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Development of a Closed-Loop High-Cycle Resonant Fatigue Testing System

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Abstract

In this paper, a vibration-based testing methodology to assess fatigue behavior of a metallic structure is presented. To minimize the testing duration, the test setup is designed for a base-excited multiple-specimen arrangement driven in a high-frequency resonant mode, which allows completion of fatigue testing in an accelerated period. The shaker operates in closed-loop control with dynamic specimen response feedback provided by a scanning laser vibrometer. A test coordinator function is developed to synchronize the shaker controller and the laser vibrometer and complete the closed-loop scheme: the test coordinator monitors structural health of the test specimens throughout the test period, recognizes change in specimen dynamic behavior due to fatigue crack initiation, terminates test progression, and acquires test data in an orderly manner. The test methodology is demonstrated with cantilever specimens that are clasped on the shaker armature with specially-designed clamp fixtures. Experimental stress evaluation is carried out to verify the specimen stress predictions. A successful application of the experimental methodology is demonstrated by validation tests with Al 6061-T6 aluminum specimens subjected to fully-reversed bending stress.

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Acknowledgements

The authors would like to proclaim sincere gratitude to all those who contributed to the success of the research project reported in this study. The authors appreciate the inspiration and support provided by Dick Shaltens, Wayne Wong, Jeff Schreiber, Lanny Thieme, and Geoff Bruder, as well as the technical management of Drs. Ajay Misra and Steven Arnold. The authors thank Ralph Pawlik and Frank Bremenour for their expert experimental advice and technical collaboration. The Science Mission Directorate at NASA Headquarters provided funding to complete the work described herein, and the authors truly are grateful for that enduring commitment. The authors highly appreciate the efforts and cooperation enjoyed from Sunpower, including the professional work of Kyle Wilson, Doug Mansfield, Courtney Lenart, and their consultant Barry Penswick. The authors also would like to thank Mr. Brett Bell, Mr. William Wenzel and Mr. Dale Ertley (all from College of Engineering, the University of Akron) for their strong support in manufacturing and machining of materials.

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  1. Department of Civil Engineering, The University of Akron, 244 Sumner St. ASEC 209F, Akron, OH, 44325–3905, USA

    G. J. Yun, A. B. M. Abdullah & W. Binienda

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  1. G. J. Yun
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  2. A. B. M. Abdullah
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  3. W. Binienda
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Correspondence to G. J. Yun.

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Yun, G.J., Abdullah, A.B.M. & Binienda, W. Development of a Closed-Loop High-Cycle Resonant Fatigue Testing System. Exp Mech 52, 275–288 (2012). https://doi.org/10.1007/s11340-011-9486-z

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  • DOI: https://doi.org/10.1007/s11340-011-9486-z

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