Design, Fabrication, and Performance Analysis of Rotary Bending Machine for Fatigue Testing

Project Title

Design, Fabrication, and Performance Analysis of Rotary Bending Machine for Fatigue Testing

Project Area of Specialization Mechanical EngineeringProject Summary

Fatigue fracture is the most common type of failure as more than 75-80% of documented materials’ failure in engineering components is due to cyclic loading. So, it is preeminent to test the materials before use. Many engineering machines and mechanical components are subjected to fluctuating stresses, taking place at relatively high frequencies and under these conditions, fatigue failure is found to occur. So, the knowledge of fatigue crack growth under typical loading conditions of axles and shafts with rotating bending and steady torsion has been an object of research to apply damage tolerance concepts, mainly for maintenance and failure analysis purposes. Given an effective design that will not fail accidentally, this testing machine 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 no. of cycles are counted till the breakage of specimen and results are plotted.

Project Objectives

1. To design and generate a solid model of the rotary bending machine which is simple to understand, perform, portable, safe for use and economical (up to 40% cheaper) than the market.
2. To fabricate the structure of the RBM for the rotating bar fatigue test.
3. To install instrumentation and calibrate the rotary bending machine.
4. To evaluate the performance of the rotary bending machine by testing the fatigue life of various samples of the specimen of standard specifications.

Project Implementation Method

1. Requirements analysis of fatigue testing to determine the various loading combinations under different operating conditions and parameters to safely design the rotary bending machine.
2. Designing the 3-dimensional model of the rotary bending machine with an optimum factor of safety to test various materials.
3. Transient structural analysis of the whole machine to check its feasibility for testing advanced materials with sufficient fatigue life.
4. Fabrication and instrumentation of the rotary bending machine to ensure successful operation with minimum error.
5. Performance evaluation of the rotary bending machine by analyzing the experimental results and the software (ANSYS Workbench) results.
6. Results analysis of the fatigue testing to draw the final and detailed conclusion with future work.

Benefits of the Project

The price of RBM is continuously increasing ($3000 – $5000) and testing services are costly ranging from $20 to $90 per specimen in Pakistani laboratories. This project is;

1. 20% economical
2. has minimized experiment time
3. ease of operation and maintenance
4. safety for use
5. Can test wide range of materials including aluminium, steel, magnesium alloys, and carbon fibre composites.

Technical Details of Final Deliverable

1. 2-dimensional drawings of all components of the machine with the 3-dimensional model of the machine.
2. Static and transient structural analysis of the machine and specimen.
3. The fabricated machine with necessary instrumentation including sensors, switches, display unit, and control box.

Final Deliverable of the Project HW/SW integrated systemCore Industry ManufacturingOther IndustriesCore Technology Clean TechOther TechnologiesSustainable Development Goals Good Health and Well-Being for People, Quality Education, Industry, Innovation and Infrastructure, Responsible Consumption and ProductionRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	80000
Drive Motor	Equipment	1	15000	15000
Universal Joint	Equipment	2	2000	4000
Universal Axle	Equipment	2	1500	3000
Drill Chuck	Equipment	2	1100	2200
Axle Bracket	Equipment	4	900	3600
Nuts & Bolts	Equipment	8	250	2000
Bracket Spacer for Casting	Equipment	4	500	2000
Motor Coupler	Equipment	1	1000	1000
Pratt Sensor	Equipment	1	450	450
Weights Hanger	Equipment	1	500	500
DB Stand	Equipment	1	1000	1000
Counter Meter	Equipment	1	2600	2600
Limit Switch	Equipment	2	120	240
U-type Photoelectric Sensor	Equipment	1	1800	1800
Contactor Switch	Equipment	2	240	480
Acrylic Switch	Equipment	1	2700	2700
Universal Shaft	Equipment	2	900	1800
On\Off Switch	Equipment	1	150	150
LED Light	Equipment	3	100	300
Push Button	Equipment	2	150	300
Multimeter	Equipment	1	360	360
Wires for Main Supply	Equipment	1	780	780
Hinge	Equipment	4	100	400
Specimen Material	Equipment	1	740	740
Specimen Machining	Equipment	8	200	1600
Eraction	Equipment	1	11000	11000
MS Sheet	Equipment	1	9000	9000
Dead Weight	Equipment	10	100	1000
Paint	Miscellaneous	1	3000	3000
Thesis Printing	Miscellaneous	2	1000	2000
Poster Printing	Miscellaneous	1	1500	1500
Carriage	Miscellaneous	1	3500	3500