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ll
"#$%&'(%
laLlgue LesL machlnes currenLly on Lhe markeL, such as Lhose from lnsLron, offer hlgh levels of
preclslon aL a hlgh cosL. 1he purpose of Lhls lnvesLlgaLlon was Lo develop a deslgn for a low cosL
faLlgue LesL rlg capable of applylng a non-zero mean sLress ln a corroslve fluld. 1he alm of Lhe rlg was
Lo dellver conslsLenL resulLs, sacrlflclng preclslon lf necessary. 8esearch lndlcaLed LhaL a number of
loadlng mechanlsms were avallable for use. AfLer evaluaLlon, canLllever bendlng was selecLed as Lhe
loadlng mechanlsm as lL provlded Lhe easlesL meLhod Lo consLrucL an economlcal machlne. lurLher
alms were Lo employ pro[ecL managemenL Lechnlques LhroughouL Lhe duraLlon of Lhe lnvesLlgaLlon.
1hese ranged from communlcaLlon Lools Lo pro[ecL sLrucLure and proved successful ln dellverlng a
funcLlonal, economlcal faLlgue LesL rlg. 1he flnal machlne has an esLlmaLe cosL of 874.72, well
wlLhln Lhe budgeL of 3000.



lll
)*+%,+%$
6+N9OAPH!QH;H91< L
L R912O!S+1RO9 J
J NHI O?TH+1RUH< O. V2OTH+1 J
W V2OTH+1 VP699R9Q 69! ;696QH;H91 J
WFL V2OTH+1 <12S+1S2H J
WFJ 2OPH< 69! 2H<VO9<R?RPR1RH< M
WFW ;696QH;H91 1H+X9RYSH< Z
3.3.1 S18uC1u8L 3
3.3.2 8LSCu8CL MAnACLMLn1 6
M !H<RQ9D +O22O<RO9 .61RQSH 1H<1R9Q ;6+XR9H [
MFL ?6+NQ2OS9!D PR1H261S2H 2HURHA [
4.1.1 Cu88Ln1 1LCPnCLCClLS 7
4.1.2 CC88CSlCn lA1lCuL 7
4.1.3 nCn-ZL8C MLAn S18LSS 9
4.1.4 LCAulnC MLCPAnlSM 9
4.1.4.1 Comparlson of Loadlng 1ypes 9
4.1.4.2 ConLrol Mechanlsm 11
4.1.3 CALl88A1lCn 12
MFJ !H<RQ9 V2O+H<< LM
4.2.1 uS 14
MFW +O9+HV1S6P !H<RQ9 LM
4.3.1 CALCuLA1lCnS 13
4.3.2 CCnCL1uAL uLSlCn 2 13
4.3.3 CCnCL1 SLLLC1lCn 19
4.3.4 uLSlCn uLvLLCMLn1 20
MFM !H16RPH! !H<RQ9 +O;VO9H91< JL
4.4.1 MC1C8 SLLLC1lCn 21
4.4.1.1 uC MoLors 21
4.4.1.2 AC MoLors 21
4.4.1.3 8equlremenLs of Lhe moLor 22
4.4.1.4 Chosen MoLor 23
4.4.2 CC88CSlCn CPAM8L8 23
4.4.2.1 ueslgn 23
4.4.2.2 MaLerlal 26
4.4.2.3 Seallng 26
4.4.2.4 ump SelecLlon 26
4.4.2.3 LnvlronmenLal ConLrol 27
4.4.3 8ASL & l8AML 27
4.4.3.1 ueslgn 28


lv
4.4.3.2 MaLerlal 28
4.4.4 MC1C8 LA1L Au!uS1MLn1 28
4.4.4.1 ueslgn 29
4.4.4.2 MaLerlal 30
4.4.3 CCnnLC1lnC SL1 u 30
4.4.3.1 LccenLrlc CenLre 30
4.4.3.2 8earlng SelecLlon 31
4.4.3.3 ConnecLlng 8od 31
4.4.6 SLClMLn CLAMS 32
4.4.6.1 8oLLom Clamp SeL 32
4.4.6.2 1op Clamp SeL 33
4.4.7 CCun1lnC S?S1LM 33
4.4.8 CWL8 SuL? (Cl8Cul1 88LAkL8, L-S1C SWl1CP, Au1C SPu1-Cll SWl1CP) 37
4.4.9 CALl88A1lCn SLClMLn 37
4.4.9.1 Cvervlew 37
4.4.9.2 CffseL nulllng 39
4.4.9.3 ShunL CallbraLlon 40
4.4.10 1LS1 SLClMLn 40
4.4.10.1 AS1M SLandard 40
4.4.10.2 MaLerlal 41
4.4.10.3 Pand CalculaLlons 41
4.4.10.4 lLA Analysls of Speclmen 41
4.4.10.3 ulmenslons 44
4.4.11 Auul1lCnAL SLClMLn lnlC8MA1lCn 44
4.4.12 lLA AnAL?SlS Cl S?S1LM Anu C8l1lCAL A81S 44
4.4.12.1 Analysls of Assembly 44
4.4.12.2 Analysls of MoLor ShafL 43
4.4.13 CCS1lnC 46
4.4.14 llnAL 8CuuC1 46
Z Q2OSV !I96;R+ 69! +O;;S9R+61RO9 M\
ZFL <S++H<< O. 2OPH< 69! 2H<VO9<R?RPR1RH< M\
3.1.1 8C!LC1 MAnACL8 48
3.1.2 1LAM MLM8L8S 48
ZFJ +O;;S9R+61RO9 M]
ZFW !H+R<RO9-;6NR9Q 69! +O9.PR+1 2H<OPS1RO9 ;H1XO!< ZK
3.3.1 uLClSlCn MAklnC 30
3.3.2 CCnlLlC1 8LSCLu1lCn 30
ZFM H^6;VPH +O9.PR+1< 69! 2H<OPS1RO9< ZK
3.4.1 1LAM MLM8L8 SCPLuuLLS 30
3.4.2 ul8LC1lCn Cl 8C!LC1 31
3.4.2.1 lnLerlm 8eporL lormaL 31
3.4.2.2 llnal ueLalled ueslgn MeeLlng 31
_ .S1S2H AO2N ZL


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6VVH9!R^ JD <VH+R;H9 X69! +6P+SP61RO9< Z[
6VVH9!R^ WD Q6911 +X621 Z\
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6VVH9!R^ ZD +O<1 696PI<R< _M






1
"(-+*./,01,2,+%$
1he group would llke Lo Lhank rofessor Mackenzle for hls help and guldance LhroughouL Lhe
pro[ecL. We would also llke Lo Lhank: ur Comlekcl and ur Podgkless for Lhelr lnpuL durlng Lhe
research and lnlLlal deslgn sLage of Lhe pro[ecL, !ohn 8edgaLe for hls help durlng Lhe deslgn of Lhe
elecLrlc and elecLronlc clrculLry, and lab Lechnlclans AllsLalr uuff and !lm uoherLy for Lhelr asslsLance
durlng Lhe LesLlng of varlous seallng meLhods.



2
3 4+%&*05(%6*+
Corroslon faLlgue ls a ma[or fallure mode for equlpmenL operaLlng under cycllc loadlng ln corroslve
envlronmenLs. 1hls ls of crlLlcal lmporLance Lo Lhe analysls of machlnery LhaL ls operaLlng ln an
offshore envlronmenL, as lL ls consLanLly exposed Lo sallne condlLlons. undersLandlng Lhe faLlgue
performance of Lhe equlpmenL maLerlal ls fundamenLal Lo evaluaLlon of lLs expecLed operaLlng llfe.
1hls pro[ecL enLalls deslgnlng an lnsLrumenLed LesL machlne LhaL wlll apply conLrolled cycllc loadlng
wlLh a non-zero mean sLress Lo maLerlal speclmens ln an approprlaLe corroslve medlum. 1he deslgn
should be low cosL, so LhaL several machlnes can be manufacLured Lo carry ouL mulLlple corroslon
faLlgue LesLs slmulLaneously 1he scope of Lhe pro[ecL was Lo produce a package conLalnlng a deLalled
deslgn, cosL analysls, and manufacLurlng drawlngs ready for fabrlcaLlon. Along wlLh Lhe Lechnlcal
challenges lnvolved ln Lhe successful lmplemenLaLlon of produclng a deLalled deslgn package, a loL of
aLLenLlon was focussed on Lhe managemenL and dynamlc of Lhe group. LffecLlve pro[ecL plannlng
and resource managemenL formed a slgnlflcanL parL of Lhe pro[ecL ln order Lo meeL all Lhe
dellverables ln an efflclenL and professlonal manner.
7 8,9 :#;,(%6<,$ *= >&*;,(%
1he maln ob[ecLlve of Lhe pro[ecL was Lo deslgn a corroslon faLlgue LesL rlg wlLh Lhe followlng
parameLers:
ueslgn a LesL rlg capable of applylng a non-zero mean sLress on a speclmen
ueslgn a LesL rlg wlLh Lhe capablllLy of applylng varylng sLress ampllLudes Lo a speclmen
ueslgn a LesL rlg capable of rellably LesLlng a range of speclmens
CapablllLy of LesLlng speclmen aL low frequency ln a corroslve envlronmenL
LsLabllsh deslgn parameLers: speclmen slze, loadlng, callbraLlon and measuremenL
ueslgn load conLrol sysLem and monlLorlng sysLem
CuLwlLh Lhe deslgn ob[ecLlves of Lhe pro[ecL, educaLlonal ob[ecLlves exlsLed, focused on galnlng an
undersLandlng of Lhe complexlLles of organlslng a group pro[ecL and enhance Leam worklng,
communlcaLlon and managemenL skllls. 1hese lmporLanL sofL skllls were developed over Lhe course
of Lhe pro[ecL.
? >&*;,(% >/'++6+1 '+0 @'+'1,2,+%
?A3 >&*;,(% B%&5(%5&,
1he pro[ecL adopLed a phase-gaLe approach Lo Lhe work scope from Lhe ouLseL. A phase-gaLe
approach lnvolves ldenLlfylng Lhe key sLages, or phases, of a pro[ecL and ldenLlfylng key ob[ecLlves
wlLhln Lhese sLages. AfLer ldenLlfylng Lhe key sLages lnvolved ln Lhe pro[ecL, each of Lhe sLages are
separaLed by a declslon gaLe. AL each declslon gaLe, Lhe group meL Lo dlscuss Lhe sLaLus of Lhe
ob[ecLlves assoclaLed wlLh Lhe relevanL sLage. hase-gaLes, or SLage-gaLes, provlde a useful
Lechnlque ln assesslng Lhe quallLy of crlLlcal pro[ecL sLages and allowlng Lhe approprlaLe acLlon Lo be
Laken ln response Lo Lhls assessmenL. 1hls acLlon can range from repeLlLlon of a speclflc sLage Lo
progresslon onLo Lhe proceedlng sLage. 1he sLages were ldenLlfled Lhrough Lhe selecLlon of Lhe
deslgn framework of Lhe pro[ecL. 8elng a deslgn pro[ecL, lL was planned ln accordance wlLh ugh's


3
1oLal ueslgn lramework [1]. ugh's 1oLal ueslgn lramework offers a slmple, naLural way of
ldenLlfylng key sLages wlLhln Lhe pro[ecL. 1hese sLages are ouLllned as follows:
ueclslon CaLe 1 - 8esearch
ueclslon CaLe 2 - ConcepLual ueslgn
ueclslon CaLe 3 - ueLalled ueslgn
ueclslon CaLe 4 - llnal ackage wlLh ManufacLurlng urawlngs ready for fabrlcaLlon
llgure 1 ldenLlfles Lhe key dellverables and ob[ecLlves wlLhln each declslon gaLe sLage of Lhe pro[ecL.

.$%0," LD N"G </*%" Q*/"# *&7 !"5$b",*45"# )(, V,(8"@/
AL Lhe end of each sLage, a declslon gaLe meeLlng was held by Lhe pro[ecL Leam Lo dlscuss Lhe
progress of Lhe relevanL sLage, relaLlve Lo Lhe expecLed dellverables and ob[ecLlves. 1hese meeLlngs
were used Lo measure boLh Lhe quallLy and progress of Lhe pro[ecL coupled wlLh declslons on
progresslon. As a Leam, lL was declded LhaL declslons would be made aL Lhese meeLlngs lnvolvlng Lhe
enLlre Leam. 1he flnal declslon was always glven Lo Lhe acLlng pro[ecL manager aL LhaL perlod ln Llme,
however a group consensus was generally reached aL each of Lhese meeLlngs. 1he process for
declslon-maklng ls dlscussed ln SecLlon 3.3.1.
1he SLage-CaLe process was used alongslde oLher Lools, namely a CanLL charL, Lo form a conLracLual
pro[ecL proposal and plan LhaL was agreed upon beLween Lhe CllenL and ConLracLor. 1he
comblnaLlon of Lhese Lools provlded ueclslon CaLes LhaL ouLllned speclflc dellverables alongslde
daLes LhaL Lhese dellverables needed Lo be compleLed. 1hls allowed progress wlLhln sLages Lo be
monlLored and adapLed. 1he backbone of Lhe pro[ecL sLrucLure was regular meeLlngs, much more
frequenLly Lhan Lhe ueclslon CaLe meeLlngs. lL was recognlsed LhaL regular meeLlngs would offer
flexlblllLy ln plannlng LhaL would be unaLLalnable oLherwlse. 1hls comblnaLlon formed Lhe basls of
Lhe pro[ecL sLrucLure.
- 8esulLs of research are presenLed.
- Lveryone has an undersLandlng of exlsung corroslon faugue LesL
equlpmenL and procedures.
- A feaslble deslgn be creaLed wlLhln budgeL and umeframe.
- uS has been wrluen.
CaLe 1
- CCMs have been used eecuvely Lo selecL a nal concepLual deslgn.
- ueslgn meeLs every aspecL of Lhe uS.
- 1he cosL lmpllcauons have been consldered.
- ueslgn has been approved by cllenL. CaLe 2
- ueLalled deslgn sull meeLs Lhe uS.
- An accuraLe 3u CAu model has been creaLed.
- All aspecLs of Lhe manufacLurlng deLalled have been consldered.
- WrlLe operaung speclcauons for Lhe LesL rlg.
CaLe 3
- 8lg ls ready Lo be manufacLured.
- All pro[ecL ob[ecuves have been meL.
- llnal reporL ls submlued.
- CllenL ls saused. CaLe 4


4
?A7 C*/,$ '+0 C,$D*+$6#6/6%6,$
1he Leam declded from Lhe ouLseL Lo appolnL a pro[ecL manager for each ma[or sLage ln Lhe pro[ecL.
ugh's 1oLal ueslgn lramework gulded our ueclslon CaLes, whlch ln Lurn lenL Lhemselves Lo be spllL
beLween Lwo ma[or scopes of work:
Scope 1 - 8esearch and ConcepLual ueslgn
Scope 2 - ueLalled ueslgn and CompleLlon
ln order Lo appolnL a pro[ecL manager LhaL would be besL sulLed Lo Lhe role, an lmporLance was
placed on deLermlnlng Lhe sLrengLhs and weaknesses of each Leam member prlor Lo allocaLlng roles.
8elbln's 1eam 8ole 1heory [2] was used Lo ldenLlfy Lhese sLrengLhs and allocaLe Lhem an approprlaLe
role wlLhln a Leam. 1he Lheory suggesLs LhaL an ldeal Leam ls composed of a varleLy of Lypes of
personnel LhaL represenL Lhe followlng caLegorles:
Company Worker - ConLrolled and sLable and a pracLlcal organlser.
Chalrman - SLable, domlnanL exLroverL. 8arely Lhe mosL lnLelllgenL member of Lhe
Leam, buL ls respecLed and can see Lhe Leams sLrengLhs and weaknesses.
Shaper - Anxlous, domlnanL exLroverL and usually Lhe Lask leader. CuLgolng, lmpulslve
ad lmpaLlenL. lorceful and drlven by ob[ecLlves.
lanL - uomlnanL, hlgh lC and lnLroverLed. 1he mosL lnLelllgenL ln Lhe Leam. Source of
orlglnal ldeas.
8esource lnvesLlgaLor - SLable, domlnanL and exLroverLed. Llkable, soclal and
gregarlous. ln sLyle poslLlve, enLhuslasLlc and makes frlends easlly.
MonlLor LvaluaLor - Plgh lC, sLable and lnLroverLed. Serlous naLure, noL creaLlve buL
capable of measured analysls.
1eam Worker - lnLroverLed and sLable and Lhe mosL senslLlve member of Lhe Leam. An
acLlve communlcaLor, sLrong ln empaLhy. Pelps and encourages oLhers.
CompleLer llnlsher - Anxlous lnLroverL who worrles abouL whaL mlghL go wrong. non-
asserLlve buL galvanlses oLhers Lo acLlon Lo meeL deadllnes.
1eam members compleLed a proflllng quesLlonnalre Lo deLermlne a prlmary and secondary Leam
role LhaL would be mosL sulLable Lo Lhem, accordlng Lo 8elbln. 1he mosL sulLable prlmary and
secondary roles for each Leam member are deLalled ln 1able 1.
9*>" V,$>*,G 1"*> 2(5" <"@(&7*,G 1"*> 2(5"
9$@(5* 6&7,"C# CompleLer llnlsher Shaper
9"$5 ?,*@="&,$7%" Shaper Chalrman
;*,= +*>34"55 Shaper Chalrman
+(5$& </*,= MonlLor LvaluaLor Company Worker
65$#/*$, AB$/" MonlLor LvaluaLor Company Worker
1*45" LD V,$>*,G *&7 <"@(&7*,G 1"*> 2(5"# )(, H*@B 1"*> ;">4",
1he resulLs of Lhe quesLlonnalre ylelded a varled seL of recommended roles for Lhe group. 1he range
of recommended roles wlLhln Lhe Leam covered an exLenslve number of roles crlLlcal Lo a successful
Leam. lmporLanLly, Lhere were Lwo members who were ldeally sulLed Lo leadlng and managlng Lhe
pro[ecL ln Lhe form of Shaper and Chalrman. 1hls resulL also meanL LhaL Lhere was Lhe opLlon Lo
appolnL Lwo pro[ecL managers LhroughouL Lhe pro[ecL. nell and Mark were appolnLed pro[ecL


3
manager due Lo Lhelr compeLencles ln leadershlp and ob[ecLlve drlven menLallLles. lL was declded
LhaL Lhe nell would Lake on Lhe responslblllLy of pro[ecL manager for Lhe flrsL scope of work, Lhe
research and concepLual deslgn sLages, and Mark would Lake on Lhls responslblllLy for Lhe second
scope of work, Lhe deLalled deslgn and dellvery. Scope Lwo ln parLlcular requlred an ob[ecLlve drlven
pro[ecL manager LhaL would ensure LhaL deadllnes were achleved and LhaL Lhe scope of work was
geLLlng compleLed ln llne wlLh Lhe pro[ecL plan.
CuLwlLh Lhe pro[ecL manager role, Lhe remalnlng members of Lhe group assumed slmllar roles. 8oles
and responslblllLles of lndlvlduals varled LhroughouL Lhe duraLlon of Lhe pro[ecL dependanL on whlch
sLage was acLlve. lnlLlally, durlng Lhe research sLage, each member was allocaLed speclflc areas Lo
conducL research, varylng from corroslon Lo Lhe effecL of mean sLress on faLlgue, whlch would Lhen
be shared wlLh Lhe resL of Lhe Leam aL frequenL Leam meeLlngs, and areas LhaL proved lmporLanL Lo
Lhe pro[ecL were researched furLher. As such, members had shorL-Lerm ob[ecLlves LhaL would vary
from meeLlng Lo meeLlng dependanL on Lhe group's needs. 1he meeLlngs served as a medlum for
each member Lo share knowledge galned from Lhelr research wlLh Lhe resL of Lhe Leam. 1hls was
lmporLanL Lo bulld a general knowledge of lmporLanL Lechnlcal componenLs of Lhe deslgn, requlred
prlor Lo concepLual deslgn. Movlng lnLo concepLual deslgn, Lhere was a worry LhaL Lhe lack of a
creaLlve presence, a planL, would cause lssues wlLh lack of lnnovaLlve deslgns, someLhlng cenLral Lo
Lhe pro[ecL ob[ecLlves. 1he roles of each member agaln changed sllghLly. AL Lhe beglnnlng of Lhe
concepLual deslgn sLage, members compleLed a range of general concepLs each, presenLlng Lhem aL
frequenL meeLlngs. As Lhls process progressed Lowards Lhe deLalled deslgn sLage, members became
more lnvolved wlLh Lhe aspecL of Lhe deslgn LhaL Lhey were mosL compeLenL wlLh, belng lL corroslon,
conLrol sysLems or loadlng mechanlsms.
8oles and responslblllLles changed slgnlflcanLly movlng lnLo Lhe deLalled deslgn secLlon of Lhe
pro[ecL. Cnce a flnal deslgn was chosen, lL was posslble Lo segmenL Lhe deslgn lnLo essenLlal secLlons
of deslgn. Lach Leam member was asslgned a secLlon of work Lo conducL a deLalled deslgn on. AL Lhls
sLage, each member was responslble for LhaL secLlon, wlLh progress belng shared aL regular Leam
meeLlngs. Members were responslble for Lhe dellvery of Lhelr own respecLlve scope of deLalled
deslgn. 1hls work lnvolved a number of lnLerfaces beLween members and secLlons of Lhe deslgn, so
consLanL communlcaLlon was requlred. WhllsL Lhe core responslblllLles of each of Lhe group
members were slmllar, Lhe Leam roles ldenLlfled Lhrough Lhe 8elbln quesLlonnalre were reflecLed ln
Leam meeLlngs, where LhoughLs and ldeas could be shared wlLh Lhe resL of Lhe group, and progress
was monlLored.
?A? @'+'1,2,+% E,(F+6G5,$
?A?A3 B%&5(%5&,
As dlscussed ln SecLlon 3.2, nell and Mark were appolnLed pro[ecL manager for Lhe concepLual and
deLalled deslgn respecLlvely. 1hls Lechnlque allowed for conLlnulLy wlLhln Lhe Leam and worklng
sLrucLure, as each of Lhese secLlons accounLed for approxlmaLely a semesLer each. 8egulaLlng Lhe
number of managers LhroughouL Lhe pro[ecL allowed for Lhe Leam Lo develop and work proflclenLly,
as Lhe Leam sLrucLure remalned consLanL for a susLalned perlod of Llme. 1hls also allowed each of
Lhe members Lo famlllarlse Lhemselves wlLh Lhe responslblllLles of Lhelr roles. 1hls Lechnlque
allowed Llme for Lhe pro[ecL manager Lo undersLand Lhe characLerlsLlcs of each of Lhe members, and
how each member would be besL sulLed Lo dlfferenL roles. Pavlng Lhe Llme Lo undersLand Leam


