SDM COLLEGE OF ENGG AND TECH

PRACTICAL METHOD FOR FATIGUE CRACK INITIATI

ON DETECTION USING AN
ION-SPUTTERED FILM
 
 

UNDER GUIDE
Prof. A.V.Kulkarni

Presented By
Srinivas Shiggavi
1
 SDM COLLEGE OF ENGG AND TECH

• The fatigue life is considered to consist of the fatigue

crack initiation life and the fatigue crack growth
life.
• The fatigue growth life can now be predicted after a
fatigue crack has been detected or after a crack becomes
larger than a micro crack.

•Surface condition has strong effects on the fatigue

strength of machine elements
• The fatigue crack initiation life remains
very difficult to estimate

2
 SDM COLLEGE OF ENGG AND TECH

• The estimation of fatigue crack initiation life is

very important in fatigue strength design

• Makabe et al. used a strain waveform for

the detection of fatigue crack of 0.5 — 1 mm on a
round test piece with a small hemispherical pit.

• Katayama et al and Lee and Sakane detected

crack initiation using an AC potential method
on a sharply notched test piece
3
 SDM COLLEGE OF ENGG AND TECH

• practical method is presented for detecting

fatigue crack initiation during fatigue
tests using an ion-sputtered film.

• Ion-sputtered films were formed on acrylic and

Steel test pieces having especially designed
round notch

• ion-sputtered film method consists of DC power source,

electric resister, Digital recorder

4
 SDM COLLEGE OF ENGG AND TECH

Electric Resistance Measurement of the Ion-Sputtered Film.

5
 SDM COLLEGE OF ENGG AND TECH

• Piece and Test Method

Three-Point Bending Test Piece.

Electric Resistance Measurement of the

Ion-Sputtered Film.

Fatigue Test Rig and Test Method.

Durability of the Ion-Sputtered Film.

6
 SDM COLLEGE OF ENGG AND TECH

• Fatigue Crack Initiation Detection Method

Principle Of The Method

7
 SDM COLLEGE OF ENGG AND TECH

Three-Point Bending Test Piece.

8
 SDM COLLEGE OF ENGG AND TECH

View of a test piece with an ion –sputtered film on the test

 

9
 SDM COLLEGE OF ENGG AND TECH

• Durability of the Ion-Sputtered Film

Ion-sputtered film is formed by the adhesion of ions

Electric resistance of an ion-sputtered film during the test

10
without
 SDM COLLEGE OF ENGG AND TECH

• Crack Initiation Detection for Acrylic Test

Pieces
Changes in the Electric Resistance Due to Crack Initiation

Change in the electric resistance of the ion-sputtered

11
film during fatigue crack initiation
 SDM COLLEGE OF ENGG AND TECH

A view of the micro crack initiated on the notch surface

 
12
 SDM COLLEGE OF ENGG AND TECH

• Effect of Ion-Sputtered Film Shape on the Response to

Crack Initiation.

variation in the electric resistance of the ion-sputtered

film is very small at the beginning of crack initiation

13
Electric resistance increase rate for different shapes of films
 SDM COLLEGE OF ENGG AND TECH

• Crack Initiation Detection for Steel Test Pieces

A very thin insulating film is necessary between the ion-sputtered
film and the steel surface to obtain a good response to
crack initiation.

Section view of the crack initiation detection

14
spot of a steel test piece
 SDM COLLEGE OF ENGG AND TECH

• Crack Initiation Detection for Steel Test Pieces .

Fatigue crack initiation detection tests were performed for
the test pieces made of carbon steel

The maximum load was 8500 N

The loading frequency was 30 Hz
The film thickness was about 50 nm
The electric resistance of the ion-sputtered film decreased
gradually after the beginning of the test

15
SDM COLLEGE OF ENGG AND TECH

16
 SDM COLLEGE OF ENGG AND TECH

Change in the electric resistance of the ion-sputtered film

during crack initiation on a steel test piece
  17
 SDM COLLEGE OF ENGG AND TECH

Conclusions

• Method for detecting fatigue crack initiation is proposed

using an ion-sputtered film and is based on the change in the
film’s electric resistance, due to crack initiation and crack
growth.

18
 SDM COLLEGE OF ENGG AND TECH

References
[1] Kato, M., Deng, G., Inoue, K., and Takatsu, N., 1993,
“Evaluation of the Strength of Carburized Spur Gear Teeth Based on
Fracture Mechanics,” JSME Int. J., Ser. C, 36(2), pp. 233—240.

[2] Inoue, K., Sonoda, H., Deng, G., Yamanaka, M., and Kato, M., 1998,
“Effect of CBN Grinding on the Bending Strength of Carburized Gears,”
ASME J. Mech. Des., 120(4), pp. 606—611.

[3] Damir, T. J., Srecko, G., and Srdian, P., 2003,

“Numerical Modeling of the Crack Propagation Path at Gear Tooth,” Proceedings
of the Ninth International Power Transmission and Gearing Conference.

[4] ASME Journals on materials structure.

19