This document summarizes a student project to design and develop an experimental setup for an integrated fatigue testing machine. A group of 8 students worked on the project under the guidance of a professor. The machine was designed to perform both fatigue tests and torsional tests to study the effects of fluctuating stresses on materials. It includes an electric motor, adjustable chucks to hold different sized samples, and sensors to collect computerized data on sample failures. The design was analyzed using ANSYS and the components were fabricated according to the design. The future scope discusses expanding the design to handle larger samples and additional tests like compression.

1. Topic -
Introduction to Engineering Metallurgy
Presented by -
Prof. Ajay A. Joshi
Project Title: “DESIGN & DEVELOPMENT OF EXPERIMENTAL SETUP OF
INTEGRATED FATIGUE TESTING MACHINE.”
Presented By –
1. AMAN S. SONI
2. AVINASH P. BARVE
3. BHUSHAN D. CHAPKE
4. HARDIK D. BHAUTKAR
5. PARESH D. SETIYA
6. PRAVIN A. PANDAGRE
7. RAHUL L. JANGAM
8. SHANTANU D. BANKAR
Guide –
Mr. Faisal Hussain
Session – 2018-2019

2. Introduction
The fatigue testing machine mostly used for industrial or laboratory applications which are
limited to performing single fatigue tests with high leading cost. In the present paper the experimental
setup of the traditional fatigue testing machine is integrated with torsional test, to experimentally study
the effect of fluctuating stresses on the material under service. In contradiction to earlier machines, the
machine herein developed provides uniform bending and twisting moment distribution along the length of
the test specimen. The machine performs fatigue test and torsional test, which provides the extreme force
needed to understand the properties and behavior of materials. The machine consists of an electric motor
to provide the required torque and two circular arms with adjustable chucks to fit test samples of various
sizes. The machine provides computerized data for samples fails with data pertaining to each sample. The
experimental model is designed and fabricated to match our customers unique test objective.

3. Methodology
Fabrication &
Interfacing
Machine Design &
Analysis
Literature Review
& Data Collection
• Research
Papers
• Industries
• MATLAB
1. Calculations
2. Graphs
3. Sensors
• CAD
Design
• Analysis of
model using
ANSYS
• MATLAB
• Fabication
as per
design.
• Interfacing
of the
components
with sensors
using
MATLAB.

4. Project Planning Activities

5. 7/19/2018 8/8/2018 8/28/2018 9/17/2018 10/7/2018 10/27/2018 11/16/2018 12/6/2018 12/26/2018
Research
Design
Material
Selection
Fabrication
Finishing

6. Design Analysis
AISI 1018 (MS)
Load
(Kg)
Total
Deformatio
n (mm)
Stress
generated
(Mpa)
Strain
generated
(mm)
Factor of safety
(minimum)
10 12.203 6.599e8 0.0032 0.56065

7. Aluminium
Load
(Kg)
Total
Deformatio
n (mm)
Stress
generated
(Mpa)
Strain
generated
(mm)
Factor of safety
(minimum)
10 13.715 6.256e8 0.00916 0.3996

8. INITIAL PROPOSED LAYOUT

9. BLOCK DIAGRAM OF FINAL LAYOUT
Clutch
Gearbox

10. SENSORS
• Torque Sensor - A torque sensor, torque transducer or torque
meter is a device for measuring and recording the torque on a rotating
system, such as an engine, crankshaft, gearbox, transmission, rotor,
a bicycle crank or cap torque tester. Static torque is relatively easy to
measure. Dynamic torque, on the other hand, is not easy to measure,
since it generally requires transfer of some effect (electric, hydraulic or
magnetic) from the shaft being measured to a static system.
• One way to achieve this is to condition the shaft or a member attached
to the shaft with a series of permanent magnetic domains. The
magnetic characteristics of these domains will vary according to the
applied torque, and thus can be measured using non-contact sensors.

11. • Load Cells:- Load cells are used to measure weight. They are an
integral part of our daily life. "In your car or at the cheese counter in
the supermarket – we encounter load cells everywhere," says HBM
Product Manager Stefan Schmidt. Of course they are usually not
immediately recognizable, because they are hidden in the inner
workings of instruments.

12. SENSORS
• Revolution counter- Digital revolution counter is a device which is
used to find the number of revolution on Rotating output shaft and
with the help of number of revolution we find the S-N curve for
fatigue test.

13. Motar

14. PHOTOS

15. Future scope
• By using the hydraulic system we can make the system which can be
used for heavy or big dia shaft also i.e more than 8 mm.
• By use of hydraulic system no need of manual loading of the system.
• By use of hydraulic system we can performed the double shear test on
the metals also.
• By the design of a appropriate attachment the setup can performed the
operation like compressive failure test also.

16. Conclusion
Hence from the mathematical calculation and virtual analysis of the
design we can conclude that the a single machine set up can be
made for performing and analyzing the various material failure
phenomenon like fatigue, bending, torsion and double shear test on
various materials.

17. REFRENCES
• [1] Shreyas P., Trishul M. A., Chethan Kumar R., Karthik Babu K.R. (2015). Design and
fabrication of dual specimen rotating bending fatigue testing machine. International Advanced
Research Journal in Science, Engineering and Technology, 2, 25-27.
• [2] Bhatkar O.P. , Mhatre S.Y. , Pilankar A. S. , Desai V.S. , Katlikar M. J. (2016). Design and
fabrication of combined fatigue testing machine .The International Journal of Innovative Research
in Science, Engineering and Technology, 2, 194-201.
• [3] Chauhan S. J., Misal A., Jadhav A., Jadhav B., Bhalavi A., Jagdale R. (2016). Design and
Fabrication of Rotating Bending Fatigue Testing Machine – A Laboratory Development Project.
International Research Journal of Engineering and Technology (IRJET), 3, 816-819.
• [4] Mohan. M., Ranjith. B., Sharath. V., Shashidhara M. (2017). Design and Fabrication of Fatigue
Testing Machine under Combined Loading. International eJournal for Technology And Research,
1-3.
• [5] S.Rajesh , N. Saravanan (2016). Design and Fabrication of Low Cost Fatigue Test Rig.
Imperial Journal of Interdisciplinary Research, 2, 684- 688. [6] Omkar P. Bhatkar ,Sameer Y.
Mhatre , Ashish S. Pilankar , Vibhavari S. Desai ,Mohsin J. Katlikar (2016). Design of Combined
Fatigue Testing Machine. International Journal of Research in Advent Technology, 4, 32-34

18. THANK YOU