Many engineering machines and mechanical components are subjected to fluctuating stresses, taking place at relatively high frequencies and under these conditions, failure is found to occur. This is “fatigue failure”. Fatigue is a failure of material or machine due to the action of repeated or fluctuating stress on a machine member for some number of times/cycles. This failure begins with a small crack. The initial crack is so minute that it cannot be detected by the naked eye and is even quite difficult to locate . And this led to the invention of a fatigue the testing machine. In view of effective design that will not fail accidentally, this research is conceived. This testing machine will determine the strength of materials under the action of fatigue load. Specimens are subjected to repeated varying forces or fluctuating loading of specific magnitude while the cycles or stress reversals are counted to destruction. The first test will include the fatigue test of the material . The second test which we are going to combine testing of bending or torsion. Thus the results of these processes will be plotted through software integration.

1. Presentation on
Presented by:
Avinash Barve
Design & Fabrication of Low Cost
Small-Scale Fatigue Testing Machine

2. CONTENTS
Sr. No. Contents
1. Introduction
2. Why we choose FTM?
3. Objectives
4. Methodology
5. Design Analysis
6. Design
7. Description of Components
8. Working Principle
9. Conclusion

3. INTRODUCTION
 Many engineering machines and mechanical components are subjected to fluctuating stresses,
taking place at relatively high frequencies and under these conditions failure is found to occur. This
is “fatigue failure”.
 A fatigue is a failure of material or machine due to the action of repeated or fluctuating stress on a
machine member for some number of times/cycles . This failure begins with a small crack. The
initial crack is so minute that it cannot be detected by the naked eye and is even quite difficult to
locate .And this led to the invention of a fatigue testing machine.
 In view of effective design that will not fail accidentally, this research is conceived. This testing
machine will determine the strength of materials under the action of fatigue load. Specimens are
subjected to repeated varying forces or fluctuating loading of specific magnitude while the cycles or
stress reversals are counted to destruction. The first test will include the fatigue test of the material .
The second test which we are going to combine testing of bending or torsion . Thus the results of
these processes will be plotted through software integration.

4. Why we choose a FTM?
 We know about fatigue and feel it many times in our body after long workout.
Similarly engineering components also fails due to fatigue. Fatigue in any
engineering component occurs when these components are subjected to cyclic
loading or we can say that the fluctuating stresses are induced in the components.
 Fatigue is the time dependent permanent deformation which is seen in almost every
engineering component when they work under cyclic loading conditions.
 Most of the time the engineering components fails only because of fatigue. Due to
this, this machine help us to know about the life of the material under test because of
which many hazardous accidents due to fatigue can be prevented.
 Thus, FTM is capable of testing the fatigue life of various specimen and help us to
determine the life of various materials.

5. OBJECTIVE
 Objective of fatigue testing is generally to determine the fatigue
life and the location of danger point i.e Location of failure of a
specimen subjected to sequential stress amplitude.
 To design and fabricate a machine in low cost which is capable
of performing fatigue test.
 Purpose of a fatigue test is to determine the lifespan of the
material subjected to cyclic loading.

6. METHODOLOGY
Literature Review
& Data Collection
• Research
Papers
• Industries
• Calculations
• Graphs
• Sensors
Machine Design
& Analysis
• CAD Design
• Analysis of
model using
ANSYS
Fabrication
• Fabrication as
per design.

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

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

9. CAD MODEL

10. DESCRIPTION OF COMPONENTS
Part Description
Electric motor single phase AC 0.745KW, 1 horse power
motor
Shaft and specimen A high carbon alloy steel that is AISI 1018
(MS)
Flexible coupling transmit power or torque form one shaft to
another
Pedestal bearing Bearings of 20 mm bore diameter
Drill chucks A three jaw drill chuck with taper fittings
Weight hanger and U
clamps
to apply load on overhang bearing
Analog counter The output of the counter can be used to
count the number of pulses.

11. WORKING PRINCIPLE
 The fatigue-testing machine is of the simply supported beam type. The
specimen functions as a single beam which is loaded at both the side point
load. When rotated, the stresses on the fibers originate above the neutral
axis of the specimen and are reversed from compression to tension for equal
intensity.
 Upon completing the revolution, the stresses are again reversed, so that
during one complete revolution the test specimen passes through a complete
cycle of flexural stress.
 Rotating beam type machine for a simply supported beam, the specimen of
circular cross- section is held at its ends in holders(chucks) and loaded
through two bearings with equal distance from the center of the span.
 Thus, equal loads on these bearings are applied by means of weights
that create a uniform bending moment in the specimen between the
loaded bearings.

12. CONCLUSION
Material testing equipment is generally very expensive, this has given us a
challenge to make a low cost testing machine , but we had made a machine that
is easy to fabricate and procure accurate and precise results and compete with the
equipment already available in the market. According to the planned
methodology the machine is fabricated and tested. The experimental results are
compared with theoretical calculations and it was found that there is little
variations in results. On completion and testing, it was observed that the machine
has the potentials of generating a reliable bending stress number of cycle data.
The machine has the advantages of ease of operation and maintenance, and is
safe for use.