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Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

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Page 1: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Fatigue testing machine

Fatigue Group :-Abed Al Salam HammouzAhmad AbazaAla’ MustafaMohammad Bahish

Supervised by :-Dr. Ahmad Al Ramahi

Page 2: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Outline

•Part one Review.

•Design stage.

•Manufacturing and Assembly

•Testing and documentation

•Cost analysis and further work

Page 3: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Part One Review

•Literature review about fatigue

•Preliminary design

Page 4: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Preliminary Design - Specimens

• Four point clamping test specimen .

• Three point clamping test specimen .

Page 5: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Preliminary Design – Life Estimation

Stress based approach :

1 10 100 1000 10000 100000 1000000 10000000 100000000150

1500

350

588.14

350

700588.14

The Expected S-N diagram for AISI 1050 - Theoretically

low Cycle Fatigue Power (low Cycle Fatigue ) High Cycle Fatigue Power (High Cycle Fatigue ) Infinte life

Number of load cycles

Fati

gue s

trength

Page 6: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Project Stages

Fatigue Testing Machin

e

Design

Fabrication

Testing

Page 7: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Design stage

1. Machine Functions and Layout.

2. Design Calculation.

Page 8: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Machine Functions and Layout

Rotating bending

Cantilever

Page 9: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Rotating bending test•Put the specimen under pure bending

moment

Page 10: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Rotating bending test

Forcing method using dead weights.

F/2F/2

Page 11: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Rotating Bending

Page 12: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Rotating Bending

Page 13: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Cantilever

Page 14: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Cantilever

Page 15: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Manufacturing and Assembly Used Manufacturing processes

Welding

Turning

Milling

Page 16: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

video

Page 17: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Manufacturing Challenge

Page 18: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Machine Features •Ease of use.

Page 19: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Machine Features •It has a good flexibility.

Page 20: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Electrical Circuit

•Ease of operate machine.

•Control the time of experiment .

•Give accurate results for number of

cycles to failure .

•Support safety for both user and

machine .

Page 21: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Electrical Circuit

Page 22: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Electrical Circuit

Safety mode

•The motor does not work until:

•The main switch is ON.

•Emergency switch and (ON/OFF switch)

are ON.

•Cover of the motor is completely closed.

Page 23: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Electrical Circuit

Accuracy in reading results

•To get the accuracy in results.

• The normally open limit switches are ON.

• The normally closed limit switches are

ON.

• Then sensor feeds signals.

Page 24: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Electrical Circuit

•Open limit switches are ON means the

cover of the motor is closed, the house is

not aligned, does not happen any failure

in the specimen.

•Closed limit switches are ON means, the

contactor start connecting, and there is a

load affecting on the specimen.

Page 25: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Electrical Circuit

•When start getting signals from the

sensor,

•counter counting until the specimen

fails, then:-

•The motor stop rotating,

• Sensor stop feeding with signals,

•And the counter holds the values on.

Page 26: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Cost analysis and similar machines

Comparison criteria

Our Fatigue Testing Machine(FTM)

Other manufacturer (OM)

Marks

Cost 2500 $ 12,000 $ FTM

Machine functions

Three types of tests.

One type. FTM

Productivityexperience

Lake of experience, first trial.

Professional work.

FTM

Page 27: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Specimen Forming

Page 28: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Specimen Forming

•video

Page 29: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Polishing

Page 30: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Testing and Documentation •Testing operation

Page 31: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Testing and Documentation

1 10 100 1000 10000 100000 1000000 10000000 100000000150

1500

Experimental Results Plotted on Theoretically obtained S-N Curve

low Cycle Fatigue Power (low Cycle Fatigue ) High Cycle Fatigue Infinte life Test No. 1 Test No. 2 Test No.3

Number of load cycles

Fati

gue s

trength

Page 32: Fatigue testing machine Fatigue Group :- Abed Al Salam Hammouz Ahmad Abaza Ala’ Mustafa Mohammad Bahish Supervised by :- Dr. Ahmad Al Ramahi

Thanks