Fatigue Testing: What Is It And How Can You Benefit From It?

fatigue testing machine

The overall goal of fatigue testing is to define the necessary fatigue life of machine components. This, in turn, determines if the life and/or reliability can be maintained over the lifespan of the components in the design of the system. Fatigue testing is a method to determine the early onset of fatigue in a specific equipment item.

What is Fatigue?

Fatigue is the non-combustive deterioration of structural parts that occurs during normal operation. Some of the early signs of fatigue in a component include premature cracks, delamination of material, and premature failure of the material under high loads. These early signs of fatigue can occur over weeks or months. These signs are not always a result of a catastrophic failure of the physical system. 

Key Benefits of Fatigue Testing 

Below are some of the benefits of fatigue testing:-

  • Helps to define the maintenance- Fatigue testing helps to define the maintenance and repair cycle requirements of the components in its operational environment. When testing for fatigue or breaking, machines are typically tested in the high-load scenarios with longer “conditions” (repetitive stress increases of over 100 percent) than in the other fatigue cycles. Some machines, however, are designed to withstand the fatigue cycles but may have breaks in the same location, which in some cases may produce increased pressure and shock load that is not recognized by most analysis tools.
  • The safe operating life of machines– To achieve maximum product and machine utilization, it is essential to get the relevant results from the tools to ensure the safety of the machines and personnel involved in their operation. For safe and reliable machine operation, it is vital to test the quality and durability of the components using advanced and accurate test equipment. Compared to traditional bench testing, the rate and repetition range of test results are not always high, which leads to false assumptions. The result of these methods is an inability to generate essential and accurate performance data that enables proper machine and component optimization.
  • Provides the most relevant test data-Test Devices has the tools and facilities to conduct accurate and repeatable, useful, and dependable fatigue testing for the major types of machines. With a team of highly experienced engineers, the testing procedures are more detailed and applicable to all types of equipment.
  • It can be used in any industry-Fatigue and wear condition testing can be used for any process or material in any industry. While the expertise is geared towards heavy-duty motive equipment, the knowledge base covers the entire life cycle of products and manufacturing processes. When used effectively, fatigue testing and failure analysis tools are a great way to improve machine reliability and design. Fatigue can cause a machine to wear out prematurely. By understanding the causative factors for wear, you can identify which preventative measures need to be taken.

To have the best understanding of the data needed for life-cycle costs, failure modes, and hazardous environments, it is crucial to define the correct data. Fatigue testing is the process of acquiring a data set to demonstrate how the components interact with the loads applied and characterize how the components will respond to overloads.

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