6
members' sLrengLhs and weaknesses allowed for proper allocaLlon of resources ln Lerms of
personnel, coupled wlLh Lhe pro[ecL manager's undersLandlng of Lhe LargeLs and deadllnes of Lhe
pro[ecL was deLermlned Lo be Lhe sysLem LhaL had Lhe mosL poLenLlal for Lhe pro[ecL.
1he use of a pro[ecL manager provlded a flgure Lo sLeer Lhe pro[ecL Lowards deadllnes and
mllesLones as agreed by Lhe group, whllsL Lhe oLher members of Lhe Leam undersLood LhaL each
lndlvldual was responslble for lndlvldual scopes of work whllsL malnLalnlng an lnLeresL ln each of Lhe
oLher scopes. lL was Lhe lnLenLlon from Lhe ouLseL LhaL Lhe pro[ecL manager would Lake
responslblllLy for ensurlng LhaL Lhe work had been dlvlded approprlaLely beLween Leam members,
and Lhen Lhe responslblllLy fell upon Lhe lndlvldual Lo dellver Lhelr scope for Lhe agreed upon daLes.
1he dlvlslon of Lhe work was done Lhrough regular Leam meeLlngs of frequency 1 per week, aL whlch
members dlscussed Lhelr sLrengLhs and weaknesses, and expressed preferred areas of work. 1hls
sLrucLure was adopLed early ln Lhe pro[ecL, and reflecLed a democraLlc sysLem LhaL Lhe Leam wanLed
Lo use.
?A?A7 C,$*5&(, @'+'1,2,+%
WlLh llmlLed resources wlLhln Lhe Leam ln Lerms of Llme and members, a sysLem was requlred Lo
manage Lhese resources effecLlvely. llrsLly, as deLalled ln SecLlon 3.1, Lhe ma[or mllesLones and
gaLes were ldenLlfled LhroughouL Lhe llfe of Lhe pro[ecL. 1hese were Lhen adopLed ln a CanLL charL,
deLalllng Llmescales for key Lasks. A CanLL lllusLraLes Lhe sLarL and end daLes of a pro[ecL and show
Lhe dependency relaLlonshlps beLween acLlvlLles. Ma[or scopes of work wlLhln Lhe pro[ecL were
lncluded ln Lhe CanLL charL, each belng allocaLed a Llme frame Lo be compleLed wlLhln. Some of Lhe
Lasks covered ln Lhe CanLL charL lnclude:
8esearch
lnlLlal ConcepLual ueslgn
ConLrolled Convergence MaLrlx AppllcaLlon
ueLalled ComponenL ueslgn (lrame, ConLrol SysLem, Speclmen eLc)
Model CeneraLlon
Lach of Lhe ldenLlfled scopes of work was asslgned a Llme scale, endlng wlLh Lhe compleLlon daLe of
14
Lh
Aprll 2014. 1hls daLe was flnallsed, and alongslde deadllnes for Lhe lnLerlm reporL, were Lhe only
deadllnes LhaL were mandaLory. When asslgnlng Llmescales for each Lask, conLlngency was
consldered, allowlng room for delays ln work as Lhe pro[ecL develops. Ma[or Lasks wlLh Lhe poLenLlal
for delay, such as deLalled deslgn, were glven a bullL ln conLlngency along wlLh a serles of mlnor
Lasks such as webslLe deslgn. 1he CanLL charL can be found ln Appendlx 3.
Pavlng esLabllshed regular Leam meeLlngs Lo updaLe each oLher on progress, a sysLem for sharlng
knowledge was ldenLlfled as a requlremenL. 1he besL opLlon ldenLlfled for Lhls was Lhe creaLlon and
use of a shared folder on 'uropbox', allowlng an unllmlLed number of flles Lo be shared amongsL Lhe
group. 1hls was creaLed Lo encourage knowledge sharlng beLween members of Lhe group. 1oplcs
covered wlLhln Lhe Leam meeLlngs could Lhen be enforced wlLh Lhe relevanL arLlcles or webslLes
belng uploaded Lo Lhe 'uropbox' for oLher members Lo read. CreaLlng an efflclenL knowledge-sharlng
devlce addressed Lhe lssue of poLenLlal losses of lnformaLlon beLween members, and allowed Leam
members Lo undersLand Lhe lssues LhaL oLher members were addresslng. ln addlLlon Lo Lhls, durlng


7
meeLlngs, mlnuLes were Laken Lo documenL Loplcs covered wlLhln Lhese meeLlngs, and uploaded Lo
'uropbox' provldlng lndlvlduals Lhe opporLunlLy Lo furLher research oLher areas.
H I,$61+J )*&&*$6*+ K'%615, E,$%6+1 @'(F6+,
HA3 L'(-1&*5+0J M6%,&'%5&, C,<6,.
laLlgue ls Lhe progresslve and locallsed sLrucLural damage LhaL occurs when a maLerlal ls sub[ecLed
Lo cycllc loadlng. lf Lhe local sLresses are hlgh enough, Lhls wlll lead Lo Lhe lnlLlaLlon of a crack, Lhe
growLh of Lhe crack and flnally fracLure [3]. 1he faLlgue llmlL of a maLerlal depends on a number of
facLors such as slze, Lype of loadlng, LemperaLure, corroslve envlronmenL, mean sLress, sLress
concenLraLlon and resldual sLresses. 1hls pro[ecL ls concerned wlLh deslgnlng a machlne capable of
LesLlng maLerlal speclmens ln a corroslve envlronmenL whllsL under non-zero mean sLress. 8esearch
lnLo Lhe effecL of Lhese facLors has been underLaken alongslde Lhe currenL Lechnologles avallable on
Lhe markeL, Lhe flndlngs are presenLed below. WlLh regard Lo machlne deslgn Lhe Lwo mosL
lmporLanL polnLs Lo conslder are loadlng mechanlsm and callbraLlon, Lhe resulLs of research lnLo
Lhese areas are also presenLed below.
HA3A3 )5&&,+% E,(F+*/*16,$
8esearch was carrled ouL Lo lnvesLlgaLe Lhe dlfferenL Lypes of
corroslon faLlgue LesL machlnes avallable on Lhe markeL. llgure
2 shows Lhe lnsLron 88 Moore machlne. A wlde varleLy of
machlnes were found, and deLalls of Lhree dlfferenL Lypes of
machlne are shown ln Lhe 1able 2.


1*45" JD !"/*$5# () )*/$%0" /"#/ >*@B$&"# (& /B" >*,="/
lrom Lhe markeL research lL was concluded LhaL an accuraLe machlne able Lo perform faLlgue LesLlng
ln a corroslve envlronmenL wlLh a non-zero mean sLress ls very expenslve. 1here wlll need Lo be a
Lrade off beLween cosL and LesLlng accuracy durlng Lhe deslgn sLage.
HA3A7 )*&&*$6*+ K'%615,
Corroslon faLlgue ls a promlnenL problem wlLhln mechanlcal equlpmenL LhaL handles corroslve
slurrles such as pumps. Cenerally, Lhe faLlgue llmlL of meLals ls governed by crack nucleaLlon as
over 90 of Lhe faLlgue llfe ls ln Lhe crack nucleaLlon phase [4]. 1he corroslve medlum decreases Lhe
.$%0," J R&#/,(& 22 ;((," >*@B$&"


8
faLlgue reslsLance of meLals as lL lnlLlaLes cracks wlLhln Lhe speclmens vla elecLrochemlcal reacLlons
wlLh Lhe speclmen.
1he corroslon mechanlsm lnvolves Lhe Lransfer of elecLrlcal charge beLween a poslLlve anode and
negaLlve caLhode vla an elecLrochemlcal reacLlon [4]. 1he anodlc reacLlon ls responslble for Lhe
mass loss of Lhe meLal by Lransfer of mass and charge Lo Lhe surroundlng fluld, shown ln Lhe reacLlon
shown ln LquaLlon 1.
M - M
n+
+ne
-
4>(? @

1he caLhodlc reacLlon where Lhe surroundlng fluld consumes elecLrons ls shown ln 8eacLlons 2 and
3. ln an aqueous soluLlon Lhe hydrogen producLlon, 8eacLlon 2, and oxygen reducLlon, 8eacLlon 3,
are Lhe promlnenL caLhodlc reacLlons occurrlng.
2P
+
(aq)
+
2e
-
- P
2
4>(? A
C
2 (aq)
+ 2P
2
C + 4e
-
- 4(CP)
-
4>(? B
1he anodlc and caLhodlc reacLlons are boLh occurrlng slmulLaneously over Lhe surface of Lhe meLal.
1he anodlc reacLlon ls responslble for Lhe maLerlal loss of Lhe meLal buL as boLh are occurrlng
slmulLaneously Lhe raLe of corroslon can be conLrolled by Lhe raLe of Lhe caLhodlc reacLlon, whlch ls
hlghly dependenL on envlronmenLal condlLlons.
revlous research lnLo Lhe phenomenon of corroslon faLlgue has ldenLlfled plLLlng corroslon as Lhe
mosL plauslble mechanlsm of corroslon LhaL lnlLlaLes a crack on Lhe meLal surface [3]. lLLlng
corroslon occurs when a locallsed area ls corrodlng aL a much greaLer raLe Lhan Lhe resL of Lhe meLal
surface. 1he plL acLs as an anode and Lhe exLernal surface of Lhe meLal acLs as Lhe caLhode
acceleraLlng Lhe corroslon raLe. 1hls ls shown dlagrammaLlcally ln llgure 3. laLlgue cracks LhaL lead
Lo fallure can propagaLe from corroslon plLs on Lhe surface of Lhe meLal.

.$%0," WD V$//$&% +(,,(#$(& ;"@B*&$#> cJd
1he mosL concernlng facLor of corroslon faLlgue when deslgnlng equlpmenL ls shown graphlcally ln
llgure 4. A meLal ln a corroslve envlronmenL does noL have a faLlgue llmlL, as Lhe maLerlal wlll


9
conLlnue Lo wear as Lhe number of cycles ls lncreased. 1hls means from a deslgn englneerlng
vlewpolnL LhaL Lhere ls no 'safe sLress range' aL whlch Lhe meLal has lnflnlLe llfe.

.$%0," MD Q,*3B #B(C$&% %"&",*5 "))"@/ () +(,,(#$(& .*/$%0" (& #/""5 cWd
Corroslon ls a Llme-dependenL process so Lhe frequency of Lhe LesL ls one of Lhe maln consLralnLs on
Lhe deslgn of Lhe corroslon faLlgue LesL rlg. lncreaslng Lhe frequency of Lhe cycllc loadlng decreases
Lhe effecLs of Lhe corroslve envlronmenL on Lhe faLlgue llfe. lL has Lherefore been declded Lo use
low frequency faLlgue LesLlng (2-6Pz). 1he machlne wlll also be deslgned ln order Lo have a
deLachable corroslve conLalner capable of submerglng Lhe gauge lengLh of Lhe meLal ln Lhe corroslve
medlum whllsL proLecLlng Lhe resL of Lhe machlne from wear.
HA3A? N*+OP,&* @,'+ B%&,$$
Mean sLress ls Lhe average of Lhe maxlmum and mlnlmum applled sLresses durlng cycllc loadlng.
laLlgue daLa ls generally only avallable for cycllc loadlng abouL a zero mean sLress alLhough
englneerlng componenLs and sLrucLures are ofLen sub[ecLed Lo cycllc loads ln Lhe presence of non-
zero mean sLress and sLraln. revlous research lndlcaLes LhaL Lenslle mean sLresses are deLrlmenLal
Lo Lhe faLlgue llfe of maLerlals buL compresslve mean sLresses are beneflclal. lor Lhe purposes of
Lhls pro[ecL a Lenslle mean sLress wlll be applled Lo Lhe maLerlal speclmens. 1hls, alongslde Lhe use
of a corroslve medlum, wlll reduce Lhe faLlgue reslsLance of a maLerlal and Lhus glve a closer
represenLaLlon Lo Lhe acLual servlce llfe of a maLerlal.
HA3AH M*'06+1 @,(F'+6$2
!"#"!"# $%&'()*+%, %. /%(0*,1 23'4+
8esearch was done lnLo Lhe effecL of dlfferenL loadlng mechanlsms and conLrol of LesLs on Lhe
faLlgue llfe of a speclmen. 1hls research led Lo a varleLy of arLlcles and furLher lssues Lo be
lnvesLlgaLed. lL was found LhaL ln Low Cycle laLlgue (LCl), uslng a sLraln-based faLlgue approach, LhaL
Lhe faLlgue llfe for a speclmen ln pure Lenslon was lower Lhan a speclmen ln elLher Lorslon or under
comblned Lenslon and Lorslon [6]. llgure 3 demonsLraLes Lhese dlfferences, wlLh Lhe largesL faLlgue
llfe from Lhese speclmens belng a speclmen sub[ecLed Lo pure Lorslon.


10

.$%0," ZD +(>3*,$#(& () .*/$%0" P$)" .(, P(*7$&% 4G 1(,#$(&e 1"&#$(& *&7 +(>4$&"7
lL was concluded LhaL Lorslonal cycllc sLress-sLraln and sLraln-llfe response was adequaLely predlcLed
by axlal faLlgue properLles, suggesLlng LhaL Lhe dlfferences ln resulLs beLween Lorslonal and axlal
faLlgue LesLs may be overlooked. 1hese concluslons were reached by conducLlng slmllar LesLs for
boLh Lorslon and axlal loadlng, wlLh Lhe wall Lhlckness of Lhe speclmen ln Lhe Lorslonal LesL equal Lo
Lhe radlus of Lhe speclmen ln Lhe axlal LesL.
lL was found LhaL ln Lorslonal LesLlng, predlcLlons were non-conservaLlve aL low cycles and over-
conservaLlve aL hlgh cycles. ln conLrasL, bendlng predlcLlons were Loo conservaLlve aL long llfe and
non-conservaLlve aL low cycles [7]. 8esearch found LhaL, ln plplng faLlgue, faLlgue sLrengLh from
roLaLlng bendlng speclmen LesLs was lower Lhan LhaL for boLh canLllever and four polnL bendlng,
especlally ln LCl. 1hese resulLs are shown ln boLh llgure 6 and 7, wlLh 8oLaLlng bendlng LesL
compared agalnsL four-polnL bendlng and canLllever bendlng respecLlvely.

.$%0," _D +(>3*,$#(& () .*/$%0" P$)" )(, 2(/*/$&% ?"&7$&% *&7 .(0,-V($&/ ?"&7$&% 1"#/#


11

.$%0," [D +(>3*,$#(& () .*/$%0" P$)" )(, 2(/*/$&% ?"&7$&% *&7 +*&/$5"b", ?"&7$&% 1"#/#
lL can be seen LhaL four polnL bendlng offers greaLer faLlgue llfe Lhan roLaLlng bendlng LesLs over Lhe
enLlre llfe cycle, whereas canLllever LesLs offer a greaLer faLlgue llfe for LCl and a lower faLlgue llfe ln
Lhe longer cycle range.
Comparlng Lhe roLaLlng bendlng LesL Lo an axlal LesL also ylelds dlfferlng resulLs. An axlal faLlgue LesL
was found Lo faLlgue aL a lower llfe Lhan ln a roLaLlng bendlng LesL. 1he mechanlcs of Lhls are shown
ln llgure 8. uue Lo Lhe loadlng mode, dlfferenL sLress gradlenLs resulL ln each of Lhe speclmens. ln an
axlal speclmen, Lhe loadlng ls unlform wlLh no sLress gradlenL as opposed Lo Lhe roLaLlng bendlng
faLlgue LesL, whlch has a sLress gradlenL, resulLlng ln less of Lhe speclmen experlenclng Lhe maxlmum
sLress.

.$%0," \D </,"## Q,*7$"&/ $& `*a *f$*5 5(*7$&% *&7 `4a ,(/*/$&% 4"&7$&% )*/$%0" /"#/#
1he dlfference beLween Lhe varlaLlons of bendlng LesLs occurs because Lhe roLaLlng bendlng LesL
exposes Lhe enLlre clrcumference aL Lhe polnL of maxlmum bendlng Lo Lhe maxlmum sLress. 1hls ls
noL Lhe case ln four polnL bendlng or canLllever bendlng, where only a slngle polnL ls exposed Lo Lhe
maxlmum sLress. 1hls lncreased exposure decreases Lhe faLlgue llfe as lL presenLs more flaws and
cracks Lo Lhe posslblllLy of propagaLlon.
1hls research lndlcaLes LhaL axlal faLlgue LesLlng ls wldely used as lL glves Lhe lowesL faLlgue llfe for a
glven speclmen. 1hls promoLes a conservaLlve approach Lo faLlgue, however afLer conslderaLlon of
Lhe purpose of Lhe faLlgue rlg, lL was concluded LhaL conservaLlve resulLs were noL a prlorlLy, raLher a
mechanlsm Lo compare numerous maLerlals under Lhe same condlLlons.
!"#"!"5 $%,6)%7 849:(,*+&
laLlgue LesLs are conLrolled by elLher keeplng Lhe load, hence Lhe sLress, consLanL LhroughouL Lhe
LesL or Lhrough keeplng Lhe dlsplacemenL, or Lhe sLraln consLanL LhroughouL. Load-conLrolled LesLs
are commonly carrled ouL ln hlgh cycle faLlgue Lo obLaln an S-n curve. Load-conLrolled LesLs are noL
sLrlcLly accuraLe ln reglons of plasLlc deformaLlon, as ln Lhese areas bendlng relaLlons are do noL


