SM1090V

Rotating Fatigue Machine

User Guide

© TecQuipment Ltd 2016, Original Instructions

Do not reproduce or transmit this document in any form or by
any means, electronic or mechanical, including photocopy,
recording or any information storage and retrieval system
without the express permission of TecQuipment Limited.
TecQuipment has taken care to make the contents of this
manual accurate and up to date. However, if there are any
errors, please let us know so we can rectify the problem.
TecQuipment supply a Packing Contents List (PCL) with the
equipment. Carefully check the contents of the package(s)
against the list. If any items are missing or damaged, contact
TecQuipment or the local agent.

DB/BW/0122
 Symbols Used in this Manual

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 SM1090V Rotating Fatigue Machine

Contents
Introduction .................................................................. 1

Description ................................................................... 3

Specimens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Versatile Data Acquisition System (VDAS®) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Technical Details ............................................................ 5

Rotating Fatigue Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Noise Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specimens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Assembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Location and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Connection to VDAS® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Notation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Rotating Cantilever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Stress () . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cantilever Theory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Stress in the Specimen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Low Cycle and High Cycle Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
High Cycle S-N Curves and Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Experiments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Useful Note - Test Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Normal Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Experiment 1 - Basic Tests (Aluminium Specimens Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Experiment 2 - High Cycle Fatigue Tests (All Specimens) . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Typical Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Experiment 1 - Basic Tests (Aluminium Specimens Only) . . . . . . . . . . . . . . . . . . . . . . . 29

Experiment 2 - High Cycle Fatigue Tests (All Specimens) . . . . . . . . . . . . . . . . . . . . . . . 31

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References and Useful Textbooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Maintenance, Spare Parts and Customer Care . . . . . . . . . . . . . . . . . . . . . . . 35

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Customer Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
 SM1090V
Rotating Fatigue
Machine
User Guide
Introduction

Figure 1 The Rotating Fatigue Machine (SM1090V)

This product works with VDAS

Designers know that parts stressed above their yield strength will usually break or permanently deform
(making them unfit for purpose). However, many parts stressed below their yield strength repeatedly for
long periods will also break, due to fatigue. Unfortunately, many designs include parts that must flex,
bend or twist repeatedly, to work correctly (for example - springs). Also, many parts of a product flex
repeatedly while they work (for example - aircraft wings).

Human lives depend on good design and known lifespans of many products. So, engineers need to know
how long the important parts of their design can take a known, repeated stress before they break.

In the Nineteenth Century, a German engineer (August Wohler) created the first standardised test for
material fatigue failure. He also created the industry-standard S/N (stress to number of cycles or ‘stress-
life’) curves to compare results. Based on Wohler’s test, TecQuipment’s Rotating Fatigue Machine
(SM1090V) repeatedly stresses a test specimen for a known number of cycles. It helps engineers
understand fatigue failure and how to use Wohler’s methods to compare results.

TecQuipment also makes many other products to help engineers understand how different materials and
structures work under different loads. Contact our sales department for details.

VDAS is a registered trademark of TecQuipment Ltd.

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 SM1090V Rotating Fatigue Machine

Description

Figure 2 The Rotating Fatigue Machine (SM1090V)

The Rotating Fatigue Machine (SM1090V) has two main parts: a main unit and a separate Control and
Instrumentation Unit. The main unit has a motor that rotates a test specimen under constant load
(stress). The motor turns a coupling and a short driveshaft. The driveshaft turns a collet type chuck that
grips the ‘driven end’ of the test specimen with uniform pressure around its circumference. This is
important because it gives an even stress distribution on the specimen and grips it with minimum
eccentricity. The coupling and driveshaft help to remove any unwanted lateral forces from the
mechanical link to the motor.

At the ‘loading end’ of the specimen, an adjustable ‘dead weight’ applies a vertical (downwards) load on
the specimen. It does this through a self-aligning bearing inside a gimbal. The gimbal is important as it
allows movement, but also ensures vertical loading even when the specimen deflects.

