Phoenix is delighted to have worked with German manufacturing company Heinrich Jungeblodt GmbH & Co KG, based in Warstein. They specialise in producing fasteners, including bolts, head screws, washers and nuts for worldwide distribution. With over 170 years of expertise in bolt manufacturing, Jungeblodt believes that quality and competence is the basis of their daily activities. They are passionate about delivering bolts of the highest quality to a wide range of sectors and industries, such as energy and power generation, construction, transport, and medical industries.
Fatigue Testing on Batches of Fasteners
We were tasked with performing fatigue testing on eight off bolts from three separate batches, to determine how many cycles each bolt could withstand before fracture or failure.
The customer specifications included; a minimum pass criteria of 45,000 cycles per bolt, and a maximum of 130,000 cycles to be performed. Each batch needed a minimum of 2 bolts to be tested, with an average of 65,000 cycles.
We used bespoke fixtures to suit the sample size and geometry into our 250kN Vienna test machine. Due to the frequencies of the tests, we changed our fixtures between every 10-15 test cycles. The tests were carried out at an ambient temperature, with loads ranging from 13kN to 142kN.
The test results showed that four off bolts did not have any fractures or failures after the maximum 130,000 cycles. We then performed the same fatigue test parameters on the rest of the bolts, from two separate batches.
The results showed that these bolts were more susceptible to failure; three of the bolts in these tests were able to achieve the minimum cycle rate of 45,000 tests before fracturing in the thread of the bolt. The fourth bolt experienced failure at approximately 38,000 cycles and did not pass the requirements.
Case Study Highlights
- Fatigue testing on eight off bolts as part of three separate batches
- Pass criteria included cycles of 45,000 cycles for each bolt without failure
- Maximum of 130,000 cycles to be performed
- Bespoke fixtures were developed to hold the sample in place
- Fixtures changed every 10-15 tests
- Using our 250kN Vienna test machine, we carried out fatigue testing with loads ranging from 13kN to 142kN
- Four off bolts passed the testing criteria, but the remaining four showed signs of fracturing or failure.
Find out more about our Fastener Testing services
Verifying Fasteners is a Crucial Element of the Manufacturing Process
Fasteners, such as bolts, head screws, nuts, and studs, are a crucial element of any structure, as they provide strength, durability and structural integrity for holding other materials and components together.
Without appropriate testing to understand how they will perform in real-service conditions, there is an increased risk for health and safety, quality compliance, and even legal implications if fasteners were to fail.
"If expert verification is not conducted, we have products that cause catastrophic health and safety issues, and devastating environmental, human and economic impact."
We work with many fastener manufacturers, both nationally and globally, to provide fatigue testing on large bolts up to size M42 to verify if a customer’s product is fit for purpose.
Christophe Welzel, Quality Manager for Heinrich Jungeblodt says, “Compromising quality is not an option. Measurement and checking processes are essential for our production procedures, so we sub-contracted fatigue testing on our samples to Phoenix for additional verification and quality control checks.
It is crucial that we are very precise when checking the stress that our samples can withstand, and Phoenix worked with us to develop a contract review and testing programme that was suitable for our needs.
We were recommended to Phoenix by a mutual contact, as they had a great experience with their own similar testing needs.
We have found the service from Phoenix to be very communicative, they have kept us up to date with the progress of the tests and results, and overall, we have been very happy with our experience. We look forward to working with Phoenix again in the future.”
If you would like to find out more about our sub-contract testing services, and how we can support your bespoke testing projects including consultancy and full contract review, call us on 01384 382 253 or contact us online.
Ask Us For A Consultation Call
Or you can call us on +44(0)1384 382 253
Certifications
Rolls Royce Technical Approval for High Temperature and Environmental Testing
The Design, Manufacture, Commissioning, Maintenance and support of Materials Testing Machines. ISO 9001 - ISO 14001, Cert. No. 15997