12
apply as expecLed [8]. uurlng a faLlgue LesL, a speclmen undergoes changes ln lLs sLlffness, due Lo Lhe
lnlLlaLlon and propagaLlon of cracks. Cracks decrease Lhe sLlffness of Lhe speclmen, and hence
decrease Lhe force requlred Lo produce Lhe same dlsplacemenL as aL Lhe sLarL of Lhe LesL. 1hls
relaLlonshlp ls shown ln LquaLlon 4.
!"#$$%&'' !
!"#$%
!"#$%&'()(*+
4>(? C
1hls relaLlon led Lo Lhe undersLandlng LhaL load-conLrolled LesLlng would requlre an exLenslve seL of
feedback channels, alongslde a loadlng mechanlsm capable of auLomaLlcally varlable ampllLude, as
Lhls would be requlred Lo lncrease Lhe dlsplacemenL as Lhe speclmen weakened Lo keep Lhe force
consLanL for Lhe enLlreLy of Lhe LesL. lL was found LhaL dlsplacemenL-conLrolled LesLs were much
cheaper and easler Lo seL up. 1hls was due Lo Lhe facL LhaL wlLh a dlsplacemenL conLrolled LesL, no
ad[usLmenL Lo Lhe LesLlng apparaLus would be requlred whllsL Lhe LesLs were llve, and would rely
purely on callbraLlon aL Lhe beglnnlng of Lhe LesL. urawlng on LquaLlon 4, lL also follows LhaL lf Lhe
dlsplacemenL ls kepL consLanL, as Lhe sLlffness decreases, Lhe force musL decrease proporLlonally.
Pence, ln a dlsplacemenL-conLrolled Lhe sLress decreases wlLh Llme. lL ls common pracLlce Lo
comblne dlsplacemenL-conLrolled low cycle faLlgue LesLs wlLh load-conLrolled hlgh cycle faLlgue LesLs
on Lhe same S-n curve by mulLlplylng Lhe sLraln based resulLs by ?oung's Modulus Lo obLaln
equlvalenL sLresses.
urawlng from Lhese flndlngs, lL was recommended LhaL a dlsplacemenL-conLrolled approach would
be Lhe mosL approprlaLe Lo obLaln a deslgn LhaL would be wlLhln budgeL, due Lo Lhe more slmple
naLure of Lhe loadlng mechanlsm lnvolved ln Lhls Lype of LesLlng.
HA3AQ )'/6#&'%6*+
lnlLlal research lnLo callbraLlon meLhods for corroslon faLlgue LesLlng machlnes focussed on Lhe
callbraLlon of LesLlng machlnes wlLh ln-bullL force measurlng devlces. 1he meLhods examlned
lncluded dynamlc callbraLlon as well as sLaLlc callbraLlon Lhrough Lhe use of sLandard welghLs, equal-
arm balances & sLandard welghLs, and elasLlc callbraLlon devlces. 1hls lnlLlal research ldenLlfled
sLaLlc callbraLlon Lhrough Lhe use of elasLlc callbraLlon devlces as Lhe opLlmum meLhod of callbraLlon
for Lhe LesL machlne due Lo Lhe excesslvely hlgh cosL of sLandard welghLs requlred for Lhe oLher
sLaLlc callbraLlon meLhods and Lhe hlgh cosL, ln Lerms of boLh Llme and money, of dynamlc
callbraLlon. Powever, slnce Lhese meLhods deal prlmarlly wlLh Lhe callbraLlon of force measurlng
devlces wlLhln LesLlng machlnes, lL was dlscovered LhaL none of Lhese meLhods would be sulLable for
our deslgn glven Lhe facL LhaL our LesLlng machlne was Lo be sLraln-conLrolled raLher Lhan sLress-
conLrolled. 1hus Lhe focus shlfLed Lowards Lhe callbraLlon of our chosen sLraln conLrol devlce.
lL was declded LhaL ln order Lo conLrol Lhe sLraln experlenced by Lhe LesL speclmens, a speclal
callbraLlon speclmen would be flLLed wlLh a serles of sLraln gauges ln a wheaLsLone brldge
conflguraLlon ln order Lo measure Lhe sLraln experlenced by a speclmen durlng LesLlng. Powever, ln
order Lo have confldence ln Lhe resulLs glven by Lhls speclmen, lL was lmporLanL Lo be able Lo
callbraLe and verlfy Lhe accuracy of Lhe sLraln gauge conflguraLlon. A full-brldge Lype ll conflguraLlon
was chosen for Lhe sLraln gauges as Lhls conflguraLlon allows for Lhe hlghesL senslLlvlLy Lo changes ln
sLraln whlle also compensaLlng for Lhe effecLs of LemperaLure change, lead wlre reslsLance and Lhe
cumulaLlve effecL on Lhe prlnclple sLraln measuremenL due Lo Lhe olsson's raLlo of Lhe speclmen


13
maLerlal [9]. 1hese compensaLory aLLrlbuLes precluded Lhe need Lo callbraLe Lhe devlce agalnsL Lhese
exLernal effecLs.
AlLhough Lhe cholce of sLraln gauge conflguraLlon removed Lhe need for cerLaln callbraLlons lL dld
noL alLer Lhe facL LhaL a comblnaLlon of sllghL varlaLlons ln reslsLance beLween Lhe brldge arms and
sLraln lnduced by Lhe appllcaLlon of Lhe sLraln gauges almosL lnvarlably resulLs ln some small lnlLlal
offseL volLage when Lhe speclmen ls unsLralned whlch musL be compensaLed for. ln order Lo
callbraLe Lhls lnlLlal volLage offseL, an offseL nulllng should be carrled ouL. 1hls procedure ls usually
carrled ouL ln one of Lwo ways, elLher by Lhe use of sofLware or by Lhe use of a rheosLaL. SofLware
compensaLlon lnvolves Laklng a volLage readlng whlle Lhe speclmen ls unsLralned and uslng sofLware
Lo compensaLe for Lhls value ln successlve readlngs. AlLhough Lhls meLhod ls relaLlvely slmple and
does noL requlre any manual ad[usLmenLs, lL also does noL acLually remove Lhe offseL and Lhls can
have a negaLlve lmpacL on Lhe poLenLlal range of measuremenL.
1he use of a rheosLaL, whlle lnvolvlng manual ad[usLmenL, ls a permanenL soluLlon Lo Lhe offseL
problem and was Lherefore declded Lo be Lhe besL meLhod of offseL nulllng. 8y applylng a small
rheosLaL across one of Lhe acLlve sLraln gauges lL ls posslble Lo manually ad[usL Lhe volLage offseL Lo
zero volLs, effecLlvely ellmlnaLlng Lhe lnlLlal offseL volLage [10].
CffseL nulllng callbraLes Lhe sLraln gauge conflguraLlon buL lL was also declded LhaL Lhe accuracy of
Lhe measuremenL devlce should be verlfled. 1he usual meLhod of verlfylng a wheaLsLone brldge ls Lo
carry ouL a shunL callbraLlon. 1hls lnvolves shunLlng a large flxed reslsLor across one arm of Lhe
wheaLsLone brldge Lo slmulaLe Lhe appllcaLlon of sLraln. 1he measured offseL volLage can Lhen be
compared Lo Lhe expecLed volLage for LhaL sLraln. ln Lhls way, Lhe accuracy of Lhe devlce may be
deLermlned [11].




14
HA7 I,$61+ >&*(,$$
1he deslgn process followed SLuarL ugh's 1oLal ueslgn model [1]. 1he deslgn process was carrled
ouL up Lo Lhe flnallsed deLalled deslgn sLage, wlLh Lhe deslgn ready Lo be manufacLured. An overvlew
of Lhe deslgn process ls shown ln llgure 9.

.$%0," ]D Ob",b$"C () </*%"# $& !"#$%& V,(@"##
Lach aspecL of Lhe deslgn process from Lhe roducL ueslgn SpeclflcaLlon (uS) Lhrough Lo deLalled
deslgn ls shown below.
HA7A3 >IB
1he roducL ueslgn SpeclflcaLlon acLs as a reference for every ldea LhaL ls generaLed, and every
concepL has Lo be checked agalnsL Lhe uS. 1he uS was wrlLLen wlLh as much deLall as posslble,
whlch enables Lhe group Lo produce deslgns based on lnformed declslons and Lhus feaslble concepLs
Lo be generaLed. 1hls pro[ecL has a number of lmporLanL consLralnLs based on accuracy of machlne,
Llme-scale, budgeL and performance of Lhe machlne. 1he uS ls a dynamlc documenL. 1he full uS ls
shown ln Appendlx 1.
HA? )*+(,D%5'/ I,$61+
1he group declded Lo sLarL Lhe concepLual deslgn ln parallel wlLh Lhe sub[ecL research. Lach member
of Lhe group was Lasked wlLh generaLlng machlne deslgns LhaL meL all aspecLs of Lhe uS. A selecLlon
of Lhese concepLs can be found ln Appendlx 4.
upon revlew of Lhe lnlLlal concepLs aL declslon gaLe 1, Lhe group reallsed LhaL Lhere were several key
problems wlLh Lhe lnlLlal concepLs. A loL of Lhese deslgns would noL be feaslble and lL would be
exLremely expenslve and dlfflculL Lo callbraLe and conLrol Lhe loadlng. MosL of Lhe machlnes deslgns
also had many connecLlng bodles, whlch would cause problems wlLh faLlgue of Lhe machlne lLself. A
number of deslgns also had movlng parLs of machlne LhaL would be exposed Lo Lhe corroslve fluld,
8esearch
- LlLeraLure revlew
- MarkeL 8esearch
uS
- roducL ueslgn Speclcauon wrluen
- As much deLall as posslble aL Lhls sLage, Lhough uS can be developed LhroughouL
deslgn process
ConcepLual
ueslgn
- lnlual ConcepLs
- ueveloped ConcepL
- llnal chosen ConcepL
ueLalled
ueslgn
- ueLalls of all aspecLs of Lhe Corroslon laugue 1esL 8lg
- 8eady Lo be manufacLured


13
whlch poses Lhe problem of corroslon faLlgue of Lhe machlne requlrlng regular replacemenL of parLs
or use of expenslve Corroslon 8eslsLanL Alloys (C8A's).
1he lssues wlLh Lhese concepLs arose from a lack of knowledge of faLlgue procedures and sLandards
of pracLlce. lL was declded Lo Lake a week Lo focus solely on research Lo lncrease awareness of
faLlgue procedures, avallable Lechnologles, corroslon processes, effecLs of loadlng and oLher
experlmenLal research. ueclslon CaLe 1 was revlewed agaln afLer Lhls week of research and all Lhe
crlLerla Lo move Lo ueclslon CaLe 2 (ConcepLual ueslgn) had been fulfllled. CalculaLlons were carrled
ouL Lo esLlmaLe Lhe requlred force and dlsplacemenL for dlfferenL loadlng cases.
HA?A3 )'/(5/'%6*+$
Slmple calculaLlons were carrled ouL Lo esLlmaLe Lhe maxlmum forces and dlsplacemenLs of a
speclmen, requlred for faLlgue LesLlng, Lo ald Lhe concepLual deslgn process. 1he maLerlal used for
Lhe calculaLlons was 1018 mlld sLeel wlLh !"#$%&' )"*#+#', - . /00 123, 3$* 456+* '786$%79, :456+* .
;<0 =23> ?96 )3@5)#) '786'' '9"#+* $"7 6@A66* B 456+*, '" :)3@ . /C< =23>
1he calculaLlons were carrled ouL uslng excel, and 1able 3shows Lhe speclmen dlmenslons, and Lhe
maxlmum dlsplacemenLs and forces for each loadlng case.
Loadlng 1ype
Speclmen ulmenslon Max lorce/
1orque
(n(m))
Max
ulsplacemenL
(mm/)
1hlckness (mm) WldLh (mm) LengLh (mm)
CanLllever 8endlng 2 20 100 48 4.111
3-polnL 8endlng 2 20 100 192 1.028
4-polnL 8endlng 2 20 100 288 (x2 loads) 0.400
Axlal
[Square] 10 (square) 100 24,700 0.123
[Clrcular] 10 C 100 19,400 0.123
1orslon
[Solld] 10 C 100 16.66 nm 3.33
1 [Pollow] 10 C (ouLer) 100 48.43 nm 3.33
1*45" WD .(,@" *&7 !$#35*@">"&/# $& <3"@$>"& )(, +*&/$5"b",e W-3($&/ ?"&7$&%e M-3($&/ ?"&7$&%e 6f$*5 *&7 1(,#$(&*5 1"#/#
HA?A7 )*+(,D%5'/ I,$61+ 7
1he second round of concepL generaLlon proved Lo be much more consLrucLlve. Lessons had been
learnL Lhrough Lhe lnlLlal concepL generaLlon phase and alLhough mosL of Lhe second round concepLs
were sLrongly based on some of Lhe ldeas presenLed ln Lhe flrsL round, Lhe quallLy of concepLs had
noLlceably lmproved. Cne of Lhe maln lssues ldenLlfled wlLh Lhe flrsL round of concepL generaLlon
was an lssue wlLh lnduclng force conLrolled faLlgue ln Lhe speclmen and Lherefore lL was agreed LhaL
dlsplacemenL conLrolled faLlgue was a more reallsLlc opLlon. 1hls agaln hlghllghLed Lhe lmporLance of
a sLrong pro[ecL framework LhaL resulLed ln an lLeraLlve process for concepL generaLlon Lo allow Lhe
group Lo move on wlLh a feaslble ldea.
ConcepL 1 was based on Lhe prlnclpal of 4 polnL bendlng, shown ln llgure 10. A load frame could be
manufacLured Lo clamp a double acLlng hydraullc cyllnder above a 4-polnL bendlng seL-up. 1he
hydraullc sysLem could be elLher dlsplacemenL or force conLrolled. 1he speclmen would be clamped,
ensurlng Lhe clamps do noL lnLerfere wlLh Lhe bendlng and an approprlaLely shaped frame would be
aLLached ln order Lo lnduce 4-polnL bendlng ln Lhe speclmen. A sLress would be creaLed been Lhe
Lwo lnner clamps, where a speclally deslgned baLh would be used Lo submerge Lhe speclmen ln a
corroslve fluld.


16
AdvanLages: lorce or dlsplacemenL conLrolled.
Plgh accuracy.
8ellable seLup wlLh llLLle mechanlcal componenLs.
ulsadvanLages: Pydraullc conLrol sysLems could be very cosLly.
ulfflculL Lo seal baLh round speclmen because Lhe speclmen would
have sllghL verLlcal moLlon.


.$%0," LKD +(&@"3/0*5 !"#$%& L ?*#"7 (& .(0,-V($&/ ?"&7$&%
ConcepL 2 was based on Lhe Lheory of a comblned Lorslon and bendlng seLup, shown ln llgure 11. A
clrcular speclmen would be fully clamped aL Lhe boLLom and Lhen acLuaLed a pre-deLermlned
amounL Lhrough a cranked arm aL Lhe Lop, resulLlng ln comblned Lorslon and bendlng. 1hls comblned
loadlng resulLs ln a unlform Lorque and a non-unlform bendlng sLress belng applled Lo Lhe speclmen.
1he speclmen would be sLandlng uprlghL ln a baLh of corroslve fluld Lo lnduce corroslon ln Lhe
speclmen.
AdvanLages: ulsplacemenL conLrolled.
Lasy Lo callbraLe
Comblned loadlng.
Lasy Lo submerge ln a corroslve fluld.


17
ulsadvanLages: Mechanlcal llnkages could wear or fall.
CompllcaLed sLress dlsLrlbuLlon ln Lhe speclmen.
Small dlsplacemenLs resulL ln hlgh sLress.


.$%0," LLD +(&@"3/0*5 !"#$%& J ?*#"7 (& 1(,#$(&*5 P(*7$&%
ConcepL 3 was based on lnduclng faLlgue ln a Lhln walled cyllnder Lhrough Lhe means of an
alLernaLlng lnLernal pressure, llgure 12. 1hls ls a very effecLlve way of lnduclng faLlgue and repllcaLes
a real faLlgue lssues LhaL can commonly be found ln pumps and pressure vessels, whlch ls of lnLeresL
Lo Lhe group. A Lhln-walled cyllnder would be clamped and sealed aL Lhe boLLom, fllled wlLh a non-
compresslble fluld and a pressure cap screwed onLo Lhe Lop Lo creaLe a sealed pressure vessel. 1he
exLernal surface of Lhe fluld would Lhen be exposed Lo a corroslve envlronmenL Lhrough Lhe use of a
surroundlng baLh. A pump conLrolled by an elecLronlc conLrol sysLem would pulsaLe fluld Lo Lhe
speclmen aL hlgh pressure, lnduclng a cycllc sLress ln Lhe wall of Lhe pressure vessel.
AdvanLages: AccuraLe force conLrol.
8eallsLlc LesL scenarlo.
Lasy Lo change ampllLude, range and frequency of pressure.
no mechanlcal parLs.



18
ulsadvanLages: SafeLy lssue of faLlgulng a pressure vessel Lo fallure.
1esL machlne envlronmenL may need Lo be enclosed durlng LesLlng.
ump would need Lo be carefully chosen for long llfe expecLaLlon.
Lxpenslve pump and conLrol sysLem.


.$%0," LJD +(&@"3/0*5 !"#$%& W ?*#"7 (& R&/",&*5 V,"##0," P(*7$&%
ConcepL 4 proved Lo be Lhe mosL popular concepL among Lhe group based on flrsL lmpresslons.
llgure 13 shows Lhe seLup of Lhe canLllever faLlgue LesL sysLem. A speclmen would be clamped Lo a
polnL on Lhe base of Lhe machlne and Lhen a moLor wlLh a cam or offseL connecLlng rod would be
aLLached Lo produce a dlsplacemenL aL Lhe Lop of Lhe speclmen, resulLlng ln canLllever bendlng. 1he
speclmen would requlre Lo be speclally shaped ln order Lo move Lhe maxlmum bendlng sLress from
Lhe rooL of Lhe speclmen Lo around Lhe cenLre. A slmple conLrol sysLem could be seLup Lo monlLor
Lhe cycles unLll fallure and also Lhe dlsplacemenL could be conLrolled and alLered dependlng on Lhe
lengLh of speclmen and requlred bendlng sLress Lhrough an ad[usLable connecLlng rod.
AdvanLages: ulsplacemenL conLrolled.
Lasy Lo callbraLe and seL up.
Ad[usLable dlsplacemenL and frequency.



19
ulsadvanLages: Mechanlcal connecLlons could wear or fall.
llndlng a reasonably prlced, long llfe moLor.
Lnsurlng a rellable aLLachmenL of connecLlng rod Lo speclmen.

.$%0," LWD +(&@"3/0*5 !"#$%& M ?*#"7 (& +*&/$5"b", ?"&7$&%
HA?A? )*+(,D% B,/,(%6*+
ConLrolled Convergence MaLrlces (CCMs) were used Lo selecL Lhe besL concepL Lo be chosen. 1he
CCM shown below ln 1able 4 used concepL 1 as Lhe daLum. 1he mosL lmporLanL aspecLs of Lhe uS
was used as crlLerla for comparlng how well each concepL meeLs Lhe uS.
ConcepL 1 ConcepL 2 ConcepL 3 ConcepL 4
SlmpllclLy
u
A
1
u
M

+ - +
Lase of speclmen
aLLachmenL
S + +
CosL + - +
Lase of
manufacLure
S + +
8ellablllLy - - +
SafeLy - - +
MalnLenance S - S
ConLalnmenL of
fluld
S - S
1ransporLable S S S
1esL frequency S - +
g h J J [
g - J [ K
g < _ L W
1*45" MD ++; S#$&% +(&@"3/ L *# * !*/0>


20
1he CCM show LhaL concepL 4 appears Lhe sLrongesL concepL. AnoLher CCM was performed uslng
concepL 2 as Lhe daLum, and concepL 4 was agaln shown Lo be Lhe sLrongesL concepL. ConcepL 4 was
checked agalnsL each aspecL of Lhe uS Lo ensure LhaL Lhe deslgn meL all requlremenLs. ConcepL 4
was Lhen chosen as Lhe flnal concepL, shown more clearly ln llgure 14 below. 1hls concepL ls a
slmple deslgn wlLh a moLor drlvlng a connecLlng rod LhaL performs canLllever bendlng on Lhe LesL
speclmen.

.$%0," LMD .$&*5 +(&@"3/0*5 !"#$%& <"5"@/"7 /( V,(@""7 /( !"/*$5"7 !"#$%&
1he flnal deslgn conslsLs of a moLor flxed Lo a rlgld frame, conLrolled by a conLrol sysLem LhaL wlll
also lnclude a counLlng sysLem (noL shown ln Lhe dlagram). 1he moLor drlves a flywheel, whlch ls
aLLached Lo Lhe connecLlng rod by a bearlng. 1he connecLlng rod ls Lhen aLLached onLo Lhe free end
of Lhe speclmen, whlch ls clamped securely aL Lhe base, ouLslde Lhe chamber conLalnlng Lhe
corroslve fluld, Lo allow canLllever bendlng of Lhe speclmen. 1he speclmen wlll be sealed ln Lhe
corroslon chamber [usL above where Lhe boLLom clamp ls aLLached, and Lhe corroslve fluld wlll
surround Lhe speclmen. 1he moLor wlll operaLe conLlnuously beLween aL a consLanL speed beLween
0.3 and 6Pz and perform cycllc canLllever bendlng on Lhe speclmen. 1he bendlng wlll lnduce a
sufflclenLly hlgh sLress ln Lhe speclmen Lo cause faLlgue damage and lead Lo fallure. 1he speclmen
wlll also be shaped ln such a way LhaL Lhe hlgh sLress wlll occur over Lhe LesLlng area, whlch wlll
always remaln submerged ln Lhe corroslve fluld.
HA?AH I,$61+ I,<,/*D2,+%
1here were maln Lwo maln componenLs of Lhe deslgn LhaL were modlfled as Lhe flnal deslgn was
developed Lhrough Lhe deLalled deslgn process. 1he flrsL feaLure LhaL was changed was Lhe flywheel
on Lhe moLor shafL LhaL drlves Lhe connecLlng rod. 1he flnal concepL had an offseL arm wlLh a
bearlng connecLlng Lhe connecLlng rod. AfLer furLher ln-depLh research lnLo beLLer opLlons LhaL
would be also capable of changlng Lhe slze of Lhe dlsplacemenL of Lhe speclmen for dlfferenL LesLs,
Lhe deslgn was changed Lo lncorporaLe an eccenLrlc bearlng. 1hls means LhaL Lhe moLor shafL wlll flL
onLo a solld clrcular sLeel lnserL LhaL wlll be flxed Lhe lnner race of a bearlng. 1he moLor shafL wlll
have an offseL cenLre of roLaLlon from Lhe bearlng cenLre. 1he connecLlng rod wlll be flxed Lo Lhe
ouLer race of Lhe bearlng, whlch wlll allow Lhe llnear moLlon Lo cause canLllever bendlng of Lhe
speclmen. 1he eccenLrlc bearlng deslgn also allows for dlfferenL slzes of offseL bearlngs Lo be used,