Included with the equipment is a spare self-aligning bearing. TecQuipment

recommend that this bearing is kept coated in a suitable lubricating oil and in
a sealed bag.

The driven end and loading end make the specimen an axially rotating cantilever with a point load near
its end.

A sensor counts the rotations (cycles) of the specimen and a load cell measures the force that is applied
to the specimen (determined by the dead weight position). A separate control box contains an electronic
motor drive and a display that shows the load, speed of rotations (cycle rate) and the number of rotations
(cycle count) since the start of the test. A socket on the control box allows the Fatigue Testing Machine
to be connected to a suitable computer (not supplied) for automatic data acquisition.

The motor control box includes; ‘Start’ and ‘Stop’ buttons for the motor and a control to adjust the cycle
rate (motor speed) along with an Emergency Stop button. In normal use, the Start / Stop buttons should
be used. The Emergency Stop should only be used in the case of an emergency. After activating the
Emergency Stop, it will be necessary to reset it by turning it clockwise.

A transparent safety guard protects the user in case small parts of the specimen fly off when it fractures.
An interlock switch disconnects the motor power if the guard is not fitted.

When the specimen breaks, a switch at the loading end switches off the motor power and the display
stops counting so it is known how many cycles the specimen has done up to the point of failure. If

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necessary, a separate timer can be used or the time to failure can be calculated from the cycle count
and the cycle rate.

If using VDAS, it can be set to count time as it records data.

Specimens
Supplied with the equipment is a set of mild steel test specimens, a set of aluminium specimens and a
set of brass specimens. Contact our Sales Department for further specimens.

Versatile Data Acquisition System (VDAS®)

Figure 3 The VDAS Software

TecQuipment’s VDAS is available Onboard the Rotating Fatigue Machine, it will:

• Automatically log data from the experiments

• Automatically calculate data

• Save time

• Reduce errors

• Create charts and tables of the data

• Export the data for processing in other software

A suitable computer (not supplied) is required to use TecQuipment’s VDAS.

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 SM1090V Rotating Fatigue Machine

Technical Details

Rotating Fatigue Machine

Part Details

Main Unit 600 mm x 350 mm x 400 mm high and 30 kg

Control and Instrumentation Unit 650 mm x 360 mm x 180 mm and 11 kg

Operating Environment Altitude up to 2000 m

Temperature range 5°C to 40°C
Maximum relative humidity 80% for temperatures up to
31°C, decreasing linearly to 50% relative humidity at 40°C
Overvoltage category 2 (as specified in EN61010-1).
Pollution degree 2 (as specified in EN61010-1).

Electrical Supply Single Phase, 220 - 240 VAC, 50 / 60 Hz, 5A OR

(specified on order) Two Phase, 220 - 240 VAC, 50 / 60 Hz, 5A

Circuit Protection and ON/OFF switch Main switch - 6 A 2-pole circuit breaker

External Connections 
VDAS - Extra low voltage (communications)
Interlock - Extra low voltage (motor drive start stop circuit)
Motor - Three phase 230 VAC nominal
Thermistor - Extra low voltage
Counter - Extra low voltage
Load Cell - Extra low voltage

Maximum Stress Approximately 350 MPa

Maximum Cycle Count 9.99 x 108

Specimens Included 20 RF1010 (Steel)

20 RF1020 (Aluminium)
20 RF1030 (Brass)

Oil needed for bearing (not supplied) Good quality engine oil between SAE 30 and SAE 50

Noise Levels
This equipment generates noise levels lower than 70dB(A).

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Specimens

Figure 4 Specimen Details

If higher stress levels are necessary, specimens with a thinner neck

must be used, or add a ‘notch’ to the neck to cause a known localised
stress concentration.
Do not try to increase the stress on the specimen by adding extra dead
weights.

