Fatigue Testing Machine: TCF

Project Summary

This project aims to develop an automated test stand for Twin City Fan to evaluate the fatigue life and material properties of their axial fan blades. The primary objective is to design and prototype a machine that can apply adjustable sinusoidal loading perpendicular to the fan blades, mimicking turbulent airflow conditions. The system will measure blade deformations, vibrations, and stress over a high number of loading cycles, generating empirical data to validate and refine Twin City Fan's computational models for blade fatigue analysis. By correlating physical testing results with simulations, the improved models will enable optimized blade designs, reducing reliance on costly prototypes and ensuring product longevity and reliability.

Design Goal

Our overall goal is to create a proof-of-concept prototype structure that can apply and withstand the forces required to perform a fatigue test and fit each size of hub/blade assembly that TCF has to offer. Along with this, design a safety device to shield users from potential injuries.

Design Constraints

• Blade Sizes - The system is required to fit the 18in. hub size.
• Fatigue Cycling - The system should be able to subject the blades to a high number of loading cycles to evaluate fatigue life.
• Safety considerations - The design should prioritize user safety.
• Loading mechanism - The loading mechanism must be able to apply an adjustable force, perpendicular to the blade surface to simulate turbulent airflow conditions.