21
whlch wlll allow varlable dlsplacemenL of Lhe speclmen for dlfferenL LesLs. See secLlon on eccenLrlc
bearlng for more deLalls.
AnoLher feaLure LhaL was added Lo Lhe deslgn durlng Lhe developmenL of Lhe concepL was a
supporLlng sLand for Lhe connecLlng arm. 1hls was lncluded Lo prevenL Lhe connecLlng rod from
falllng onLo Lhe corroslon chamber when Lhe speclmen falls. 1hls sLand wlll also lncorporaLe a cuL-off
swlLch, so LhaL when Lhe speclmen breaks, Lhe connecLlng arm wlll fall onLo Lhe sLand and sLop Lhe
moLor and counLer, so LhaL Lhe cycles Lo fallure of Lhe speclmen wlll be recorded.
HAH I,%'6/,0 I,$61+ )*2D*+,+%$
HAHA3 @*%*& B,/,(%6*+
A moLor wlll be used Lo drlve a connecLlng rod LhaL wlll apply a force Lo Lhe free end of Lhe canLllever
speclmen. 1he Lwo Lypes of elecLrlc moLor used are uC moLors and AC moLors. ulfferenL Lypes of
each moLor wlll be dlscussed, Lhe requlremenLs of Lhe moLor for Lhe corroslon faLlgue LesL rlg wlll be
looked aL, and Lhen an approprlaLe moLor wlll be selecLed.
!"!"#"# ;$ 8%6%)+
uC moLors operaLe on a dlrecL currenL (uC) supply, so lL would requlre a Lransformer Lo run from a
malns supply, whlch would noL be an lssue. Ad[usLlng Lhe volLage conLrols uC moLors, Lherefor a
slmple poLenLlomeLer would allow preclse speed conLrol, so uC moLors are good for low speed
appllcaLlons. uC moLors also have a slmple conflguraLlon and a cheap drlve deslgn, so Lhey have a
low lnlLlal cosL. 1he maln drawback of uC moLors ls Lhe need Lo replace Lhe brushes and sprlngs due
Lo normal wear. 1he llfe of brushes ls around 1,000 hours, so, dependlng on Lhe speed aL whlch Lhe
corroslon faLlgue LesLs are run, Lhe brushes may noL even lasL Lhe lengLh of one LesL (a LesL aL 2Pz
run Lo 10 mllllon cycles would lasL 1,389 hours). uC moLors also have shorLer llfe spans compared Lo
AC moLors, so Lo Lhe wear of parLs ln conLacL.
Also avallable on Lhe markeL are brushless uC (8LuC) moLors. 1hese are powered by a uC source,
and lnsLead of uslng a commuLaLor and brushes, an lnLegraLed lnverLer power supply ls used, whlch
wlll generaLe an alLernaLlng currenL (AC) supply Lo drlve Lhe moLor. 8LuC moLors are more compacL
compared Lo uC (and some AC) moLors, and a smaller moLor can provlde Lhe same power. 1hese
8LuC moLors have Lhe same advanLages as uC moLor: Lhey allow preclse speed conLrol and are good
for low speed appllcaLlons. 8LuC moLors ellmlnaLe a loL of Lhe malnLenance problems assoclaLed
wlLh uC moLors, as Lhere are no brushes are sprlngs LhaL need Lo be replaced durlng malnLenance.
1he maln dlsadvanLages of 8LuC moLors are LhaL Lhey are expenslve and requlre compllcaLed speed
conLrollers.
!"!"#"5 <$ 8%6%)+
AC moLors operaLe for alLernaLlng currenL (AC) supply, so Lhey can be run dlrecLly from malns
volLage. AC moLors are good for flxed speed appllcaLlons. 1he speed ls conLrolled by Lhe frequency
of Lhe supply so an lnverLer would be needed Lo conLrol Lhe speed of Lhe moLor. 1hey have a long
llfe span as Lhere are no brushes Lo wear ouL, and only Lhe bearlngs need replaced every few years.
AC moLors glve rellable operaLlon, agaln due Lo Lhe low malnLenance requlred. Cne slgnlflcanL
dlsadvanLage of an AC moLor for Lhe requlremenLs of Lhe corroslon faLlgue LesL rlg ls Lhe lnablllLy for
AC moLors Lo operaLe aL low speeds. AC moLors should noL be operaLed aL less Lhan 1/3 of Lhe base
speed of Lhe moLor (deLermlned by Lhe number of poles ln Lhe moLor). Also, Lhe back elecLromoLlve


22
force (emf) LhaL Lhe moLor produces wlll slow Lhe moLor down and does noL lnlLlally appear when
Lhe moLor ls swlLched on, so aL Lhe sLarL of a faLlgue LesL, Lhe speed would need Lo be ad[usLed unLll
lL seLLles, or use a feedback conLroller.
llgure 13 shows Lhe conflguraLlon on 8LuC, AC, and uC moLors.

.$%0," LZ +(&#/,0@/$(& () ?P!+e 6+ *&7 !+ >(/(,# `B//3DEECCCF(,$"&/*5>(/(,F@(>E/"@B&(5(%GE*,/$@5"#E6+-4,0#B5"##-
4,0#B"7->(/(,#FB/>5a
!"!"#"= >4?@*)4&4,6+ %. 6:4 &%6%)
1he corroslon faLlgue LesL machlne ls requlred Lo operaLe aL speeds from 0.3 Lo 6Pz (30 - 360 rpm),
whlch ls a low speed appllcaLlon for a moLor. A faLlgue LesL aL 2Pz would Lake 139 hours Lo run Lo 1
mllllon cycles (~6 days) so Lhe moLor should be able Lo run for Lhls perlod of Llme conLlnuously (n8 lL
ls expecLed LhaL Lhe effecLs of corroslon wlll slgnlflcanLly shorLen Lhls Llme, however Lhe moLor
should be deslgned Lo lasL Lhls lengLh of Llme). 1he moLor should have a long operaLlonal llfe and
requlre as llLLle malnLenance as posslble. AccepLable malnLenance beLween LesLs wlll lnclude
lubrlcaLlon and reaLLachlng moLor ln place.
1he budgeL for Lhe manufacLurlng of Lhe proLoLype corroslon faLlgue LesL rlg ls 3,000. 1he moLor
wlll be Lhe slngle mosL expenslve componenL on Lhe machlne so wlll requlre a slgnlflcanL porLlon of
Lhe budgeL. Powever Lhe overall alm of bulldlng Lhe LesL rlg ls Lo keep lL low cosL so LhaL mulLlple
machlnes can be produced, so cosLs should be kepL Lo a mlnlmum. AL a group meeLlng lL was agreed
Lo allocaLe a maxlmum of 300 Lo Lhe purchase of a moLor and speed conLrol sysLem.
A deslgn feaLure of Lhe corroslon faLlgue LesL machlne ls Lo have Lhe poslLlon of Lhe moLor ad[usLable
Lo Lhe non-zero mean sLresses can be applled Lo Lhe speclmen durlng a LesL, so Lhe moLor needs Lo
be able Lo be moved on Lhe sLand onLo whlch lL ls flxed. 1he moLor wlll need Lo be able Lo be
secured Lhrough bolL flxlng onLo Lhe plaLe on Lhe moLor sLand. 1he slze of Lhe moLor should be as
compacL as posslble, as Lhe moLor has been deslgn Lo be flxed onLo a sLand. 1here ls also scope Lo
bulld mulLlple corroslon faLlgue LesL machlnes, Lherefor Lo llmlL Lhe lab space necessary Lo
accommodaLe several of Lhese machlne, Lhe slze of Lhe moLor should be compacL.
1he Lorque requlred Lo bend Lhe speclmen was calculaLed uslng LquaLlon 3. 1he maxlmum Lorque
requlred ls when Lhe applled force ls 30n wlLh a 6mm offseL beLween Lhe cenLres. 1hls glves a
Lorque of 0.18nm. 1he frlcLlonal Lorque would arlse from Lhe frlcLlon ln Lhe eccenLrlc bearlng aL Lhe
moLor shafL, and Lhe frlcLlon
1 = l r 4>(? D


23

Where 1 ls Lhe requlre Lorque, . ls Lhe force applled Lo Lhe speclmen, and , ls Lhe dlsLance beLween
Lhe cenLre of Lhe moLor shafL and Lhe cenLre of Lhe eccenLrlc bearlng.

!"!"#"! $:%+4, 8%6%)
1he chosen moLor manufacLured by CrlenLal MoLor (uk) LLd, ls a brushless moLor wlLh lnLegraLed
dlglLal conLroller, as shown ln llgure 16. lL ls a 30W 8LA serles moLor, wlLh a geared 1:3 moLor
(producL code 8LA330C8-3). ueLalled speclflcaLlons of Lhe moLor are glven below.

.$%0," L_D O,$"&/*5 ;(/(, ?P6ZZK+?-Z ?,0#B5"## 6+-$&30/ *55-$&-(&" >(/(,
1he moLor wlll be aLLached Lo Lhe mounLlng brackeL on Lhe moLor plaLe. 1he moLor wlll be mounLed
horlzonLally onLo Lhe brackeL wlLh M8x70 bolLs. 1he poslLlon of Lhe moLor wlll be ad[usLable Lo allow
a non-zero mean sLress, vla Lhe Lhreaded shafL as prevlously dlscussed. 1he dlglLal conLroller easlly
conLrols Lhe speed of Lhe moLor. 1he speed ls seL on Lhe dlglLal dlsplay uslng Lhe conLrol buLLons,
and Lhen Lhe moLor ls seL Lo sLarL. 1here ls a 0.2 speed regulaLlon ln Lhe moLor, so Lhe speed wlll
be accuraLe. WlLh Lhe lnLegraLed gear head, Lhe speed ls varlable beLween 0.6 and 8Pz. 1he
eccenLrlc bearlng conLalned wlLhln Lhe connecLlng rod wlll be aLLached onLo Lhe moLor shafL, wlLh a
6mm parallel key. 1he moLor shafL wlll roLaLe Lhe eccenLrlc bearlng, and Lhe offseL cenLre wlll
Lransfer llnear moLlon Lhrough Lhe connecLlng rod Lo apply a canLllever-bendlng load Lo Lhe
speclmen. 1he moLor wlll be powered by a 230v slngle-phase malns supply. 1here wlll be an
emergency cuL off swlLch wlll be wlred lnLo Lhe malns cable Lo allow safe operaLlon of Lhe moLor.
1he speclflcaLlons of Lhe moLor are deLalled ln llgure 17.


24

.$%0," L[D 1"@B&$@*5 !"/*$5# () <"5"@/"7 ?,0#B5"## !+ ;(/(,


llgure 18 shows Lhe deLalled dlmenslons of Lhe moLor, supplled by Lhe manufacLurers webslLe.



23

.$%0," L\D !"/*$5"7 !$>"&#$(&# () <"5"@/"7 ;(/(,

1he moLor has a gearlng raLlo of 1:3, so L = 43mm ln Lhe drawlng.
HAHA7 )*&&*$6*+ )F'2#,&
1he corroslon chamber encapsulaLes Lhe speclmen applylng a corroslve envlronmenL represenLaLlve
of Lhe condlLlons LhaL Lhe maLerlal wlll be exposed Lo ln Lhe fleld. WlLh reference Lo Lhe roducL
ueslgn SpeclflcaLlon (uS) Lhe lmporLanL requlremenLs of Lhe corroslon chamber are: speclmen
gauge lengLh musL be fully submerged ln corroslve fluld, corroslve medlum should be conLalned
approprlaLely, and corroslve fluld should be conLlnually aglLaLed. 1he producL musL allow easy
lnsLallaLlon and removal of speclmens whllsL also belng deLachable. 1he lssues of deslgn, maLerlal,
seallng, pump selecLlon and envlronmenLal conLrol were addressed allowlng a funcLlonal producL Lo
be deslgned.
!"!"5"# ;4+*1,
1he deslgn ls a slmple box shape allowlng an assembled box Lo be commerclally sourced. 1wo 6mm
bore holes cuL ln Lhe box Lo accommodaLe Lhe pump connecLlons, Lhe lnleL wlll be aL Lhe base of Lhe
conLalner and Lhe ouLleL wlll clrculaLe corroslve fluld over Lhe gauge lengLh of Lhe speclmen. 1hls
allows a conLrolled corroslve envlronmenL. A sloL wlll be cuL ln Lhe base of Lhe conLalner Lo enable
Lhe speclmen Lo proLrude Lhrough and Lhls wlll be approprlaLely sealed. A larger sloL ls cuL ln Lhe lld
of Lhe box Lo allow Lhe canLllever movemenL of Lhe speclmen. 1hls wlll also acL Lo conLrol Lhe
corroslve envlronmenL by prevenLlng evaporaLlon and splashlng of fluld. 1he sloLs ln Lhe acryllc box
wlll be laser cuL allowlng a hlgh preclslon and smooLh flnlsh.



26
!"!"5"5 8(64)*(7
1he conLalner needs Lo be chemlcally lnerL and unaffecLed by corroslon. 1he conLalner wlll be
acryllc, acryllc ls boLh lmmune Lo corroslon and does noL creep aL room LemperaLure. 1ygon Lublng
wlll be used for Lhe pump connecLlons, as lL ls lnerL and reslsLanL Lo chemlcals LhaL may be conLalned
ln Lhe corroslve fluld.
!"!"5"= A4(7*,1
1he box wlll be lsolaLed from Lhe resL of Lhe mechanlsm so wlll requlre seallng aL Lhe [uncLlons. A
number of experlmenLs were performed on poLenLlal seallng soluLlons Lo ensure LhaL Lhe corroslve
fluld would be compleLely sealed around Lhe recLangular speclmen. As each speclmen wlll be
manufacLured Lo Lhe same dlmenslons a mechanlcal seal was deslgned whlch wlll be easlly
reproduclble. 1he chosen seallng soluLlon for Lhe base of Lhe conLalner, shown ln llgure 19,
lncorporaLes a laser cuL 1.3mm Lhlck rubber gaskeL, 3mm Lhlck acryllc sheeL and 8x3.3mm bore
holes equally spaced for nylons nuLs and bolLs whlch have flbre washers for exLra seallng. 1he wldLh
of Lhe hole cuL ln Lhe speclmen wlll be 0.6mm less Lhan Lhe acLual speclmen wldLh. 1hls wlll allow
Lhe gaskeL Lo lnlLlally seaL and LhereafLer absorb Lhe maxlmum dlsplacemenL of 0.23mm aL Lhe base
of Lhe conLalner due Lo a 6mm canLllever movemenL aL Lhe Lop clamp. 1he rubber gaskeLs wlll be
mass manufacLured and a new gaskeL wlll be applled prlor Lo each experlmenL provldlng an effecLlve
seal aL Lhe [uncLlon beLween Lhe clamp and chamber. All componenLs of Lhe seal are lmmune Lo
corroslon so wlll noL lnLeracL wlLh Lhe LesL speclmen. ueLalls of dlmenslons and seal assembly are
shown ln Lhe ManufacLurlng urawlngs and CperaLlng Manua. 1he pump connecLlons wlll be sealed
uslng Lhe approprlaLe slze of C-rlng. As Lhere are no movlng parLs Lhere wlll be no problem wlLh
seallng Lhe pump connecLlons.

.$%0," L]D <"*5$&% <(50/$(& )(, ?*#" () +(&/*$&",
!"!"5"! B@&' A47496*%,
1he pump ls requlred Lo re-clrculaLe Lhe fluld wlLhln Lhe chamber. 1he pump selecLed for Lhls
appllcaLlon ls a cenLrlfugal mlcro-pump, whlch has capaclLy Lo clrculaLe fluld aL 2.8l/mln. 1he
corroslon chamber ls relaLlvely small only 70x70x130mm so wlll noL requlre a powerful pump Lo
achleve Lhe aglLaLlon necessary. 1hls parLlcular pump can also be conLrolled Lo change Lhe veloclLy of
Lhe movlng fluld allowlng anoLher varlable wlLhln experlmenLal LesLlng. As Lhe veloclLy of corroslve
fluld lncreases Lhe raLe of corroslon lncreases so condlLlons of Lhe LesL can be alLered Lo deLermlne
how domlnanL Lhls facLor ls ln corroslon faLlgue. 1he pump ls supplled by 8S ComponenLs and offers
reslsLance Lo chemlcals LhaL may be conLalned wlLhln Lhe corroslve fluld. 1he body of Lhe pump ls






27
Alumlnlum wlLh SLalnless SLeel parLs. 1hls ls lmporLanL because Lhere wlll be no lnLeracLlon beLween
Lhe pump connecLlons and speclmen.
!"!"5"C D,E*)%,&4,6(7 $%,6)%7
1he concenLraLlon of Lhe corroslve fluld needs Lo be conLrolled LhroughouL Lhe LesL. 1hls can
achleved economlcally by fllllng Lhe chamber wlLh a known volume of llquld aL 3.3 naCl, lndlcaLlve
of seawaLer condlLlons. 1he level of waLer ln Lhe conLalner wlll be checked regularly and wlll be
Lopped up as requlred. AnoLher opLlon whlch was consldered was Lo have a waLer level sensor whlch
would sense when Lhe waLer level drops below a speclfled level and lL would auLomaLlcally reflll Lhe
depleLed waLer level. 1hls ls an exLremely cosLly opLlon for an easlly remedled problem. 1he
LemperaLure range over Lhe LesL perlod ls exLremely lmporLanL as Lhls wlll affecL Lhe corroslon raLe
so wlll be monlLored by placlng a LhermomeLer Lhrough a sloL ln Lhe lld of Lhe box and recordlng Lhe
LemperaLure aL speclfled lnLervals.
HAHA? L'$, R K&'2,
8oLh Lhe base and Lhe frame, lllusLraLed ln llgure 20, are vlLal componenLs Lo Lhe successful
operaLlon of Lhe corroslon faLlgue LesL machlne. 1he base and frame boLh need Lo be sLlff enough Lo
reslsL Lhe loadlng from Lhe moLor and speclmen, and also reslsLanL Lo faLlgue. A solld base LhaL all
componenLs would be aLLached Lo was ldenLlfled as Lhe mosL approprlaLe deslgn Lhrough Lhe
concepLual sLage and reflned ln Lhe deLalled deslgn. 1he beneflL of Lhls ls Lo allow Lhe machlne Lo be
seL up correcLly once durlng Lhe manufacLure, ensurlng all dlsLances and Lhe layouL of cerLaln
componenLs are correcLly placed and fully flxed ln order Lo allow for conslsLenL LesLlng as opposed Lo
bulldlng Lhe machlne and seLLlng lL up for dlfferenL experlmenLs whlch could resulLs ln lnaccuracles
beLween LesLs.

.$%0," JKD +6! ;(7"5 () ?*#" i .,*>" () .*/$%0" ;*@B$&"



28
!"!"="# ;4+*1,
1he base of Lhe LesL rlg wlll be a solld recLangular plaLe. 1hls wlll allow componenLs Lo be easlly
bolLed or welded onLo Lhe base plaLe Lo allow a permanenL flxLure. 1he base plaLe wlll have 4x16mm
holes drllled Lhrough lL LhaL wlll allow lL Lo be flxed Lo a surface durlng LesLlng. 1wo addlLlonal holes,
Lhreaded wlLh an M6x1 Lhread wlll be machlned lnLo Lhe plaLe for Lhe aLLachmenL of Lhe boLLom
rlghL clamp. lour locaLor holes, 3mm ln dlameLer wlll also be machlned Lo a depLh of 3mm from Lhe
surface, lnLo Lhe base Lo acL as locaLor sloLs for Lhe 4 supporLs on Lhe corroslon box, reduclng Lhe
rlsk of Lhe corroslon box Llpplng over. 1hls may be necessary due Lo sllghL vlbraLlons caused by Lhe
eccenLrlc forces acLlng aL Lhe moLor shafL. 1he frame secLlons wlll be manufacLured from 20x20mm,
2mm Lhlck, square secLlon. 1he square sLeel secLlon glves a sLlff, llghLwelghL alLernaLlve Lo a solld
sLeel bar. 1hls wlll be manufacLured wlLh 43 angles aL Lhe ends ln order Lo allow for a sLrong [olnL aL
Lhe corner. 1he frame wlll be welded LogeLher and Lhen welded Lo Lhe base Lo ensure LhaL Lhe base
for Lhe moLor ls fully flxed and allow for conslsLenL LesLlng.
!"!"="5 8(64)*(7
Crade 8S970 080M40, medlum carbon sLeel wlLh mlnlmum yleld sLrengLh of 330 Ma would be used
for Lhe base and Lhe frame of Lhe LesL rlg. 1he proposed grade of sLeel was ldenLlfled as Lhe mosL
approprlaLe sLeel due Lo lLs hlgh yleld sLrengLh buL also lLs properLles enabllng lL Lo sLlll be easlly
machlned and welded. SLeel wlLh a hlgher yleld sLrengLh Lhan around 400Ma may sLarL Lo cause
lssues durlng Lhe manufacLurlng of Lhe componenLs due Lo lLs hlgh sLrengLh properLles.
HAHAH @*%*& >/'%, "0;5$%2,+%
1he moLor plaLe ad[usLmenL mechanlsm, llgure 21, ls Lhe plaLe on whlch Lhe moLor wlll be fully flxed
LhaL wlll allow horlzonLal ad[usLmenL of Lhe moLor poslLlon ln order Lo ad[usL Lhe dlsLance of Lhe
moLor ouLpuL shafL from Lhe Lop of Lhe speclmen. 1hls ls essenLlal ln order Lo alLer Lhe lnlLlal
dlsplacemenL of Lhe LesL speclmen and Lherefore alLerlng Lhe mean sLress of Lhe LesL speclmen. 1hls
wlll allow for Lhe LesLlng of maLerlals Lo see how Lhe faLlgue llfe ls affecLed by a change ln Lhe mean
sLress as sLaLed ln Lhe producL deslgn speclflcaLlon as a LesL requlremenL of Lhe machlne. 1hls ls also
a cauLlonary devlce ln case Lhe assembly of Lhe machlne ls noL exacLly as expecLed, whlch wlll allow
Lhe moLor poslLlon be ad[usLed and callbraLed accordlngly. 1he moLor plaLe ad[usLmenL assembly
wlll be welded Lo Lhe Lop of Lhe frame.