Code Description

RF1010 Mild Steel BS 970 230M07

Tensile Strength 460 MPa
Yield Stress 310 MPa

RF1020 Aluminium Alloy 2011 T6

Tensile Strength 395 MPa
Minimum Yield Stress 220 MPa

RF1030 Brass Alloy CZ121

Tensile Strength 410 MPa
Yield Stress 160 MPa

These specifications are nominal. For extra accuracy, test a sample of the
specimens on an accurate tensile test machine to find yield stress and tensile
strength.

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Assembly and Installation

The terms left, right, front and rear of the apparatus refer to the operators’ position, facing the unit.

A wax coating may have been applied to parts of this apparatus to prevent
corrosion during transport. Remove the wax coating by using paraffin or white
spirit, applied with either a soft brush or a cloth.
Follow any regulations that affect the installation, operation and maintenance
of this apparatus in the country where it is to be used.

Location and Assembly

Use the Rotating Fatigue Machine in a clean, well-lit laboratory or classroom type area. Put it on the top
of a solid, level workbench.

It uses a bench area of 1200 mm x 600 mm. If using VDAS, allow room nearby for a computer.

Always use assistance to move the Rotating Fatigue Machine, it is

heavy (30 kg).
To lift the equipment, always use the handles provided.

Installation
Cables
Put the Control and Instrumentation Unit next to the Main Unit and connect the cables from the Main Unit
to the Control and Instrumentation Unit. Figure 6 shows the cable connections. Each cable has its own
special plug and each is different. Do not push the wrong plug into the wrong socket.

Do not forget to connect the motor thermistor cable. The motor will not work
if this cable is not connected.

Dummy Specimen
For transport, TecQuipment fit a ‘dummy’ specimen in the chuck, to stop the gimbal moving around.
Leave this dummy in the chuck until performing a test. Use the same procedure as for a specimen to
remove and refit the dummy specimen (see the experiments section).

Always refit the dummy specimen if transporting the equipment.

Dead Weight
For transport, TecQuipment pack the ‘Dead Weight’ separately. To fit it, slide it into the loading arm and
fit the plastic clip (see Figure 5).

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Figure 5 Slide the Dead Weight into the Loading Arm and Fit the Plastic Clip

Electrical Connection

Figure 6 Electrical Connections

Use the cable supplied with the apparatus to connect it to an electrical supply.

Connect the Control and Instrumentation unit to the electrical supply

through a plug and socket. The apparatus must be connected to earth.
The plug and socket are the mains disconnect devices. Make sure the
user can easily reach them.

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Single Phase:

E / Earth / Ground / Green / Yellow OR Green

L / Live / Phase / Hot Brown OR Black

N / Neutral / Cold Blue OR White

Two Phase Supply or Split Phase Supply:

E / Earth / Ground / Green / Yellow OR Green

L1 / Live 1 / Phase 1 / Hot 1 Brown OR Black

L2 / Live 2 / Phase 2 / Hot 2 Black OR Red

Connection to VDAS®
If using VDAS with the Rotating Fatigue Machine, connect the USB cable (supplied) and computer (not
supplied) as shown in Figure 7.

Figure 7 Connection to VDAS

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Theory

Notation

Symbol Details Units

A Cross-sectional Area m2

D Diameter m

F Force (due to load) N

I Second Moment of Area m4

l Distance to load m

M Bending Moment Nm

y Vertical distance from the load m

point to the neutral axis

 Stress Pa

Table 1 Notation

Rotating Cantilever

Figure 8 The Rotating Cantilever

The Rotating Fatigue Machine clamps the specimen as a cantilever (see Figure 8). The load on its free
end creates tension on the upper half of the specimen and compression on the lower half. However,
because it rotates, it has alternate compressive and tensile stress on any given part along the
unsupported length of the test specimen.

