A tension-torsional fatigue testing apparatus for micro-scale components

Device for Torsional Fatigue Strength Assessment Adapted for Pulsating Testing Machines

The torsional fatigue test determines the fatigue limit for a certain asymmetry coefficient of the cycle. The assessment of fatigue tests is performed on specialized machines. There are two types of torsion testing machines: universal machines that have the torsion component and specialized machines only for torsion testing. Nevertheless, no matter which proposed option we choose, the purchase prices for these testing machines or the values spent for self-management are quite high. This paper presented a device used for torsion fatigue testing, adaptable to a universal pulsating testing machine, designed to determine the torsion fatigue limit for different materials. The built device is simple and reliable, and therefore inexpensive. By using this device, we can determine the limit of the torsional fatigue after any stress cycle and we can use the parameters obtained from the universal machine to which it was attached. The torque and twisting angle of the test specimen during the test can be determined by calculation. The paper also presented an experimental method for determining shear strains based on calibration experiment, using a specimen on which strain gauges were mounted. The values taken from this calibration experiment were compared with those obtained from the theoretical calculation.

Non-contact temperature control and stereo digital image correlation for high-temperature testing of miniature tubular specimens

Component failures very often occur due to high temperature and multiaxial stress states arising at critical component locations. To imitate such loading conditions, a multiaxial miniature testing system (MMTS) with axial, torsional, and internal pressurization capabilities for high-temperature testing of miniature tubular specimens has been developed. Among many challenges of developing the MMTS, uniform heating, temperature measurement and control, and surface strain measurement on a miniature tubular specimen at high temperatures have significant difficulties. This paper addresses two significant challenges: first, the development of a non-contact temperature control system using infrared thermography to uniformly heat a miniature specimen of 1 mm outer diameter (OD), and second, the development of a stereo digital image correlation (stereo-DIC) setup for strain measurement on the miniature specimen subjected to high temperature. The developed control system maintains the test temperature through a closed feedback loop and employs a fail-safe mechanism to protect the MMTS load frame components against unanticipated temperature rises. The thermocouple wire-size effect on the measured temperature was examined for three different wire sizes: 0.05, 0.25, and 0.5 mm for accurate emissivity determination required for infrared thermography. Emissivities of the specimen surface at different high temperatures were experimentally determined. Inherent error analysis of the developed high-temperature stereo-DIC setup showed acceptable strain measurement uncertainty. The effectiveness of the developed non-contact temperature control system and high-temperature stereo-DIC setup has been verified by performing tensile testing of a 1 mm OD specimen at 500 °C.

Nanorobotic System iTRo for Controllable 1D Micro/nano Material Twisting Test

In-situ micro/nano characterization is an indispensable methodology for material research. However, the precise in-situ SEM twisting of 1D material with large range is still challenge for current techniques, mainly due to the testing device's large size and the misalignment between specimen and the rotation axis. Herein, we propose an in-situ twist test robot (iTRo) to address the above challenges and realize the precise in-situ SEM twisting test for the first time. Firstly, we developed the iTRo and designed a series of control strategies, including assembly error initialization, triple-image alignment (TIA) method for rotation axis alignment, deformation-based contact detection (DCD) method for sample assembly, and switch control for robots cooperation. After that, we chose three typical 1D material, i.e., magnetic microwire Fe74B13Si11C2, glass fiber, and human hair, for twisting test and characterized their properties. The results showed that our approach is able to align the sample to the twisting axis accurately, and it can provide large twisting range, heavy load and high controllability. This work fills the blank of current in-situ mechanical characterization methodologies, which is expected to give significant impact in the fundamental nanomaterial research and practical micro/nano characterization.

Development of a high-frequency and large-stroke fatigue testing system for rubber

The limited capabilities of current fatigue testing machines have resulted in studies on the fatigue behavior of rubber under large-displacement amplitude and high frequency being very sparse. In this study, a fatigue testing system that can carry out large-displacement amplitude and high-frequency fatigue tests on rubber was developed using a moving magnet voice coil motor (MMVCM) actuator, with finite element analysis applied to analyze the thrust of the MMVCM actuator. The results of a series of cyclic tension tests conducted on vulcanized natural rubber specimens using the developed fatigue testing system verify that it has high precision, low noise, large-stroke, and high-frequency characteristics. Further, the load frame with the developed MMVCM actuator is feasible for material testing, especially for large-stroke and high-frequency fatigue tests.