29

.$%0," JLD +6! ;(7"5 () P$&"*, ;(/$(& ;"@B*&$#> () ;*@B$&"
!"!"!"# ;4+*1,
1he deslgn of Lhe moLor plaLe ad[usLmenL comprlses of a plaLe LhaL can be ad[usLed Lhrough a
Lhreaded shafL. 1he plaLe wlll slL on Lwo ralls LhaL are [olned by a fronL secLlon and a rear secLlon.
1he screw goes Lhrough Lhe fronL secLlon, Lhreads lnLo a fabrlcaLed brackeL proLrudlng from Lhe
boLLom of Lhe moLor plaLe and Lhe end ls flxed ln Lhe rear secLlon by means of Lwo sloLLed sprlng
plns. 1he sloLLed sprlng plns wlll be normal Lo Lhe Lhreaded shafL and lock Lhe end of Lhe shafL by
passlng Lhrough a recess ln Lhe end of Lhe shafL as seen ln llgure 22. 1he handle aL Lhe end of Lhe
Lhreaded shafL wlll be used Lo move Lhe moLor plaLe ln a conLrolled moLlon by Lurnlng Lhe llnearly
flxed shafL, Lhe moLor plaLe wlll reLracL or move closer Lo Lhe LesL speclmen. 1he ad[usLmenL wlll be
made easler by a scale on boLh sldes of Lhe plaLe so Lhe user can see how far Lhe plaLe ls movlng
wlLh each Lurn of Lhe handle. Cnce Lhe plaLe has been seL, 4 sloLs are poslLloned ln each corner of
Lhe plaLe Lo securely bolL Lhe plaLe Lo Lhe ralls and reduce Lhe rlsk of movemenL durlng or beLween
LesLlng Lo ensure conslsLency.

.$%0," JJD +6! ;(7"5 +,(##-<"@/$(& () <B*)/ .$f$&%# () P$&"*, ;(/$(& ;"@B*&$#>


30
!"!"!"5 8(64)*(7
Crade 8S970 080M40, medlum carbon sLeel wlLh mlnlmum yleld sLrengLh of 330 Ma would be used
for Lhe fabrlcaLlon of Lhe moLor plaLe ad[usLmenL assembly, Lhe same as Lhe base and frame. 1he
same grade of sLeel wlll allow Lhe assembly Lo be easlly welded onLo Lhe Lop of Lhe frame.
HAHAQ )*++,(%6+1 B,% SD
1he connecLlng seL up ls made up of an eccenLrlc bearlng cenLre, sLandard slzed bearlng and a
connecLlng rod LhaL ls used Lo Lurn Lhe roLaLlonal moLlon of Lhe moLor shafL lnLo a llnear
dlsplacemenL aL Lhe Lop of Lhe speclmen. 1hls ls achleved by eccenLrlcally mounLlng Lhe bearlng Lo
offseL Lhe cenLre of roLaLlon of Lhe bearlng from Lhe axls of roLaLlon of Lhe moLor and Lherefore a
resulLanL llnear horlzonLal moLlon aL Lhe end of Lhe connecLlng rod. 1hls seL up ls a very effecLlve
way of creaLlng a consLanL slnusoldal dlsplacemenL aL Lhe Lop of Lhe speclmen, also allowlng for
dlsplacemenL ad[usLmenL by means of changlng Lhe eccenLrlc cenLre, and frequency ad[usLmenL
Lhrough Lhe moLor Lo beLLer sulL Lhe requlremenLs of Lhe LesL. 1o ad[usL Lhe dlsplacemenL aL Lhe Lop
of Lhe speclmen, dlfferenL slzed eccenLrlc cenLres LhaL provlde Lhe correcL dlsplacemenL for Lhe
maLerlal or LesLlng condlLlons can be pressed lnLo Lhe bearlng. 1hls makes Lhe seL-up very adapLable
for a range of dlfferenL maLerlals and condlLlons for LesLlng. llgure 23 shows Lhe connecLlng rod
assembly.

.$%0," JWD +6! ;(7"5 () +(&&"@/$&% 2(7 6##">45G
!"!"C"# D994,6)*9 $4,6)4
1he eccenLrlc cenLre ls a solld clrcular sLeel round LhaL
wlll be pressed lnslde Lhe lnner rlng of Lhe sLandard
bearlng. 1he exLernal surface of Lhe bearlng cenLre wlll
be machlned on a laLhe Lo ensure a perfecLly round flL
lnslde Lhe bearlng once lL has been lnsLalled by a
hydraullc press. 1he hole ln Lhe cenLre wlll be a
dlameLer of 18mm ln order Lo flL Lhe shafL dlrecLly from
Lhe moLor. 1he cenLre wlll also have a keyway
fabrlcaLed, maLchlng Lhe keyway on Lhe moLor Lo
ensure Lhe moLor shafL does noL spln lnslde Lhe bearlng
cenLre. A number of dlfferenL cenLres can be
manufacLured ln order Lo conducL LesLs wlLh dlfferenL
.$%0," JMD +6! ;(7"5 () H@@"&/,$@ +"&/," )(,
+(&&"@/$&% 2(7 *&7 ;(/(, R&/",)*@"


31
dlsplacemenLs, buL for Lhe purposes of Lhe currenL machlne, Lhe cenLre wlll be deslgned Lo allow for
dlsplacemenLs of 1mm Lo 6mm.
!"!"C"5 F4()*,1 A47496*%,
1he bearlng for Lhe connecLlng seL-up wlll be a sLandard bearlngs purchased
dlrecLly from Skl bearlng supplles. An oll-sealed bearlng was ldenLlfled as
Lhe mosL sulLable bearlng for Lhe connecLlng seL up. lL conslsLs on a deep
groove ball bearlng and an lnLegral radlal seal as shown ln llgure 23. A
sealed bearlng was ldenLlfled as Lhe mosL approprlaLe due Lo lLs long,
malnLenance free llfe. 1he oll-sealed bearlngs need less space Lhan common
Lwo-componenL arrangemenLs, LhaL slmpllfles mounLlng, and avolds
expenslve machlnlng of Lhe shafL because Lhe lnner rlng shoulder ls an
excellenL counLerface. 1he radlal shafL seal ls made of acrylonlLrlle-
buLadlene rubber (n88) and has a sprlng-loaded Waveseal llp. 1he
permlsslble operaLlng LemperaLure range for Lhe seal ls -40 Lo +100 C and up Lo +120 C for brlef
perlods. 1he speed llmlL for Lhe bearlng ls based on Lhe permlsslble clrcumferenLlal speed for Lhe
seal, whlch ln Lhls case ls 14 m/s. 1he speclflcaLlon for Lhe selecLed bearlng can be seen ln llgure 26.


.$%0," J_D ?"*,$&% <3"@$)$@*/$(& A(,=#B""/ ),(> ;*&0)*@/0,",
!"!"C"= $%,,496*,1 >%0
1he connecLlng rod ls used Lo Lransfer Lhe dlsplacemenL from Lhe eccenLrlc seL up aL Lhe moLor shafL
Lo Lhe Lop of Lhe speclmen. lL allows for Lhe roLaLlonal moLlon Lo be converLed Lo a llnear moLlon aL
Lhe speclmen, requlred for Lhe faLlgulng of Lhe LesL speclmen. AL Lhe moLor end lL ls deslgned as a
bearlng houslng so LhaL Lhe oll-sealed bearlng can be pressed lnLo lL uslng a hydraullc press. 1he
clrcular end ls of sufflclenL Lhlckness Lo ensure LhaL Lhe forces durlng Lhe lnsLallaLlon of Lhe bearlng
wlll noL crack or break Lhe clrcular bearlng houslng. 1he long shafL ls Lhen connecLed vla a plnned
[olnL Lo Lhe Lop lefL clamp aL Lhe Lop of Lhe speclmen. 1he plnned [olnL ls requlred as Lhere wlll be a
verLlcal moLlon of Lhe shafL aL Lhe moLor end due Lo Lhe eccenLrlc cenLre, Lherefore lL can noL be
.$%0," WZD ?"*,$&% <"/ S3


32
fully flxed Lo Lhe Lop clamp of Lhe speclmen and musL have a degree of free roLaLlon aL Lhe end. 1he
[aw deslgn plnned [olnL aL Lhe end of Lhe connecLlng rod ls Lo ensure LhaL Lhe llnear movemenL from
Lhe shafL ls applled dlrecLly ln llne wlLh Lhe roLaLlng cenLre, reduclng Lhe chance of LwlsLlng and
mlsallgnmenL durlng operaLlon. A cross secLlon of Lhe connecLlng seL up can be seen ln llgure 27.
1he same grade 8S970 080M40, medlum carbon sLeel wlLh mlnlmum yleld sLrengLh of 330 Ma
would be used for Lhe fabrlcaLlon of Lhe eccenLrlc cenLre of Lhe bearlng and also Lhe connecLlng rod.
1hls allows for a hlgh performance sLeel Lo be used wlLhouL lncreaslng Lhe compllcaLlons and cosL of
Lhe manufacLurlng process.

.$%0," J[D +6! ;(7"5 () +(&&"@/$&% 2(7 6##">45G +,(##-<"@/$(&
HAHAT BD,(62,+ )/'2D$
1he clamps for Lhe speclmen ensure Lhe LesL speclmen ls robusLly secured and Lhe loads are
Lransferred from Lhe connecLlng rod evenly. 1he clamp seLs conLaln a Lop seL Lo apply Lhe
dlsplacemenL Lo Lhe Lop of Lhe speclmen and Lhe boLLom seL are used Lo securely consLraln Lhe
boLLom of Lhe speclmen Lo Lhe base. 1he Lop seL ls bolLed Lo Lhe speclmen and Lhen aLLached Lo Lhe
plnned connecLlon on Lhe connecLlng rod vla a plnned [olnL. Cne of Lhe boLLom clamps wlll be fully
flxed Lo Lhe base and Lhe oLher poslLloned afLer Lhe speclmen has been lnsLalled. A bolLed plaLe seL
up has been used for Lhe deslgn of boLh Lhe boLLom and Lop clamp seL. 1hls was ldenLlfled as Lhe
mosL approprlaLe way Lo consLraln Lhe speclmen and apply Lhe loadlng, as lL wlll noL lnLerfere wlLh
Lhe LesLlng of Lhe speclmen.
!"!"G"# F%66%& $7(&' A46
1he boLLom clamp seL, as shown ln llgure 28, ls
made up of Lwo slmllar clamps Lo reduce Lhe
compllcaLlons of dlfferenL parLs durlng manufacLure
and assembly. 1he clamps are L-shaped ln form
wlLh Lhe lefL slde clamp welded Lo Lhe base Lo keep
a consLanL daLum for Lhe speclmen, whlch means
LhaL Lhe ad[usLmenL of Lhe moLor plaLe ls Lhe only
ad[usLmenL meLhod for Lhe dlsLance from Lhe
moLor Lo Lhe speclmen. Cnce Lhe speclmen has
been lnsLalled, Lhe rlghL hand clamp can be
lnsLalled. 1he bolLs Lhrough Lhe boLLom of Lhe
speclmen wlll be LlghLened flrsL Lo allow Lhe clamp
Lo be LlghL agalnsL Lhe speclmen and Lhen Lhe Lwo
.$%0," J\D +6! ;(7"5 () ?(//(> +5*>3 6##">45G



33
remalnlng bolLs Lhrough Lhe sloLs ln Lhe boLLom of Lhe clamp wlll be LlghLened Lo ensure Lhe boLLom
of Lhe speclmen ls securely flxed Lo Lhe base.
!"!"G"5 2%' $7(&' A46
1he Lop clamp seL, ln llgure 29, ls made up of a lefL
hand clamp and a rlghL hand clamp and ls
poslLloned aL Lhe very Lop of Lhe speclmen so LhaL
Lhe Lop of Lhe clamp ls horlzonLally allgned wlLh Lhe
Lop of Lhe speclmen. 1he lefL clamp has a pad eye
shaped secLlon of sLeel proLrudlng from Lhe surface
of Lhe plaLe ln order Lo allow for Lhe connecLlon aL
Lhe plnned [olnL of Lhe connecLlng arm. 1he back
plaLe ls Lhe same slze as Lhe fronL plaLe Lo ensure
LhaL Lhe loadlng ls conslsLenL ln boLh Lhe rlghL and
lefL dlsplacemenL of Lhe speclmen. Cnce Lhe Lop
clamp seL ls lnsLalled, a pln can be used Lo connecL
Lhe clamp seL-up, lncludlng Lhe speclmen Lo Lhe
connecLlng seL up, a washer and clrcllp can Lhen be
used Lo secure Lhe pln.
1he same grade 8S970 080M40, medlum carbon sLeel wlLh mlnlmum yleld sLrengLh of 330 Ma
would be used for Lhe fabrlcaLlon of boLh Lhe Lop and boLLom clamps. 1hls allows for a hlgh
performance sLeel Lo be used for securlng Lhe speclmen and Lransferrlng Lhe loads wlLhouL
lncreaslng Lhe compllcaLlons and cosL of Lhe manufacLurlng process. 1he cholce of maLerlal also
allows for Lhe easy of weldlng Lhe boLLom clamp Lo Lhe base, as Lhe base maLerlal and clamp
maLerlal wlll noL be dlsslmllar.
HAHAU )*5+%6+1 $9$%,2
Cne key aspecL ln Lhe deslgn of Lhe corroslon faLlgue LesL machlne ls Lhe ablllLy Lo accuraLely counL
and record Lhe number of cycles Lo fallure for a glven LesL scenarlo. 1he requlremenLs of Lhe chosen
counLlng sysLem lnclude Lhe followlng:
MusL be able Lo accuraLely counL elLher Lhe number of moLor roLaLlons or Lhe number of
connecLlng rod osclllaLlons.
MusL be able Lo reLaln Lhe number of cycles and dlsplay LhaL number clearly.
MusL have a counLlng dlsplay of aL leasL 7 dlglLs.
MusL sLop counLlng Lhe number of cycles once Lhe LesL speclmen has falled.
1o LhaL end, a number of poLenLlal sysLems were lnvesLlgaLed lnvolvlng varlous meLhods of roLaLlon
and osclllaLlon deLecLlon.
1he flrsL meLhod LhaL was looked lnLo made use of a slmple mechanlcal counLlng mechanlsm. 1he
mechanlcal counLer would be mounLed ln llne wlLh Lhe moLor and Lhe roLaLlon mechanlsm would be
palred wlLh Lhe moLor shafL. 1hus, when Lhe moLor was acLlvaLed each roLaLlon of Lhe moLor shafL
would cause Lhe mechanlcal counLer Lo roLaLe once, addlng one Lo Lhe counL dlsplay.
.$%0," J]D +6! ;(7"5 () 1(3 +5*>3 <"/


34
A mechanlcal counLer has a number of advanLages lncludlng Lhe slmpllsLlc naLure of Lhe deslgn,
whlch requlres no exLernal power supply or elecLrlcal connecLlons. 1hey are durable, so would be
capable of wlLhsLandlng Lhe vlbraLlons of Lhe LesL machlne wlLhouL faulLs. Powever, Lhere are also a
number of dlsadvanLages Lo uslng such a devlce. A mechanlcal counLer wlLh a 7-dlglL dlsplay would
be of slmllar dlmenslons Lo Lhe moLor lLself maklng mounLlng Lhe counLer securely wlLhouL
unbalanclng Lhe LesL machlne very dlfflculL. ln addlLlon Lo Lhls, because Lhe LesL machlne relles on
Lhe use of varlous eccenLrlc bearlngs Lo supply dlfferenL osclllaLlon ampllLudes and Lhese bearlngs
musL be mounLed beLween Lhe moLor and Lhe counLer, lL would be necessary Lo noL only mounL Lhe
counLer securely buL also ln such a way as Lo allow lLs removal and replacemenL whenever a new
eccenLrlc bearlng ls requlred. 8ecause of Lhe dlfflculLles encounLered ln deslgnlng a sulLable
mounLlng sysLem, Lhe mechanlcal counLer was deemed an unsulLable cholce for Lhe counLlng
sysLem.
1he second poLenLlal counLlng sysLem lnvesLlgaLed lnvolved Lhe use of llghL gaLes Lo counL Lhe
number of osclllaLlons of Lhe connecLlng rod. 1he ldea was Lo mounL a llghL gaLe seLup nexL Lo Lhe
connecLlng rod wlLh a small hole drllled ln Lhe rod so LhaL on each osclllaLlon Lhe llghL beam would
pass Lhrough Lhe hole and compleLe Lhe clrculL, sendlng an lmpulse Lo an elecLronlc counLer.
Powever, Lhe way Lhe LesL machlne ls deslgned allows for Lhe poslLlon of Lhe moLor Lo be ad[usLed,
whlch ln Lurn means Lhe poslLlon of Lhe connecLlng rod ls varlable as well. 8ecause Lhe conLrol rod
poslLlon can vary from LesL Lo LesL, Lhe hole ln Lhe rod for Lrlggerlng Lhe llghL gaLe clrculL also moves
and Lhls movemenL would requlre Lhe llghL gaLe Lo be reposlLloned as well. Slnce Lhe moLor ls belng
moved accuraLely from 1 Lo 6mm aL a Llme, Lhe llghL gaLe would also be requlred Lo move wlLh Lhe
same level of accuracy. 1hls would Lherefore requlre Lhe deslgn of anoLher movemenL sysLem slmllar
Lo Lhe one used Lo ad[usL Lhe moLor poslLlon for Lhe llghL gaLe clrculL. uue Lo Lhe complexlLy of
addlng such a sysLem as well as Lhe preclslon requlred from Lhe user Lo correcLly poslLlon Lhe llghL
gaLe for each LesL, Lhls ldea was deemed unsulLable as well.
1he Lhlrd mechanlsm consldered for Lhe counLlng sysLem uLlllsed a magneL and reed swlLch
comblnaLlon Lo counL Lhe number of moLor shafL roLaLlons. ln Lheory, a small hlgh-powered magneL
would be aLLached on a rod Lo Lhe moLor shafL and a reed swlLch would be mounLed Lo Lhe moLor
ad[usLmenL baseplaLe such LhaL Lhe magneL passed wlLhln a few mllllmeLres of Lhe reed swlLch
durlng each roLaLlon of Lhe moLor shafL. Slnce reed swlLches are elecLrlcal swlLches LhaL can be
closed or opened by Lhe presence of a magneLlc fleld, Lhe reed swlLch would be wlred Lo an exLernal
elecLronlc counLer, whlch would add one Lo Lhe counL each Llme Lhe magneL passed by and closed
Lhe reed swlLch, compleLlng Lhe clrculL. AlLhough Lhe ldea of uslng a magneL/reed swlLch
comblnaLlon was feaslble, Lhe maln problem wlLh Lhe ldea was Lhe safe aLLachmenL of Lhe rod and
magneL Lo Lhe moLor shafL. lL was declded LhaL weldlng Lhe rod ln place was noL sulLable due Lo Lhe
small slze of Lhe moLor shafL and Lhe poLenLlal for warplng and Lhere were fears LhaL weaker
meLhods of aLLachmenL would noL be sLrong enough Lo secure Lhe rod ln place agalnsL Lhe roLaLlon
and vlbraLlons of Lhe moLor shafL. ulLlmaLely, lL was declded LhaL Lhe rlsk of Lhe magneL becomlng
deLached from Lhe moLor shafL was Loo greaL a safeLy hazard and Lhe ldea was abandoned.
1he counLlng sysLem LhaL was ulLlmaLely declded on was based on slmllar prlnclples Lo Lhe
magneL/reed swlLch comblnaLlon descrlbed above buL wlLhouL Lhe need Lo mounL anyLhlng Lo Lhe
moLor shafL lLself. 1he ldea lnvolves mounLlng a small opLlcal swlLch Lo Lhe moLor ad[usLmenL
sLrucLure [usL below Lhe moLor shafL. An opLlcal swlLch ls made up of Lwo componenLs, an LLu and a


33
phoLoLranslsLor. 8y wrapplng Lhe moLor shafL dlrecLly above Lhe opLlcal swlLch ln black elecLrlcal
Lape and Lhen placlng a Lhln sLrlp of reflecLlve Lape over Lhe elecLrlcal Lape, Lhe opLlcal swlLch can be
made Lo Lrlgger each Llme Lhe reflecLlve Lape passes over lL. 1hls occurs because when Lhe llghL
from Lhe LLu sLrlkes Lhe black Lape, very llLLle ls reflecLed back Lo Lhe phoLoLranslsLor so no currenL
ls produced. Powever, when Lhe llghL from Lhe LLu sLrlkes Lhe reflecLlve Lape a much larger porLlon
of Lhe llghL ls reflecLed back Lo Lhe phoLoLranslsLor, Lhus generaLlng a currenL, whlch can be used Lo
Lrlgger Lhe counL funcLlon of an elecLronlc counLer.
1he opLlcal swlLch chosen for Lhls purpose ls Lhe CpLek C8704. 1hls parLlcular model of opLlcal
swlLch was chosen based on Lhe recommendaLlons of Lhe elecLrlcal englneerlng deparLmenL aL Lhe
unlverslLy of SLraLhclyde where Lhls componenL ls commonly used for Lhls purpose ln a number of
experlmenLs. revlous uses by Lhe elecLrlcal englneerlng deparLmenL have shown LhaL Lhls model ls
sulLable for use ln a varleLy of envlronmenLal condlLlons much harsher Lhan Lhe condlLlons Lhls unlL
ls expecLed Lo operaLe ln. 1he poslLlonlng of Lhe opLlcal swlLch on Lhe moLor frame behlnd Lhe
connecLlng rod ls shown below ln flgures 30 and 31.