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Figure 9 Cycles and Reversals

Figure 9 shows a cross section through the specimen as it rotates. Any fixed point on the unsupported
length of the specimen (the drawing shows a point on the outside of its diameter) moves through one
cycle of compression and tension. In each cycle, the stress at that point moves from a zero stress point
(at the neutral axis) to maximum tension (+), back through zero stress and to a maximum
compression (-) point. It then moves back to zero stress and repeats the cycle. As the stress fully
reverses (from positive to negative or negative to positive stress), this is called a reversal. Each cycle
has two reversals.

Stress ()
This is the force applied to a material over a known area, shown by Equation 1.

 = F
--- (1)
A

Compressive stress is where the material is compressed. It has a negative value.

Tensile stress is where the material is stretched. It has a positive value.

Cantilever Theory
Second Moment of Area and Stress
The second moment of area for either axis of a symmetrical circular cross-section beam is:

4
D
I x = ---------- = I y
64

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Figure 10 Cantilever Circular Cross-section Beam

Figure 11 Bending Moment for a Beam

Beam Bending Moment (M)

For a cantilever beam (supported at one end), the bending moment:

M = Fl (2)

Stress Along A Beam

From the Engineer’s theory of bending, the theoretical stress at any point along a uniform cross-section
cantilever beam (in elastic bending) is:

My
 = -------
- (3)
Ix

Where y in this case is D/2

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Figure 12 Stress and Distance Charts for Uniform and Non-uniform Cantilevers

The upper drawing of Figure 12 shows that for a uniform cross-section cantilever with a load at its end,
maximum stress is at the clamped end. It is most likely to break at that point.

The lower drawing of Figure 12 shows that for a non-uniform cross-section beam, the maximum stress
point may be somewhere else along the beam. The standard specimen has a maximum stress point
halfway along the thinner section (its ‘neck’) and it should fail at this point.

Stress in the Specimen

The standard bending equations for the specimen as a circular cross-section cantilever can combine to
give:

lF  32
 = -----------------
3
(4)
D

This gives the stress at a given diameter and distance from a given load. For the standard specimen, the
distance is 28 mm (see Figure 13).

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Figure 13 Distance to Load in a Standard Specimen

Using Equation 4 and a known diameter for the thinnest part (‘neck’) of the specimen, the stress for any
given load can be found.

For example, a 50 N load on a specimen with 4 mm diameter neck gives:

 = 0.028  50  32-
------------------------------------- 44.8
3
= --------------------6- = 222.9 MPa
3.142  0.004 0.2 10

The Rotating Fatigue Machine produces a maximum stress of approximately 360 MPa to match the yield
stress of the strongest standard (steel) specimens supplied by TecQuipment. This also gives a safe
working stress range to test the standard aluminium specimens in both low cycle and high cycle fatigue.

Do not try to increase the stress on the specimen by adding extra dead
weights. This is dangerous and may damage the equipment. If higher
stress levels are needed, use specimens with a thinner neck, or add a
‘notch’ to the neck to cause a known localised stress concentration.

Low Cycle and High Cycle Fatigue

Normal ‘high cycle’ fatigue tests use forces that stress the specimen in its elastic region (below its yield
strength). This will take many stress reversals (and therefore cycles) before the specimen fails. The high
number of cycles needed to fail the specimen gives this type of fatigue the name ‘high cycle fatigue’.
High cycle fatigue tests usually last for at least 100000 cycles.

Another useful and equally valid test is the low cycle fatigue test, which uses larger forces than the high
cycle tests and stresses the specimen in its plastic region (above yield strength). Low cycle fatigue tests
usually last for between 100 and 10000 cycles.

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High Cycle S-N Curves and Fatigue

Figure 14 Typical S-N Curves (High Cycle Tests)

Figure 14 shows typical S-N (stress - number of cycles) high cycle test curves for identical parts made
of two different metals. The curves help engineers to compare different materials to choose the best for
the job.

