1.

Introduction:
Fatigue is a form of failure that occurs in structures subjected to dynamic and fluctuating stresses (e.g., bridges, aircraft, and machine components). Under these circumstances it is possible for failure to occur at a stress level considerably lower than the tensile or yield strength for a static load The process is dangerous because a single application of the load would not produce any ill effects, and a conventional stress analysis might lead to an assumption of safety that does not exist. For some ferrous (iron base) and titanium alloys, the SN, Fig (1) becomes horizontal at higher N values; or there is a limiting stress level, called the fatigue limit (also sometimes the endurance limit), below which fatigue failure will not occur. This fatigue limit represents the largest value of fluctuating stress that will not cause failure for essentially an infinite number of cycles. For many steels, fatigue limits range between 35% and 60% of the tensile strength. Fatigue strength, which is defined as the stress level at which failure will occur for some specified number of cycles Fatigue life Nf. It is the number of cycles to cause failure at a specified stress level,

Fig (1): S-N Diagram 1

Fatigue of materials is a well-known situation whereby rupture can be caused by a large number of stress variations at a point even though the maximum stress is less than the proof or yield stress. The fracture is initiated by tensile stress at a macro or microscopic flaw. Once started the edge of the crack acts as a stress raiser and thus assists in propagation of the crack until the reduced section

can no longer carry the imposed load. While it appears that fatigue failure may occur in all materials, there are marked differences in the incidence of fatigue. For example, mild steel is known to have an 'endurance limit stress' below which fatigue fracture does not occur, this is known as the fatigue limit. This does not occur with non-ferrous material, such as aluminum alloys, however, there is no such limit.

Fig (2): Fatigue test

Fig (3): Radius of fillet Endurance Limit:

Certain materials have a fatigue limit or endurance limit which represents a stress level below which the material does not fail and can be cycled infinitely. If the applied stress level is below the endurance limit of the material, the structure is said to have an infinite life. This is the characteristic of steel and titanium in benign environmental conditions. The concept of an endurance limit is used in infinite-life or safe stress designs. It is due to interstitial elements (such as carbon or nitrogen in iron) that pin dislocations, thus preventing the slip mechanism that leads to the formation of micro cracks.

The endurance limit is not a true property of a material, since other significant influences such as surface finish cannot be entirely eliminated.

Fig (4): S-N Diagram 2

Endurance Limit affected by some factors listed below: Effect of surface finish:

The surface of the standard rotating bending specimen is carefully finished by grinding and polishing to remove any circumferential scratches. Most actual parts have a less well finished surface and have a reduced endurance limit as a result. Effect of size:

The probability of finding a bigger flaw increases as the size of components is increased. In part, this leads to a finding that, all other things being equal, larger components have reduced fatigue strength. Effect of fillet radius:

Most components have one or more dimensions which vary greatly from the main dimensions, for example in bearings. Such differences in dimensions create concentration of tension. A material of low fillet radius sensitivity should be selected when dimensioning a component which will be subjected to fatigue stresses.

Temperature Stress Concentration Notch Sensitivity Environment Reliability

2. Objective:
To become familiar with Fatigue Testing Machine. Investigate the effect of the radius of the fillet and surface smoothness. Draw a simple Whler diagram.

3. Equipment:
Fatigue tester MT 3012. The motor is connected on one side to a counter mechanism, which can record 7 figure numbers. Attached to the shaft at the other end is a fixture. The loading device consists of a spherical ball bearing and a micro switch, which automatically switches off the motor

Fig (5): Fatigue tester MT 3012 when the fracture occurs.

4. Procedure:
At first prepare your test piece and the Fatigue tester MT 3012. Put a workpiece in the machine and adjust the load. Turn on the Fatigue tester and see the number of N which need to the piece to break. Put another piece in the machine and repeat the previous steps. Use the data stress and N to make a plot (S_N Diagram).

5. Results:
Table (1): Readings sample No. 1 2 3 4 Force (N) 197 170 120 89 No. of Cycles 19395 80299 337172 933953 Log Stress 4.2E+08 8.623727 3.63E+08 8.559709 2.56E+08 8.408442 1.9E+08 8.27865 Stress log No. of cycles 4.287689784 4.904710137 5.527851502 5.970325021

Fig (6): S-N diagram

8.7 8.65 8.6 8.55 y = -0.2069x + 9.5377

Stress

8.5 8.45 8.4 8.35 8.3 8.25 4 4.5 5 5.5 6 6.5

Cycle of Failure

Then, at N2 = 10^7 S2= 122.857 MPa.

6. Conclusion:
We see some error is huge and unacceptable, that mean there is error, which, listed below: Human error: the experimenters who takes the readings dealt with the machine as a beginner, therefor the outputs of machine will not be accurate. Some error appears environment, condition of use, place.

Recommendations: Be careful when you takes the readings. It should to the experimenter to see and analysis the readings by engineering sense and make comments.

7. References:
Books: Callister, Jr, William D. and others. Materials Science and Engineering An Introduction, Eighth Edition.