Design and development of test rig of axle and suspension for fatigue test.
Product definition : <ul><li>Test rig to test fatigue strength of front axle and suspension system. This test gives effect of given types of fatigue stresses : </li></ul><ul><li>Completely reversed stresses. </li></ul><ul><li>Alternating stresses </li></ul><ul><li>Fluctuating reversed stresses </li></ul><ul><li>Repeated reversed stresses. </li></ul>
Clarification and elaboration : <ul><li>Test rig: </li></ul>Test rig assembly consist of mechanical type fatigue test fixture having bell crank mechanism which is attached to flywheel driven by an electric motor through a suitable that provides the desired oscillating or cycle speed.
Clarification and elaboration : (approximate estimates) Max length 1500. Max Diameter 250. Dimension of axle: (mm) 3 to 5. Test rig weight : (metric tones) 3000Wx2000Dx1000H Space availability: (mm)
List of components: <ul><li>Mechanical test rig fixture. </li></ul><ul><li>Electric motor </li></ul><ul><li>Flywheel </li></ul><ul><li>Strain gages </li></ul><ul><li>Amplifier </li></ul><ul><li>Gear reduction drive </li></ul>
Schedule: Jan Feb March April Phase 0 Phase 1and 2 Phase 3
PHASE 0: <ul><li>(1) Overall function of project </li></ul><ul><li>(2)Clarification and elaboration. </li></ul><ul><li>(3)Product research. </li></ul><ul><li>(4)Presentation . </li></ul>phase0 Overall function Clarification and elaboration Product research requirements schedule
Bell cranck mechanism attached to a flywheel driven by an electric motor . Energy requirement: Mechanical energy and electrical energy. Test rig should apply loads by combination of two or three basic means of energy available, (flexibility of energy resource). Wish: Loading frequency depends on type of fatigue load on axle to be applied during test. It also depends on design characteristics of axle. Technical requirement: fatigue test should be conducted in a reasonable loading frequency. Test rig should Produce Meaningful and reliable acclerated test results in a reasonable period of time. Demand: Details Requirements or means to satisfy demand/wish. Demand /wish
Strain gages : Load cells Torque cells Amplifier Oscilloscope. Equipment requirement: All measuring gages should be permanently attached to the test rig. Accurate measurement and calibration of load and uniform test results can be produced. Demand : Elctrohydraulic test systems. Equipment requirement: Specimens can be fatigue tested by such equipment which can be programmed or tape controlled. Actual service condition can be duplicated in the laboratory. Wish:
monitoring records. Recording device: Keep record of tests and prevent loss of test evidence in case of test failure. It should maintain history of previous test. Wish: Mechanically or by means of strain gages. Test must be terminated at required point of time. Test rig should be safe . Demand: