the testXpert software).
Figure 3.2: Zwick/Roell Z020.
3.3 Spreadsheets and calculations
It is fundamental to solve several basic equations for
determining the right dimensions of the different elements
that characterize the entire apparatus. With the use of
spreadsheets it is possible to manipulate the main fomulae of
the bending moment and stress, giving in input the
dimensions of the specimen (cross-section and length). Thus
to find its theoretical curvature under bending, the axial
displacement (figure 3.3) and, more important, the definition
of the optimum moment's arm (figure 3.4). Since the goal is
to test different materials (with dissimilar mechanical
properties), it has been necessary to define an optimum range
 of lengths for the arm to satify all the cases. To obtain this,
the starting point was the data of the load cell installed in the
actuator, which is the responsible of the setting and control of
the amount of load. In particular this load cell can reach 20
kN, and its accuracy is guaranteed from 0.2% of the
maximum load, at 40 N. Beside this wide variation, the
choice of three different positions for the load's application,
which define the arms of the moment, allows to cover a large
range of bending moments (and subsequently bending
stresses) required for testing different classes of materials.

4 points rotating bending fatigue machine

specimen data
material name C40 Ti
E-modulus 210000 120000 [MPa]
parallel length 200 100 [mm]
diameter 20 10 [mm]
surface moment of inertia 7853,98 490,87 [mm^4]

Figure 3.5: shafts' critical cross-sections.

test environment
Original moment's arm 105 35 [mm]
bending force 4000 3300 [N]
height load-support 40 40 [mm]
3.4 3D project's drawings
constant moment on specimen 210000 57750 [Nmm]
sigma_max on specimen surface 267 588 [MPa] With the 3D modelling software SolidWorks it is possible to
curvature of specimen 0,000127324 0,000980394 [1/mm]
realise the model of the RB machine, from every single
curvature of specimen (radius) 7853,98 1020,00 [mm] component until the final assembly. Here are shown examples
bending angle (Thèta) 0,012732739 0,049039376 [] of views of the designed machine.
bending angle (Thèta) 0,729532234 2,809749251 [°]
specimen arc length 200,005404191 100,040092254 [mm]
axial displacement 0,005404191 0,040092254 [mm]

distance load-support 112,361025271 53,150729064 [mm]

Final moment's arm 105,500784494 36,918712276 [mm]
Variation moment's arm 0,500784494 1,918712276 [mm]

Variation of moment 1001,57 3165,88 [Nmm]

Final sigma on surface 268,66 620,48 [MPa]

Figure 3.3: curvature and displacement's calculations.

Definition of the optimum moment's arm

load cell grade 1 (= reliability from 0.2% of capacity)

Fmax 20000 [N] clamp section max 26 [mm]

Fmin (0.2%) 40 [N] clamp section min 4 [mm]
diameter_specimen 20 [mm]

@ Fmax, sigma_max, section_max

M_max 1725519,76 [Nmm] arm_min 172,55 [mm]
arm_min_adj 105 [mm]

@ Fmax, arm_min_adj, section_max

sigma_max_obt 608,51 [MPa]

@ Fmin, arm_min_adj, diameter_specimen

M_min 2100 [Nmm] sigma_min_obt 2,67 [MPa] lower stress

@ sigma_min, Fmin, arm_min_adj

diameter_specimen obt 7,53 [mm]

@ Fmax, arm_min_adj, diameter_specimen

sigma_obt 1336,9 [MPa] upper stress

Figure 3.4: optimum moment's arm.

The dimensions of the critical cross-sections of the main

shafts under load are also found applying the fatigue's theory
(figure 3.5). Figure 3.6: frontal view setup with Zwick/Roell actuator.

4
 Figure 3.9: section view of a part of machine.

Figure 3.7: general view setup with Zwick/Roell actuator.

Figure 3.10: clamping system and bearing detail view.

Figure 3.8: frontal section view of the machine.

5
Load bearings
If we bend a beam, we obtain an axial displacement along the
bending axis. If the beam is embedded at the extreme edges,
the result is an axial stress. Since we want to test only in pure
bending condition, we need to avoid this axial stress. Thus,
the axial displacement is guaranteed by the shifting of the
bearings inside the housing. To assure a perfect alignment of
the shafts with the specimen, spherical bearings are used.
Figure 3.11: load bearing detail section view.
Support bearings
When applying the load, the specimen is subjected (even if
small) of a curvature. To allow this, ball bearings are used as
support points. The double row type guarantees the
appropriate static load strength.
Figure 3.12: support bearing detail section view.
6
Figure 3.12: support bearing detail section view.
4 Control of the machine
As mentioned before, the magnitude of the load is given by
the electromechanical actuator. This one is controlled by the
Zwick/Roell TestXpert II software: since the moment's arm is
known, it is easy to control the wanted applied load, and then
find the moment for the test.
Also the electrical motor must be controlled, thus to set the
rotational speed, which is important for the definition of the
“speed” of the test: taking into account different factors and
considerations, rising the rotation, it is possible to accelerate
the experiment, reaching for instance the rupture of the
specimen in less time.
The revolution counting can be achieved with precision by
setting the rotational speed and knowing the time, this to
obtain the exact number of cycles at which the specimen
reaches the rupture (in other words, to detect the specimen's
life).
As shown in the 3D sketches, in unload conditions the length
of the moment's arm is exactly defined. When the load is
applied, due to the turning of the two housings around the
support points, the arm is subjected to a small variation,
which induces an error in the calculation of the bending
moment. This is compensated thanks to the capability to
adjust the load at this variation. The bending moment is then
constant and well defined. The sketch below shows the entire
control system of the apparatus.
 5 Conclusions
The RB test is reliable for determining the fatigue's behaviour
of the materials. In particular this project, with the use of the
electromechanical actuator, is able to give high precision (due
to the controlled loading), time-saving tests for the
companies' requests and possibilities to carry out studies and
researches between the interaction of different factors.
The prospect of development in RB fatigue testing machines
is open thanks to the recent technologies.

Figure 4.1: control scheme of the system.

4.1 Investigations
This apparatus enables the determination of the Wohler's
diagram, which describes the fatigue's behaviour of the tested
material plotting the applied stress versus the number of
cycles. Since the goal is to spot the failure of the specimen,
and thus observing the amount of cycles reached to trace the
diagram, a particular method must be realised.
Several different investigations and studies can be also
attained with this machine.

One of these could be the study of the crack growth 2 and

propagation using the setup shown in figure 4.1 which
involves other particular devices such a camera, a shaft
encoder and a PC.

Figure 4.2: hypothetical experimental setup.

2
A comparison of two experimental methods for assessing the influence of initial defects
on fatigue life - H.-P. Gänser, I. Gódor, W. Eichlseder, R. Pippan, R. Ofner, R. Vollgger