Materials Lab. (0944374) Lab. Report: Total

Materials Lab.
(0944374)
Lab. Report
Faculty of Engineering & Technology
The University of Jordan, Amman – Jordan

Fatigue Test Report
By Yousef Alsharif
Items Max. grade Evaluation Mark

Cover Page 5
Abstract 10
Data Observed 10
Sample of Calculations 10
Results & Discussion 20
Uncertainly Analysis 10
Practical Examples 5
Conclusions 10
Correct Language 10
Page Numbering 5
Figures and Tables 5
Total 100
Materials Lab Page 1

• Introduction :-
Fatigue of metals is a well-known situation where yielding (and then
rupture) can be caused by a large number of stress variations (magnitude and/or
direction) at a point even though the max stress is less than the yield stress, and
respectively the ultimate stress.
A fatigue failure begins with a small crack resulting from a tensile stress at a
macro or microscopic flaw. Once started, the crack will develop at a point of
discontinuity in the material, such a change in cross section, a keyway, or a
hole. Less obvious points at which fatigue failure is likely to begin are internal
cracks, or even irregularities caused by machining. In other words, when a load
below the yield strength of a material is applied repeatedly to a metallic
specimen, localized hardening occurs. Then a small crack appears, this crack is
a line of stress concentration, which causes it to grow, as the crack grows, the
cross sectional area of the metal gets smaller until it can no longer support the
load. When fracture takes place, the loading is called fatigue loading and the
fracture is called fatigue failure.
Cracks generally start at the surface of the metallic material. As the crack
grows, the two surfaces rub against each other, polishing both faces to a dull
metallic finish, whereas the fractured surface show signs of plastic deformation
and a crystalline finish.
To determine the strength of materials under the action of fatigue loads,

specimens are subjected to repeated or varying forces of specified magnitudes
while the material, quite numbers of tests are necessary. For the rotating test, a
constant bending load is applied, and the number of revolutions (stress
reversals) of the beam required for failure is recorded. The first test is made at a
stress which is somewhat under the ultimate strength of the material. The
second test is made with a stress which is less than that used in the first.

The process is continued, and the results plotted as an S-N diagram. This
chart may be plotted on a semi log papers or on Log-Log papers.
The ordinate of the S-N diagram is called the fatigue strength; (Ϭfat , the
stress above endurance limit at which failure is likely to occur after a given
number of cycles) a statement of this strength must always be accompanied by a
statement of the number of cycles, N, to which it corresponds.
In the case of STEELS, a knee occurs in the graph, and beyond this knee
failure will not occur, no matter how great the number of cycles. The strength
corresponding to the knee is called the endurance limit S, or the fatigue limit.
• Objectives :-
The object of the experiment is to make an introductory study using a Wohler
rotating apparatus.
• Apparatus :-
In the revolving fatigue testing machine, a rotating sample which is clamped
on one side is loaded with a concentrated force. As a result, an alternating
bending stress is created in the cylindrical sample. Following a certain number
of load cycles, the sample will rupture as a result of material fatigue. The
revolving fatigue testing machine essentially consist of:
1- Spindle with sample receptacle.
2- Drive motor.
3- Load device.

4- Switch box with the electrical control and counter.
5- Protective hood.
The spindle is mounted on two amply dimensioned rolling-contact bearings.

The spindle is driven by a smooth running AC motor with a speed of
approximately 2880 RPM.
Test specimen:-
Mild steel specimen.
• Data Observed & Calculations :-

1) Diameter of specimen = 8.03 mm.
2) Gage length of specimen = 102.4 mm.
3) Load applied in the specimen in each trail and the number of revolutions
needed for the specimen to break.
Specimen number Load applied (N) No. of revolutions (N)
1 180 17613
2 190 15240
3 220 10247
• Results & Discussion :-

1- We calculated stress, fatigue strength, R (ratio between fatigue strength
and ultimate strength) and time needed for specimen to break.
Load Number Stress Fatigue R=S/S Time (s)

(P) (N) of cycles Ϭ = 2P Strength ult
(N) S = 2Ϭ
180 17613 360 720 0.514285 382.8913043
190 15240 380 760 0.542857 331.3043478
220 10247 440 880 0.628571 222.7608696
2- In order to draw the relationship S-N and Ϭ-t we must calculate the
logarithm for each one.
Log (S) Log (N) Log (Ϭ) Log (t)

2.857332496 4.245833335 2.556302501 2.583075503
2.880813592 4.182984967 2.579783597 2.520227135
2.944482672 4.010596736 2.643452676 2.347838905

3- Fatigue must be considered in the design of all structural and machine
components which are subjected to repeated or fluctuating loads:
a) Usage of endurance limit: with a material like mild steel, the actual
stress range could be kept below the endurance limit.