1he elecLronlc counLer chosen ls Lhe PengsLler 0 731 101. 1hls model of counLer was chosen
because lL lncludes an 8-dlglL dlsplay, an lnLernal power supply conslsLlng of a long-llfe llLhlum
baLLery and a very slmple wlrlng mechanlsm LhaL can be used Lo easlly counL each elecLrlcal lmpulse
from Lhe opLlcal swlLch.
1he clrculL used Lo connecL Lhe opLlcal swlLch Lo Lhe counLer ls shown below ln llgure 32.
.$%0," WKD <$7" U$"C () O3/$@*5
<C$/@B ?"B$&7 +(&&"@/$&% 2(7
.$%0," WLD W! U$"C () O3/$@*5 <C$/@B


36

.$%0," WJD +$,@0$/ !$*%,*> )(, /B" +(0&/$&% <G#/">
ln order Lo proLecL Lhe LLu from drawlng Loo much currenL and burnlng ouL, a sulLable reslsLor musL
be selecLed. 1he necessary reslsLance value can be calculaLed from LquaLlon 6.
! !
!
!
!!
!
!
!
4>(? E
Where 8 = reslsLor value (U), v
S
= supply volLage (v), v
l
= LLu forward volLage (v) and l
l
= LLu
forward currenL.
ln Lhls case, a 9v baLLery was chosen as Lhe power supply and Lhe forward volLage and currenL were
speclfled ln Lhe opLlcal swlLch documenLaLlon as 1.7v and 40mA respecLlvely. 1hus, Lhe mlnlmum
reslsLance value requlred was found Lo be ! !
!!!!!
!!!"
! !"#!!".
1he reslsLor power requlred was also calculaLed from LquaLlon 7.
! ! !
!
! !
!
! !
!
! ! ! !!! ! !!!" ! !!!"!! 4>(? F
1herefore, Lhe reslsLor chosen was a 200U, 0.3W reslsLor. A reslsLor musL also be chosen for Lhe
phoLoLranslsLor buL slnce Lhe phoLoLranslsLor only needs Lo be saLlsfled Lo lLs mlnlmum
requlremenLs, a 1kU reslsLor wlll provlde enough reslsLance ln Lhls case.
WlLh Lhe opLlcal swlLch wlred up, Lhe counLer can be connecLed Lo Lhe clrculL Lhrough lLs 0v and
CCun1 Lermlnals as shown above. 1hus, when Lhe phoLoLranslsLor ls noL generaLlng a volLage, Lhe
counLer wlll deLecL 0v and when Lhe reflecLlve Lape passes over Lhe opLlcal swlLch generaLlng a
volLage ln Lhe phoLoLranslsLor, Lhe counLer wlll deLecL 3v, whlch wlll add one Lo Lhe counL.
1he counLer comes wlLh a bullL-ln reseL swlLch, whlch can be used Lo reseL Lhe counL Lo zero
beLween LesLs. 1he flnal requlremenL of Lhe counLlng sysLem regardlng sLopplng counLlng once Lhe
LesL ls compleLe ls handled by a separaLe clrculL LhaL auLomaLlcally cuLs power Lo Lhe moLor upon
speclmen fallure. 1hls ls dlscussed ln more deLall ln SecLlon 4.4.8.


37
HAHAV >*.,& B5DD/9 W)6&(56% L&,'-,&X YO$%*D $.6%(FX '5%* $F5%O*== $.6%(FZ
1he flnal elecLrlcal componenL LhaL musL be consldered ln Lhe deslgn of Lhe LesL machlne ls Lhe
power supply and assoclaLed safeLy devlces. ln accordance wlLh Lhe CrlenLal MoLor 8LA Serles
CperaLlng Manual, a malns supply cable raLed above 230v was chosen for Lhls purpose. 1he flrsL
proLecLlve devlce LhaL musL be wlred uslng Lhls power cable ls a clrculL breaker. As speclfled ln Lhe
moLor operaLlng manual, a clrculL breaker raLed for 10A was selecLed. 1hls clrculL breaker wlll
proLecL Lhe moLor from damage ln Lhe evenL LhaL Lhe currenL drawn from Lhe malns becomes Loo
hlgh.
1he nexL proLecLlve devlce Lo be consldered was an emergency sLop swlLch. 1he emergency sLop
swlLch ls vlLal Lo proLecL agalnsL Lhe posslblllLy of a dangerous malfuncLlon of Lhe machlne. ln Lhe
evenL LhaL Lhe machlne musL be qulckly shuL off for any reason Lhe emergency sLop swlLch can be
depressed whlch wlll lmmedlaLely cuL Lhe power supply Lo Lhe moLor, kllllng Lhe LesL machlne. 1he
LesL machlne wlll Lhen be unable Lo draw power from Lhe malns unLll Lhe emergency sLop swlLch ls
reseL. A large pull release L-sLop swlLch was sourced for Lhls funcLlon. 1he swlLch enclosure ls brlghL
yellow and Lhe buLLon lLself ls brlghL red Lo easlly dlsLlngulsh lL from oLher componenLs of Lhe
conLrol panel.
1he flnal componenL Lo be wlred Lo Lhe power supply ls Lhe auLo shuL-off swlLch. 1hls swlLch ls noL a
safeLy devlce ln Lhe same way as Lhe L-sLop swlLch. lnsLead, Lhls swlLch ls used Lo auLomaLlcally cuL
power Lo Lhe moLor upon compleLlon of a LesL cycle. 1he swlLch ls mounLed Lo Lhe connecLlng rod
supporL arm so LhaL when Lhe LesL speclmen falls Lhe connecLlng rod wlll fall onLo Lhe supporL arm,
depresslng Lhe auLo shuL-off swlLch and shuLLlng off Lhe moLor. 1hls means LhaL when Lhe LesL ls
compleLe, Lhe moLor wlll sLop roLaLlng and Lhe counLlng mechanlsm wlll sLop counLlng allowlng an
accuraLe number of cycles Lo fallure Lo be read from Lhe counLer.
HAHA[ )'/6#&'%6*+ BD,(62,+
!"!"H"# IE4)E*4J
ln order Lo work ouL Lhe sLresses experlenced by Lhe LesL speclmens durlng a LesL, lL ls necessary Lo
use sLraln gauges Lo measure Lhe bendlng sLraln ln Lhe speclmens. ldeally, Lhe LesL machlne would
allow Lhe use of sLraln gauges durlng LesLlng Lo provlde real-Llme sLraln measuremenLs LhroughouL
Lhe llfe of Lhe LesL. Powever, slnce Lhe LesL machlne lnvolves slmulaLlng Lhe effecL of corroslon on
Lhe LesL speclmens as well as faLlgue, Lhls ls noL posslble slnce Lhe corroslve fluld would qulckly
desLroy any sLraln gauges lefL submerged ln lL. 1herefore, lL was declded LhaL a callbraLlon
speclmen" would be creaLed wlLh sLraln gauges aLLached Lo lL. 1hls callbraLlon speclmen would be a
regular LesL speclmen wlLh sLraln gauges aLLached Lo Lhe surface of Lhe LesL speclmen aL Lhe cenLre
of Lhe gauge and would be placed ln Lhe LesLlng machlne before Lhe beglnnlng of each LesL and
sub[ecLed Lo Lhe same loads used ln Lhe acLual LesL lLself. ln Lhls way, Lhe maxlmum, mlnlmum and
mean sLraln experlenced by a LesL speclmen for LhaL speclflc LesL scenarlo could be measured. 1he
LesL speclmen would Lhen replace Lhe callbraLlon speclmen before fllllng Lhe baLh wlLh corroslve
fluld and carrylng ouL Lhe LesL.
8ecause sLraln measuremenLs are usually exLremely small (a few mllllsLraln ls common) lL ls
necessary Lo be able Lo accuraLely measure very small changes ln Lhe reslsLance of a sLraln gauge.
lor Lhls reason, sLraln gauges are almosL always wlred ln a wheaLsLone brldge conflguraLlon.
WheaLsLone brldge clrculLs acL as Lwo parallel volLage dlvlder clrculLs, wlLh one palr of reslsLors


38
composlng one volLage dlvlder and Lhe oLher palr of reslsLors composlng Lhe second volLage dlvlder.
lf Lhe raLlos of reslsLances ln each arm are equlvalenL Lhen Lhe volLage dlfference measured beLween
Lhe mlddle nodes of each volLage dlvlder wlll be zero. ln Lhls condlLlon, a wheaLsLone brldge ls
consldered balanced. ln a balanced brldge, a physlcal effecL such as a change ln sLraln or
LemperaLure occurs, Lhe reslsLance of Lhe senslng elemenLs ln Lhe brldge wlll also change whlch wlll
cause Lhe brldge Lo become unbalanced and Lhe volLage dlfference beLween Lhe Lwo arms Lo
become non-zero. 1herefore, by measurlng Lhe volLage dlfference beLween Lhe Lwo arms of Lhe
brldge clrculL lL ls posslble Lo accuraLely measure Lhe small changes ln reslsLance experlenced by Lhe
senslng elemenLs of Lhe wheaLsLone brldge.
1here are Lhree maln wheaLsLone brldge conflguraLlons dependlng on Lhe number of acLlve sLraln
gauge elemenLs presenL ln Lhe clrculL. A quarLer-brldge clrculL has one acLlve sLraln gauge, a half-
brldge clrculL has Lwo acLlve sLraln gauges and a full-brldge clrculL has 4 acLlve sLraln gauges. 1hese
conflguraLlons are furLher broken down lnLo varlous Lypes dependlng on Lhe orlenLaLlon of Lhe sLraln
gauges and Lhe Lype of sLraln belng measured.
A quarLer-brldge clrculL can be used Lo measure elLher axlal or bendlng sLraln and conLalns one
acLlve sLraln gauge. lL can also be conflgured wlLh a second dummy" sLraln gauge LhaL ls placed
Lransverse Lo Lhe dlrecLlon of sLraln buL noL bonded Lo Lhe speclmen. 1he dummy sLraln gauge acLs
as a LemperaLure-senslng elemenL, helplng Lo ellmlnaLe Lhe effecL of LemperaLure change on Lhe
sLraln measuremenLs. 1he quarLer-brldge clrculLs are Lhe leasL senslLlve brldge conflguraLlon.
A Lype l half-brldge clrculL can measure elLher axlal or bendlng sLraln and conLalns Lwo acLlve sLraln
gauges, one mounLed ln Lhe dlrecLlon of Lhe sLraln and Lhe oLher mounLed Lransverse Lo Lhe
prlnclpal axls of sLraln. 1he Lransversely mounLed sLraln gauge acLs as a olsson gauge, whlch helps
Lo compensaLe for Lhe cumulaLlve effecL on Lhe prlnclple sLraln measuremenL due Lo Lhe olsson's
raLlo of Lhe maLerlal. 1he Lype ll conflguraLlon has Lhe Lransverse sLraln gauge lnsLead mounLed ln
Lhe dlrecLlon of sLraln buL on Lhe opposlLe slde of Lhe speclmen Lo Lhe flrsL sLraln gauge. 8ecause of
Lhls new layouL, Lhls clrculL can only measure bendlng sLraln and re[ecLs axlal sLraln buL Lhe overall
senslLlvlLy of Lhe clrculL Lo bendlng sLraln ls lncreased over Lhe Lype l conflguraLlon. 8oLh half-brldge
clrculL Lypes compensaLe for Lhe effecL of LemperaLure changes.
1he full-brldge clrculLs can be arranged lnLo Lhree Lypes dependlng on Lhe deslred ouLpuL. 1ype l
clrculLs are arranged ln Lhe same manner as Lype ll half-brldge clrculL excepL Lhey use anoLher Lwo
sLraln gauges mounLed ln Lhe dlrecLlon of sLraln lnsLead of compleLlon reslsLors for Lhe second half
of Lhe brldge. 1hls conflguraLlon ls hlghly senslLlve Lo bendlng sLraln buL re[ecLs axlal sLraln. lL also
compensaLes for Lhe effecLs of LemperaLure change and lead wlre reslsLance. A Lype ll full-brldge
clrculL ls Lhe same as uslng Lwo Lype l half-brldge clrculLs l.e. one axlally mounLed and one
Lransversely mounLed sLraln gauge on boLh sldes of Lhe speclmen. 1hls clrculL ls sllghLly less
senslLlve Lo bendlng sLraln Lhan Lhe Lype l conflguraLlon buL, due Lo Lhe Lwo Lransverse sLraln gauges
acLlng as a olsson gauge, lL has Lhe beneflL of compensaLlng for Lhe cumulaLlve effecL on Lhe
prlnclple sLraln measuremenL due Lo Lhe olsson's raLlo of Lhe maLerlal as well as Lhe effecLs of
LemperaLure and lead wlre reslsLance. llnally, Lhe Lype lll conflguraLlon ls arranged ln Lhe same way
as Lhe Lype ll full-brldge clrculL buL ln Lhls case, each arm of Lhe brldge conLalns one axlal sLraln
gauge and one Lransverse sLraln gauge. 1hls conflguraLlon has Lhe same beneflLs and drawbacks as


39
Lhe Lype ll brldge buL due Lo Lhe sllghLly dlfferenL arrangemenL of sLraln gauges, lL only measures
axlal sLraln and re[ecLs bendlng sLraln.
lL was declded LhaL for Lhe purposes of Lhls LesL machlne, a full-brldge Lype ll conflguraLlon would be
used as Lhe full-brldge clrculL provldes Lhe hlghesL senslLlvlLy Lo changes ln sLraln of all Lhe brldge
Lypes. 1he Lype ll conflguraLlon was chosen as Lhe sllghL reducLlon ln senslLlvlLy Lo bendlng sLraln
compared Lo a Lype l brldge ls made up for by Lhe ln-bullL compensaLlon agalnsL Lhe effecLs of Lhe
olsson's raLlo of Lhe speclmen maLerlal.
1he flnal clrculL used for Lhe LesL machlne ls shown below ln llgure 33. noLe LhaL 81 and 82 are Lhe
Lransversely mounLed sLraln gauges and 83 and 84 are Lhe axlally mounLed sLraln gauges.

.$%0," WWD +$,@0$/ !$*%,*> () <G#/"> S#"7 )(, +*5$4,*/$(& <3"@$>"&
!"!"H"5 I..+46 K@77*,1
ln a perfecL clrculL, Lhe volLage dlfference beLween Lhe Lwo arms of Lhe brldge would read exacLly
zero when Lhe speclmen ls unsLralned. Powever, due Lo sllghL varlaLlons ln reslsLance beLween Lhe
brldge arms and sLraln lnduced by Lhe appllcaLlon of Lhe sLraln gauges Lhere wlll almosL always be a
sllghL lnlLlal offseL volLage. ln order Lo callbraLe Lhe wheaLsLone brldge clrculL lL ls Lherefore
necessary Lo carry ouL offseL nulllng. CffseL nulllng can be carrled ouL ln Lwo ways, Lhrough Lhe use
of sofLware compensaLlon or Lhrough Lhe use of a poLenLlomeLer or rheosLaL.
uslng sofLware compensaLlon lnvolves Laklng an lnlLlal volLage readlng across Lhe wheaLsLone brldge
before any sLraln ls applled and Lhen use sofLware Lo compensaLe for Lhls offseL ln successlve
readlngs. AlLhough Lhls meLhod ls useful and requlres no manual ad[usLmenLs, lL does noL acLually
remove Lhe offseL and Lhls can have a llmlLlng effecL on Lhe dynamlc range of Lhe measuremenL.
1he use of a rheosLaL was Lherefore declded Lo be Lhe besL meLhod of offseL nulllng Lhe brldge
clrculL. 8y applylng a rheosLaL across one of Lhe acLlve sLraln gauges, Lhe reslsLance can be manually
ad[usLed unLll Lhe brldge ls balanced. 1he general rule for selecLlng Lhe range of a rheosLaL for Lhls
purpose ls Lo make lL 10 of Lhe gauge reslsLance of Lhe sLraln gauges ln use. ln Lhls case Lhe gauge
reslsLance ls 120U so Lhe range of Lhe rheosLaL should be aL sllghLly above 1.2U. 1he chosen


40
rheosLaL measures up Lo 2.2U so lL has a sulLable reslsLance range whlle sLlll allowlng flne
ad[usLmenLs Lo be made Lo Lhe reslsLance.
!"!"H"= A:@,6 $(7*L)(6*%,
ln addlLlon Lo carrylng ouL a null offseL, lL ls also necessary Lo verlfy Lhe accuracy of Lhe sLraln gauge
measuremenL sysLem. 1hls ls usually achleved by carrylng ouL a shunL callbraLlon. A shunL
callbraLlon lnvolves connecLlng (shunLlng) a large flxed reslsLor across one arm of Lhe wheaLsLone
brldge ln order Lo slmulaLe a known sLraln. 8ecause Lhe value of Lhe shunL reslsLor ls known, Lhe
expecLed volLage dlfference can be calculaLed and compared wlLh Lhe acLual measured volLage
dlfference. 1he full procedure for carrylng ouL a shunL callbraLlon ls ouLllned ln ChapLer 3:
lnsLallaLlon: ShunL CallbraLlon ln Lhe supplled CperaLlng Manual.
HAHA3\ E,$% BD,(62,+
1he LesL speclmen ls one of Lhe maln drlvlng facLors ln Lhe deslgn of Lhe componenLs ln Lhe corroslon
faLlgue LesL rlg. lL was declded aL a group meeLlng, wlLh rofessor Mackenzle, LhaL Lhe LesL
speclmens were golng Lo be recLangular cross-secLlon, and approxlmaLely 200mm ln lengLh.
rofessor Mackenzle also dlscussed Lhe maxlmum bendlng sLress ln Lhe speclmen durlng LesLlng
should be around 230Ma. 1he LesL speclmen was also proposed Lo be of 3mm Lhlckness. lL ls vlLal
LhaL Lhe enLlre gauge lengLh of Lhe LesL speclmen wlll be submerged ln Lhe corroslve fluld, so Lhe
gauge lengLh dld noL necessarlly need Lo be ln Lhe cenLre of Lhe speclmen.
!"!"#M"# <A28 A6(,0()0
1he LesL speclmens for Lhe corroslon faLlgue LesL rlg were deslgn ln accordance wlLh AS1M L466
sLandard. 1here are many speclmen varlables LhaL need Lo be kepL consLanL durlng LesLlng such as
hardness, cleanllness, composlLlon, dlrecLlonallLy, surface resldual sLress, surface flnlsh eLc. 1hese
varlables wlll be Lhe responslblllLy of Lhe researcher uslng Lhe LesL rlg, Lo ensure Lhe research ls valld.
1he sLandards for Lhe dlmenslons of Lhe LesL speclmen are shown ln llgure 34. 1he flgure also shows
Lhe radlus of Lhe fllleLs beLween Lhe gauge lengLh and Lhe grlpped area should be LangenLlal Lo Lhe
gauge secLlon of Lhe speclmen.

.$%0," WMD <3"@$>"&# C$/B /*&%"&/$*55G 45"&7"7 )$55"/# 4"/C""& /B" 0&$)(,> /"#/ #"@/$(& *&7 /B" "&7#e 6<1; HM__-K[
1he sLandard sLaLes LhaL Lhe speclmen should be deslgned Lo fall aL Lhe LesL secLlon, where Lhere ls a
reduced cross-secLlonal area. 1o ensure LhaL fallure occurs ln Lhls area, Lhe cross-secLlonal area of
Lhe ends of Lhe speclmen should be aL leasL 1.3 Llmes greaLer Lhan Lhe LesL secLlon of Lhe speclmen,
buL Lhe sLandard recommends LhaL Lhe grlp cross-secLlonal area aL Lhe ends should be aL leasL 4
Llmes greaLer. 1he blendlng fllleL radlus should also be aL leasL 8 Llmes greaLer Lhan Lhe LesL secLlon
wldLh Lo mlnlmlse Lhe sLress concenLraLlon facLor.


