Designing and Fabrication of state of the art low frequency torsional fatigue testing machine for testing of Aerospace Alloys

We have to design a torsional fatigue testing machine at low cost. A Torsional fatigue machine is used to measure the torsional fatigue at various torque levels and different frequencies of the loading, of a specimen it may be cylinder or  spring etc. Torsion is the twisting or wrenching of a b

Project Title

Designing and Fabrication of state of the art low frequency torsional fatigue testing machine for testing of Aerospace Alloys

Project Area of Specialization

Mechatronics Engineering

Project Summary

We have to design a torsional fatigue testing machine at low cost. A Torsional fatigue machine is used to measure the torsional fatigue at various torque levels and different frequencies of the loading, of a specimen it may be cylinder or  spring etc. Torsion is the twisting or wrenching of a body by the exertion of forces tending to turn one end or part about a longitudinal axis while the other is held fast or turned in the opposite direction. And Fatigue is the weakness in the materials, especially metals, caused by the repeated variations of stress. Torsion fatigue is dependent on various parameters i.e. torque, frequency of fatigue, amplitude and the more important phenomenon is the mechanical property of that material. Torsional fatigue is usually concern with Mechanical engineers to determine how efficient and stable the material is when evaluating components that operates under high oscillating torque at various frequencies.

There are various  machines working in our daily lives which are in under consideration with the torsional fatigue systems. So, it is the basic need of Manufacturing engineer to calculate the life cycle of the product and to test specimen. Torsion fatigue testing machine is used by engineers, metallurgists and students to create a torsion fatigue curve that on how much oscillating torque is required to fail the material strength

Project Objectives

To estimate the life cycle of AEROSPACE ALUMINIUM ALLOYS under the torsional fatigue mechanisms.

To use the the machine in material testing labs for the research on the material behaviours at univerity level.

To analyze the material according to the international standards like ASTM.

To commercialize the state of the art torsional fatigue testing machine at industrial level.

AEROSPACE INDUSTRIES like PAC KAMRA in pakistan can utilize this state of art for their testing of AEROSPACE ALLOYS.

Project Implementation Method

General Methodology of Project

Literature Review of project

Project proposed time schedule

Designing of article on CAD/CAM

Implementation of Project

Analysis of Aerospace Alloys

Gathers graphical analysis

Maintainance 

Thesis

Benefits of the Project

Fatigue testing machines of this kind (with electro-servomotor) is not available on the 
market. A vast majority of these machines are large hydraulic testers, primarily made for 
axial testing of larger size specimens with only a few exceptions, such as when hydraulic 
systems are also used for torsion testing (For example, INSTRON and MTS, the world 
leading producers, have recently started the production of medium-size hydraulic torsion 
testing machines.).

The system being proposed here is not to be compared with large and expensive systems. 
It has its own characteristics, and it has been designed for meeting other requirements. Its 
main properties are :

1) Low-production price, up to ten times less than the price of a comparable hydraulic machine.

2) Low-torque and small size.

3) Additional strain (stress) measuring devices are unnecessary.

4) The system has one moving part only ( the motor shaft).

5) Easy to produce and maintain.

6) High precision.

7) The system operation is computer controlled and easy to configure and conduct 
experiments.
8) It meets the current market demands (torsion testing, small size, low cost). 

Technical Details of Final Deliverable

There will be a computer controlled system for the variation or all parameters like Torque, amplitude & frequency.

In each parameter, there will be a specific uncertainity .

Unsymmetrical amplitude tests can also be performed.

Direct and numerical, both control are applicable.

mesurement of torque can be done by two methods :

                         By Ccurrent variation in motor.

                         By Torque sensor or Load cell assembly

Optical encoders are used which can measure upto 0.1mm accuracy.

Final Deliverable of the Project

Hardware System

Core Industry

Manufacturing

Other Industries

Education

Core Technology

Others

Other Technologies

Sustainable Development Goals

Quality Education, Industry, Innovation and Infrastructure

Required Resources

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