Important Information Taken from High Cycle S-N Curves

Figure 14 also shows a special property of steel - it has a fatigue limit. This means that below a given
applied stress, it will not fail due to fatigue. So, designers would normally make sure that any parts made
of steel do not have repeated applied stress above its fatigue limit.

Aluminium will fail due to fatigue even at low repeated stress levels. It has a zero or a very small fatigue
limit. So, if designers use aluminium and it is under repeated stress, they can use the curves to find a
fatigue life for a given applied stress (its fatigue strength).

Because some metals (including aluminium) have no fatigue limit, specifications for these metals show
fatigue strength. This is the maximum stress that can be used for a given number of cycles. The dotted
line under the aluminium curve in Figure 14 shows this. Textbooks and other sources of specifications
normally show fatigue strength based on a given number of cycles (for example - 5 x 107 or 5 x 108
cycles).

Engineers often use fatigue ratio to compare materials. This is the ratio of the fatigue limit to the tensile
strength of the material.

Fatigue Limit
Fatigue Ratio = --------------------------------------
-
Tensile Strength

Fatigue ratio is normally approximately 0.5 for most iron based (ferrous) materials, because its fatigue
limit is usually approximately half its tensile strength.

Tables 2 and 3 give typical specifications for some common metals.

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Fatigue Ultimate
Strength at Tensile
107 Cycles Strength
Metal Grade (MPa) (MPa) Fatigue Ratio

Carbon Steel BS970/070M20 193 400-430 0.45-0.48

Titanium Grade 1 193 345 0.56

Grade 9 373 740 0.50

Brass ISO CuZn30 105 365 0.28

Table 2 Typical Specifications for Steel, Titanium and Brass (107 Cycles)

Fatigue Ultimate
Strength at Tensile
5 x 107 Cycles Strength
Metal Grade (MPa) (MPa) Fatigue Ratio

Wrought N3 48 110 0.44

Aluminium
H9 80 155 0.52

Table 3 Typical Specifications for Aluminium (5 x 107 Cycles)

Other Useful Information about Fatigue

Fatigue and Temperature

Temperature affects fatigue resistance in most materials. As they get hotter, they also get weaker and
their fatigue life decreases.

Fatigue and Stress Concentrations

Fatigue tests use ideal specimens tested in ideal conditions. The fatigue fracture occurs at the known
point of highest stress. In reality, many parts may have localised points of stress concentration, which
will cause premature fatigue failure.

See Figure 15. Sharp corners and rough or scratched surfaces cause stress concentration at the corner
or scratch. So, smooth or rounded surfaces give a better stress distribution and help to reduce fatigue
fracture. Also, surface corrosion of the material causes an uneven surface and will cause premature
fatigue fracture. The De Havilland Comet - a British airliner made in the 1950’s, developed structural
faults caused by localised premature fatigue failure. Some windows and access points in its fuselage
had sharp corners instead of rounded corners.

Consistent material quality is important. If part of the material is incorrectly made, or changed during
manufacture (for example - uneven heat treatment), its tensile strength will be wrong and it may have
localised stress concentrations. Both will cause unpredictable and possibly premature fatigue failure.

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Figure 15 Stress Concentration

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Experiments

Safety

Make sure all guards are in place before using this

equipment.

If the equipment is not used as described in these instructions, its

protective parts may not operate correctly.

Useful Note - Test Times

Table 4 shows approximate times needed for tests over a given cycle count at the recommended 60 Hz
cycle rate. It shows 1 x 108 for reference only - TecQuipment recommend tests up to a maximum of 107.

Cycle Count 1 x 10 1 x 10 1 x 10 1 x 10 1 x 10 1 x 10

Approximate 17 seconds 2 minutes 28 minutes 4 hours 46 hours 19 days

Time Needed 45 seconds 40 minutes 18 minutes 7 hours
(at 60 Hz cycle rate)

Table 4 Approximate Times for Given Cycle Counts at 60 Hz Cycle Rate

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Normal Procedure
.

Fatigue Test

Specimen Type

Material

Yield Stress

Tensile Strength

Surface Finish

Diameter at neck

Test Test Load (N)

Test Stress (MPa)

Cycle Rate (Hz)

Start time of test

Stop time of test

Cycles to fatigue fracture

(Cycle Count)

Time taken to fracture

Table 5 Blank Results Table

1. Create a blank table of results similar to Table 5.

2. Choose a test specimen and check that it is straight and not damaged. This can be checked by
rolling the specimen along a flat surface.

3. Accurately measure the neck dimensions of the specimen and write the details of the specimen into
the table.

4. Move the dead weight along to the furthest left position (lowest or neutral stress position).

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Figure 16 Moving the Dead Weight to the Left (lowest stress position).

5. Switch off the Control and Instrumentation Unit and remove the safety guard from the Main Unit.

6. Fit the Ø6mm Tommy Bar (supplied) into the hole in the driveshaft to stop the driveshaft rotating
while loosening the collet chuck with the 16mm spanner (supplied) (see Figure 17).

Picture shows a complete

specimen for clarity.

Figure 17 Using the Tommy Bar to Lock the Driveshaft and Using the Spanner to Loosen the Chuck

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7. Use the 2mm hexagon key (supplied) to loosen the grub screw in the top of the gimbal assembly.
Carefully slide out the dummy specimen (or broken specimen if a test has already been conducted),
along with the self-aligning bearing from the gimbal assembly (see Figure 18).

8. If removing a broken specimen, also remove the broken half from the collet chuck.

Figure 18 Loosen the Screw and Carefully Slide Out the Specimen

9. Make sure the Tommy Bar has been removed from the drive shaft before switching on the Control
and Instrumentation Unit.

10. Support (do not pull or push) the gimbal assembly while holding up the loading arm (see Figure19),
ask an assistant to press the ‘press and hold to zero’ button on the Control and Instrumentation Unit

Figure 19 Support the Gimbal Assembly and the Loading Arm

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11. Add suitable oil to the ball race and the inner diameter of the self-aligning bearing and slide the new
specimen into it (see Figure 20). Carefully slide the specimen and the self-aligning bearing into
place, making sure the bearing fits fully into the gimbal assembly.

The self aligning bearing will only fit into the gimbal assembly correctly if care
is taken and it is pushed in squarely. Do not try to force it in.

Figure 20 Add oil to Bearing and Slide Specimen into it

Figure 21 Inserting the Specimen into the Driven End Chuck

12. Use the 16mm spanner and Tommy Bar to tighten the collet chuck and make sure the end of the
specimen stays level with the edge of the self-aligning bearing, or the distance to load dimension (l)
will be wrong. Take great care whenever tightening the collet chuck down onto a specimen to use
the correct size spanner (16mm), and not to over tighten or use excessive force, as this can result
in damaging the chuck.

The collet chuck tries to push the specimen out slightly as it is tightened, so
it may be necessary to gently ‘tap’ the end of the specimen to push it back
into the chuck (see Figure 22).

Do not use excessive force to tighten the collet chuck, the spanner may slip
and the chuck may be damaged.

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Figure 22 Use the Spanner to tap the End of the Specimen

13. If there are problems fitting the specimen into the collet chuck, remove the collet chuck and check
it is correctly assembled and aligned correctly as shown in Figure 23.

Figure 23 Collet Chuck Correctly Aligned

14. Use the hexagon key to tighten the small screw that holds the self aligning bearing in place.

Do not use excessive force to tighten the small screw or it will press on the
self aligning bearing and the bearing will not turn correctly.

15. Look at the load arm while rotating the chuck by hand. Check that the load arm does not move,
showing that the specimen ‘runs true’ (is straight).