b) Usage of number of reversals, N: alternatively, one can design for a
specified number of stress variations (magnitude and direction) on
condition that the element will be in many situations we need a rapid
estimate of the endurance limit. It was found that for steel the
following could be used:
Se = 0.5 Sult , Sult ≤ 1400 MPa
Se = 700 MPa , Sult > 1400 MPa
4- When the specimen broke, we noticed that there are two different colors at
the area of fracture and the explain is that dark area of striations: slow
crack growth. Bright granular area: sudden fracture.
c) Increasing fatigue life of parts. Cracks occur usually under the action
of tensile stresses.
Therefore, reduction of tensile stresses will prevent fatigue and

thus make the part lire longer. Tensile stress reduction can be
achieved through creating a constant compressive stress
(compressive a stress closes cracks). Two method for creating
constant compressive stresses are known:

• Cutting-slots method.
• Shot-peening method.
5- Factors affecting fatigue life of materials:
a) Surface condition of material: it is known that highly polished

elements withstand fatigue much better than normally machined
ones.
b) Type of stress: the most damaging type of stress variation is the

complete reversals for which the stress range S=2Ϭ. Fluctuating
stresses are less damaging, the stress range is S=Ϭ.
c) Influence of the shape of specimen on stress flow: the shape (if the
specimen is very important, since at corners ant notches the local
stress can be several times more than the calculated average value.
d) Influence inside the material and the surface: in certain materials,

failure as result of repeatedly cycled stress generates localized slip
pattern. Each slip segment works so that very small cracks form in
the material. The notch effect causes the cracks to multiply until a
network develops to cause fracture, if these cracks are reversible
sealed-with the cycle, the material is said to be ductile. If not, it will
fracture. It is, therefore, important that when a structure is to be
cycled, sharp corners, surface scratches, or notches must be avoided
by the designer.
• Sample of calculations :-
1) Stress (Ϭ) = 2P = 2(1/mm^2) * 180 = 360 N/mm^2
2) Fatigue strength (S) = 2 Ϭ = 2 * 360 = 720 N/mm^2
3) Time needed = (17613*60) / 2760 = 382.8913043 seconds

• Conclusions :-
1- Comment on your results.
After doing this experiment we had noticed that repeated force on any
cross section in the specimen may cause fracture even though the stress that
force (fatigue strength) caused it is less than ultimate stress. When we apply
force repeatedly on the specimen, it makes it weak and easy to get broken.
2- Discuss in details how you can use the endurance limit and the number of
reversals in design? Give examples.
Designing an object needs to be critically accurate and in safe side by

taking the endurance limit as a reference to prevent the object from failure.
Bridges are good examples for this test.
• Uncertainty analysis :-
There are lots of errors that affect on our results and make our calculations
not accurate, we can classify them into two groups:-
1) Personal errors:- summarize in taking readings of specimen such as

gage length and diameter of the specimen.
2) Systematic errors:- summarize in load device than can give us

inaccurate reading for applied load.
Also, to make sure of our results we must repeat this experiment on a set of
specimens that it must give me the same results or at least close to them.

• Practical examples :-
Bridges are the best practical examples than can be mentioned in this
report since the applied loads on bridges are variable and repeated, so the
civil engineer who designs this bridge must pay attention for endurance
limit.
Thank you

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Materials Lab.

Faculty of Engineering & Technology

The University of Jordan, Amman – Jordan

Items Max. grade Evaluation Mark

Materials Lab Page 1

To determine the strength of materials under the action of fatigue loads,

Materials Lab Page 2

1- Spindle with sample receptacle.

Materials Lab Page 3

The spindle is mounted on two amply dimensioned rolling-contact bearings.

• Data Observed & Calculations :-

2) Gage length of specimen = 102.4 mm.

Specimen number Load applied (N) No. of revolutions (N)

• Results & Discussion :-

Materials Lab Page 4

Load Number Stress Fatigue R=S/S Time (s)

190 15240 380 760 0.542857 331.3043478

220 10247 440 880 0.628571 222.7608696

Log (S) Log (N) Log (Ϭ) Log (t)

2.880813592 4.182984967 2.579783597 2.520227135

2.944482672 4.010596736 2.643452676 2.347838905

Materials Lab Page 5

Materials Lab Page 6

Se = 0.5 Sult , Sult ≤ 1400 MPa

Se = 700 MPa , Sult > 1400 MPa

Therefore, reduction of tensile stresses will prevent fatigue and

Materials Lab Page 7

5- Factors affecting fatigue life of materials:

a) Surface condition of material: it is known that highly polished

b) Type of stress: the most damaging type of stress variation is the

d) Influence inside the material and the surface: in certain materials,

2) Fatigue strength (S) = 2 Ϭ = 2 * 360 = 720 N/mm^2

3) Time needed = (17613*60) / 2760 = 382.8913043 seconds

Materials Lab Page 8

Designing an object needs to be critically accurate and in safe side by

1) Personal errors:- summarize in taking readings of specimen such as

2) Systematic errors:- summarize in load device than can give us

Materials Lab Page 9

Materials Lab Page 10

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