Design of a device for measuring contact fatigue behaviour of materials

Abstract

This report explored the design of an experimental setup for measuring contact fatigue

behaviour of materials. Contact fatigue is a concern for many mechanical elements subject

to contact loading, including many components in aerospace applications. Many

components with contact loading are enhanced using surface coatings. This design aims to

create a standalone testing device for measuring contact fatigue properties of metallic

coatings, and facilitate future study into the quality and characterization of material

coatings.

The report reviewed the fundamental principles of Hertzian contact and the existing

experimental set-ups used in contact fatigue testing. A systematic design analysis was

conducted, starting from conceptual design and functional analysis to embodiment design

and detailed design. Three concept designs were proposed and evaluated. The selected

design was refined through several design iterations with key components specified and

options identified for the next phase of implementation.

This report included full engineering drawings of all the components and the design

discussed in terms of its functionality, bill of materials and total cost for implementation. As

the first stage of the project, a part of the design was prototyped and recommendations for

the following phase of implementation were proposed.