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Figure 24 Use the Hexagon Tool to Tighten the Self Aligning Bearing

16. Make sure the speed control of the Control and Instrumentation Unit is set to minimum (fully
anticlockwise).

17. Fit the safety guard.

18. Move the adjustable dead weight along the load arm to select a suitable load for the specimen
material, determined by the material and the experiment (see Technical Details on page 5 for
standard yield strength values for the specimen).

19. Gently support the loading arm so the load display shows zero and press the motor start button on
the Control and Instrumentation Unit.

The loading arm may move up and down with a large amplitude for the first
few turns of the motor at low speed, so it must be supported until the motor
reaches full speed. If the arm continues to move up and down, stop the test
and use a new specimen.

20. Slowly turn the motor speed up until the cycle rate is 60 Hz (+/- 1 Hz).

21. Take hand away from the loading arm and allow the motor to run. Record the cycle rate.

22. When the specimen breaks, record the cycle count.

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Experiment 1 - Basic Tests (Aluminium Specimens Only)

Aim
To show how to use the Rotating Fatigue Machine to test aluminium specimens and use the results to
find the stress levels for a given number of stress cycles.

Notes
In many applications (for example - aerospace products), a part must withstand a given minimum
number of stress cycles at a given stress. This experiment tests the aluminium specimens at the highest
of the available stress levels, covering low and part of high cycle fatigue up to a maximum 105 cycles.
This shows the principles of the fatigue tests in a relatively short time, and is should be possible to do
this in a normal laboratory session.

This experiment also allows more tests to be done (to get the complete S-N curve for the specimen).
However, remember that these extra tests will take more time than a normal laboratory session to
complete.

Procedure
1. Fit an aluminium specimen to the machine as shown in Normal Procedure on page 20.

2. Adjust the dead weight to the furthest right hand position on the load arm to give the maximum
allowable stress level.

3. Start and run the motor as shown in Normal Procedure on page 20.

4. Note the cycle count when the specimen breaks.

5. Repeat the test for at least four more stress levels, moving the dead weight to the left by five notches
for each stress.

6. If more time is available, continue the experiment for other (lower) stress levels to give more (high
cycle) results.

Results Analysis
Using the results from below and up to 105 cycles, create a chart of stress (vertical axis) against the cycle
count (logarithmic horizontal axis).

Comment on the results. Are the low cycle results (from stresses higher than yield strength) a realistic
and useful measurement to help when designing parts? If not, explain why.

Draw a vertical line on the chart at 105 cycles and estimate where it would cross the curve of the results
(extending the results if necessary). Use this to predict the stress at 105 cycles and comment on the
reliability of the estimate.

If there are more results for tests up to 107 cycles, complete the results curve and compare it with
standard curves for this type of aluminium.

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Experiment 2 - High Cycle Fatigue Tests (All Specimens)

At least five specimens of the chosen material are needed to produce

acceptable S-N curves.

Aim
To show how to use the Rotating Fatigue Machine in high cycle tests to find the S-N curves for different
materials.

Notes
This experiment shows how to create S-N curves for specimens of a given material (for example -
aluminium). These tests can take many hours and days and are less suitable for normal student
laboratory exercises.

Procedure
1. Prepare at least five identical specimens.

2. Fit the first specimen to the machine as shown in Normal Procedure on page 20.

3. Set the load to give a stress level of approximately 0.9 x yield strength of the material.

4. Run the experiment until the specimen breaks and record the cycle count.

5. Repeat the test for at least five gradually reducing stress levels until a test of 107 cycles is reached
or 0.4 x the tensile strength of the material (for steel specimens only).

If the specimen does not break after 107 cycles (2 days at 60 Hz), remove it
and label it ‘not failed’.

Results Analysis
From the results, plot S-N curves of stress (linear vertical axis) against cycle count (logarithmic horizontal
axis) and compare them with standard results for the material.

For the steel specimens, do the results show the fatigue limit, and is the fatigue ratio approximately 0.5
as expected?

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Typical Results

These results are typical only - actual results may be slightly different.