41
!"!"#M"5 8(64)*(7
1he maLerlal of Lhe LesL speclmen wlll vary dependlng on whaL Lhe research ls belng carrled ouL
uslng Lhe corroslon faLlgue LesL rlg. 1he cllenL conflrmed LhaL varlous maLerlals were Lo be LesLed on
Lhe rlg buL Lhe ma[orlLy of Lhe research Lo be carrled ouL was Lo collecL corroslon faLlgue daLa for 316
sLalnless sLeels. lor Lhe deslgn of Lhe LesL speclmen, Cambrldge Lnglneerlng SelecLor (CLS) was used
Lo obLaln maLerlal properLles for SLalnless sLeel, ausLenlLlc, AlSl 316, wroughL, annealed, shown ln
1able 3.
V,(3",/G U*50"
uenslLy 7827 kg/m
3

?oung's Modulus 200 Ca
?leld SLrengLh 310 Ma
olsson's 8aLlo 0.27
1*45" _D ;*/",$*5 3,(3",/$"# () WL_ #/*$&5"## #/""5
!"!"#M"= N(,0 $(79@7(6*%,+
Pand calculaLlons were used Lo approxlmaLe Lhe dlmenslons of Lhe speclmen requlred Lo saLlsfy
AS1M L466 sLandard, and also meeL Lhe requlremenLs of Lhe cllenL. 8efore a flnlLe elemenL (lL)
model of Lhe speclmen was creaLed, hand calculaLlons were used Lo verlfy Lhe maxlmum
dlsplacemenL of baslc lL models on Creo arameLrlc. lor more deLalls of Lhe calculaLlons, see
Appendlx 2. 1he hand calculaLlons also showed LhaL a force of approxlmaLely 30n ls requlred Lo
bend Lhe speclmen Lo maxlmum dlsplacemenL of 6mm.
!"!"#M"! OD< <,(73+*+ %. A'49*&4,
llnlLe LlemenL model was creaLed based on Lhe resulLs of Lhe hand calculaLlons. 8oundary
condlLlons applled Lo Lhe model Lo slmulaLe Lhe clamp aL Lhe base of Lhe speclmen were Lo fully
consLraln Lhe clamped area aL Lhe base of Lhe speclmen. 1he loadlng condlLlons were applled as a
force over Lhe area where Lhe speclmen would be clamped Lo Lhe connecLlng rod. An auLo-
generaLed mesh was used when several analyses were carrled ouL, Lo ad[usL Lhe dlmenslons of Lhe
speclmen Lo manlpulaLe Lhe maxlmum bendlng sLress ln Lhe gauge lengLh of Lhe speclmen, and Lhe
maxlmum deflecLlon aL Lhe speclmen Llp.
When Lhe dlmenslons of Lhe speclmen were flnallsed
(deLalled below), a mesh convergence sLudy was carrled
ouL. Convergence of Lhe mesh was analysed Lhrough
reflnlng Lhe maxlmum elemenL edge lengLh across Lhe
gauge lengLh of Lhe speclmen, slnce Lhls ls Lhe area of
lnLeresL. 1he resulLs are shown on Lhe graph ln llgure 33.
1he mesh was shown Lo converge aL a maxlmum edge
lengLh of 2mm. 1he mesh conLrols were seL Lo llmlL Lhe
maxlmum elemenL edge lengLh across Lhe gauge lengLh of
Lhe speclmen Lo 2mm. 1he oLher secLlons of model were
meshed uslng Lhe AuLoCLM funcLlon ln Creo.
A sLaLlc analysls was carrled ouL on Lhe lL model of Lhe LesL speclmen Lo ensure fallure would occur
wlLhln Lhe LesL area of Lhe speclmen, and Lo deLermlne Lhe maxlmum bendlng sLress (wlLhln Lhe LesL
area) and Lhe maxlmum deflecLlon where Lhe speclmen ls aLLached Lo Lhe connecLlng rod. 1he
.$%0," WZD ;"#B +(&b",%"&@" </07G )(,
<3"@$>"& .H6 ;(7"5


42
requlred force Lo bend Lhe speclmen Lo a maxlmum dlsplacemenL of 6mm was 33n. noLe LhaL a
callbraLlon speclmen wlll be used Lo callbraLe sLresses ln Lhe real LesL speclmen so LhaL Lhese sLress
values can be accuraLely ploLLed on an S-n curve.
llgure 36 shows a ploL of Lhe von Mlses sLress ln Lhe speclmen, when ls lL benL Lo maxlmum
deflecLlon.

.$%0," W_D U(& ;$#"# #/,"## 35(/ () #3"@$>"& 0&7", >*f$>0> 5(*7$&% @(&7$/$(&#
1he ploL shows LhaL a maxlmum von Mlses sLress of 233Ma ls found wlLhln Lhe gauge lengLh of Lhe
speclmen, so fallure would occur ln Lhls reglon. 1he sLress ln all oLher parLs of Lhe speclmen was aL
leasL half Lhe magnlLude of Lhe maxlmum sLress. 1here ls an lncrease ln sLress shown aL Lhe base of
Lhe speclmen where Lhe speclmen ls clamped. 1hls sLress ls sLlll kepL below half of Lhe sLress across
Lhe deslgn area of Lhe speclmen, so fallure would noL occur here. 1hls ls shown for Lhe maxlmum
sLress case, buL for lower sLresses, fallure would sLlll occur ln Lhe LesL area of Lhe speclmen.
llgure 37 shows a ploL of Lhe deflecLlon of Lhe speclmen under maxlmum loadlng condlLlons.


43

.$%0," W[ V5(/ () /B" 7$#35*@">"&/ () /B" #3"@$>"& 0&7", >*f$>0> 5(*7$&% @(&7$/$(&#
1he dlsplacemenL ploL of Lhe speclmen shows a maxlmum dlsplacemenL of 6mm aL Lhe Llp of Lhe
speclmen. 1hls would correspond Lo a 6mm offseL ln Lhe eccenLrlc bearlng. 1o change Lhe sLress
ampllLude ln Lhe speclmen for dlfferenL LesLs, dlfferenL slzes of eccenLrlc bearlng would be used,
wlLh Lhe maxlmum belng 6mm. See secLlon on eccenLrlc bearlng for more deLall.
A modal analysls was also carrled Lo deLermlne Lhe modal frequencles of Lhe speclmen when
clamped aL Lhe base. 1hls analysls was carrled ouL Lo ensure LhaL resonance dld noL occur ln Lhe
speclmen durlng operaLlon of Lhe corroslon faLlgue LesL rlg. 1he Lable ln llgure 38 shows Lhe
frequency of Lhe flrsL 10 modes of Lhe speclmen when clamped aL Lhe base.

.$%0," W\ .,"j0"&@G () )$,#/ LK >(7"# () #3"@$>"&
1he resulLs show LhaL Lhe fundamenLal frequency of Lhe speclmen ls 60Pz, and Lhls mode shape
corresponds wlLh Lhe canLllever bendlng performed by Lhe LesL rlg. 1hls resulL shows LhaL Lhe LesL
machlne wlll never exclLe Lhe naLural frequency of Lhe speclmen, as Lhe machlne wlll only operaLe
beLween 0.3 - 6Pz.


44
!"!"#M"C ;*&4,+*%,+
ulmenslons of Lhe LesL speclmen are shown below ln llgure 39. 1he fllleL radll are aL a LangenL Lo Lhe
gauge lengLh on Lhe LesL speclmen. 1he cross secLlonal area of Lhe speclmen aL Lhe clamped end ls 4
Llmes greaLer Lhan Lhe cross secLlonal area of Lhe LesL secLlon, as recommended by AS1M L466. 1he
overall mass of Lhe speclmen ls 0.144kg. Poles are drllled ln Lhe speclmen where Lhe bolLs wlll clamp
Lhrough Lhe speclmen. 1hls wlll noL affecL Lhe analysls performed, as a plaLe wlll be clamped Lo
elLher slde of Lhe speclmen and bolLed LlghL, whlch wlll supporL Lhe area where holes are Lo be
drllled.

.$%0," W]D !$>"&#$(&# () /"#/ #3"@$>"&
HAHA33 "006%6*+'/ BD,(62,+ 4+=*&2'%6*+
lor faLlgue LesLlng, Lhe flnlsh of Lhe LesL speclmen ls very lmporLanL, so speclmens musL be pollshed
and flnlshed Lo preclse sLandards. 1he user of Lhe corroslon faLlgue LesL rlg should refer Lo sLandards
for speclmen flnlshes when preparlng speclmens.
1hls LesL speclmen deslgn ls Lo be manufacLures uslng 316 sLalnless sLeel. ulfferenL heaL LreaLmenLs
and surface wlll affecL Lhe valldlLy of Lhe speclmen, as each dlfferenL speclmen wlll be callbraLed
lndlvldually. Powever, lf vasLly dlfferenL maLerlals are Lo be LesLed on Lhls LesL rlg, careful callbraLlon
should be carrled ouL Lo analyse Lhe speclmen sLresses.
HAHA37 KY" "+'/9$6$ *= B9$%,2 '+0 )&6%6('/ >'&%$
llnlLe LlemenL Analysls (lLA) was conducLed on Lhe sysLem as a whole and parLs seen as Lhe hlghesL
rlsk Lo fallure.
!"!"#5"# <,(73+*+ %. <++4&L73
An lLA analysls of Lhe assembly was conducLed uslng Creo arameLrlc sofLware. 1he analysls
lndlcaLed LhaL Lhe maxlmum sLresses ln Lhe assembly occurred ln Lhe speclmen, whlch ls whaL was
expecLed. 1he secondary hlghesL sLresses occurred ln Lhe moLor shafL, 26.3Ma, provldlng
slgnlflcanLly hlgher sLresses Lhan any oLher area ln Lhe sysLem. llgure 40 shows Lhe resulLs of Lhe lLA
analysls.


43

.$%0," MKD .H6 </,"## 6&*5G#$# () H&/$," .*/$%0" 1"#/ 2$%
!"!"#5"5 <,(73+*+ %. 8%6%) A:(.6
1he lLA analysls of Lhe sysLem hlghllghLed Lhe mosL hlghly sLressed reglons ln wlLhln Lhe assembly.
1he moLor shafL was Lhe slngle area LhaL requlred furLher deLalled analysls on sLresses and
dlsplacemenLs Lo ensure LhaL lL would noL fall or dlsplace Loo greaLly for Lhe purpose of Lhe LesLlng.
1he hlghesL sLresses occurred aL Lhe key of Lhe moLor shafL, 27.7Ma as shown ln llgure 41. 1hls ls
well wlLhln Lhe allowable sLresses for Lhe maLerlals dlscussed prevlously.

.$%0," MLD .H6 </,"## 6&*5G#$# () ;(/(, <B*)/
lurLher Lo Lhe allowable sLresses, dlsplacemenLs were of lnLeresL Lo ensure LhaL Lhe moLor shafL
does noL deflecL slgnlflcanLly ln comparlson wlLh Lhe requlred dlsplacemenLs of Lhe connecLlng rod.
llgure 42 shows LhaL Lhe hlghesL deflecLlons found were 0.017mm. 1hls ls negllglble when compared
Lo Lhe deflecLlons of Lhe whole dynamlc sysLem of lncremenLs of 1mm.


46

.$%0," MJD .H6 !$#35*@">"&/ 6&*5G#$# () ;(/(, <B*)/
HAHA3? )*$%6+1
1he budgeL for Lhe corroslon faLlgue LesL rlg ls 3,000. 1he beneflL of maklng an lnexpenslve machlne
(compared Lo sophlsLlcaLed machlnes on Lhe markeL) ls LhaL mulLlple machlnes can be manufacLured
so LhaL mulLlple LesLs can be run slmulLaneously, as corroslon faLlgue LesL wlll Lake a long Llme Lo
run. 1he alm was Lo keep Lhe cosL of each componenL Lo a mlnlmum, wlLhouL compromlslng
accuracy of LesLlng. ueLalled cosLlng analysls of Lhe corroslon faLlgue LesL rlg can be found ln
Appendlx 3. 1he LoLal cosL of all Lhe parLs ls k\[MF[JF 1hls cosL ls well wlLhln Lhe 3,000 budgeL, Lhe
parLs for 3 machlnes would be able Lo be purchased wlLhln Lhe glven budgeL. 1he slngle mosL
expenslve parL of Lhe machlne ls Lhe collecLlve cosL of Lhe maLerlals and fasLenlng for manufacLurlng
Lhe frame, whlch comes ln aL 326.36. 1he second mosL expenslve componenL ls Lhe moLor, aL a cosL
of 272. 1hls was anLlclpaLed Lo be Lhe mosL expenslve aspecL of Lhe machlne, whlch lsn'L Lhe case.
1he cosLlng of Lhe machlne has meL Lhe LargeL seL ouL and has comes well wlLhln Lhe pro[ecL budgeL.
HAHA3H K6+'/ >&*05(%
A full assembly CAu model of Lhe flnal faLlgue LesL rlg ls shown over Lhe page ln llgure 43 below. An
exploded vlew of Lhe assembly ls shown Lhen ln llgure 44.



47

.$%0," MWD .055 *##">45G () +6! >(7"5 () @(,,(#$(& )*/$%0" /"#/ ,$%


.$%0," MWD Hf35(7"7 *##">45G () +6! >(7"5 () @(,,(#$(& )*/$%0" /"#/ ,$%


48
Q ]&*5D I9+'26( '+0 )*225+6('%6*+
1he Leam was organlsed as descrlbed ln SecLlon 3.1 wlLh a varleLy of Lechnlques Lo manage
workloads and address concerns and ldeas of each of Lhe Leam members. 1hese Lechnlques were
puL ln place as a framework for Lhe duraLlon of Lhe pro[ecL, aL Llmes some flexlblllLy was requlred Lo
overcome lssues experlenced LhroughouL.
QA3 B5((,$$ *= C*/,$ '+0 C,$D*+$6#6/6%6,$
QA3A3 >&*;,(% @'+'1,&
1he appolnLmenL of separaLe pro[ecL managers LhroughouL Lhe pro[ecL proved Lo be a successful
Lechnlque ln Lerms of Lhe pro[ecL as a whole, provldlng a number of mlnor challenges Lo overcome
for Leam members. MalnLalnlng conLlnulLy wlLhln Lhe Leam for Lhe duraLlon of a semesLer and ma[or
secLlon of Lhe pro[ecL proved Lo be an effecLlve managemenL meLhod, as lL allowed an
undersLandlng Lo develop beLween Leam members regardlng roles and responslblllLles. Allowlng
Llme for Lhe Leam Lo undersLand Lhelr roles and responslblllLles promoLed progress on lndlvlduals'
Lasks, as each member knew Lhelr long-Lerm focus and goals. 1he pro[ecL managers for each
semesLer, nell and Mark respecLlvely, were also afforded Lhe Llme Lo galn an lnslghL lnLo Lhe
sLrengLhs and weaknesses of each of Lhe members, alongslde preferred communlcaLlon sLyles for
each of Lhe members.
1he lncluslon of Lwo pro[ecL managers LhroughouL Lhe pro[ecL was a declslon LhaL provlded boLh
beneflLs and drawbacks for Lhe Leam. lL meanL LhaL each pro[ecL manager had only one semesLer Lo
assess Lhe varlous aspecLs of members and Lhe Leam as a whole, ln conLrasL Lo havlng one manager
who would have boLh semesLers Lo assess and adapL Lhelr approach accordlngly. WhllsL Lhls may
have been an advanLage of havlng a slngle pro[ecL manager, adopLlng Lhe approach of changlng Lhe
pro[ecL manager afLer CaLe Lwo offered Lhe advanLage of havlng a pro[ecL manager wlLh a change of
perspecLlve and fresh drlve. Slnce Lhe Llme each manager had ln charge of Lhe pro[ecL was llmlLed Lo
one semesLer, lL meanL LhaL boLh nell and Mark had Lo push Lhe pro[ecL forward lmmedlaLely. 1hls
underllned Lhe lnLenslLy LhaL Lhe pro[ecL requlred Lo compleLe lL wlLhln Lhe deadllnes esLabllshed.
AdopLlng Lwo pro[ecL managers proved Lo be a successful sysLem, as lL creaLed few problems and
allowed Lhe pro[ecL Lo malnLaln a hlgh lnLenslLy LhroughouL Lhe duraLlon, someLhlng LhaL may have
been lacklng under a slngle manager.
1he Leam had orlglnally planned Lo adopL Lhree pro[ecL managers LhroughouL Lhe pro[ecL, as Colln
was golng Lo Lake charge for Lhe compleLlon of Lhe deslgn package and reporLs. As Lhe pro[ecL
progressed however, lL was declded LhaL Lhls would noL be a beneflclal sLraLegy, as lL would dlsrupL
Lhe rhyLhm and workload of Lhe Leam aL a crlLlcal sLage of Lhe pro[ecL.
QA3A7 E,'2 @,2#,&$
ln general, Leam members were glven lndlvldual Lasks Lo be compleLed as parL of a group ob[ecLlve.
1hls was Lhe case wlLhln Lhe deLalled deslgn secLlon of Lhe pro[ecL ln parLlcular. uurlng Lhe research
phase, members were asslgned broad areas of lnLeresL Lo research ln depLh, wlLh Lhe lndlvldual
responslble for dellvery of relevanL lnformaLlon. 1he creaLlon of Lhe 'uropbox' Lo share Lhe
lnformaLlon provlded a plaLform for each of Lhe members Lo galn a broad undersLandlng of a range
of sub[ecLs LhaL Lhey hadn'L dlrecLly researched. 1hls was useful, buL once agaln Lhe onus was on Lhe
lndlvldual Lo furLher Lhelr learnlng. ln a few lnsLances, Lhls rellance on lndlvlduals Lo undersLand


49
whlch areas of research had Lhe mosL relevance led Lo Llme belng wasLed readlng abouL sub[ecL
areas LhaL dld noL hold a large slgnlflcance ln Lerms of Lhe pro[ecL. 1eam meeLlngs provlded
background Lo areas of lnLeresL, however more care could have been Laken ln some lnsLances ln
Lerms of sharlng only relevanL lnformaLlon wlLh Leam members.
ln Lhe deLall deslgn secLlon, lL was qulckly found LhaL communlcaLlon beLween cerLaln members of
Lhe Leam was paramounL Lo Lhe success of Lhe deslgn phase. A key lnLerface was beLween Lhe
speclmen and Lhe connecLlng rod for example. 1he connecLlon beLween Lhese Lwo key feaLures was
lnLegral Lo Lhe funcLlon of Lhe machlne. As such, communlcaLlon was vlLal beLween Lhe members
deslgnlng each of Lhese key feaLures. lL was esLabllshed early on ln Lhe process LhaL each secLlon
would have a number of lnLerfaces Lo communlcaLe wlLh, and Lhese were mapped ouL. 1hls allowed
each member Lo be aware from Lhe ouLseL Lhe relaLlonshlps LhaL would lmpacL Lhelr speclflc secLlon
of deslgn. 1he Lechnlque of keeplng Lhe group's goal ln mlnd LhroughouL Lhe deslgn process mlxed
wlLh lndlvldual LargeLs ensured LhaL Lhe flnal deslgn would merge seamlessly as Lhe lnLerfaces had
been consldered LhroughouL.
QA7 )*225+6('%6*+
numerous meLhods were employed Lo ensure clear and conclse communlcaLlon amongsL Lhe Leam.
1he needs ranged from arranglng meeLlngs wlLh ease Lo sharlng knowledge. lrom Lhe ouLseL, lL was
ldenLlfled LhaL regular meeLlngs wlLh Lhe cllenL would be beneflclal, parLlcularly ln Lhe lnlLlal phases
of Lhe pro[ecL. As such, Lhrough Lhe use of emalls and shared calendars, weekly meeLlngs were
scheduled wlLh Lhe cllenL. 1hese meeLlngs proved very useful ln shaplng Lhe pro[ecL and ldenLlfylng
Lhe needs of Lhe cllenL. lL became apparenL LhaL oLher forms of communlcaLlon were requlred for
lnLernal communlcaLlon, and as such a prlvaLe soclal medla group was seL up where members could
address any lssues or brlng up any pro[ecL relaLed Loplc. 1hls group became a key llne of
communlcaLlon for Lhe Leam. 1hls group had a flle sharlng capablllLy, however lL was ldenLlfled ln Lhe
research phase of Lhe pro[ecL LhaL a 'uropbox' would prove useful, as lL allows Lhe sharlng of a large
amounL of daLa free of charge. An accounL was creaLed amongsL Lhe Leam, and formaLLed for Lhe
duraLlon of Lhe pro[ecL. 1he ease ln whlch research could be shared amongsL Lhe group was vasLly
lmproved. 1he avallable daLa on Lhe 'uropbox' dld, however, have some drawbacks. Pavlng
unllmlLed daLa encouraged members Lo share every paper LhaL Lhey had come across, even lf lL was
deemed Lo be mosLly lrrelevanL. 1hls lssue would perhaps have been avolded lf Lhere had been a
daLa llmlL on Lhe 'uropbox.'
1he cenLral llne of communlcaLlon for Lhe group was Lhrough regular meeLlngs. 1hese meeLlngs
were Lo dlscuss progress, share research and ldeas and Lalk abouL any pro[ecL relaLed lssues.
uecldlng Lhe frequency of Lhese meeLlngs Look a number of weeks and ln Lhe end an exacL
frequency was noL ouLllned. MeeLlngs were generally once per week, however aL some sLages ln Lhe
pro[ecL, deadllnes came around qulckly and as such meeLlngs were changed Lo Lwlce per week.
lrequenL meeLlngs proved Lo ald Lhe process by addresslng any lssues when Lhey arose, raLher Lhan
leLLlng Lhem escalaLe. 1he deslgn of Lhe Leam meanL a large focus was placed on lndlvldual work,
however Lhe Leam goals and deadllnes were Lhe mosL lmporLanL lssue. 8egular Leam meeLlngs
served as an encouragemenL Lo lndlvlduals Lo compleLe Lhelr Lasks ln a Llmely fashlon, as progress
was dlscussed aL each of Lhe meeLlngs, allowlng Lhe pro[ecL manager Lo monlLor progress of all
secLlons of Lhe Leam.


30
QA? I,(6$6*+O@'-6+1 '+0 )*+=/6(% C,$*/5%6*+ @,%F*0$
QA?A3 I,(6$6*+ @'-6+1
1he meLhodology for declslon maklng wlLhln Lhe group was a democraLlc one wlLh a flnal verdlcL
from Lhe pro[ecL manager. 1he democraLlc sysLem was deemed sulLable Lo Lhe our Leam as Lhe Leam
lncluded a range of personallLy Lypes, and Lhls sysLem gave members Lhe opLlon Lo express
Lhemselves prlor Lo declslons belng made. lrom Lhe ouLseL of Lhe pro[ecL, members were
encouraged Lo share ldeas Lo shape Lhe pro[ecL. ulscusslons were a regular feaLure for Lhe Leam,
heavlly so aL Lhe fronL end of Lhe pro[ecL. 1he focus on dlscusslon and conslderaLlon of all oplnlons
led Lo a group dynamlc LhaL promoLed sharlng of ldeas and dlscusslon of problems.
1he approach Lhe group Look Lo declslon-maklng had boLh beneflLs and llmlLaLlons Lo lL. All members
of Lhe group evaluaLed opLlons, and lndlvldual oplnlons were expressed and dlscussed aL declslon-
maklng meeLlngs. 1he process resulLed ln declslons belng made LhaL were dlscussed aL lengLh where
needed and a declslon belng approprlaLely made. 1hls declslon came elLher Lhrough dlscusslon and
an agreemenL on a slngle course of acLlon, or Lhrough compromlse ln oplnlons Lo form a common
declslon LhaL pleased everyone. Maklng use of Lhls approach ensured LhaL Leam members were
lnvolved ln all sLages of Lhe declslon maklng process, and were conLenL wlLh Lhe course LhaL Lhe
pro[ecL was Laklng. 1he prlmary drawback of Lhls process was Lhe Llme lL Look Lo make declslons,
boLh ma[or and mlnor. Appeaslng all Leam members ln regards Lo declslons meanL LhaL a loL of
dlscusslon had Lo be done Lo conslder an approprlaLe paLh for each declslon. lL was declded LhaL Lhls
was a sacrlflce wllllng Lo be made Lo allow Lhe group Lo have an open, frlendly dynamlc Lo lL.
QA?A7 )*+=/6(% C,$*/5%6*+
ConfllcL resoluLlon used Lhe same framework as Lhe declslon-maklng. 1he open, frlendly dynamlc
creaLed Lhrough a number of meLhods meanL LhaL members were able Lo freely volce concerns over
aspecLs of Lhe pro[ecL, knowlng LhaL Lhey would be llsLened Lo. ConfllcLs were generally resolved
qulckly Lhrough group dlscusslon, raLher Lhan leLLlng any lssue escalaLe over Llme. Lxamples of
confllcLs and how Lhey were resolved durlng Lhe pro[ecL are descrlbed ln SecLlon 3.4. Croup
meeLlngs were Lhe mosL common plaLform for a member Lo dlscuss any lssues Lhey were havlng,
however as dlscussed prevlously, Lhere were a number of plaLforms, lncludlng emall and soclal
medla, LhaL were used Lo conLacL oLher members lf a meeLlng wasn'L necessary. 1he approach Laken
LhroughouL Lhe pro[ecL Lo manage declslon-maklng and confllcL resoluLlon was very effecLlve ln
ensurlng Lhe happlness of all members. 1he lnvolvemenL of all members LhroughouL Lhe process
ensured LhaL lndlvlduals felL parL of Lhe Leam, and as such were wllllng Lo compromlse on lssues, as
Lhey knew all members were lnLeresLed ln Lhe long-Lerm goals of Lhe pro[ecL.
QAH Y^'2D/, )*+=/6(%$ '+0 C,$*/5%6*+$
1hroughouL Lhe pro[ecL, a number of slLuaLlons arose LhaL requlred addresslng Lo promoLe an
effecLlve worklng envlronmenL. 1hese slLuaLlons covered a range of lssues lncludlng Llme
managemenL, confllcLs ln schedules, dlfference of oplnlons on Lhe besL course of acLlon and
problems wlLh managemenL sysLems ln place.
QAHA3 E,'2 @,2#,& B(F,05/,$
Managlng Lhe schedules of lndlvldual Leam members and adapLlng Lhe plans of Lhe Leam Lo Lhese
schedules was ldenLlfled early as an lmporLanL lssue wlLhln Lhe pro[ecL. WlLh members Laklng a


31
range of classes, provldlng a range of schedules and workloads, lL was key Lo remaln flexlble Lo Lhe
needs of each of Lhe members.
An lncldenL occurred durlng Lhe second semesLer precedlng a key meeLlng wlLh Lhe cllenL. A meeLlng
had been arranged wlLh Lhe cllenL, who had llmlLed avallablllLy, whlch clashed wlLh Lhe schedule of
one of Lhe Leam members. A hlgh prlorlLy meeLlng for anoLher sub[ecL had already been arranged
and Lhe Leam member had commlLLed Lo Lhls meeLlng prlor Lo Lhe arrangemenL of Lhe Leam
meeLlng. A dlscusslon was held beLween Lhe Leam member and pro[ecL manager, Lo ouLllne Lhe
lmporLance of each of Lhe members. lL was expecLed LhaL all Leam members would be presenL aL Lhe
meeLlng wlLh Lhe cllenL, however Lhls was noL posslble, and agreemenL for all of Lhe Leam member's
work Lo be relayed vla Lhe pro[ecL manager was made. 1he flexlble approach of Lhe Leam was puL
lnLo pracLlce and seLLled any poLenLlal confllcL.
QAHA7 I6&,(%6*+ *= >&*;,(%
C"!"5"# P,64)*& >4'%)6 O%)&(6
ulfferlng vlews on Lhe formaL and presenLaLlon of Lhe lnLerlm reporL requlred a dlscusslon and
agreemenL on how Lo proceed. WlLh llLLle dlrecLlon glven as Lo Lhe formaL and conLenL requlremenLs
of Lhe reporL, Lhere were dlfferlng vlews on Lhe balance of Lechnlcal and non-Lechnlcal conLenL of
Lhe paper. 1hrough dlscusslon aL a Leam meeLlng, ouLllnlng Lhe marklng scheme and Lhe merlLs of
Lechnlcal and non-Lechnlcal conLenL, lL was declded Lo proceed wlLh a reporL LhaL had slmllar
amounLs of boLh Lypes of conLenL. 1hls had orlglnally been planned Lo lnclude a large ma[orlLy of
Lechnlcal conLenL.
C"!"5"5 O*,(7 ;46(*740 ;4+*1, 8446*,1
LaLe ln Lhe second semesLer, Lhere was a push Lo submlL Lechnlcal drawlngs of ma[or componenLs Lo
Lhe workshop for manufacLure before flnallslng Lhe remalnder of Lhe pro[ecL. 1hls was suggesLed as
deadllnes were loomlng and Lhere was poLenLlal Lo feel as Lhough Lhese deadllnes may noL be meL.
1hls approach would have been ln confllcL wlLh Lhe orlglnal plan and Lhe sLage gaLe procedure belng
followed LhroughouL Lhe process. 1he suggesLlon drew some crlLlclsm, wlLh oLher members
confldenL LhaL Lhe deadllnes were sLlll achlevable, and submlLLlng an lncompleLe plece of work
would noL be an approprlaLe course of acLlon for Lhe pro[ecL. 1hls was followed by an exLended
dlscusslon, where Lhe advanLages and dlsadvanLages of submlLLlng Lhe work aL LhaL sLage were
ouLllned and evaluaLed as a group. AfLer exLended dlscusslon and conslderaLlon, lL was declded as a
group LhaL Lhe orlglnal plan would be followed. 1hls was accompanled wlLh a new deLalled schedule
Lo manage Lhe remalnlng workload and ensure Lhe deadllnes were meL.
T K5%5&, _*&-
1he pro[ecL deflnlLlon meanL LhaL Lhe flnal handover would lnvolve a compleLe manufacLurlng
package, LesLlng manual and operaLlon manual. 1he deslgn package was compleLed, lncludlng
everyLhlng need Lo Lake Lhe deslgn Lo manufacLure and operaLlon. WhllsL llmlLed LesLlng was done,
on selecLed componenLs, enough analysls has been done Lo conflrm Lhe feaslblllLy of Lhe deslgn. All
of Lhe work done Lo daLe wlll enable oLhers Lo puL Lhe package lnLo producLlon, Lo be LesLed and
flnally operaLlonal wlLh flrm guldance from manuals and procedures.


32
U )*+(/5$6*+
1he ob[ecLlves of Lhe deslgn pro[ecL evolved as research and dlscusslon progressed. As Lhe deslgn
progressed from concepLual Lo flnallsed deLalled deslgn, lL evolved and underwenL several changes
as lnvesLlgaLlon uncovered unforeseen lssues and lmprovemenLs. 1hrough Lhese adapLaLlons, a
flnallsed deslgn package LhaL fulfllled all of Lhe pro[ecL ob[ecLlves was compleLed and submlLLed ln
llne wlLh agreed deadllnes. uesplLe on-golng changes Lo speclflc aspecLs of Lhe deslgn, Lhe process
remalned consLanL and all gaLes were meL on LargeL. 1hls was due Lo conLlngency Llme bullL lnLo Lhe
lnlLlal pro[ecL schedule, allowlng for Lhe Leam Lo adapL Lo new challenges as Lhey arose.
1he pro[ecL meL all of Lhe deslgn ob[ecLlves ln llne wlLh agreed deadllnes. 1hls was posslble due Lo
Lhe lmplemenLaLlon and use of managemenL sysLems. 1he Leam performed well LogeLher, gelllng
early on ln Lhe pro[ecL, allowlng progress Lo be achleved on Lhe ob[ecLlves from Lhe offseL. 1he
lmplemenLaLlon of Lhese sysLems and Lhe undersLandlng of Lhe Leam members were crlLlcal Lo
ensure LhaL deadllnes were meL LhroughouL Lhe pro[ecL.



33
V C,=,&,+(,$

[1] S. ugh, G*&$0 !"3/5( H I(&"5%$&"; ,"&.*;3 +*% :J--"33+J0 K%*;J-& 4(5/(""%/(5, Parlow uk:
Addlson-Wesley ubllshlng Company, 1991
[2] 8elbln, 8 MeredlLh, ,$($5"'"(& G"$'3L M.9 G."9 :J--""; *% N$/06 Cxford: 8uLLerworLh-
Pelnemann, 1981
[3] Mohamed, A. N$&/5J" $(; O*%%*3/*( N$&/5J" P".$8/*J% *+ Q/-R"0 200*93 /( :$0/(" :*0J&/*(36
Memorlal unlverslLy, lnLernaLlonal !ournal of Modern Lnglneerlng 8esearch, vol. 3, lssue 3. 2013.
[4] Podgkless, 1. O*%%*3/*( *+ ,$%/(" O*'#*("(&3 $(; :&%J-&J%"3, Clasgow unlverslLy 'MaLerlals M4'.
2009.
[3] Corrosloncllnlc.com. 2014. !/++"%"(& G9#"3 *+ O*%%*3/*(L O*%%*3/*( N$&/5J". [onllne] Avallable aL:
hLLp://www.corrosloncllnlc.com/Lypesofcorroslon/Corroslon20laLlgue.hLm [Accessed: 16 nov
2013]
[6] Kim et al (2002), Estimation Methods for Fatigue Properties of Steels Under Axial and
Torsional Loading, Pohang University of Science and Technology, International Journal of
Fatigue Volume 24, pg. 783-793
[7] Hassan et al (2000), On the Difference of Fatigue Strengths from Rotating Bending,
Four-Point Bending, and Cantilever Bending Tests, North Carolina State University,
International Journal of Pressure Vessels and Piping Issue 78, pg. 19-30
[8] Roessle et al (1999), Strain-Controlled Fatigue Properties of Steels and some Simple
Approximations, The University of Toledo, International Journal of Fatigue Volume 22,
pg. 495-511
[9] naLlonal lnsLrumenLs SLraln Cauge ConflguraLlon 1ypes, 2006 [Cnllne] hLLp://www.nl.com/whlLe-
paper/4172/en/, [Accessed: 20 nov 2013]
[10] naLlonal lnsLrumenLs Measurlng SLraln wlLh SLraln Cauges, 2014 [Cnllne]
hLLp://www.nl.com/whlLe-paper/3642/en/, [Accessed: 26 nov 2013]
[11] C8 ShunL CallbraLlon of a SLraln Cage Sensor [Cnllne]
hLLp://www.pcb.com/LechsupporL/docs/fLq/Ln-9-0202shunLcallbraLlon.pdf, [Accessed: 29 nov
2013]



34
"DD,+06^ 3J >&*05(% I,$61+ BD,(6=6('%6*+ W>IBZ
LF V",)(,>*&@"
1.1. 1he LesL machlne musL be capable of lnduclng faLlgue on an approprlaLe LesL speclmen
accordlng Lo 8S 3318.
1.2. 1he machlne musL allow for Lhe gauge lengLh of Lhe LesL speclmen Lo be fully submerged ln
a corroslve medlum durlng LesLlng.
1.3. 1he faLlgue LesL should be carrled ouL aL a relaLlvely low frequency, approxlmaLely 0.3 - 6Pz,
Lo allow for Lhe effecLs of corroslon Lo Lake place.
1.4. 1he corroslve medlum should be conLalned approprlaLely ln order Lo noL affecL Lhe
performance of oLher LesL machlne componenLs.
1.3. 1he corroslve medlum musL be aglLaLed/clrculaLed.
1.6. Loadlng mechanlsm musL be able Lo achleve maxlmum sLress of aL leasL 2/3 yleld sLress.

JF H&b$,(&>"&/
2.1. 1he machlne musL be deslgned Lo operaLe aL room LemperaLure.
2.2. 1he corroslve medlum musL be approprlaLely conLalned and fllled/empLled wlLh ease Lo
prevenL splllage.
2.3. Any vlbraLlon caused by Lhe normal operaLlon of Lhe LesL machlne musL be dampened and
noL passed onLo surroundlng surfaces.
2.4. 1he machlne musL operaLe below 90d8 nolse level.

WF ;*$&/"&*&@"
3.1. 1he LesL machlne should noL requlre excesslve malnLenance - more Lhan 1 hour
malnLenance beLween LesLs.
3.2. Any movlng componenLs musL be regularly lubrlcaLed and lnspecLed for wear.
3.3. MalnLenance procedure and Llme scale musL be supplled ln supporLlng documenLs.

MF 1*,%"/ V,(70@/ +(#/
4.1. 1he flnal producL musL noL cosL more Lhan 3,000 Lo manufacLure.
4.2. no cosLs should be aLLrlbuLed Lo Lhe deslgn of Lhe machlne.
4.3. ManufacLurlng esLlmaLes should be supplled ln Lhe supporLlng documenLs.

ZF Y0*&/$/G
3.1. 1he producLs should be deslgned wlLh Lhe vlew LhaL more Lhan one flnal producL wlll be
manufacLured.

_F ;*&0)*@/0,$&% .*@$5$/G
6.1. 1he producL would be preferably manufacLured wlLhln Lhe unlverslLy laboraLorles.
6.2. ln Lhe evenL Lhe laboraLorles cannoL underLake Lhe manufacLurlng, an ouLslde conLracLor
may be Lasked wlLh bulldlng Lhe LesL machlne.

[F <$l"
7.1. 1he LesL speclmen wlll be manufacLured Lo AS1M L466 sLandard.
7.2. 1he slze of Lhe LesL machlne musL be of sufflclenL slze Lo supply requlred force/
dlsplacemenL Lo Lhe speclmen wlLhouL faLlgulng Lhe load frame.
7.3. 1he producL musL be deslgned wlLh a vlew Lo lncrease Lhe overall slze of Lhe LesL rlg
proporLlonally wlLh an lncrease ln Lhe slze of LesL speclmen.
7.4. 1he producL musL be of a sulLable slze where lL can be LransporLed beLween laboraLorles
wlLh Lhe use of a Lrolley/holsL.


33

\F ;*/",$*5#
8.1. 1he maLerlals musL be of a sufflclenL sLrengLh Lo carry large cycllc loads wlLhouL faLlgue.
8.2. 1he maLerlals used for Lhe conLalnmenL of a corroslve medlum musL be sulLable for such
envlronmenLs.
8.3. MaLerlals LhaL may come lnLo conLacL wlLh Lhe corroslve medlum should be selecLed or
proLecLed approprlaLely.

]F </*&7*,7# i <3"@$)$@*/$(&#
9.1. 1he LesL speclmens should be manufacLured Lo Lhe AS1M L466 sLandard.

LKF H,%(&(>$@#
10.1. 1esL Speclmens musL be able Lo be monlLored Lhrough vlsual lnspecLlon.
10.2. 1esL speclmens musL be accesslble for Lhe aLLachmenL of any monlLorlng/callbraLlon
equlpmenL requlred.
10.3. 1he producL musL be deslgned Lo allow easy removal and lnsLallaLlon of Lhe LesL
speclmen.
10.4. 1he producL musL be easlly handled and moved wlLh Lhe use of a Lrolley/holsL.
10.3. 1he machlne musL be able Lo supporL a deLachable corroslon baLh.

LLF +0#/(>",
11.1. 1he cusLomer musL be consulLed LhroughouL Lhe deslgn sLage.

LJF Y0*5$/G i 2"5$*4$5$/G
12.1. 1he machlne should be capable of carrylng ouL conLlnuous LesLlng for up Lo a year.
12.2. 1he LesL machlne should be durable enough Lo lasL 3 years.
12.3. 1he producL musL be exLremely rellable as any lnLerrupLlons Lo LesLs due Lo
mechanlcal fallure could resulL ln slgnlflcanLly exLended LesL Llmes.

LWF 1$>" <@*5"
13.1. 1he full deslgn porLfollo for Lhe producL musL be compleLed and ready for
submlLLlng Lo manufacLure by 14Lh Aprll 2014.
13.2. ManufacLurlng should noL be expecLed Lo Lake more Lhan 3 monLhs.

LMF 1"#/$&%
14.1. A LesL procedure musL be produced by Lhe deslgn Leam and lssued wlLh Lhe producLs
supporLlng documenLs.
14.2. 1esLlng should be carrled ouL before any declslon ls made on Lhe producLlon of any
more LesL machlnes.
14.3. CallbraLlon of Lhe machlne may Lake place durlng Lhe LesLlng phase.

LZF <*)"/G
13.1. 1he producL musL proLecL Lhe end user from any movlng parLs uslng approprlaLe
covers.
13.2. 1he fllllng/empLylng of Lhe corroslve medlum musL be done ln a conLrolled and safe
manner Lo prevenL splllage or conLamlnaLlon of oLher producLs,
13.3. uurlng LesLlng, Lhe corroslve medlum musL be fully covered and unable Lo splash.
13.4. 1he deslgn musL comply wlLh Lhe approprlaLe 8rlLlsh SLandards on safeLy.
13.3. 1he machlne musL have an emergency cuL-off swlLch.



36
L_F !(@0>"&/*/$(&
16.1. All documenLs musL be professlonally presenLed as parL of a deslgn package Lo Lhe
cusLomer for submlsslon for manufacLurlng.
16.2. SupporLlng documenLs should lnclude deslgn process, cosLlng, maLerlals
speclflcaLlon, manufacLurlng speclflcaLlon, LesLlng procedure and also correcL operaLlng
procedure.
16.3. uocumenLaLlon should also lnclude lnformaLlon on Lhe approprlaLe slze and shape
of LesL speclmens.



37
"DD,+06^ 7J BD,(62,+ `'+0 )'/(5/'%6*+$
Pand calculaLlons were carrled ouL Lo deLermlne Lhe bendlng sLress and maxlmum dlsplacemenL ln
Lhe LesL speclmen before carrylng ouL a flnlLe elemenL analysls. 1he calculaLlons shown below were
carrled ouL uslng MaLhcad 13. lL models of baslc recLangular speclmens were verlfled Lhrough Lhese
sLress and maxlmum dlsplacemenLs shown below.




















d 3mm := y
d
2
:= l 160mm := P 30N := E 200GPa :=
M
max
l P ! := M
max
4.8 N m ! ! = M
gauge
0.8M
max
:= M
gauge
3.84 N m ! ! =
b1 40mm :=
b2 10mm :=
I2
b2 d
3
!
12
:=
I1
b1 d
3
!
12
:= I2 2.25 10
11 !
" m
4
=
I1 9 10
11 !
" m
4
=
!2
M
gauge
y "
I2
:= !2 256 MPa " =
!1
M
gauge
y "
I1
:= !1 64 MPa " =
!
max2
P l
3
"
3 E " I2 "
:= !
max2
9.102mm " =
!
max1
P l
3
"
3 E " I1 "
:=
!
max1
2.276mm " =
38
"DD,+06^ ?J ]'+%% )F'&%


























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