Experiment 1 - Basic Tests (Aluminium Specimens Only)

Figure 25 Typical Results for Less than 105 Cycles Aluminium Specimen

For the small range of cycles in this basic test, the points will give an approximate straight line. From this
the curve can be extended reasonably accurately if necessary.

Figure 26 shows typical results for the full range of available stress for comparison. It shows the results
are a gentle curve. To linearise it, use a logarithmic vertical axis, with the logarithmic horizontal axis.

Figure 26 Typical Results for the Full Range of Stress up to 106 Cycles Aluminium Specimen

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Typical Results for the Full Range of Stress up to 107 Cycles Brass Specimen

Figure 27 Typical Results for the Full Range of Stress up to 107 Cycles Steel Specimen (note this chart
has a different stress scale to the other charts)

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Experiment 2 - High Cycle Fatigue Tests (All Specimens)

Experiment 1 shows typical results for the full range of tests with the aluminium specimens up to 107
cycles. Refer to steel and brass manufacturer’s data to check the results for the other specimens.

The results should match well with manufacturer’s data and show the fatigue limit for the steel specimens
at approximately 0.5 of tensile strength, giving a fatigue ratio of approximately 0.5.

Figure 28 Typical Results for Mild Steel Specimens

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References and Useful Textbooks

The Science and Engineering of Materials

by Donald R Askeland

Published by Chapman and Hall

ISBN 0 412 34260 X

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Maintenance, Spare Parts and Customer Care

Maintenance
General
Regularly check all parts of the equipment for damage, renew if necessary.

When not in use, store the equipment in a dry dust free area, preferably covered with a plastic sheet.

If the equipment becomes dirty, wipe the surfaces with a damp, clean cloth. Do not use abrasive
cleaners.

Regularly check all fixings and fastenings for tightness; adjust where necessary.

Renew faulty or damaged parts with an equivalent item of the same type or
rating.

Self-aligning Bearing
TecQuipment supply a spare bearing with the Rotating Fatigue Machine. Until it is needed, keep the
spare bearing coated in a thin layer of suitable oil and in its protective bag.

If they are kept lubricated and used correctly, the self-aligning bearings will last for many hundreds of
hours. Change the bearing if it does not move smoothly in all directions, or if its metal balls become loose
or have a dull grey finish (not bright).

Electrical

Only a qualified person may carry out electrical maintenance.

Obey these procedures:

• Assume the apparatus is energised until it is known to be isolated from the electrical supply.
• Use insulated tools where there are possible electrical hazards.
• Confirm that the apparatus earth circuit is complete.
• Identify the cause of a tripped circuit breaker before renewing.

To reset a tripped circuit breaker

• Isolate the apparatus from the electrical supply.

• Reset the circuit breaker.
• Reconnect the apparatus to the electrical supply and switch on.
• If the apparatus fails again, contact TecQuipment Ltd or the agent for advice.

Renew faulty or damaged parts or detachable cables with an equivalent item

of the same type or rating.

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Circuit Protection Location

The main switch (circuit breaker) for the machine is at the back of the Control and Instrumentation Unit.

Spare Parts
Check the Packing Contents List to see what spare parts we send with the apparatus.

If technical help or spares are needed, please contact the local TecQuipment Agent, or contact
TecQuipment direct.

When asking for spares, please tell us:

• Contact Name
• The full name and address of the college, company or institution
• Contact email address
• The TecQuipment product name and product reference
• The TecQuipment part number (if known)
• The serial number
• The year it was bought (if known)

Please give us as much detail as possible about the parts needed and check the details carefully before
contacting us.

If the product is out of warranty, TecQuipment will advise the price of the spare parts for confirmation.

Customer Care
We hope our products and manuals are liked. If there are any questions, please contact our Customer
Care department:

Telephone: +44 115 9722611

Fax: +44 115 973 1520

email: [email protected]

For information about all TecQuipment Products and Services, visit:

www.tecquipment.com

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